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Navigating the EZ-ZONE PM Integrated Controller

1. Power Supply poe se es E de common a O dc o O Load Output 1 3 Mechanical Relay Form C SlotA B_e 5 A at 240V ac or 30V dc 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_ normally open 2070 K_ common J normally closed Output 1 3 Universal Process 0 to 20 mA into 800 Q maxi Slot A B mum load volts or current F 0 to 10V dc into 1 KQ mini Weisel mum load 7G scalable current t 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 JF negative one to20m a 4 volts HH l current 4 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 sta
2. SItB E Wire T R to the B termi CB nal of the EIA 485 port CA Wire common to the com mon terminal of the EIA CC 485 port CB Do not route network wires with power wires Connect CA network wires in daisy C5 chain fashion when connect ing multiple devices in a C3 network C2 e A termination resistor may be required Place a 120 0 resistor across T R and T R of last controller on network Do not wire to both the EIA 485 and the EIA 232 pins at the same time Two EIA 485 terminals of T R are provided to assist in daisy chain wiring Do not connect more than one EZ ZONE PM controller on an EIA 232 network Do not connect more than 16 EZ ZONE controllers on a Standard Bus EIA 485 network Maximum number of EZ ZONE controllers on a Mod bus network is 247 maximum EIA 232 network length 15 meters 50 feet maximum EIA 485 network length 1 200 meters 4 000 feet 1 8th unit load on EIA 485 bus Communications instance 2 Slot B PM 6 2 Slot E PM 489 I21 Modbus IDA EIA TIA 485 Watlow Termi Function Terminal Name nal Label o h oro w Watlow EZ ZONE PM Integrated Controller 29 o 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
3. Minimum Maximum Ratings 85 to 264V ac 100 to 240V ac Semi Sig F47 47 to 63 Hz 14VA maximum power consumption PMA 8 and 9 10VA maximum power consumption PM6 PM 12 Digital Input 5 6 98 99 CF CD _ CE common 2C Input DC Input Slot C B5 D6 D5 Digital Input Update rate 10 Hz e Dry contact or de voltage DC Voltage e Input not to exceed 36V at 3 mA Input active when gt 3V 0 25 mA Input inactive when 2V Dry Contact Input inactive when gt 500 Q e Input active when lt 100 Q e maximum short circuit 13 mA Voltage Input PM 24 E Dry Contact Explosion Hazard Do not disconnect while the circuit is live or unless the ER ETE area is known to be free of ignitable common concentrations of flammable sub B_ stances m a Warning N D s Explosion Hazard Dry contact closure Digital Inputs shall not be used in Class Apo I Division 2 Hazardous Locations unless 24 Vdc switch used is approved forthisap 0000000000000 poo o o LM plication Watlow EZ ZONE PM Integrated Controller e 22 Chapter 2 Install and Wire Warning AN A Use National Electric NEC or other country specific standard wiring and safety prac
4. Lo Ru o e o 3o D 7o o 70 20 e o LO 20 o r Ec D m Ri o o D d D o m 7o o 0 0 2 2 D D o rr Q rr Ru D tr uc o O C 3 fr o c D c Ru n M 3 m c Q a n a0 5 o aM o ro r o 1 o Watlow EZ ZONE PM Integrated Controller ePi Ramping 1 or 2 33 Thermistor Resistance ange 58 Ramp Rate 69 108 Ramp Scale 69 108 RTD Leads 57 Ramping Type 80 Sensor Backup Enable 103 Software Build 96 Sensor Type 57 101 103 Source Function A 73 Source Function A 77 Source Function B 77 Source Function E 76 Scale High 57 72 103 Event Input Source Instance 80 Source Instance A 77 Event Input Source Instance 80 81 Source Instance B 77 Source Instance 76 Scale Low 57 72 103 Set Lockout Security 95 3 Serial Number 96 Special Output Function enu 50 Step Time Remaining 53 Active Step 51 Active Step Type 51 Source Value 1 50 Source Value A 41 Source Value 2 50 Source Value B 41 Source Value E 49 User Tune Aggressiveness 2 N I x 4 nr 3 tr uc o Dx C REDLTEE ds EPEEEERE d m ee LO 5 o oco em ea LO 5 User Tune Aggressiveness 00 TRU TUNE Band 67 TRU TUNE Band 101 Ther
5. Lo e L FCEY Calibration Menu C 4 to CAL Calibration m dD Watlow EZ ZONE PM Integrated Controller e 92 Chapter 8 Factory Page Parameter name Description Custom Menu Par Custom Menu Parameter 1 to 20 Select the param eters that will ap pear in the Home Page The Parameter 1 value will appear in the upper dis play 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 dis play in the Home Page It can be changed with the Up and Down Keys if the pa rameter is a writ able one Scroll through the other Home Page parameters with the Advance Key e Note Factory Page Modbus Relative Ad dress Parameter Default Appears in Menu When non None d l Guaranteed Soak Deviation 1 Value dg Guaranteed Soak Deviation 2 Value P RC Profile Action Request PSE Profile Start Idle Set Point EE Un TRU TUNE Ramp Rate f Cool Hysteresis C P b Cool Proportion al Band Heat Hysteresis Heat Propor Band Dead Band Time Derivative Time Integral Cool Power Heat Power User Control Autotune Open Loop Set Active Set Point Active Process Set Point Custom Menu Alarm Hysteresis Alarm High Set Alarm Low Set User Restore Set Display Units Input Calibration Process Current Read Limit Low Set Limit High Set Limit Hysteresis Some values will be r
6. A A EIA 485 T R Slot E PM 4 89 _ 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 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 JOB ys Watlow EZ ZONE PM Integrated Controller e 20 e Chapter 2 Install and Wire Back View Back View Slot Orientation Slot Orientation 1 4 DIN Horizontal PM4 1 16 DIN PM6 Note PM Integrated Isolation Block Slot B above can also be configured with a communications card Low voltage Isolation 42V peak Safety Isolation 2300V ac Watlow EZ ZONE PM Integrated Controller e 21 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 elect
7. Available with PM4 PM8 and PM9 models only Modbus Rela tive Address Instance 1 Map 1 Map2 1884 2364 Instance 2 Map 1 Map2 1954 2434 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 Map2 1958 2438 Instance 1 Map 1 Map2 1910 2390 Instance 2 Map 1 Map2 1980 2460 Instance 1 Map 1 Map2 1912 2392 Instance 2 Map 1 Map2 1982 2462 Instance 1 Map 1 Map2 1914 2394 Instance 2 Map 1 Map2 1984 2464 CIP Class Instance Attribute hex dec 0x97 151 1 to 2 3 0x97 151 1to2 4 0x97 151 1to2 5 0x97 151 1to2 0x10 16 0x97 151 1to2 0x11 17 0x97 151 1to2 0x12 18 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Setup Page Parameter name Description Control Loop 1 to 2 Autotune Aggres siveness Select the aggres siveness of the auto tuning calculations Under damped 99 Critical damped 21 Over damped 69 Control Loop 1 to 2 0 0 to 5 0 seconds Peltier Delay Set a value that will cause a delay when switching from heat mode to cool mode Control Loop 1 to 2 User Failure Action Select what the con troller 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 096 14 PAAn Manual Fixed sets output power to Manual Power se
8. Output 3 none switched dc open collector 5A mechanical relay form C process 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 EZKey 1 amp 2 Programmable Functions Digital Input or Output 5 amp 6 optional Programmable Functions EIA 485 Communication Standard Bus optional Modbus RTU 100 to 240Vac 20 to 28 Vac or 12 to 40Vdc Note ai If limit this output must be limit Modbus Address 1 247 Standard Bus Zone Address 6 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 LS Digital Output or Input 5 amp 6 optional none switched dc off heat cool alarm or event Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail LEDs Zone UIDES Address Channel 12 Indicates Zone Address amp Channel 3 4 Indicates I O 5 6 Status 7 8 Watlow EZ ZONE PM Integrated Controller Chapter 1 Overview EZ ZONE PM Integrated Model 1 8 and 1 4 DIN System Diagram With 6 Digital 1 0 slot
9. PID Controller Optional Ramp Soak max 4 files 40 steps Slots A Optional y B d none CT Thermocouple RTD 100 or 1k Potentiometer PID Controller Limit or Current Transformer Sense CT Output 1 none switched dc open collector 5A mechanical relay form C process 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 Output 3 none switched dc open collector 5A mechanical relay form C process or 0 5A SSR form A utput Slots B Optional E Bes Tug 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 none 15A NO ARC switched dc 5A mechanical relay form A or 0 5A SSR form A If limit this output must be limit Communications Board Communications ee Modbus RTU
10. 111 Chapter 9 Features 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 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 pro cess temperature has to enter the normal operat ing 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 val ue 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 through the c
11. EZ ZONE RM o o PR power 4 m power common im Li d m pui mai TII m m EIE galt Power l ial bm Em LER EZ ZONE PM cd 234 i cat 4 jB5 PUT Del lot D5 fl r OOOO0O90999 Ses suasa E RUI Gateway 2 EZKB A E mec pg Power F common common Li ep 1 B eB Y A network with all devices configured using Modbus RTU EZ ZONE ST ST__ BorF _M_ Power Supply 5 EZ ZONE RM Warning A HHH HHHH Fx nem c K rm Frm Explosion Hazard Substitution of ISSESGOZDSS Hom component may impair suitability for T power i H CLASS I DIVISION 2 mp leant 4 Z i Pt m Warning A Z a Explosion Hazard Do not disconnect Z EI while the circuit is live or unless the ee ower t E E area is known to be free of ignitable prellem d LEX UE concentrations of flammable sub EZZONEPM r o zit stances S TTF1 Slot C ps I i SSSSSesesesg SS8SE RB FSB HEEL Cc n E LL I c
12. Note Communications 1 Protocol Set the protocol of this controller to the protocol that this network is using Range 0 to 9999 seconds Comm port 2 1189 Comm port 1 1190 Comm port 1 and 2 Off 62 Off 62 On 63 Off 62 On 63 User Set 1 101 User Set 2 102 None 61 Factory 31 nong None 61 User Set 1 101 User Set 2 102 Setup Page Default oth On On 2 St d Standard Bus 1286 P 1o d Modbus RTU 1057 CIP Modbus Rela Class tive Instance Address Attribute hex dec If4th digit Instance 1 7A 122 in controller Map 1 Map2 1 part num 4484 0x49 73 ber is a B or an E Always Instance 1 0x6A 103 Map1 Map2 1 1856 2326 OxOE 14 Always Instance 1 0x6A 103 Map1 Map2 1 e 2350 0x1A 26 Always Instance 1 0x6A 103 Map1 Map2 1 ae yt 2352 Ox1B 27 Always Instance 1 0x6A 103 Map1 Map2 1 eus 2354 0x1C 28 Always Instance 1 0x6A 103 Map1 Map2 1 Ee M er 2356 Ox1D 29 Always Instance 1 0x 101 Map1 Map2 1 Instance 1 0x65 Map1 Map2 101 24 24 1 OxD 13 Always if Instance 1 2492 2972 Parameter Appears in Menu When E c c za ZB za S S S e e e 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 Chapter 6 Setup Page Setup Page Parameter
13. 1 3 5 2 4 Zone Address D Digital Output or Input 5 amp 6 optional none switched dc Eai 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 Limit 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 Zone Address Indicates I O Status Integrated PID and Limit Controller e Reduces wiring time and termination complexity compared to connecting separate products Reduces panel space Reduces installation costs Increases dependability with backup control sensor operation Increases user and equipment safety for over under temperature conditions Watlow EZ ZONE PM Integrated Controller Chapter 1 Overview EZ ZONE PM Integrated Model 1 16 DIN System Diagram with Expanded Communications Slot B Input Output Functions Metus Output 1 Functions none switched dc open collector 5A anneal els Analog Input 1 AR ERR NA duplex event none CT Thermocouple RTD 100 Optional Input Sensor gt Q 1kQ Thermistor 5kO 10kO 20kQ 40kQ Process V mV mA None Idle set point Tune Alarm clear request Force alarm Silence alarm Manual aut
14. Chapter 5 Operations Page Parameter name Description Profile Status Target Set Point Loop 1 View or change the target set point of the current step Profile Status Target Set Point Loop 2 View or change the target set point of the current step 1 999 000 to 1 128 000 to 1 999 000 to 1 128 000 to Profile Status Produced Set Point 1 1 128 000 to 1 999 000 to Display the current set point even if the profile is ramping Profile Status Produced Set Point 2 1 128 000 to Display the current set point even if the profile is ramping 1 999 000 to Note 9 999 000 F or units 5 537 000 C 9 999 000 F or units 5 537 000 C 9 999 000 F or units 5 537 000 C 9 999 000 F or units 5 537 000 C Operations Page Parameter Default Appears in Menu When a profile is active a profile is active 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 Map1 Map2 2542 4362 Instance 1 Map1 Map2 4434 Instance 1 Map 1 Map2 Instance 1 Map 1 Map2 CIP Class Instance Attribute hex dec Ox7A 122 1 OxC 12 Profibus Index Ox7A 122 1 0x30 48 Watlow EZ ZONE PM Integrated Controller 52 o Chapter 5 Operations Page Operations Page CIP Parameter Class Display LE
15. Dual Channel Controller e For selected models provides two PID controllers Watlow EZ ZONE PM Integrated Controller 2 Chapter 1 Overview in one space saving package Enhanced Control 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 e 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 th
16. 0x68 104 1to2 0x1A 26 0x86 134 1to2 5 0x86 134 1to2 0x29 41 Watlow EZ ZONE PM Integrated Controller e 59 e Chapter 6 Setup Page Parameter name Description 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 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 Note Range 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 Parameter Default DHL in Menu When Always Instance 1 Mapl1 Map2 3574 Instance 2 Map 1 Map2 3644 Always Instance 1 Map 1 Map2 3594 Instance 2 Map 1 Map2 3664 Always Instance 1 Map 1 Map2 3576 Instance 2 Map 1 Map2 3646 Always Instance 1 Map 1 Map2 3597 Instance
17. Make sure all input and output impedances are compatible 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 r amp y Assign the function of switching to a remote set point to a digital input with Digital Input Function F n Setup Page Digital Input 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 3 3 Outputs Duplex Certain systems require that a single process output control both heating and cooling outputs An EZ ZONE PM controller with a process output 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 9 Set the range of the process output
18. Output Value Sof Special Output Function Menu C y S oF Special Output Function ou Output Value PSEA Profile Status Menu I to PSEA Profile Status PSE Profile Start A Action Request Active Step Active Step Type Target Set Point Loop 1 Target Set Point Loop 2 Produced Set Point 1 Produced Set Point 2 Step Type Remaining Active Event Output 1 Active Event Output 2 Jump Count Remaining Available with PM4 8 and 9 only with gth digit of part number equal to C or J AND with 12th digit equal to C PM 4 8 9 C J __ IC 1 o F3 4 d fr uc o T3 o rr D Pu dr E D D Di Ou m 3 fr m 3 nr fu C A Watlow EZ ZONE PM Integrated Controller e 39 o Chapter 5 Operations Page Operations Page Parameter Parameter name LE Description Analog Input Menu Analog Input 1 to 2 Process Value View the process value 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C Aun None 61 Open 65 Fail 32 Er i Er Analog Input 1 to 2 Error Status View the cause of the most recent error If the EER En message ct Shorted 127 is Er I or E Ef 9 Measurement this cie will Error 140 display the cause of CAL Bad Calibra the input error tion Data 139 E H5 Ambient Er ror 9 Ertd 141 NSrce 246 1 999 000 to 9 999 0
19. Pressing the Function Key will toggle the selected action Note Setup Page Range Default 0 to 9 999 seconds 10 to 9 999 seconds 1 0 to 100 0 h 9h High 37 Low 53 0 to 9 999 seconds Parameter Appears in Menu When Function is set to Compres sor Function is set to Compres sor Function is set to Motorized Valve Function is set to Motorized Valve 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 0x87 135 Map 1 Map2 1 NEN 3882 0x16 22 Modbus Rela tive Address Instance 1 0x87 135 Mapl1 Map2 1 M 3884 0x17 23 Instance 1 0x87 135 Map1 Map2 1 330 3886 0x18 24 Instance 1 0x87 135 Map1 Map2 1 S 3888 0x19 25 Instance 1 Ox6E 110 Map1 Map2 1to2 1320 1560 1 Instance 2 Map1 Map2 1340 1580 Watlow EZ ZONE PM Integrated Controller 78 Chapter 6 Setup Page Parameter name play Description Fn Function Key 1 to 2 Fn Digital Input Func tion 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 available any selection will af fect it g9LbL Global Menu Global Menu Display U
20. deviation band that B N or E will be used in all profile step types The process value must enter the devia tion band before the Step can proceed Global Menu Ox7A 122 Source Instance A 1 Set the source for part num Ox1A 26 WEIL ber is an R Global Menu 7A 122 Source Instance B Map 2 1 Set the source for Ox1B 27 WE2 ber is an R B N or E 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 80 e Chapter 6 Setup Page Parameter name Description Global Menu Power Out Time If profile is running and power is lost profile will resume where it left off pro vided time set has not expired prior to power restoration Global Menu Communications LED Action Turns comms LED on or off for selected comms ports Global Menu Zone Turns Zone LED on or off based on selec tion Global Menu Channel Turns Channel LED on or off based on selection Global Menu Display Pairs Defines the number of Display Pairs Global Menu Display Time Time delay in tog gling between chan nel 1 and channel 2 Global Menu User Settings Save Save all of this con troller s settings to the selected set Global Menu User Restore Set tings Replace all of this controller s settings with another set Communications Menu Plol PCoL
21. y 216 Panel thickness 060 1 53 to 375 9 52 85 216 85 Watlow EZ ZONE PM Integrated Controller e 16 e Chapter 2 Install and Wire Installing and Removing the PM EZ ZONE PM PM6 amp PM8 Shown Below Retention Collar LAD 1 Make the panel cutout using the mounting tem plate dimensions in this chapter Insert the case 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 UL650 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
22. 0 001 to 9 999 000 F or units 0 001 to 5 555 000 C L hy Limit 1 Set Point Limit High Set the high end of the limit set point range Limit 1 Set Point Limit Low Set the low end of the limit set point range 5PLh 1 999 000 to 9 999 000 SP Lh 1 999 000 to 9 999 000 SP LL Limit Integrate In a limit state the controller will turn off the outputs ter minate an active pro file and freeze PID and TRU TUNE calculations No 59 YES Yes 106 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 Default Direction is set to Out put CIP Class Instance Attribute hex dec Instance 1 Ox6E 110 Map1 Map2 5to12 1326 4 0x70 112 1 5 1 1 Parameter Appears in Menu When Modbus Rela tive Address Offset to next instance Map 1 amp Map 2 equals 20 Always Instance 1 Map1 Map2 688 728 Always Instance 1 0x70 112 Map 1 Map2 682 722 2 9 999 000 Always Instance 1 0x70 112 Map 1 Map2 696 736 9 1 999 000 Instance 1 0x70 112 Map1 Map2 1 698 738 0x0A 10 No Always Instance 1 0x70 112 Map 1 Map2 1 694 734 8 40 1 2 4 4 uint RWES float RWES float RWES float RWES uint RWES Watlow EZ ZONE PM Integrated Controller e 66 e Chapter 6 Setup Page Parameter name Description Cont
23. 0x68 104 1to2 OxC 12 0x86 134 1to2 4 0x86 134 1to2 6 Profibus Index Watlow EZ ZONE PM Integrated Controller e 40 e Chapter 5 Operations Page Parameter name Description Linearization 1 to 2 Output Value View the value of this function s output Linearization 1 to 2 Output Error View reported cause for Linearization out put malfunction L Pu loPEr Process Value Menu Su Sv A Process Value 1 to 2 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 Process Value 1 to 2 Source Value B View the value of Source B Sub Sv 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 Process Value 1 to 2 Offset Set an offset to be ap plied to this function s output oF SE oF St Note 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 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 or units 1 128 000 to
24. 0x86 134 1to2 0x17 23 0x86 134 1to2 OxE 14 0x86 134 1to2 0x18 24 0x86 134 1to2 OxF 15 0x86 134 1to2 0x19 25 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Setup Page Parameter le Parameter name Appears anco loc By Ose AA Range Default PP tive Instance Description in Menu Add When ress Attribute hex dec 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 1to2 oe 3590 0x10 16 Instance 2 Map 1 Map2 3660 Instance 1 0x86 134 Map 1 Map2 1to2 RN 3610 Ox1A 26 Linearization 1 to 2 1 999 000 to 9 999 000 Output Point 9 Set the value that will be mapped to input 9 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 2 Map1 Map2 3680 Instance 1 0x86 134 Map1 Map2 1to2 T EL 3592 Ox11 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 be mapped to Instance 1 0x86 134 Map 1 Map2 1to2 3612 Ox1B 27 Instance 2 Map 1 Map2 3682 Process Value 1 to 2 Off 62 Function u SL A Vaisala RH Compen Set the function that sation 1648 will be applied to the 5 JB Wet Bulb Dry Bulb source or sources 1369 Note Differential and bA Sensor Backup
25. 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 Parameter Default Appears in Menu When If 9th digit in part number is a Uia Dude If 9th digit in part number is a Wr If 9th digit in part number is a Wo If 9th digit in part number is a Wo Always if digit 12 of part num ber is C Math Func tion Setup Page is set to Process Scale Devi ation Scale Math Func tion Setup Page is set to Process Scale Devi ation Scale Math Func tion Setup Page is set to Process Scale Devi ation Scale Math Func tion Setup Page is set to Process Scale Devi ation Scale 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 1120 1360 Instance 1 Map 1 Map2 1160 1400 Instance 1 Map 1 Map2 1124 1364 Instance 1 Map 1 Map2 1160 1400 Instance 1 Map 1 Map2 3030 Instance 1 Map 1 Map2 3032 Instance 1 Map 1 Map2 3038 Instance 1 Map 1 Map2 3044 Instance 1 Map 1 Map2 3042 CIP Class Instance Attribute hex dec 0x73 115 1 1 0x73 115 1 2 0x73 115 1 3 0x73 115
26. 1 Tuning 1 or 2 I Ramping 1 or 2 I Loop Open Error 1 or 2 1 Loop Reversed Error 1 or 2 Current Error I Heater Error Parameters that appear only in the Home Page Navigating the EZ ZONE PM Integrated Controller EZ ZONE9 EZ ZONE Home Page from anywhere Press the Infinity Key for two seconds to return to the Home Page Watlow EZ ZONE PM Integrated Controller 33 o Chapter 3 Keys and Displays EZ ZONE EZ ZONE Factory Page from Home Page Press both the Advance and Infinity keys for six seconds Watlow EZ ZONE PM Integrated Controller e 34 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
27. 1to4 9 Ox6A 106 1to4 OxA 10 0x76 118 lor3 1 0x76 118 lor3 2 0x76 118 lor3 3 R Read W Write E EE PROM S User Set Watlow EZ ZONE PM Integrated Controller e 71 Chapter 6 Setup Page Setup Page Parameter Cle arameter Modbus Rela Class Parameter name Appears S Description Danse in Menu NS Instance Wh Address Attribute en hex dec Output 1 or 3 pro 1 to 4 Always if Instance 1 0x76 118 cess digit 6 or Map1 Map2 lor3 Function Instance 10 of part 726 846 Set the instance of number is Instance 3 the function selected an F above Mapl1 Map2 806 926 Output 1 or 3 pro 100 0 to 100 0 Always if Instance 1 0x76 118 cess digit 6 or Mapl1 Map2 lor3 Scale Low 10 of part 736 856 Set the minimum number is Instunce3 value of the output an F M Mi range ap 1 ap 2 816 936 Output 1 or 3 pro 100 0 to 100 0 Always if Instance 1 0x76 118 cess digit 6 or Map1 Map2 lor3 Set the maximum number is Instanee3 value of the output an F range Output 1 or 3 pro 1 999 000 to 9 999 000 F or j Always if Instance 1 0x 76 118 float RWES cess units i digit 6 or Map 1 Map 2 lor3 Range Low 1 128 000 to 5 537 000 C lOofpart 749 360 03B 1D Set the minimum number is value of the retrans an F mit value range in process units When the retrans mit source is at this value the retransmit output will be at its Scale Low value Instance 3 Map 1 Map2 820 940
28. 246 Stale 1617 Can t process 1659 Instance 1 Map1 Map2 3860 Available with PM8 9 only CIP Class Instance Attribute hex dec 0x87 135 1 OxC 12 Some parameters in the Profile Status Menu can be changed for the cur rently running profile but should only be changed by knowledgeable personnel and with caution 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 Changes made to profile parameters in the Profiling Pages will be saved and will also have an immediate impact on the running profile 1 Always Instance 1 Map1 Map2 2520 4340 None Always Instance 1 Map1 Map2 2540 4360 0 none a profile is Instance 1 active Map1 Map2 USt Pj Unused Step a profile is 50 active End End 27 Jl Jump Loop 116 CL oC Wait For Time 1543 b dbo Wait For Both 210 i Wait For Pro 209 Wait For Event 144 OAH Soak 87 C E s Time 143 c AEE Rate 81 None 61 Terminate Resume 147 Pause 146 Profile 77 2526 4346 Instance 1 Map1 Map2 2544 4364 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 Ox7A 122 1 1 0x7A 122 1 OxB 11 Ox7A 122 1 4 0x7A 122 1 OxD 13 Watlow EZ ZONE PM Integrated Controller e 51
29. 42 0x68 104 1to2 OxF 15 0x68 104 1to2 0x10 16 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Note Parameter name Description Analog Input 1 to 2 Range Low Set the low range for this function block s output Analog Input 1 to 2 Range High Set the high range for this function block s output Analog Input 1 to 2 Process Error En able Turn the Process Er ror Low feature on or off Analog Input 1 to 2 Process Error Low If the process value drops below this value it will trigger an input error Analog Input 1 to 2 Thermistor Curve Select a curve to ap ply to the thermistor input Analog Input 1 to 2 Resistance Range Set the maximum resistance of the thermistor input Analog Input 1 to 2 Filter Filtering smooths out the process signal to both the display and the input Increase the time to increase filtering 1 999 000 to 9 999 000 1 999 000 to 9 999 000 oF F Off 62 Low 53 100 0 to 1 000 0 Curve A 1451 Curve B 1452 Curve C 1453 Custom 180 5K 1448 10K 1360 20K 1361 40K 1449 0 0 to 60 0 seconds Setup Page Range Default Parameter Appears in Menu When Sensor Type is set to Millivolts Volts Mil liamps or Potentiom eter 1 kO Sensor Type is set to Millivolts Volts Mil liamps or Potentiom eter 1 kO Sensor Type is set to Millivolts Volts Mil liamps or
30. L oland Scale High 5A 1 Scale the re transmit source to the process output with Range Low r l oland 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 extruders 100 80 60 Linear Curve 1 Actual Output Power 40 Curve 2 20 PID Calculation Select a nonlinear cool output curve with Cool Output 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 c
31. L Cool Power l I Cool I 1 Control Loop 2 1 om 0 to 100 i Humidity Outputn 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 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 Vaisala Een 0 to 100 Humidity Output n MON 1 MON 1 1 ar V 1 I Output n I 0 to 100 1 1 Heat 1 i Analog Input 1 Source A Heat Power 1 Cool Power 1 I Control L 1 oe LI S AR 0 to 100 I Temperature Output n L I E My A 1 t e 1 I I i L i Source A l I Analog Input 2 Source B Output y O I PV Function So eT 1 1 rng A I
32. Lock When set to yes will not allow address to be changed using software Can be changed from front panel dhL P DHCP 1281 F Add Fixed Address 1284 Communications 2 IP Address Mode Select DHCP to let a DHCP server assign an address to this module 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 digit of part number isa Dor 1 other wise 2 CIP Class Instance Parameter Appears eee Attribute hex dec Always Instance 1 0x96 150 Map1 Map2 1 2494 2974 8 t mE Modbus Rela tive Address digit 8 is a 5 Always if digit 8 is a WE Always if digit 8isa 5 Always if digit 8isa no Always if digit 8 is a 6 Always if digit 8 is a Chapter 6 Setup Page Setup Page Parameter ale Modbus Rela Class Parameter name Appears 5 AA Range Default tive Instance Description in Menu s Attribute hex dec 0 to 255 Communications 2 IP Fixed Address Part 1 Set the IP address of this module Each device on the net work must have a unique address Communications 2 IP Fixed Address Part 2 Set the IP address of this module Each device on the net work must have a unique address Communications 2 IP Fixed Address Part 3 Set the IP address of this module Each device on th
33. MJ co N IP Fixed Address Part 3 84 o hy G o N IP Fixed Address Part 4 81 5D 3 3 o roo Pu n c ry dt E dt E uh i 5 E c f o m o ry m o rr o o 1 9 o o o o p o 3 o Oo m 3 3 x E 3 3 d 3 3 3 d Pr 3 3 em Oo 4 97 IP Address Mode 83 96 IP Fixed Subnet Part 1 84 IP Fixed Subnet Part 2 85 IP Fixed Subnet Part 3 85 IP Fixed Subnet Part 3 85 IP Fixed Subnet Part 4 85 Jump Count Remaining 53 Open Loop Detect Devia on 69 Open Loop Detect Enable Open Loop Detect Time 69 Limit Hysteresis 66 Limit Error 1 33 Limit High 1 33 Limit Menu 43 66 Linearization 57 Limit Low Set Point 43 Linearization Menu 40 59 Security Setting Menu 94 Locked Access Level 95 Lock Operations Page 93 4 113 Lock Profiling Page 94 95 6 113 Control Loop Menu 67 Loop Menu 44 Loop Open Error 33 Loop Open Error 1 r2 33 Loop Reversed Error 33 Loop Reversed Er or 10r2 33 Limit Sides 66 Manual Power 68 Math Menu 49 76 Modbus TCP Enable 86 Minutes 86 Monitor Menu 43 Watlow EZ ZONE PM Integrated Controller e 124 Chapter 11 Appendix 3 3 c Electrical Measurement 98 02 Non volatile Save 82 83 Calibration Offset 73 Outp
34. On 63 nont None 61 Off 62 on On 63 nont None 61 Parameter Appears in Menu When Step Type is set to Time or Soak Step Type is set to Wait For Map 1 Process and the controller has two pro cess inputs Step Type is set to Wait For Map 1 Process Step Type is set to Wait For Map 1 Process Step Type is set to Wait Event or Wait for Both Step Type is set to Wait Event or Wait for Both Map 1 Map 1 Map 1 Modbus Relative Ad dress Instance 1 Map 2 2578 4508 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map 2 2598 4528 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map 2 2590 4520 Offset to next instance Map 1 equals 50 Map 2 equals Instance 1 Map 2 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map 2 2586 4516 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map 2 2588 4518 Offset to next instance Map 1 equals 50 Map 2 equals 100 CIP Class Instance Attribute hex dec 0x79 121 1 to 40 5 0x79 121 1 to 40 OxF 15 0x79 121 1 to 40 OxB 11 0x79 121 1 to 40 Ox1F 31 0x79 121 1 to 40 9 0x79 121 1 to 40 OxA 10 R Read W Write E EEPROM S User Set Watlow EZ ZONE PM Integrated Controller Chapter 7 Profiling Page Parameter name Des
35. Potentiom eter 1 kO Sensor Type is set to Millivolts Volts Mil liamps or Potentiom eter 1 kO and Error Enable is set to Low Sensor Type is set to Thermis tor Sensor Type is set to Thermis 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 392 392 Instance 2 Map 1 Map2 472 482 Instance 1 Map 1 Map2 394 394 Instance 2 Map 1 Map2 474 484 Instance 1 Map 1 Map2 418 388 Instance 2 Map 1 Map2 498 508 Instance 1 Map 1 Map2 420 420 Instance 2 Map 1 Map2 500 510 Instance 1 Map 1 Map2 434 434 Instance 2 Map 1 Map2 514 524 Instance 1 Map 1 Map2 432 432 Instance 2 Map 1 Map2 512 522 Instance 1 Map 1 Map2 386 386 Instance 2 Map 1 Map2 466 476 CIP Class Instance Attribute hex dec 0x68 104 1to2 0x11 17 0x68 104 1to2 0x12 18 0x68 104 1to2 Ox1lE 30 0x68 104 1to2 Ox1F 31 0x68 104 1to2 20x6 38 0x68 104 1to2 0x25 37 0x68 104 1to2 OxE 14 Watlow EZ ZONE PM Integrated Controller e 58 Chapter 6 Setup Page Parameter name Description Analog Input 1 to 2 Error Latching Turn input error latching on or off If latching is on errors must be manually cleared Analog Input 1 to 2 Display Precision Set the precision of the displa
36. Setup Page ES Off 62 PSC Process Scale 1371 d 5C Deviation Scale 1872 non None 61 F Un Function Key 1001 d o Digital I O 1142 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 0 0 to 60 0 seconds Parameter Appears in Menu When Always if 9th digit of part num ber is a C or J AND 12th digit is a C PM8 and 9 only Function is not set to Off If function is not set to off 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 Map1 Map2 3040 Instance 1 Map 1 Map2 3008 Instance 1 Map 1 Map2 3018 Instance 1 Map 1 Map2 3046 Instance 1 Map 1 Map2 3048 Instance 1 Map 1 Map2 3050 Instance 1 Map 1 Map2 3052 Instance 1 Map 1 Map2 3054 CIP Class Instance Attribute hex dec 0x7D 125 1 0x15 21 0x7D 125 1 5 0x7D 125 1 OxA 10 0x7D 125 1 0x18 24 0x7D 125 1 0x19 25 0x7D 125 1 Ox1A 26 0x7D 125 1 Ox1B 27 0x7D 125 1 Ox1C 28 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Parameter name Description SoF SEE Special Output 1 Function Set the function to match the device it will operate Special O
37. ac e NO ARC relay FormA 15A 24 to 240V ac noV dc resis tive load 2 million cycles at rated load Universal process retransmit Output range selectable 0 to 10V dc into a min 1 0000 load 0 to 20mA into max 8000 load 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 100 8 mm 100 3 mm 100 3 mm middle 9 53 mm 3 97 in 3 95 in 3 95 in 0 375 in low 7 62 mm 0 300 in up 10 80 mm 0 425 101 6 mm 53 8 mm 53 83 mm in 4 00 in 2 10 in 2 10 in low 6 98 mm 0 275 in top 11 4 mm 0 450 in 101 6 mm 100 3 mm 53 9 mm middle 9 53 mm 4 00 in 2 10 in 1 22 in 0 375 in bottom 7 62 mm 0 300 in 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 Automation Inc EtherNet IP is a trademark of ControlNet International Ltd used under
38. ae D7 Input inactive when gt 100KO NP A e Input active when 500 DC Input D8 ET i re ccm Voltage i DC Input Input inactive when lt 2V D8 D9 LI Input active when gt 3V D9 C ee DC Input Digr e a D10 Six user configurable digital in Dit c DC Input D11 TI puts outputs per slot Slot E DIO 7 12 DC Input PMI468 ICD soppy AE e oues c e Nur Sm D12 Supply D f Input 1 2 Thermocouple Slot A B Input 1 PM _ C R B ___ Input 2 PM 2K Q maximum source resistance gt 20 MO 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 S1 R1 C R L S2 R2 PM 4 8 and 9 only Input 1 2 RTD Slot A B Slot A B S2 S3 n Eal 3 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 c
39. low power 22 Modbus RTU or standard bus EIA 485 communications 29 Chapter 11 Appendix output 1 mechanical relay form C 26 output 1 switched dc open collector 25 output 1 universal process 26 output 2 mechanical relay form A 28 output 2 no arc relay form A 27 output 2 solid state relay form A 28 output 2 switched DC open collector 27 standard bus EIA 485 communications 29 X Y Z zone display 32 Watlow EZ ZONE PM Integrated Controller e 128 e 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 Classification 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 measu
40. 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 Chapter 11 Appendix Limit High set point L Poe Loop Open Error 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 LPr 1 LPre Loop Reversed Error Open Loop Detect is active and the process value is headed in the wrong direc tion when the output is activated based on devia tion value and user selected value Ramping 1 r Pg Ramping 2 Controller is ramping
41. usec E7 8 brown unused E8 cable per controller to receive 7 brown amp white E7 a 10 100 Mbps ethernet E6 m ET switch Both Modbus TCP uni pg 6 ereen recive E6 and EtherNet IP are unused E A white amp blue available on the network SS C icati EN roeie Eg ee transmit E9 white amp green Slot B p mus cmo EtherNet IP and Modbus TCP communica PMI4 8 9 3 ___ tions to connect with a 10 100 switch eee Slot E Note When changing the fixed IP address cycle module power for new address to take effect DeviceNet Communications Slot B E aA ii shield gH CH CAN_H positive side of DeviceNet CANE Oy bus negative side of DeviceNet bus Communications instance 2 Slot B PM 6 5 Slot E PM 4 8 9 _ 5 Profibus DP Communications Slot B amp E e Wire T R to the A terminal e If external termination is to 5Vde Voltage Potential 75 of the EIA 485 port be used with a 150 O cable 485 THR p e Wire T R to the B terminal place a 390 Q resistor across of the EIA 485 port pins VP and B a 220 Q resis 5T A e Wire Digital Ground to the tor across pins B and A and Digital ground common terminal of the EIA 485 port lastly place a 390 Q resistor across pins DG and A Ter
42. 0x96 150 or 2 h L o High Low 1330 issetto Map1 Map2 1 Modbus Word Or Modbus 2488 2968 5 der Select the word or der of the two 16 bit words in the floating point values 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 82 e Chapter 6 Setup Page Setup Page a 1 if 9th Parameter name Description 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 functions L YES Yes 106 no No 59 Communications 1 Non volatile Save If set to Yes all val ues written to the control will be saved in EEPROM Communications 2 DeviceNet Node Address Set the DeviceNet address for this gate way 185 125 kb 1351 250 250 kb 1352 500 500 kb 1353 Communications 2 Baud Rate Devi ceNet M Set the DeviceNet speed for this gate way s communica tions to match the speed of the serial network no No 59 C 9E S Yes 106 0 to 126 no No 59 YES Yes 106 Communications 2 DeviceNet Quick Connect Enable Allows for immediate communication with the scanner upon power up Communications 2 Profibus Node Ad dress Set the Profibus ad dress for this control Communications 2 Profibus Address
43. 1 21 0x7D 125 1 0x10 16 0x7D 125 1 0x11 17 0x7D 125 1 0x14 20 0x7D 125 1 0x17 23 0x7D 125 1 0x16 22 Watlow EZ ZONE PM Integrated Controller Chapter 5 Operations Page Parameter name Description Display Math 1 Math Output Error View reported cause for math malfunction Sof loPEr Special Output Function Menu 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 Note 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 1 128 000 to 5 537 000 C or units 1 999 000 to 9 999 000 F 1 128 000 to 5 537 000 C or units 1 999 000 to 9 999 000 F 1 128 000 to 5 537 000 C or units 1 999 000 to 9 999 000 F 1 128 000 to 5 537 000 C or units Operations Page Parameter Default Appears in Always if digit 12 of part num ber is C Special Out put Func tion is set to Compr
44. 1 to 4 0x0B 11 Offset to next instance Map1 1 equals 50 Map 2 equals 60 Instance 1 Map 1 Map2 1498 1898 0x6D 109 1to4 0x0A 10 0x73 115 1 8 float RWES 0x73 115 float 1 RWES 9 Offset to next instance Map1 1 equals 50 Map 2 equals 60 Instance 1 Map1 Map2 1134 1374 Instance 1 Map1 Map2 1136 1376 Watlow EZ ZONE PM Integrated Controller 4 8 o Chapter 5 Operations Page Display Note Parameter name Description Current 1 Read View the most recent current value moni tored by the current transformer Current 1 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 current trans former 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 Linear ization 1 Math 1 Source Value B View the value of Source B or Linear ization 2 Math 1 Source Value E Disables Process Deviation scale when on Math 1 Offset Set an offset to be applied to this func tion s output Math 1 Output Value View the value of this function s output Operations Page 1 999 000 to 9 999 000 None 61 Shorted 127 Open 65 None 61 High 37 Low 53 non None 61 FA L Fail 32 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C
45. 1201 Ratio not available Ratio 1374 using instance 2 Differential 1373 Square Root 1380 Pressure to Alti 1649 Bunt Process Value 1 to 2 Pounds per Square P Instance 1 Ox7E 126 Pressure Units 1671 Mapl1 Map2 1to2 Set the units that Pascal 1674 HELM 3334 0x1C 28 will be applied to the Atmosphere 1675 Instance Always if Instance 1 Ox7E 126 part num Mapi Map 2 1to2 ber digit 4 ee 3320 0x15 21 is C R J B EorN Instance 2 Map 1 Map2 PM4 8and 3320 off 9 only SI PS Millibar 1672 Map1 Map2 Torr 1673 Lieu 3404 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 Pressure Altitude calculation is based on the International Standard Atmosphere 1976 Watlow EZ ZONE PM Integrated Controller e 62 e Chapter 6 Setup Page Parameter name Description Setup Page eae Modbus Rela Default APP tive Jupe Address When CIP Class Instance Attribute hex dec Process Value 1 to 2 Altitude Units Set the units that will be applied to the Source Process Value 1 to 2 Barometric Pres sure 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 filtering Digital Input Output 5 to 12 Directio
46. 2 Operations Page Monitor Menu Closed Loop Set Point 2 2 Operations Page Monitor Menu User Control Mode 1 Operations Page Monitor Menu Heat Power 1 Operations Page Monitor Menu Process Value 2 erations Page Monitor Menu value Limit Status o Dd om fn Autotune 1 dle 1 10 User Control Mode 2 7 11 Heat Power 2 Cool Power 2 Autotune 9 se 14 dle 2 Operations Page Loop Menu imit Set Point Low i Operations Page Limit Menu Limit Set Point High i Operations Page Limit Menu Start Profile ction Request O ren Ol elete e aia olco e wlo i o N 2 o E Cool Power 1 i Operations Page Monitor Menu gt 2 None Note Numbers within parenthesis indicates the instance Watlow EZ ZONE PM Integrated Controller e 36 o 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
47. 2 L Outputn I 0 to 100 1 Heat L 1 Source A Heat Power 1 L Cool Power I Cool i Control Loop 2 3 F 160 C When function is set for Vaisala the PV Function out put equals the calculated relative humidity compensat ed by the sensor on Analog Input 1 Watlow EZ ZONE PM Integrated Controller e 117 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 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 e Alarm latching is active e Alarm set to incorrect output e Alarm is set to incorrect source e Sensor input is out of alarm set point range e Alarm set point is incorrect Alarm is set to incorrect type Digital input function is incorrect Alarm silencing is active Alarm blocking is active Alarm is set to incorrect output Alarm is set to incorrect sou
48. 2 Map 1 Map2 8667 Modbus Rela tive Address Always Instance 1 Map1 Map2 3578 Instance 2 Map 1 Map2 3648 Always Instance 1 Map 1 Map2 3598 Instance 2 Map 1 Map2 3668 Always Instance 1 Map 1 Map2 sere 3581 Instance 2 Map1 Map2 T 3651 3 Always Instance 1 Mapl1 Map2 3600 Instance 2 Map 1 Map2 3670 1 0 1 0 2 0 2 0 3 0 0 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 8 Profibus Index 0x86 134 1to2 0x12 18 0x86 134 1to2 9 0x86 134 1to2 0x13 19 0x86 134 1to2 OxA 10 0x86 134 1to2 0x14 20 0x86 134 1to2 OxB 11 0x86 134 1to2 0x15 21 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Parameter name Description 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 Linearization 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 Linearization 1 to 2 Output Point 7 Set the value that will be map
49. 56 81 displays 32 Display Time 81 Display Units 79 86 Down Key 32 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 103 End Set Point Value 91 EtherNet IP 30 Ethernet IP Enable 86 Event Output 1 and 2 91 EZ Key 112 F Factory Page 92 Filter Time 58 103 filter time constant 103 Function 55 101 Function Instance 64 66 Function Key Menu 112 G Global Menu 79 Setup Page 39 55 Guaranteed Soak Devia tion 56 Guaranteed Soak Deviation 80 Guaranteed Soak Enable 56 80 H Heat Algorithm 67 106 Heater Error 49 112 Heat Hysteresis 45 106 Heat Power 43 101 Heat Proportional Band 45 101 107 High Power Scale 64 71 high range 103 high scale 103 High Set Point Alarm 47 48 111 Current 48 112 Loop 69 103 Home Page 35 Hours 89 Hysteresis 66 73 111 l Idle Set Point 45 Input Error Failure 68 105 Input Error Latching 59 106 Input Error Status 40 input events 4 Input Point 1 55 Input Point 2 55 Input Point 3 55 Input Point 4 55 Input Point 5 55 Input Point 6 55 Input Point 7 55 Input Point 8 55 Input Point 9 55 Input Point 10 55 inputs 4 Input Sensor Type 101 installation 17 Instance 79 Integrate 66 IP Address Mode 83 96 IP Fixed Address Part 1 84 97 IP Fixed Address Part 2 84 97 I
50. 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 Email info watlow com sg Watlow Australia Pty Ltd 4 57 Sharps Road Tullamarine VIC 3043 Australia Tel 61 3 9335 6449 Fax 65 6778 0323 Website www watlow com sg Europe Watlow France SARL Immeuble Somag 16 Rue Amp re 95307 Cergy Pontoise CEDEX France Tel 33 0 1 30 73 24 25 Fax 33 0 1 30 73 28 75 Email info watlow fr Website www watlow fr Watlow GmbH Postfach 11 65 Lauchwasenstr 1 D 76709 Kronau 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 Notti
51. 9 Features Saving and Restoring User Settings Recording setup and operations parameter settings for future reference is very important If you uninten tionally 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 proper operation use User Save Set Fac tory Page Diagnostics 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 UJ 5 Factory Page Diagnostics 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
52. Alarm Silence Re quest Write to this register to silence an alarm Alarm 1 to 4 Alarm Silenced Write to this register to silence an alarm No Dis play Alarm 1 to 4 Alarm Latched Write to this register to silence an alarm Current 1 High Set Point Set the current value that will trigger a high heater error state Current 1 Low Set Point Set the current value that will trigger a low heater error state Note Operations Page i Clear 1003 Silence 1010 Yes 106 No 59 Yes 106 No 59 1 999 000 to 9 999 000 1 999 000 to 9 999 000 Parameter Appears in Menu When No param eter No param eter No param eter No param eter If 9th digit in part number is a T and cur rent sides is set to high or both If 9th digit in part number is a T and cur rent sides is set to low or both 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 0x6D 109 1to4 0xD 13 Profibus Index Modbus Rela tive Address Instance 1 Mapi1 Map2 1504 1904 Offset to next instance Map1 1 equals 50 Map 2 equals 60 Instance 1 Map1 Map2 1506 1906 0x6D 109 1to4 OxE 14 Offset to next instance Map1 1 equals 50 Map 2 equals 60 Instance 1 Map1 Map2 1500 1900 0x6D 109
53. CIE Modbus Rela Class Parameter name Appears fen Range Default tive Instance Description in Menu n Wh Address Attribute en hex dec i Communications 1 1to 16 Protocol Instance 1 0x96 150 Address Standard is set to Mapl1 Map 2 1 Bus Standard 2480 2960 1 Set the network ad bus dress of this control ler Each device on the network must have a unique ad dress The Zone Display on the front panel will display this number Communications 1 1 to 247 Protocol Instance 1 0x96 150 or 2 is set to Map1 Map2 1 Address Modbus Modbus 2482 2962 2 Set the network ad dress of this control ler Each device on the network must have a unique ad dress Communications 1 9 600 188 Protocol Instance 1 0x96 150 or 2 19 200 189 is set to Map1 Map2 1 Baud Rate Modbus 38 400 190 Modbus 2484 2964 3 Set the speed of this controller s communi cations to match the speed of the serial network Set the parity of this controller to match the parity of the se rial network Communications 1 Fahrenheit 30 Instance 1 0x96 150 Temperature Units Celsius 15 Map1 Map2 1 Select whether this 2490 2970 6 communications channel will display Communications None 61 Protocol Instance 1 0x96 150 Parity Modbus 1 Eu 5 Even 191 issetto Map1 Map2 1 r 2 Codd Odd 192 Modbus 2486 2966 4 in Celsius or Fahr enheit Communications 1 Loh Low High 1331 Protocol Instance 1
54. Crh Output 1 or 3 pro 1 999 000 to 9 999 000 F or 9 999 0 F i Instance 1 0x76 118 102 r hi cess units or units digi Map 1 Map2 lor3 Range High 1 128 000 to 5 537 000 C 5 537 0 C 142 362 0xC 12 Set the maximum number is value of the retrans an F mit value range in process units When the retrans mit source is at this value the retransmit output will be at its Scale High value Instance 2 Map 1 Map2 822 942 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 72 e Chapter 6 Setup Page Parameter name Description Output 1 or 3 pro cess Calibration Offset Set an offset value for a process output ALIN Alarm 1 to 4 Type Select whether the alarm trigger is a fixed value or will track the set point Alarm 1 to 4 Source Function A Select what will trig ger this alarm Setup Page 1 999 000 to 9 999 000 F or units 1 110 555 to 5 555 000 C Off 62 P AL Process Alarm 76 dERL Deviation Alarm 24 _ Analog Input 142 PL Jr Power Control Loop 73 Pu Process Value 241 Lar Linearization 238 CUr r Current 22 Default Parameter Appears in Menu Modbus Rela tive Address Instance 1 Map1 Map2 732 852 Instance 2 Map1 Map2 812 932 number is an W
55. D12 Z1 supply Internal Circuitry Watlow EZ ZONE PM Integrated Controller s 25 o 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 circuit is live or
56. Function is set to Compres sor Function is set to Compres sor 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 Modbus Rela Class tive Instance Address Attribute hex dec Instance 1 0x87 135 Map 1 Map2 8856 9 Instance 1 0x87 135 Map 1 Map2 3840 Instance 1 0x87 135 Map 1 Map2 3844 3 Instance 1 0x87 135 Map 1 Map2 8642 2 1 1 1 1 1 Instance 1 0x87 135 Map 1 Map2 1 3874 0x12 18 0x87 135 Map 2 1 0x13 19 Instance 1 Map 1 3876 Instance 1 0x87 135 Map 2 1 0x14 20 Map 1 3878 0x87 135 Map 2 1 0x15 21 Instance 1 Map 1 3880 Instance 1 0x87 135 185 Map 1 Map2 1 3846 4 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Parameter name Description Special Output 1 Minimum On Time At a minimum stay on specified amount of time Special Output 1 Minimum Off Time At a minimum stay off specified amount of time Special Output 1 Valve Travel Time The amount of time it takes the valve to fully open and then fully close Special Output 1 Dead Band Output power needs to change by speci fied level prior to turning on Function Key Function Key 1 to 2 Level The Function Key LEv LEv will always power up in the low state
57. High Set Point Setup Page 0 001 to 9 999 000 F Heat Algo or units rithm Set 1 110 555 to up Page is 5 555 000 C set to PID 0 001 to 9 999 000 F Heat Al or units gorithm 1 110 555 to Setup 5 555 000 C Page is set to On Off 0 001 to 9 999 000 F Cool Algo or units rithm Set 1 110 555 to up Page is 5 555 000 C set to PID 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 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 Instance 1 Map1 Map2 1900 2380 Instance 2 Map 1 Map2 1970 2450 Instance 1 Map 1 Map2 1892 2370 Instance 2 Map 1 Map2 1962 2442 CIP Class Instance Attribute hex dec 0x97 151 1 to 2 0x15 21 Ox6B 107 1to2 1 Ox6B 107 1to2 9 0x97 151 1to2 6 0x97 151 1to2 OxB 11 0x97 151 1to2 7 Watlow EZ ZONE PM Integrated Controller e 45 e Chapter 5 Operations Page Parameter name Description Display C hy Loop 1 to 2 Cool Hysteresis Set the control switching hysteresis for on off control This determines how far into the on region the process val
58. 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 Wiring a Serial EIA 485 Network Do not route network wires with pow 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 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 A network using Watlow s Standard Bus and an RUI Gateway EZ ZONE ST ST BoF M salt ao 3o LT sajd 9a Power Supply ig
59. Map 1 1972 Instance 1 Map 1 1894 Map 2 2522 0x97 151 Map 2 1to2 2374 Instance 2 Map 1 1964 Instance 1 Map 1 1896 Map 2 2444 0x97 151 Map 2 1 to 2 2376 9 Instance 2 Map 1 1966 Instance 1 Map 1 1898 Map 2 2446 0x97 151 1to2 OxA 10 Map 2 2378 Instance 2 Map 1 1968 Instance 1 Map 1 2162 Map 2 2448 0x6B 107 Map 2 1to2 2642 2 Instance 2 Map 1 2242 Map 2 2722 Watlow EZ ZONE PM Integrated Controller 46 Chapter 5 Operations Page Parameter name Description ALPS Alarm Menu Filo Alarm 1 to 4 A Lo Low Set Point If Alarm Type Setup Page Alarm Menu is set to process set the pro cess value that will trigger a low alarm deviation set the span of units from the closed loop set point that will trig ger a low alarm A negative set point represents a value below closed loop set point A positive set point represents 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 pro cess value that will trigger a high alarm deviation set the span of units from the closed loop set point that will trig ger a high alarm Alarm 1 to 4 Alarm State Current state of alarm Alarm 1 to 4 Alarm Clearable Current state of alarm Note Operations Page ES 1 999 000 to 9 999 000 F or units 1 128 00
60. PM Integrated Controller 109 C hapter 9 Features Differential Control The PM PM8 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 Ratio Control The PM PM8 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 produce a mixture with specified physical properties e Maintaining correct air and fuel mixture to com bustion 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 ove
61. PM4 8 and 9 models only F n Digital Input Function F Instance 9LbL SEt Global Menu 9L bL Global C_F Display Units BCLF AC Line Frequency r t YP Ramping Type Pt YP Profile type 95E Guaranteed Soak Enable 95g I Guaranteed Soak Devia tion 1 9Sd2 Guaranteed Soak Devia tion 2 5 A Source instance A 5 6 Source instance B Pot Power Out Time ion Con Zone Action ChAn Channel Action dP 5 Display Pairs dt Menu Display Timer U5Sr 5 User Save r User Restore Communications Menu to e COP Communications Protocol amp d5 Standard Bus Address bAUd Baud Rate PA Parity Modbus Word Order PPT IP Address Mode PF 1 IP Fixed Address Part 1 PF 2 IP Fixed Address Part 2 PF 3 IP Fixed Address Part 3 PF 4 IP Fixed Address Part 4 PF 5 IP Fixed Address Part 5 PF 5 IP Fixed Address Part 6 P 5 I IP Fixed Subnet Part 1 P 5g IP Fixed Subnet Part 2 1P 5 3 IP Fixed Subnet Part 3 P 5 4 IP Fixed Subnet Part 4 P 5 5 IP Fixed Subnet Part 5 P 55 IP Fixed Subnet Part 6 P9 T IP Fixed Gateway Part 1 P 92 IP Fixed Gateway Part 2 1P93 IP Fixed Gateway Part 3 P 94 IP Fixed Gateway Part 4 1P 95 IP Fixed Gateway Part 5 P 96 IP Fixed Gateway Part 6 P 5E Modbus TCP Enable E PE EtherNet IP Enable fonb Output Assembly Size A 1 nb Input
62. Part 5 Set the IP subnet mask for this module Communications 2 IP Fixed Subnet Part 6 Set the IP subnet mask for this mod ule Communications 2 Fixed IP Gateway Part 1 Communications 2 Fixed IP Gateway Part 2 Communications 2 Fixed IP Gateway Part 3 Communications 2 Fixed IP Gateway Part 4 Communications 2 Fixed IP Gateway Part 5 Communications 2 Fixed IP Gateway Part 6 Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Setup Page ES 0 to 255 0 to 255 0 to 255 0 to 255 0 to 255 If address mode is set to fixed Appears in Menu When If address mode is set to fixed If address mode is set to fixed If address mode is set to fixed If address mode is set to fixed If address mode is set to fixed If address mode is set to fixed If address mode is set to fixed If address mode is set to fixed If address mode is set to fixed If address mode is set to fixed Available with PM4 PM8 and PM9 models only Parameter CIP Class Instance Attribute hex dec Modbus Rela tive Address W Write E EE PROM S User Set Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Parameter name Description Yes 106 no No 59 Communications 2 Modbus TCP En able Activate Modbus TCP Communications 2 EtherNet IP En
63. Power Board Slot C EIA 485 Communication Standard Bus optional Modbus RTU Auxillary Input optional Output 3 none switched dc open collector Analog Input 2 V mA or 0 5A SSR form A none CT Thermocouple RTD 100 or 1k Potentiometer Output 4 none 15A NO ARC switched dc 5A mechanical relay form A or 0 5A SSR form A mechanical relay form C process 5A 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 Note Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail Output Status PET 102 gt Indicates Zone Address 3 4 Indicates I O gt 5 6 Status Remote Set Point Operation 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 Without Communications Card Slot B Input Functions Input Sensor None Limit reset Idle set point Tune Alarm clear request Force alarm Silence alarm Manual auto mode Control output
64. S So 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 115 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 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
65. Setup E Analog Input BL Digital 0 Limit Control Loop Dutput E Alam E Current E Function Key i he Function Key 1 Digital Input Function Peery en Function Instance fi FF H El BH Watlow EZ ZONE PM Integrated Controller Chapter 9 Features 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 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 Fac tory Page e Lock Operations Page sets the security lev el 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 5 E 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
66. Without Communications slot E Input Function Analog Input 1 none Thermocouple RTD 100Q Input Sensor Current _ Transformer None 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 gt 1kQ Thermistor 5kQ 10kQ 20kQ 40kQ Process V mV mA or 1k Potentiometer Analog Input 2 Current Transformer EZ Key 1 amp 2 Controllers PLC PC or HMI gt Standard Bus optional Modbus RTU I 100 to 240Vac Power Supply Programmable Functions Digital Input or Output 5 amp 6 optional Programmable Functions EIA 485 Communication 20 to 28 Vac or 12 to 40Vdc Note PID Controller Optional Ramp Soak max 4 files 40 steps Slots A Optional Output 1 none switched dc open collector 5A mechanical relay form C process 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 EN Current Transformer Sense CT Slots B Optional a Output 3 none switched dc open col
67. Y ll EL Jee c EE c E3 J c gt c 90 j 51 2 mm c 5 n LL 2 02 in C 2 2 MN D S L4 P Top 1 16 DIN PM6 Recommended Panel Spacing 45 2 mm 1 78 in 45 2 mm 1 78 in panel thickness 1 53 to 9 52 mm 0 060 to 0 375 21 6 mm 0 85 in 21 6 mm 0 85 in Watlow EZ ZONE PM Integrated Controller e 13 Chapter 2 Install and Wire 1 8 DIN PM8 Vertical Dimensions 53 34 mm 2 10 in cnn 95 in le oj S 54 86 mm 2 16 in 15 75 mm 0 62 in 1 52 mm 0 06 in ud I LU TITIT I I OOOOCOCOOSOS RB ih A Ah NEN L1 amp E 5 E G U0 1 6666969 hn e 10 16 mm 0 40 in lt lt 30 73 mm 1 21 in 4 00 in 1 8 DIN PM8 Vertical Recommended Panel Spacing 45 2 mm 1 78 in 92 3 mm 3 635 in 101 60 mm L 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
68. able Activate Ethernet IP YES Yes 106 No 59 Communications 2 Implicit Output As sembly Size Communications 2 Implicit Input As sembly Size F F 30 C C 15 Communications 2 Display Units Select which scale to use for temperature passed over commu nications port 2 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 functions Communications 2 Non volatile Save If set to Yes all val ues written to the control will be saved in EEPROM YES Yes 106 no No 59 Real Time Clock Hours Real Time Clock Minutes 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 of part number isa Dor 1 other CIP Modbus Rela Class tive Instance Address Attribute hex dec Parameter Appears in Menu When Always if digit 8isa 3 Always if digit 8 is a ugi Always if digit 8 is a ugu or 5 Always if digit 8 is a ng or 5 Instance 1 0x96 rm Map 1 Map2 2490 2970 i Instance 1 96 ae igi Map1 Map2 the part 7 number is Instance 2 2 3 or 5 Map1 Map2 4th digit i Instance 1 88 ae igi Map 1 Map2 in part EETA 4004 number is a B or i Instance 1 88 o 4th digit Map1 Map2 in part MEM 4006 numbe
69. below Default Values as delivered from the factory Conditions required for parameter to appear in menu Range Parameter Appears in Menu When Identifies unique param eters using either the Modbus RTU or Modbus TCP protocols further ex planation below Modbus Relative Ad dress Identifies unique param eters using either the De viceNet or EtherNet IP protocol further explana tion below 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 CIP Common Indus trial Protocol 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 ni I I fu i Il Il w e c Il al Uu Il Mir T PA ez r T e et 3 3 4 4 5 5 73 cl 3 i T z e I lt c T z R I B ru uc c ll CQ T oo 3 T N X z rm m e 30 I pu TEE em fraps fay fol e Range Within this column notice that on occasion there will be numbers found within parenthesis This number represents the enumerated value for that particular selection Range selections can be made simply by writing the enumerated value of choice using any o
70. by dialing 1 507 494 5656 between 7 a m and 5 p m Central Standard Time CST Ask for for an Applications Engineer Please 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 Bill to address Contact name 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
71. 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 levels 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 differentiate one level from the next Lockout Security 5L oC amp LoC Lockout Level 0 1 3 l4 5 Home Page Y YY YYIY Operations Page N N YIY Y Setup Page NIN N N Y Y Profile Page N IN N Y Y Y Factory Page Custom Menu N N N N N Y Diagnostic Menu N Y Y Y Y Y Calibration Menu N N N N N Y Lockout Menu Lot NIYIYIYIJY Y LoC P NEM Y Y Y Y PRSE Nlylylylyly crlol Y YX OY Yel Ye SLoC YIY Y JY 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 acces
72. e 14 o Chapter 2 Install and Wire 1 8 DIN PM9 Horizontal Dimensions EN L 15 75 mm 0 62 in 1 52 mm 100 33 mm 0 06 in 3 95 in 4d Y i e an i 54 86 mm l 53 34 mm 2 16 in 2 10 in Y PEE ILU Y SAL AL 10 16 mm 0 40 in 30 73 mm 1 21 in 101 60 mm rt 40i 4 1 8 DIN PM9 Horizontal Recommended Panel Spacing 92 3 mm 3 635 in zi 45 2 mm 1 78 in Panel thickness 0 060 in 1 53 mm 21 6 mm to 0 375 in 9 52 mm 0 85 in us vl 0 85 in Watlow EZ ZONE PM Integrated Controller e 15 e Chapter 2 Install and Wire 1 4 DIN PM4 Dimensions 100 33 l aud 15 75 3 95 62 dL 1 52 06 ry 2 ST qo iris D m E Ie 5 D Ci 0 100 33 ad D 3 95 aia ow n j i qi Cll m3 o Le 12 70 M 50 93073 LL 1 21 100 84 3 97 gt 1 4 DIN PM4 Recommended Panel Spacing m 92 3 l 3 635 I 92 3 3 635
73. is restricted by the Locked Access Level L o L A User with a password is restricted by the Read Lockout Security r L o C never having ac cess to the Lock Menu Ll of 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 Watlow EZ ZONE PM Integrated Controller e 114 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 oO Q 1 1 Say D SeS I looo tao DAS 1 1 1 Output n i i 0 to 100 i 1 Heat 1 Analog Input 1 Source A Heat Power 1 Cool Power i Cool i Control Loop 1 O to 100 1 o 1 1 Output n 1 Yir iin n i n yt n Ri i viii s ti a m mi ir i Dl Loop Set Point 1 Example 2 Sensor Backup Requirements Two analog inputs and the enhanced software option are required and at least one output adj
74. 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 122 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 Output 1 and 2 Hardware Options Output 1 Output 2 CA Switched dc open collector No
75. menu no submenus will appear Operations Page Analog Input Menu fto f Analog Input Process Value Error Status C A Calibration Offset CLarc Linearization Menu itol 8 Lor Linearization Source Value A oF SEt Offset Output Value C Pu Process Value Menu I to Pu Process Value Source Value A oF St Offset Output Value Digital Input Output Menu 5 to d o Digital Input Output Output State E 5 Event State d_ 5 Input State Lala Limit Menu d Limit Low Set Point L 45 High Set Point Paon Monitor Menu I Monitor Control Mode Active Heat Power C P Cool Power CSP Closed Loop Working Set Point uA Process Value Active 3 ooP oPEr Loop Menu C 1 to Loo Loop rc E n Remote Enable PA Control Mode Autotune Set Point Autotune Request Closed Loop Set Point Idle Set Point Heat Proportional Band Heat Hysteresis Cool Proportional Band Cool Hysteresis Time Integral Time Derivative Dead Band Open Loop Set Point r3 3 zB T o dD cz m d a D ia Le m D io m gt Lc nr nr Q Q e dD o o fr 73 3 Alarm Menu to RL P Alarm CAL o Low Set Point CAR High Set Point Current Menu C 4 Current Ch High Set Point CL o Low Set Point CU Read CE Error hEr Heater Error PRE Math Menu I PARAE Math oF St Offset
76. 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 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 s 38 o Chapter 4 Home Page Chapter 5 Operations Page Navigating the Operations Page To go to the Operations Page from the Home Page press both the Up O and Down Q keys for three sec onds will appear in the upper display and will appear in the lower display e Press the Up O or Down Q key to view available menus On the following pages top level menus are identified with a yellow background color Press the Advance Key to enter and view avail able prompts within a menu Note Press the Up O or Down Q key to move through available menu prompts Press the Infinity Key to move backwards through the levels parameter to submenu sub menu to menu menu to Home Page Press and hold the Infinity Key for two seconds to return to the Home Page 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
77. must be between Range High and Range Low Set Point Low Gas Pressure Range Low Range between Low Limit of Sensor and Range High 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 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 55h 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 t
78. part number is model part number is an L Heat algo rithm is not set to Off Setup Page 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 Map1 Map2 1368 1608 Instance 2 Map1 Map2 1628 Instance 1 Map 1 Map2 684 724 Instance 1 Map 1 Map2 686 726 Instance 1 Map 2 Instance 1 Map 2 720 Instance 1 Map 1 Map2 1882 2362 Instance 2 Map 1 Map2 1952 2432 Instance 1 Map 1 Map2 1904 2384 Instance 2 Map 1 Map2 1974 2454 CIP Class Instance Attribute hex dec Ox6E 110 3 to 4 5 0x70 112 1 3 0x70 112 Y 4 0x70 112 1 6 0x70 112 1 1 0x97 151 1to2 2 0x97 151 1to2 OxD 13 Watlow EZ ZONE PM Integrated Controller e 43 o Chapter 5 Operations Page Display Parameter name Description Monitor 1 to 2 Cool Power View the current cool output level Monitor 1 to 2 Closed Loop Work ing Set Point View the set point cur rently in effect Monitor 1 to 2 Process Value Active View the current fil tered process value 100 0 to 0 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 Operations Page EE Parameter Appears in Menu When Cool algo rithm is not se
79. range of protocol choices including Modbus RTU EtherNet IP Modbus TCP Watlow EZ ZONE PM Integrated Controller Chapter 1 Overview EZ ZONE PM Integrated Model 1 8 and 1 4 DIN System Diagram Without 6 Digital 1 0 slot D Without Communications slot E Input Function Inout sensor Q 1kQ Thermistor 5kO 10kQ 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 PC or HMI Power Supply Analog Input 1 none Thermocouple RTD 1000 1kQ Thermistor 5kO 10kQ 20kQ 40kQ Process V mV mA or 1k Potentiometer PID Controller Optional Ramp Soak max 4 files 40 steps Slots A Optional Output 1 none switched dc open collector 5A mechanical relay form C process or 0 5A SSR form A Output 2 hb none 15A NO ARC switched dc 5A mechanical relay form A or 0 5A SSR form A Analog Input 2 none CT Thermocouple RTD 100 20kQ 40kQ Process V mV mA or 1k Potentiometer PID Controller Limit or Current Transformer Sense CT Slots B Optional
80. taking place Use the Advance Key to step through the other parameters 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 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 wil
81. 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 TUNE 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 W
82. to new set point EUN I Autotuning 1 Controller is autotuning the EUNA Autotuning 2 control loop No heat cool action Output does not activate load No Display No display indication or LED illumination Cannot establish serial com munications with the con troller No Serial Communi cation Watlow EZ ZONE PM Integrated Controller Sensor input above high limit Temperature is greater than limit set point Limit outputs latch and require reset Incorrect 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 Incorrect controller model for applica tion Power to controller is off Fuse open Breaker tripped Safety interlock switch open Separate system limit control acti vated Wiring error ncorrect voltage to controller Address parameter incorrect ncorrec
83. triggered 6 PL of Lock Keypad level triggered 217 Restore User Set edge triggered 227 u 5 Cu tings Limit Reset edge triggered 82 Appears in Menu When Default Direction is set to input Direction is set to input Direction is set to Out put 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 Parameter Modbus Rela tive Address Instance 1 Map1 Map2 1320 1560 Offset to next instance Map 1 amp Map 2 equals 20 Instance 1 Map1 Map2 1640 Offset to next instance Map 2 equals 20 Instance 1 Map 1 Map2 1324 1564 Offset to next instance Map 1 amp Map 2 equals 20 CIP Class Instance Attribute hex dec Ox6E 110 1to2 1 Ox6E 110 5 to 12 1 Ox6E 110 5 to 12 3 Watlow EZ ZONE PM Integrated Controller e 65 e Chapter 6 Setup Page Setup Page Parameter name Description Digital Input 5 to 12 Function Instance Select which Digital Input will be trig gered by a true state ry A Limit Menu Limit 1 Sides Select which side or sides of the process value will be moni tored both Both 13 High 37 Low 53 Limit 1 Hysteresis Set the hysteresis for the limit func tion This determines how far into the safe range the process value must move be fore the limit can be cleared
84. trip set point Shorted solid state or mechanical relay Open solid state or mechanical relay Current transformer load wire associ ated to wrong output Defective current transformer or con troller Noisy electrical lines Security set to incorrect level Digital input set to lockout keypad Custom parameters incorrect EZ Key function incorrect 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 gotothe 5 Source Output In stance parameter Setup Page Current Menu to select the output that is driv ing the load Replace or repair sensor or controlle
85. volts thermistor T2 mA ac Current Transformer S2 mA ac PM mT B7 Common Digital Inputs D7 digital input or output PMI48 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 4 7 12 X1 X3 common Any switched dc output can use Switched dc open collector this common output 1 PM C _ W1 W3 dc open collector output 3 PM ec UO Y1 Y3 de W2 W4 dc Switched de o Y4 dce output 2 PM___ J Cl 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 _ E _ ___ J1 J3 normally closed output 3 PM __ E L2 L4 normally open NO ARC 15 A Form A K2 K4 common output 27PM H H ___ L2 L4 normally open Mechanical Relay 5 A Form A K2 K4 common output 2 PM J i output 4 PM _ _ J _ L1 L2 L3 L4 normally open Solid state Relay 0 5 A Form A K1 K2 K8 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 C 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 D
86. 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 together 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 ind
87. 0 to 5 537 000 C 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 300 0 F or units 150 0 C Startup 88 None 61 Blocked 12 Alarm low 8 Alarm high 7 Error 28 no No 59 JE 5 Yes 106 Parameter Appears in Menu When Alarm Sides Setup Page is not set to High Alarm Sides Setup Page is not set to Low None No param eter No param eter 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 Modbus Rela tive Address Instance 1 Ox6D 109 Map1 Map2 1to4 1482 1882 2 Offset to next instance Map 1 equals 50 Offset to next instance Map 2 equals 60 Instance 1 0x6D 109 Map1 Map 2 1to4 1480 1880 1 Offset to next instance Map 1 equals 50 Offset to next instance Map 2 equals 60 Instance 1 0x6D 109 Mapl1 Map 1 to 4 1496 1896 9 Offset to next instance Map1 50 Map 2 60 Instance 1 Map 1 Map2 1502 1902 0x6D 109 1 to 4 OxC 12 Offset to next instance Map1 1 equals 50 Map 2 equals 60 Watlow EZ ZONE PM Integrated Controller 47 Chapter 5 Operations Page Parameter name Description Display No Dis play No Dis play No Dis play Alarm 1 to 4 Alarm Clear Re quest Write to this register to clear an alarm Alarm 1 to 4
88. 00 F or units 1 110 555 to 5 555 000 C RTD Error Not Sourced Analog Input 1 to 2 Calibration Offset Offset the input read ing to compensate for lead wire resistance or other factors that cause the input read ing to vary from the actual process value CA i CA Always if part num ber digit 3 is C R J B E or N Linearization 1 to 2 Source Value A View the value of Source A Source A of Linear ization 1 is connected to Analog Input 1 Source A of Linear ization 2 is connected to Analog Input 2 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C PMS8 and 9 only Linearization 1 to 2 Offset Set an offset to be applied to this func tion s output 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C 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 Default Appears in Menu When Modbus Rela tive Address Instance 1 Map 1 Map2 360 360 Instance 2 Map 1 Map2 440 450 Instance 1 Map 1 Map2 362 362 Instance 2 Map 1 Map2 442 452 Instance 1 Map 1 Map2 382 382 Instance 2 Map 1 Map2 462 472 Instance 1 Map 1 Map2 3566 Instance 2 Map 1 Map2 3636 Instance 1 Map 1 Map2 3570 Instance 2 Map 1 Map2 Te 3640 CIP Class Instance Attribute hex dec 0x68 104 1to2 1 0x68 104 1to2 2
89. 0c cee ee eee 99 Using Lockout to Hide Pages and Menus 113 Using Password Security 0 0 cece ccc ee eens 113 Chapter 10 Applications 0 00 ccc ee eee 115 Example 1 Single Loop Control 00005 115 Example 2 Sensor Backup 00e cease 115 Example 3 Square Root 0 000 eee eee eee 115 Example 4 RaO resoni ason KANE AE REEERE AS 115 Example 5 Differential auauna 2 00 00 0 eee eee 116 Example 6 Cascade 020 sae eee eee eee 116 Example 7 Wet Bulb Dry Bulb 0 055 116 Example 8 Vaisala 0 00 cee eee eee 117 Chapter 11 Appendix 0 0 ccc cece eee eee 118 Troubleshooting Alarms Errors and Control Issues 118 Specifications 0 0 0 eee 121 Ordering Information for PM Integrated Controller Models 123 icm D Ride weed eee e a a ede baled 124 Watlow EZ ZONE PM Integrated Controller ele 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 co
90. 1 9 999 000 to 9 999 000 Current Offset Calibrate the current reading with an off set value Instance 1 0x73 115 Map 1 Map2 1 1140 1380 9xB 11 Instance 1 0x73 115 Map 1 Map2 1 1156 1396 0x13 19 Current 1 Output Source In stance Select which output instance the current transformer will monitor Current 1 Instance 1 0x73 115 Detection Thresh Map1 Map2 1 old 1142 1382 OxC 12 For factory adjust ment only 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 75 Chapter 6 Setup Page Parameter name Description Math 1 Function Set the operator that will be applied to the sources Special Output 1 Source Function E Set the type of func tion that will be used for this source Math 1 Source Instance Set the instance of the function selected above Math 1 Input Scale Low This value will cor respond to Output Range Low Math 1 Input Scale High This value will cor respond to Output Range High Math 1 Output Range Low This value will corre spond to Input Scale Low Math 1 Output Range High This value will corre spond to Input Scale High Math 1 Filter Filtering smooths out the output signal of this function block Increase the time to increase filtering Note
91. 12 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 19 e Chapter 2 Install and Wire Communications Terminal Function Configuration CB CB Modbus RTU EIA 485 T R Modbus RTU 232 485 Communications CA CA Modbus RTU EIA 485 T R Slot B PM6____ 2 AAA___ CC CC Modbus RTU EIA 485 common Slot E PMI489 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 5 AAA SH SH Shield interconnect Slot E PM 4 8 9 5 CL CL Negative side of DeviceNet bus V V DeviceNet M 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 El EtherNet IP and Modbus TCP transmit VP VP Voltage Potential Profibus Communications B B EIA 485 T R Slot B PM6___ 6 AAA
92. 47 73 Alarm Low Set Point 47 111 A L oc Profibus Address Lock 83 A o n b Implicit Output Assembly 86 RB Sd Alarm Sides 74 AS Alarm Silencing 74 112 AE SP Autotune Set Point 44 100 Attention 33 35 111 112 Alarm Type 73 111 Altitude Units 63 HUE Autotune 45 100 b P Barometric Pressure 63 Cool Algorithm 67 106 Calibration Menu 98 Cool Output Curve 67 105 Current Error 33 49 112 Current Error 33 Display Units 79 86 Channel 81 Current High Set Point 48 12 Cool Hysteresis 46 106 Communications LED Activ y 81 Current Low Set Point 48 12 Wait for Time 89 Control Mode 44 Control Mode Active 43 Public Key 96 Communications Menu 81 6 89 93 C P b Cool Proportional Band 45 01 107 Cool Power 44 101 Closed Loop Set Point 45 CSP CSP Closed Loop Working Set P oint 44 Current Read 49 Current Menu 48 75 Q m r3 Qa o PN Qa 3 j Q c Q 1 Pr 5 e Pm j F Pm o o Pm 3 m Pu Pm 09 C xo N 3 3 o a LO a gt a tm 1 a gt Lc m o A 3 a o 1 P3 Ru TRE Custom Menu 35 Date of Manufacture 96 Dead Band 46 108 Decimal 59 Digital Input Output Menu 2 63 Direction 63
93. 5 537 000 C Operations Page Default Parameter Appears in Menu When IN Modbus Rela tive Address Instance 1 Map 1 Map2 3572 Instance 2 Map 1 Map2 3642 Instance 1 Map 1 Map2 3614 Instance 2 Map 1 Map2 3684 Instance 1 Map 1 Map2 3310 Instance 2 Map 1 Map2 3380 Always if part number digit 3 is C R J B E or N PMS8 and 9 only Instance 1 Map 1 Map2 3312 Instance 2 Map 1 Map2 3382 Process Val ue Function Setup Page is not set to Off or Square Root Instance 1 Map 1 Map2 3324 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 7 0x86 134 1to2 0x1C 28 Ox7E 126 1 to2 0x10 16 Ox7E 126 1to2 0x11 17 Ox 7E 126 1to2 0x17 23 Watlow EZ ZONE PM Integrated Controller Chapter 5 Operations Page Parameter name Description Process Value 1 to 2 Output Value View the value of this function block s output Process Value 1 to 2 Output Error View reported cause for Process output malfunction 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
94. 8 Your Authorized Watlow Distributor CUSTOMER SATISFACTION Watlow EZ ZONE PM Integrated Controller 130 Chapter 11 Appendix
95. AM Instance 1 Map1 Map2 1508 1908 Offset to next instance Map 1 amp Map 2 equals 60 Instance 1 Map1 Map2 1512 1912 Type is not set to Off or devia tion Offset to next instance Map CIP Class Instance Attribute hex dec 0x76 118 lor3 7 0x6D 109 1to4 OxF 15 0x6D 109 1to4 0x11 17 1 amp Map 2 equals 60 0x6D 109 1to2 0x12 18 Instance 1 Map1 Map2 1514 1914 Instance 2 Map1 Map2 1564 1974 Alarm 1 to 2 Source Instance A Set the instance of the function selected above Type is not set to Off Alarm 1 to 4 Hysteresis Set the hysteresis for an alarm This deter mines how far into the safe region the process value needs to move before the alarm can be cleared Instance 1 0x6D 109 Map1 Map2 1to4 1484 1884 3 0 001 to 9 999 000 F or units 0 001 to 5 555 000 C Type is not set to Off Offset to next instance Map 1 equals 50 for Map 2 equals 60 Instance 1 0x6D 109 Map1 Map2 1to4 1488 1888 5 Close On Alarm 17 AL o Open On Alarm 66 Type is not set to Off Select what the out put condition will be during the alarm state 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 Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller
96. Assembly Size C_F Display Units PAAP Data Map CL Ed Communications LED Act nu 5 Non volatile Save ctCr SEL Real Time Clock hoUc Hour Minute Day of Week Watlow EZ ZONE PM Integrated Controller e 56 o Chapter 6 Setup Page Parameter name Description alog Input Menu Analog Input 1 to 2 Sensor Type Set the analog sen sor type to match the device wired to this input Note There is no open sensor detec tion for process inputs Analog Input 1 to 2 Linearization Set the linearization to match the thermo couple wired to this input Analog Input 1 to 2 RTD Leads Set to match the number of leads on the RTD wired to this input Unit Analog Input 1 to 2 Units Set the type of units the sensor will mea sure Analog Input 1 to 2 Scale Low Set the low scale for process inputs This value in millivolts volts or milliamps will correspond to the Range Low out put of this function block S hi Analog Input 1 to 2 Scale High Set the high scale for process inputs This value in millivolts volts or milliamps will correspond to the Range High out put of this function block Note Setup Page Parameter Default DD in Menu When oF F Off 62 Thermocouple 95 Mi
97. B 107 1 to 2 OxC 12 Instance 1 Map 1 Map2 2182 2662 Instance 2 Map 1 Map2 2262 2742 Ox6B 107 1 to 2 OxD 13 Instance 1 Map 1 Map2 2184 2664 Instance 2 Map 1 Map2 2264 2744 Input Error Failure is set to Manual Fixed Ox6B 107 1 to 2 OxB 11 Instance 1 Map 1 Map2 2180 2660 Instance 2 Map 1 Map2 2260 2740 Instance 1 0x97 151 Map 1 Map2 1to2 1922 2402 0x16 22 Instance 2 Map1 Map2 1992 2472 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 Chapter 6 Setup Page Note Parameter name Description Control Loop 1 to 2 Open Loop Detect Time The Open Loop De tect Deviation value must occur for this time period to trigger an open loop error Control Loop 1 to 2 Open Loop Detect Deviation Set the value that the process must deviate from the set point to trigger an open loop error Control Loop 1 to 2 Ramp Action Select when the con troller 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 parameter Control Loop 1 to 2 Low Set Point Set the minimum value of the closed loop set point ra
98. Chapter 6 Setup Page Parameter name Description Alarm 1 to 4 Both 13 Sides High 37 Select which side or Low 53 sides will trigger this alarm Alarm 1 to 4 Latching Turn alarm latching on or off A latched alarm has to be turned off by the user Alarm 1 to 4 Blocking Select when an alarm will be blocked After start up and or after the set point changes the alarm will be blocked until the pro cess value enters the normal range Alarm 1 to 4 Silencing Turn alarm silencing on to allow the user to disable this alarm Off 62 both Both 13 oF F Off 62 On 63 Alarm 1 to 4 A dSP Display Display an alarm message when an alarm is active Off 62 On 63 Note Non Latching 60 Latching 49 Startup 88 Set Point 85 Setup Page pend Modbus Rela Default APP tive in Memm Address When Both Type is not Instance 1 set to Off Map1 Map2 1486 1886 Offset to next instance Map 1 equals 50 for Map 2 equals 60 Non Type is not Instance 1 Latching set to Off Map1 Map 2 1492 1892 Offset to next instance Map 1 equals 50 for Map 2 equals 60 Type is not Instance 1 set to Off Map 1 Map 2 1494 1894 Offset to next instance Map 1 equals 50 for Map 2 equals 60 Off Type is not Instance 1 set to Off Map 1 Map 2 1490 1890 Offset to next instance Map 1 equals 50 for Map 2 equals 60 Type is not Instance 1 set to O
99. D Without Communications slot E Input Function Input Sensor 1kQ Thermistor 5kO 10kO 20kO 40kQ Process V mV mA or 1k 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 PC MI orH Power Supply Analog Input 1 none Thermocouple RTD 1000 Potentiometer Analog Input 2 none CT Thermocouple RTD 100 Q 1kQ Thermistor 5kO 10kO 20kQ 40kQ Process V mV mA or 1k Potentiometer Digital Input or Output 7 12 optional Programmable Functions Digital Input or Output 5 amp 6 optional Programmable Functions EZ Key 1 amp 2 Programmable Functions 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 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 rm A or Slots A 5A
100. Digital Output State 42 Day of Week 87 Display Pairs 56 81 Display Time 81 Ethernet IP Enable 86 Event Input Status 42 Electrical Input Offset 98 02 Electrical Input Slope 98 02 Electrical Output Offset 98 Active Event Output 1 53 Event Output 2 91 Error Input 1 or 2 k Input Error Failure 68 105 Digital Output Function Instance 64 66 Output Function Instance 0 72 Filter 58 Function 62 Output Function 70 71 Function Key Menu 78 Global Menu 79 Guaranteed Soak Deviation o Guaranteed Soak Deviation 80 Guaranteed Soak Deviation 80 Guaranteed Soak Enable o Guaranteed Soak Enable Heat Algorithm 67 106 Heater Error 33 49 112 Heater Error 33 Heat Hysteresis 45 106 Hours 86 01 107 Heat Power 43 101 Calibration Offset 40 02 103 Idle Set Point 45 E c Input Error Latching 59 Er Input Error Status 40 Input Point 1 60 ES Input Point 2 4 B 3 Input Point 3 Heat Proportional Band 45 id Input Point 4 60 25 O o ly o d in d o D J d tn o o 5 5 hy D hy fU qo Input Point 2 60 Input Point 3 60 Input Point 4 60 Input Point 5 60 61 Input Point 6 61 Input Point 7 61 Input Point 8 61 Input Point 9 62 Input Point 10 62 IP Fixed Address Part 1 84 N IP Fixed Address Part 2 84 co hy
101. E PM controllers on a network maximum network length 1 200 meters 4 000 feet 1 8th unit load on EIA 485 bus PM 4 6 8 9 _ All models include Standard Bus communications instance 1 Modbus RTU or Standard Bus EIA 485 Communications Slot C CC common cal CB 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 4 6 8 9 _ Il EIA 232 485 Modbus RTU Communications 485 T R 485 T R 485 common 485 T R 485 T R 232 common 232 TX to DB9 pin 2 RD 232 RD to DB9 pin 3 TX Wire T R to the A terminal of the EIA 485 port
102. EZ ZONE PM User s Manual Integrated Controller Models TOTAL CUSTOMER SATISFACTION bh ad ISO 9001 Le x d WwW se AA NG IJ LJ SUT 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 G Made in the U S A November 2009 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 pro
103. IO Digital input update rate 10Hz DC voltage Max input 36V 3mA Min high state 3V at 0 25mA Max low state 2V Dry contact e Min open resistance 10KQ Max closed resistance 500 Max short circuit 20mA Digital output update rate 10Hz Output voltage 24V current limit Output 6 10mA max Output 5 3 pole DIN A MITE or 24mA max 6 Digital Input Output Option 6 DIO Digital input or output Update rate 10Hz 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 OutputHardware e Switched dc 22 to 32V dc 30mA 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
104. L 50Type4X NEMA4Xindoorlocations IP66 front panel seal 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 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 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 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 e EIA232 485 Modbus RTU EtherNet IP DeviceNet ODVA certified e 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 e gt 20MO input impedance 3p open sensor
105. Map2 1346 1586 Instance 1 Map1 Map2 886 1006 Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Setup Page Parameter CIP Modbus Rela Class Parameter name faul Appears S Description Default in Menu tive Instance Attribute hex dec Global Menu Rate 81 Time If 4th digit Instance 1 Ox7A 122 Ramping Type E Time 143 in controller Map 1 Map 2 1 part num 26 38 ber is an R B N or E Global Menu Set Point 85 Set Point If 4th digit Instance 1 Ox7A 122 Profile Type Process 75 in controller Map 1 Map 2 1 Set the profile start part num 2534 4354 8 up to be based on a ber is an R set point or a process B N or E value Global Menu oF F Off 62 Off If 4th digit Instance 1 Ox7A 122 Guaranteed Soak 55 0n 63 in controller Map 1 Map 2 1 Enable part num 2530 4350 6 Enables the guaran ber is an R teed soak deviation B N or E function in profiles Global Menu 0 0 to 9 999 000 F or units 10 0 F or If 4th digit Instance 1 0x7A 122 Guaranteed Soak 0 0 to 5 555 000 C units in controller Map 1 Map 2 1 Deviation 1 6 0 C part num 2532 4352 7 Set the value of the ber is an R deviation band that B N or E will be used in all profile step types The process value must enter the devia tion band before the Step can proceed Global Menu 0 0 to 9 999 000 F or units Guaranteed Soak 0 0 to 5 555 000 C Deviation 2 Set the value of the ber is an R
106. ONG um Range Default Appears in Modbus Rela Instance Description Menu When tive Address AIR hex dec Profile Status 0 to 9 999 000 seconds Always Instance 1 Ox7A 122 Step Time Remain Map 1 Map2 1 ing 2536 4356 9 View or change the time remaining for the current step Step is displayed in seconds If the time exceeds 9 999 seconds the display will show 9 999 and remain there while the control contin ues to decrement internally Once the remaining time is equal to or less than 9 999 the display will represent the actual seconds re maining As an example if a three hour soak time is currently being monitored the first value displayed will be 9 999 and the display will remain at 9 999 until the remaining time is approximately equal to 2 hours and 46 minutes At this point the display will track the actual seconds remaining Profile Status oF F Off 62 Off Always Instance 1 Ox7A 122 Active Event Out on On 63 Mapi Map 2 1 put 1 2546 4366 OxE 14 View or change the event output states Profile Status oF F Off 62 Instance 1 0x7A 122 Active Event Out on On 63 Mapi1 Map2 1 put 2 2548 4368 OxF 15 View or change the event output states Profile Status 0 to 9 999 Always Instance 1 Ox7A 122 Jump Count Re Mapi1 Map2 1 maming 2538 4358 OxA 10 View the jump counts remaining for the current loop In a profile with nested loops this may not indicate the actual jump counts rema
107. 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 interfaces K Write EEPROM S User Set Watlow EZ ZONE PM Integrated Controller e 89 o Chapter 7 Profiling Page Parameter name Description Step Type Parameters Seconds Select the seconds plus Hours and Minutes for a timed step Step Type Parameters Wait For Process In stance Select which analog input Wait For Process will use Step Type Parameters Wait For Process Value Select which analog input Wait For Process will use Step Type Parameters Wait For Process Value Select which analog input Wait For Process will use Step Type Parameters Wait Event 5 12 Select the event state that must be satisfied during this step Digital input 5 provides the state of Event 1 and digital input 6 pro vides the state of Event 2 Step Type Parameters Wait Event 5 12 Select the event state that must be satisfied during this step Digital input 5 provides the state of Event 1 and digital input 6 pro vides the state of Event 2 Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Profiling Page Default 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 Off 62
108. P Fixed Address Part 3 84 97 IP Fixed Address Part 4 81 84 97 IP Fixed Subnet Part 1 84 IP Fixed Subnet Part 2 85 IP Fixed Subnet Part 3 85 IP Fixed Subnet Part 4 85 J Jump Count 91 Jump Count Remaining 53 54 Jump Step 91 K keys 32 L Latching 74 111 Level 78 Limit Menu 43 66 Linearization 55 57 Linearization Menu 40 59 Locked Access Level 95 Lock Operations Page 113 Lockout Menu 113 Lock Profiling Page 113 Logic 73 Loop Menu 44 Low Power Scale 64 71 low range 103 low scale 103 Low Set Point Alarm 47 111 Current 48 112 Limit 43 Loop 69 103 Manual Control Indicator Light 106 manual open loop control 105 manual tuning 100 Math 56 Math Menu 49 76 Message Action 33 message display 33 Watlow EZ ZONE PM Integrated Controller 126 Chapter 11 Appendix Minimum Off Time 56 Minimum On Time 56 Minutes 89 Modbus Register Mapping 56 Modbus TCP 30 Modbus TCP Enable 86 Modbus Word Order 82 Monitor Menu 43 N navigating Factory Page 92 pages and menus 33 Profiling Page 88 Setup Page 39 55 No arc Relay 104 Non volatile Save 56 O on off control 106 Open Loop Detect Deviation 69 Open Loop Detect Enable 68 Open Loop Detect Time 69 Open Loop Set Point 46 Operations Page 39 ordering information integrated controller models 123 output activity lights 32 output configuration 105 Output Function 71 Output Menu 70 Output Point 1 55 Output Point 2 55 Output
109. Point 3 55 Output Point 4 55 Output Point 5 55 Output Point 6 55 Output Point 7 55 Output Point 8 55 Output Point 9 55 Output Point 10 55 output power scaling 105 outputs 4 Output State 42 Output Type 71 P P3T armor sealing system 2 Parameter 1 to 20 93 Parity 82 Part Number 96 Password 96 Peltier Delay 55 68 percent units indicator light 32 Power Off Level A 56 Power On Level A 56 Power Out Time 56 81 Pressure Units 55 process alarms 111 Process Error Enable 58 Watlow EZ ZONE PM Integrated Controller Process Error Low 58 Process Value 40 55 62 Process Value Active 44 Process Value Menu 41 Profibus Address Lock 83 Profibus DP 30 38 Profibus Node Address 83 profile activity light 32 Profile Status Menu 51 Profile Type 80 Profiling Page 88 profiling parameters 88 programming the Home Page 100 proportional control plus integral PI control 107 plus integral plus derivative PID control 107 Protocol 81 Public Key 96 Q R Ramp Action 69 Ramp Rate 69 108 Ramp Scale 69 108 Range High 58 72 103 Range Low 58 72 103 Ratio Control 110 Read 49 112 Read Lockout Security 113 Real Time Clock 56 receiving a remote set point 104 Remote Enable 44 104 restoring user settings 100 retransmit 104 Retransmit Source 71 Rolling Password 95 RTD Leads 57 S saving user settings 100 Scale High 57 72 103 Scale Low 57 72 103 Seconds 90 secure settings 99 113 Securi
110. SA International for 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
111. SS 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 Output 2 4 Mechanical Relay Form A Slot A B 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 I 100 000 cycles at rated load COX eg I normally open r Output does not supply power for use with ac or dc See Quenchare note ccc Output 1 L2 K2 PM __ J Output 3 L4 K4 PM J common Output 2 4 Solid State Relay Form A 0 5 A at 20 to 264V ac maxi Slot A B mum resistive load 20 VA 120 240V ac pilot duty opto isolated without contact suppression maximum off state leakage of 105 microamperes A A y normally open Output does not supply power Do n
112. Scale 5 Set the ramping rate with Ramp Rate Setup Page Loop Menu Set Point Temperature Temperature reaches Set Point quickly Time Heating System without Ramping Set Point Temperature Temperature ramps to Set Point at a set rate Time Heating System with Ramping Watlow EZ ZONE PM Integrated Controller 108 Chapter 9 Features Cascade Control The PM PM8 9 can be configured for Cascade con trol 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 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 acceptable error Curve C represents a single control system tuned to minimize overshoot This results in unac ceptable heat up rates taking hours to reach the final value Curve B shows a cascade system that 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 i
113. TCP DeviceNet EtherNet IP Profibus Slots E RUI EZ ZONE Optional Controllers PLC PC or HMI 4 E EIA 485 Communication lt Standard Bus optional Modbus RTU 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 alarm or event off heat cool retransmit alarm duplex or event off heat cool gt alarm event or limit Digital Output or Input 5 amp 6 optional none switched dc off heat cool alarm or event i y Indicates Zone Address amp Channel Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail LEDS A a E 12522 A 3 4 5 3 7 8 Indicates I O Status Watlow EZ ZONE PM Integrated Controller e 12 e Chapter 1 Overview Chapter 2 Install and Wire 1 16 DIN PM6 Dimensions 15 8 mm 0 62 in 101 6 mm 4 00 in 53 3 mm 2 10 in CL e A N O d Lj E il T O a D it 53 3 mm i D 2 10 in ae i T 0 i sects dr Side
114. 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 Unsigned 16 bit integer Signed 16 bit 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 http www odva org Profibus DP To accomodate for Profibus DP addressing the follow ing
115. 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 CE Resume running the profile from the previously paused step Eng End the profile EEP Begin running the profile from the spec ified step number as Note Avoid continuous writes within loops Excessive writes to EE PROM will cause premature EEPROM failure The EEPROM 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 Wait For Event 1 Wait for Event 2 Day of Week Jump Step Jump Count End Type Event 1 Event 2 c c em c c e fu a o C C c WN C F3 m 3 Fr m 3 nr fu Watlow EZ ZONE PM Integrated Controller 88 Chapter 7 Profiling Page Profiling Page Parameter name Default Parameter Modbus CIP Description Appears in Relative Ad Class Menu When dress Instance Attribute hex dec 1 to 10 profile 1 Always 11 to 20 profile 2 21 to 30 profile 3 31 to 40 profile 4 Unused Step 50 Unused Always Instance 1 Select a step type End 27 Map1 Map2 Note Jump Loop 116 2570 4500 When configuring the Wait For Time profile typ
116. ability 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 B5 D6 D5 common collector out collector out 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 dc PM 24 Digital Output 7 12 Slot E B7 D7 D8 D9 D10 D11 D12 Z7 Common Collector out Collector out Collector out Collector out Collector out Collector out Supply nternal supply provides a constant power output of 750mW Maximum output sink current per output is 1 5A external class 2 or SELV supply required Total sink current for all outputs not to exceed 8A Do not connect outputs in parallel PM 46 8 _ C D _ _ Open Collector Outputs B7 common D7
117. able with the PM4 8 and 9 only 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 Advance Key Advances through para meter prompts N 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 32 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 D Parameter Name Setting Description 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 response
118. ages top level menus Press and hold the Infinity Key for two seconds are identified with a yellow background color to return to the Home Page Press the Advance Key to enter and view avail able prompts within a menu 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 submenus will appear Ai oPB Output Point 8 CC c Cool Output Curve SEE Analog Input Menu 3 Input Point 9 Et Un Tru Tune Enable 4 to o 3 Output Point 9 E bnd Tru Tune Band Analog Input Input Point 10 En Tru Tune Gain SEn Sensor Type Output Point 10 t 49 Autotune Aggressiveness L n Linearization Pu PdL Peltier Delay r tL RTD Leads Process Value r En Remote Set Point Enable Un t Units C F to c ES Remote Set Point Type SL o Scale Low C Py Process Value UFA User Failure Action uU S5 J Scale High Panction aede oe Se teil Hd Pressure Units L d E Open Loop Detect Enable r h Range High Altitu
119. ance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 1018 1138 Offset to next instance Map 1 amp Map 2 equals 30 CIP Class Instance Attribute hex dec 0x6A 106 5 to 12 6 0x6A 106 5 to 12 2 Ox6A 106 3 0x6A 106 5 to 12 9 Ox6A 106 5 to 12 OxA 10 Watlow EZ ZONE PM Integrated Controller e BE a Chapter 6 Setup Page Parameter name Description Digital Input 5 to 6 Level Select which action will be interpreted as a true state Digital Input 7 to 12 Level Select which action will be interpreted as a true state Digital Input 5 to 12 Action Function Select the function that will be trig gered by a true state for Digital Inputs 5 through 12 Note Setup Page h 9h High 37 Lobu Low 53 High 37 Lobu Low 53 on None 61 J Profile Start Stop level triggered 208 Pr oF Profile Start Number edge triggered 196 PHoL Profile Hold Resume level triggered 207 Pd 15 Profile Disable level triggered 206 Ed A TRU TUNE Dis able level triggered 219 oF F Control Outputs Off level triggered 90 PAn Manual Auto Mode level triggered 54 E Un E Tune edge triggered 98 idl E Idle Set Point Enable level triggered 107 AL Force Alarm level triggered 218 AoF Alarm Outputs amp Control Loop Off level trig gered 220 Silence Alarms edge triggered 108 L Alarm Reset edge
120. at 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 PAn 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 Loop prior to sensor failure and that power level is Watlow EZ ZONE PM Integrated Controller e 105 Chapter 9 Features less than 75 percent 4 Set Point Actual Temperature p Sensor Break Temperature 100 Output Power 40 Power lt 2 minutes Locks in Output 0 Power Time gt 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
121. ate 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 0 5 A at 20 to 264V ac maxi mum resistive load 20 VA 120 240V ac pilot duty opto isolated without contact suppression e 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 common K PM IK s Output 3 L3 K3 PM use aK een 1 Amp SSR Derating Curve Amps RMS easy buneiedo ayes 20 10 0 10 20 30 40 50 60 70 Ambient Temperatue C Output 2 4 Switched DC Slot A B SA e 10 mA DC maximum supply cur rent e short circuit limited to lt 50 mA e 22 to 32V dc open circuit volt age dc use dc and dc to drive external W solid state relay DIN A MITE compatible single pole up to 2 in series none in parallel Output 1 W2 Y2 dc lt PM C E Output 3 W4 Y4 PM C __ T common 1 fer i TR dc ee eee ee ae uei Output 2 4 NO ARC Relay Form A Slot A B 15 A at 85 to 264V ac resis tive load
122. atlow EZ ZONE PM Integrated Controller e 101 Chapter 9 Features 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 mode TRU TUNE continu ously tunes to provide the best possible PID control for the process AN 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 Inputs Calibration Offset Calibration offset allows a device to compensate for an inaccurate sensor lead resistance or other factors that affect the input value 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 M 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 Sensor Type High Source thermoco
123. 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 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 O 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 display 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 hystere
124. ay 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 123 e Chapter 11 Appendix Index Abt Alarm Blocking 74 112 AC Line Frequency 79 Alarm Delay 75 Alarm Display 74 Alarm High Set Point 47 11 Alarm Hysteresis 73 111 Analog Input Menu 40 57 Implicit Input Assembly 86 Alarm Source Instance 73 Alarm Latching 74 111 ALE C ALESALEY larm Error 1 to 4 33 A AL 9 Alarm Logic 73 ALAC RL h 3 RL h 4 Cur rr x l Alarm High 1 to 4 33 l ALL MALL SALLY Alarm Low 1 to 4 33 Alarm Menu
125. 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 Watlow EZ ZONE PM Integrated Controller 106 Chapter 9 Features have a separate proportional parameter The heating parameter takes effect 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 Adjust the proportional band with Heat Pro portional Band or Cool Proportional Band Operations Page Loop Menu A Set Point ie Proportional Band 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 t
126. ce Menu When dress Attribute hex dec Profibus Index Parameter name Security Setting Customer Specific CodE Public Key If Rolling Pass word turned on generates a ran dom number when power is cycled If Rolling Password is off fixed number will be displayed Security Setting Password Number returned from calculation found in Features section under Password Security j j 15 characters Instance 1 0x65 101 string Part Number only 1 RWE Display this 9 controller s part number Diagnostics Menu 1 to 10 Always 0x65 101 string Software Revi 1 R sion 0x11 17 Display this con troller s firmware revision number Diagnostics Menu 0 to 2 147 483 647 Always Instance 1 0x65 101 dint Software Build Map1 Map2 1 R Number 8 8 5 Display the firm ware build num ber Diagnostics Menu 0 to 2 147 483 647 Serial Number Display the serial 0x65 101 string 1 RWE 0x20 32 number Diagnostics Menu 0 to 2 147 483 647 Instance 1 0x65 101 dint Date of Manufac Map1 Map2 1 RWE ture 14 14 8 Display the date code Diagnostics Menu DHCP 1281 If Ethernet li IP Address Mode Fixed Address card pres Actual address 1284 ent see mode DHCP or part num Fixed ber Note Some values will be rounded off to fit in the four character display Full values can be read with ae other interfaces If there is only one instance of a menu no submenus will appear Watlow EZ ZONE PM I
127. 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 Closed 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 N Autotune Set Point 90 percent of Process Set Point Temperature Time Watlow EZ ZONE PM Integrated Controller 100 Chapter 9 Features 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 Go to 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 sys
128. cription 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 value 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 Step Type Parameters Profile Event Output A Select whether Event Out put 1 or 2 is on or off during this step Step Type Parameters Profile Event Output B Select whether Event Out put 1 or 2 is on or off during this step Profiling Page Range Default 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 Hol d Hold last closed loop set point in the profile 47 User reverts to pre vious set point 100 oF F Off 62 on On 63 Off 62 On 63 Parameter Appears in Menu When If real time clock is present Map 1 and StepType is set to Wait for Time Step Type is set to Jump Loop Step Type is set to Jump Loop Step Type is set to End Step Type is set to Time Rate Soak Wait Event Wait for Pro cess Wait for Both or Jump Loop Step Type is set to Time Rate Soak Wait Event Wait for Pro cess Wait for Both or Jump Loop Some values will be rounded off to fit in the four characte
129. d with other interfaces Available with PM4 PM8 and PM9 models only CIP Class Instance Attribute hex dec Ox 7E 126 1 to2 0x16 22 Profibus 0x86 134 1to2 0x1B 27 0x6A 106 5 to 6 7 0x6A 106 7 to 12 7 Ox6E 110 1to2 5 Ox6E 110 5 to 10 5 Watlow EZ ZONE PM Integrated Controller Chapter 5 Operations Page Parameter name Description Display No Dis EZ Key s 1 to 2 play Event Status View this event input state Off 62 on On 63 Limit 1 Low Set Point Set the low process value that will trig ger the limit Limit 1 High Set Point Set the high process value that will trig ger the limit Limit 1 Limit State Clear limit once limit condition is cleared 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 Off 62 None 61 Limit High 51 Limit Low 52 Error 225 Limit 1 Clear 1131 Limit Clear Request Clear limit once limit condition is cleared Pon onitor Menu Monitor 1 to 2 Control Mode Ac tive View the current con trol mode oF F Off 62 RUE o Auto 10 PAA Manual 54 Monitor 1 to 2 Heat Power View the current heat output level 0 0 to 100 0 Note Operations Page Parameter Default Appears in Menu When Limit Sides Setup Page is not set to Limit Sides Setup Page is not set to model
130. de Units E PEE Process Error Enable CBP L d t Open Loop Detect Time PEL Process Error Low bici Barometric Pressure L d d Open Loop Detect Deviation F L Filter fi L C Thermistor Curve c P Ramp Action C Re sistance Range Digital Input Output Menu c 5L Ramp Scale F Filter C 5 to r r t Ramp Rate Er Error Latching Digital Input Output LSP Low Set Point dE C Display Precisiom hSP High Set Point d r Direction e a FaF ti SPL o Set Point Open Limit Low uncon Ph Set Point Open Limit High Linearization Menu Function Instance hto e of E Control EE L ae Linearization o t b Time Base SEE es Menu n Function o L o Low Power Scale to Un re Units High Power Scale ot SEP Output P I Input Point 1 Lan F n Function oP I Output Point 1 Limit Menu F_ Function Instance oP Output Point 2 UPT Limit ot b Time Base P 3 Input Point 3 EO icd oL o Low Power Scale oP J Output Point 3 o h High Power Scale I t Point 4 L Lh J Hysteresis ot Pt Output 1 3 process iPd input rom SPL h Set Point Limit High eae o E amp PL L Set Point Limit Low t rnb don nput Poin s PS Output Point 5 LL E Limit Integrate F Function Instance P 6 Input Point 6 SL o Scale Low oPb5 Output Point 6 GEE Control Loop Menu 5h Scale High P 1 Input Point 7 to rL o Range Low oP 1 Output Point 7 LooP Control Loop r h Range High P B Input Point 8 R9 Heat Algorithm oL RJ Calibration Offset CA9 Cool A
131. ded 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 97 Chapter 8 Factory Page EL 1S ELi S Parameter name Description Calibration Menu 1 to 2 Electrical Mea surement Read the raw electrical value for this input in the units correspond ing to the Sensor Type Setup Page Analog Input Menu setting Calibration Menu 1 to 2 Electrical Input Offset Change this value to calibrate the low end of the in put range Calibration Menu 1 to 2 Electrical Input Slope Adjust this value to calibrate the slope of the input 1 999 000 to 9 999 000 Factory Page Parameter Default Appears in Menu When Modbus Relative Ad dress Instance 1 Map1 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 CIP Class Ee Profibus Index Attribute hex dec 0x68 104 1to2 0x15 21 0x68 104 1to2 0x68 104 1 to2 OxB 11 value Instance 1 0x76 118 Map1 Map2 728 848 Instance 3 Map1 Map2 808 928 the control ler has process outputs 1 or 3 Calibration Menu 1 or 3 Electrical Output Offset Change this value to calibrate the low end of the out put range Menu 2 calibrate
132. detection Max of 2KO source resistance e RTD 2 or 3 wire platinum 1000 and 10000 0 C calibration to DIN curve 0 003850 0 C Watlow EZ ZONE PM Integrated Controller Process 0 20mA 1000 or 0 10V dc 9 20kO input imped ance scalable 0 50mV 0 10000 Potentiometer 0 to 1 2000 nverse scaling Accuracy Accuracy Input Type Pairs o w nec Ges xs o so nec rewon xs 3 o oec PN ees o ro rec 8 me w w vec r e o uo rec s e o uo rec s aee m ro pec o aam o rs pec 5 sm o s vec rem am one Tre En ooa au amr o mec F PTID RTD 100 ohm RTD 1000 ohm Potentiometer 1K range Resistance 5K range Resistance 10K range 1200 5000 10000 Chapter 11 Appendix Operating Range cont Resistance 20K range ih Resistance 40K range o 0 Thermis Thermis Thermis tor 20K range Thermis tor 40K range 0 to 40K9 0 to 20KQ 0 to 10KO 0 to 5KO e 2 252KO and 10KO base at 77 F 25 C e Linearization curves built in e Third party Thermistor compatibility requirements Prompt Alpha Beta 25C Techniques THERM a curves mma f oe 2 ik cure 104A 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 D
133. 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 between 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 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 0 525 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 Warning e This equipment is suitable for use in class 1 div 2 Groups A B C and D or Non Hazardous locations only Temperature Code T4A e WARNING EXPLOSION HAZARD Substitution of component may impair suitability for class 1 div 2 e WARNING EXPLOSION HAZARD Do not disconnect equip ment unless power has been switched off or the area is known to be nonhazardous 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 s
134. e 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 Watlow EZ ZONE PM Integrated Controller e 116 Chapter 10 Applications Wet Bulb Dry Bulb I C 8 os l i SN 1 v So 1 Or VO I I Output n I i 0 to 100 1 1 Heat I i Analog Input 1 Source A Heat Power i 1 Cool Power I L Control Li 1 tool l OnO ROR 0 to 100 i I Temperature Output n I I E 1 nn A 1 I KA KA I I I l Source A I Analog Input 2 Source B Output o o 1 PV Function So IA 1 0 Op I ing Yo I 2 I Outputn 0 to 100 I L Heat l 1 Source A Heat Power I
135. e 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 caution Changing parameters via the Profile Status Menu will not change the stored profile but will have an immediate impact on the profile that is running Profiling Parameters to PY ProF Cito 10 S5 YP Step Type E SP I Target Set Point Loop 1 t 5P2 Target Set Point Loop 2 hoUrc Hours P in Minutes SEC Seconds b UP Wait For Process Instance Lb UP I Wait For Process 1 How to Start a Profile After 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 O 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
136. e 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 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
137. e filter time interval with Filter Time Setup Page Analog Input Menu Example With a filter value of 0 5 seconds if the process input value instantly changes from 0 to 100 and remained at 100 the display will indicate 100 after five time constants of the filter value or 2 5 seconds A Unfiltered Input Signal Temperature Time Filtered Input Signal Temperature Time 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 sensor 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 T Range High Range between High Limit of Sensor and Range Low Set Point High A Set Point Range
138. e net work must have a unique address Communications 2 IP Fixed Address Part 4 Set the IP address of this module Each device on the net work must have a unique address Communications 2 IP Fixed Address Part 5 Set the IP address of this module Each device on the net work must have a unique address Communications 2 IP Fixed Address Part 6 Set the IP address of this module Each device on the net work must have a unique address Communications 2 IP Fixed Subnet Part 1 Set the IP subnet mask for this mod ule Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces If address mode is set to fixed If address mode is set to fixed i i 0 to 255 1 If address mode is set to fixed If address mode is set to fixed fixed 0 to 255 If address mode is set to 0 to 255 0 to 255 If address mode is set to fixed If address mode is set to 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 2 IP Fixed Subnet Part 2 Set the IP subnet mask for this mod ule Communications 2 IP Fixed Subnet Part 3 Set the IP subnet mask for this mod ule Communications 2 IP Fixed Subnet Part 4 Set the IP subnet mask for this mod ule Communications 2 IP Fixed Subnet
139. e 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 internal 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 EZ ZONE PM Integrated Model 1 16 DIN System Diagram With a Current Transformer Without Communications Card Slot B Input Functions PID Controller Analog Input 1 none Thermocouple RTD 1000 Optional Ramp Soak max 4 files 40 steps Output 1 none switched dc open collector 5A mechanical relay form C process V mA or 0 5A SSR form A Input Sensor gt 1kQ Thermistor 5KQ 10kQ 20kQ 40kQ 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 Digital Input or Output 5 amp 6 optional none switch volts dc Output 2 none 15A NO ARC switched dc Slot A 5A mechanical relay form A or Optional 0 5A SSR form A O us Addre
140. e 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 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 a universal process output output 2 cannot use variable time base fixed time base only When output 3 is configured as a universal 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 SE PE 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
141. e there will be Offset to next a Wait For Both 210 instance Map tory default If rate is Wait For Process 1 equals 50 desired navigate to the Map 2 equals Setup Page and then the LE Wait For Event 144 100 Global Menu where Soak 87 Ramping Type can be Time 143 changed Rate 81 Step Type Parameters 1 999 000 to 9 999 000 F Step Type is Instance 1 0x79 121 float Target Set Point loop 1 or units i set to Time Map1 Map2 1to40 RWE Select the set point for this 1 128 to 5 537 000 C Rate Wait for 9579 4502 2 step Process or Wait for Both cda Offset to next instance Map 1 equals 50 Map 2 equals 100 Step Type Parameters 1 999 000 to 9 999 000 F Step Type is Instance 1 0x79 121 float Target Set Point loop 2 or units i set to Time Map1 Map2 1to40 RWE Select the set point for this 1 128 to 5 537 000 C Rate Wait for 4554 Ox1C 28 step Process or Wait for Both and loop 2 is pres ent Offset to next instance Map 2 equals 100 Step Type Parameters Step Type is Instance 1 0x79 121 uint Hours setto Timeor Map1 Map2 1to40 RWE Select the hours plus Soak 2574 4504 3 Minutes and Seconds for a timed step Offset to next instance Map 1 equals 50 Map 2 equals 100 Step Type Parameters Step Type is Instance 1 0x79 121 uint Minutes set to Time or Map1 Map2 1to40 RWE Select the minutes plus Soak 2576 4506 4 Hours and Seconds for a a
142. enus and parameters may not appear depending on the controller s options See model number infor mation in the Appendix for more information If there is only one instance of a menu no submenus will appear CUSE Pau Electrical Measurement FCEY Custom Setup Menu Electrical Input Offset to EL 5 Electrical Input Slope CUSE Custom Setup EL o o Electrical Output Offset P4 Parameter Electrical Output Slope d Instance ID Lol FCE J Security Setting Menu Lol Security Setting LoCo Operations Page LoCP Profiling Page Password Enabled Read Lock Write Security Locked Access Level Rolling Password User Password Administrator Password Rs m ui m 3 r o m r o F4 r o e p 5 o r r o 7o un c o 70 UN m cz r3 r7 rro uC e Un c urity Setting Menu Public Key Password gt o Q m D 7o Un WN W ir Ct J Diagnostics Menu d A9 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 IP Actual Address Part 4 IP Actual Address Part 5 IP Actual Address Part 6 3 1 j Q a rr m D Ru r1 D d RS Ru ry D xO ET d x L d A A UN
143. esent the first 2 pairs will be the same in that the first pair will represent 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 gt 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 e 35 e Chapter 4 Home Page Possible Home Page Defaults Dependent on Part Number Op Op Home Page Iis es Parameter Page and Menu Active Process Value 1 beoe Operations Page Monitor Menu Rb daa erations Page Monitor Menu Active Set Point 1 IF 9th digit of PN is equal to MITTIT Numerical IF 9th digit of PN is equal to IA C J R P T X Active Process Value
144. essor Special Out put Func tion Setup Page is set to Se quencer or Motorized Valve 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 Map1 Map2 1 AEN 3056 Ox1D 29 Modbus Rela tive Address Profibus Index Instance 1 Mapi Map2 3852 Instance 1 Map 1 Map2 3854 0x87 135 1 7 1 0x87 135 8 Instance 1 0x87 135 Map 1 Map2 1 aes 3858 OxA 10 Instance 1 0x87 135 Map1 Map2 1 Souk 3862 OxC 12 Watlow EZ ZONE PM Integrated Controller 50 Chapter 5 Operations Page Parameter name Description Display No Dis play tion 1 Output Error View reported cause for output malfunc tion Profile Status Menu Profile Menu appears if PM R B N E Profile Status Profile Start Select step to act upon Profile Status Action Request Profile Status Active Step View the currently running step Profile Status Active Step Type View the currently running step type Note Special Output Func Operations Page Parameter Default Appears in Menu When Modbus Rela tive Address 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
145. f 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 4 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 eter As an example look in the Operations Page for the Process Value Find the column identified in the heade
146. ff Map 1 1510 1910 Map 2 Offset to next instance Map 1 equals 50 for 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 0x6D 109 1to4 4 0x6D 109 1to4 7 0x6D 109 1to4 8 0x6D 109 1to4 6 0x6D 109 1to4 0x10 16 Watlow EZ ZONE PM Integrated Controller e 74 e Chapter 6 Setup Page Setup Page Parameter CIP Modbus Rela Class Parameter name Defaul Appears Description efault in Menu me perdis ress ttribute When hex dec 0 to 9 999 seconds Type is not Instance 1 0x6D 109 set to Off Map 1 Map 2 1to4 Set the span of time 1520 1920 0x15 21 that the alarm will be delayed after the process value exceeds the alarm set point Offset to next instance Map 1 equals 50 for Map 2 equals 60 Current Menu Current 1 oF F Off 62 Sides h 9h High 37 Select which side or Lob Ji Low 53 sides will be moni een tored both Both 13 Current 1 No 59 Read Enable Yes 106 Display under over range current Always if Instance 1 0x73 115 inpart 1198 1368 5 number is wpe Instance 1 0x73 115 Map 1 Map2 1 1126 1366 4 Current 1 0 to 9 999 000 Scaling Adjust scaling to match the transform er s high range Instance 1 0x73 115 Map 1 Map2 1 Current
147. he 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 dication on the display would then represent percent humidity and range from 0 to 100 percent with an Watlow EZ ZONE PM Integrated Controller e 103 Chapter 9 Features 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 feature or from an external switch using an event input
148. her step 7a or 8a Pushing the Up O or Down Q 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 m oL L was turned on proceed on through steps 3 9 3 Assuming the Code od E 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 the calculation defined below 7b or 8b for either the User or Administrator 5 Enter the result of the calculation in the upper dis 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 ol L is Off Password P amp 8S5 equals User Password P A 5 b If Rolling Password r oL L is On Password PAS S equals P R5 x code Mod 929 70 8 Administrator a If Rolling Password r ol L is Off Password PR55 equals User Password P A 5 8 b If Rolling Password m oL L is On Password PASS equals PA5 A x code Mod 997 1000 Differences Between a User Without Password User With Password and Administrator User without a password
149. hers without a security password Without the appropri ate password those menus will remain inaccessible If Password Enabled P 8 5 in the Factory Page under the Menu is set to on an overriding Password Security will be in effect When in effect the only Pages that a User without a password has visibility to are defined in the Locked Access Level LoC L prompt On the other hand a User with a password would have visibility restricted by the Read Watlow EZ ZONE PM Integrated Controller e 113 Chapter 9 Features Lockout Security mc L o C As an example with Pass word Enabled and the Locked Access Level t o C set to 1 and c L oC is set to 3 the available 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 acces sible with the exception of the Setup Page as defined 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 La C L Locked Access Level 1 to 5 correspond ing to the lockout table above 2 toL L Rolling Password will change the Cus tomer Code every
150. in ing 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 53 e Chapter 5 Operations Page Operations Page CIP Parameter Class Default Appears in Modbus Rela Profibus z I tive Address nstance Index Parameter name Description Menu When Attribute hex dec Profile Status off 62 Instance 1 Ox7A 122 Profile State Running 149 Map1 Map2 1 currentProfile Pause 146 2522 4342 2 state Profile Status Current File Indicates current file Instance 1 0x7A 122 Map 1 Map2 1 2524 4344 3 being executed Note Some values will be rounded off to fit in the four character display Full values can be read with E other interfaces Available with PM4 PM8 and PM9 models only E Watlow EZ ZONE PM Integrated Controller e 54 e Chapter 5 Operations Page 6 Chapter 6 Setup Page Navigating the Setup Page To go to the Setup Page from the Home Page press Press the Up O or Down Q key to move through both the Up O and Down Q keys for six seconds available menu prompts will appear in the upper display and Press the Infinity Key to move backwards will appear in the lower display through the levels parameter to submenu sub Press the Up or Down Q key to view available menu to menu menu to Home Page menus On the following p
151. input state Digital Input 7 to 12 Event Status View this event input state Note Operations Page Parameter Range Default Appears in Menu When ii 7 None Modbus Rela tive Address 1 999 000 to 9 999 000 F or units 1 128 000 to 5 537 000 C Instance 1 Map 1 Map2 3322 Instance 2 Map 2 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 Instance 1 Map 1 Map2 3332 Instance 2 Map 1 Map2 3402 Instance 1 Map 1 Map2 1012 1132 Offset to next instance equals 30 Direction Setup Page Digital In put Output Menu is set to Output Off 62 On 63 Instance 1 Map 1 Map2 1132 Offset to next instance equals 30 Direction Setup Page Digital In put Output Menu is set to Output Off 62 on On 63 Instance 1 Map 1 Map2 1328 1568 Offset to next instance equals 20 Direction Setup Page Digital In put Output Menu is set to Input Volt age or Input Dry Contact Off 62 on On 63 Instance 1 Map 1 Map2 1648 Offset to next instance equals 20 Direction Setup Page Digital In put Output Menu is set to Input Volt age or Input Dry Contact oF F Off 62 On 63 Some values will be rounded off to fit in the four character display Full values can be rea
152. l show Again push the Advance button where the prompt for the 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 P 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 y and the Active Set Point loop 1 RC S P If two channels are pr
153. larm indication of a failed load issue Watlow EZ ZONE PM Integrated Controller e 5 o Chapter 1 Overview Input Functions Input Sensor 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 RUI EZ ZONE Controllers PLC P orH Input Sensor gt Q 1kQ Thermistor 5kO 10kQ 20kQ 40kQ Process V mV mA EZ ZONE PM Integrated Model 1 16 DIN System Diagram With Auxillary Input Without Communications Card Slot B a d Output 1 Ono CN none switched dc open collector 5A mechanical relay form C process Analog Input 1 none Thermocouple RTD 1000 Optional pons gt 1KO Thermistor 5kO 10kO 20kQ Ramp Soak max 4 40kQ Process V mV mA or 1k files 40 steps Potentiometer Output 2 none 15A NO ARC switched dc Slots A 5A mechanical relay form A or Optional 0 5A SSR form A Modbus Address 1 247 Digital Input or Output 5 amp 6 optional none switch volts dc Digital Output or Input 5 amp 6 Standard B 1 A TIU optional none switched dc Zone Address EZ Key etl Programmable Event Supervisory amp
154. lector 5A mechanical relay form C process or 0 5A SSR form A 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 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 alarm or event I off heat cool retransmit alarm duplex or event off heat cool alarm event or limit Digital Output or Input 5 amp 6 optional none switched dc off heat cool alarm or event Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail LEDs Zone DS CES Channel rr Indicates Zone Address amp Channel 3 4 Indicates I O Lal 5 6 Status 7 8 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 With Communications slot E Input Function Input Sensor Input Sensor OQ 1kQ Thermistor 5kQ 10kQ 20kQ 40kQ Process V mV mA Analog Input 1 none Thermocouple RTD 1000 gt 1kQ Thermistor 5kQ 10kQ 20kQ 40kQ Process V mV mA or 1k Potentiometer Analog Input 2
155. lgorithm Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 55 e Chapter 6 Setup Page Alarm Menu Lj tol Alarm At J Type Source Function A Source Instance A Hysteresis Logic Sides Latching Blocking Silencing Display Delay uc ui D D in m go PN c Ra rd to gi zo P m zo io r Ra a u o zo o ra F3 cz y n Current Menu Current Sides Read Enable Cgt Detection Threshold CSC Input Current Scaling Heater Current Offset Output Source Instance PARE SEt Math Menu L Math Fn Function F n E Source Function E Source Instance E Input Scale Low Input Scale High Output Range Low Output Range High Filter l m j 1 i D r o 4 c m A jx 3 o Special Output Function Menu LF Special Output Function Fana Function F afi 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 dD 3 a Oro o o ma dD 7o o ojo ma oo o 2 o frm fr er a e FUn SEt Function Key Menu Lj tol Function Key Level Available with
156. ll 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 S 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 reaches 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 A the operator at this point A non Iu Low latching alarm would turn off Set Point Temperature Process Temperature automatically 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 zone to activate the alarm output function again Watlow EZ ZONE PM Integrated Controller
157. llivolts 56 Volts de 104 Milliamps de 112 RTD 100 113 RTD 1 000 114 Potentiometer 1 KQ Eh Ec Thermistor 229 H K 48 n N 58 r R 80 5 S 84 EJT 93 Sensor Type is set to Thermo couple Sensor Type is set to RTD 100 Q or RTD 1 000 Q AE P Absolute Tempera ture 1540 ch Relative Humidity 1538 Pro Process 75 PL Jc Power 73 Sensor Type is set to Millivolts Volts Mil liamps or Potentiom eter 1 kO Process 100 0 to 1 000 0 Sensor Type is set to Millivolts Volts Mil liamps or Potentiom eter 1 kO 100 0 to 1 000 0 Sensor Type is set to Millivolts Volts Mil liamps or Potentiom eter 1 kO 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 Map1 Map2 368 368 Instance 2 Map1 Map2 448 458 Instance 1 Map1 Map2 370 370 Instance 2 Map1 Map2 450 460 Instance 1 Map1 Map2 372 368 Instance 2 Map1 Map2 452 462 Instance 1 Map1 Map2 442 Instance 2 Map 1 Map2 532 Instance 1 Map 1 Map2 388 388 Instance 2 Map 1 Map2 468 478 Instance 1 Map 1 Map2 390 390 Instance 2 Map 1 Map2 470 480 CIP Class Instance Attribute hex dec 0x68 104 1to2 5 0x68 104 1to2 6 0x68 104 1to2 7 0x68 104 1to2 0x2A
158. lue or Set Point 104 Cool Output GC rve isse RI nee ek eve eee ca Red qe 105 Output Configuration isi 2 eee iaai 105 Auto closed loop and Manual open loop Control 105 OnsOTf GOTILO cst en tert Meine etal ation eee acd eee eae 106 Proportional plus Integral PI Control 0008 107 Proportional plus Integral plus Derivative PID Control 107 Dead Band iieri toe Saka o bob t dues 107 Variable Time Base rosse e uk tg ers eee ead 108 Single Set Point Ramping 0 ccc cece eee eee 108 Cascade COItrol zi ig oed SE ocd ad Padme eae Soe ae Rod 109 Compressor Control 109 Differential Control 0 0 ccc eee teen eens 110 Ratio COITtEOL 1 2 crece ee a e qe ER RUE qa 110 BITS d CONTON ERR ERE 110 AlS os aaiae en he fece e Beta de RHEVRERUR E NE TNR oan 111 Process and Deviation Alarms 0 00 cee e eee ee 111 Alarm Set Polls iusserit eue aw acamdaledwgiuegwdwa adie 111 Alarm Hysteresis 2 0 0 0 ccc cece ene 111 Alarm Latcning 22 rr pe ELE vice RET 111 Alarm Silencing 0 000 ccc cece cece II 111 Alarm BIOCKING 4 2e cnateetarnetew Rabe d ddan 112 Current Sensing 0 00 ccc ee eee 112 Programming the EZ Key S 000 cece eee eee eee 112 Using Lockout to Hide Pages and Menus 113 Using Password Security 0 0 0 0 ccc cece eee ee eee 113 Watlow EZ ZONE PM Integrated Controller e 99 o Chapter
159. ly 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 speci fied and will rep resent the value at which output scaling begins Digital Output 5 to 12 High Power Scale The power output will never be greater than the value speci fied and will rep resent the value at which output scaling stops 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 0 0 to 100 0 Setup Page Parameter Appears in Menu When Direction is set to Out Direction is set to Out put is set to Fixed Time Base Direction is set to Out put and Source is set to Heat or Cool Direction is set to Out put and Source is set to Heat or Cool 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 1010 1130 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 1002 1122 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 1004 1124 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 1016 1136 Offset to next inst
160. m set points automatically moves 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 A 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 Ao Seb Alero ews Alarm High Set Point y Alarm Hysteresis Temperature Normal Operating Range 4 Alarm Hysteresis Alarm Low Set Point Low Side Alarm Range Time Alarm Latching A latched alarm will remain active after the alarm condition has passed It can only be deactivated by the user An active message such as an alarm message wi
161. mechanical relay form A or Optional 0 5A SSR form A Output 3 PID Controller hone switched dc open collector 5 c zb mechanical relay form C process urrent Trans y mA or 0 5A SSR form A former Sense CT Output 4 none 15A NO ARC switched dc Slots B 5A mechanical relay fo Optional 0 5A SSR form A If limit this output must be limit 6 Digital Inputs Outputs Slot D Optional Digital Output or Inp ut 7 12 optional none switched dc E Modbus Address 1 247 Standard Bus Zone Address 1 16 Supervisory amp Power Board Slot C Digital Output or Inp optional none switched dc ut 5 amp 6 LEDs Sey ae i 2 I 3 4 5 6 7 8 Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail Output Function off heat cool alarm retransmit duplex or event off heat cool alarm or event off heat cool gt alarm retransmit duplex or event off heat cool alarm event or limit off heat cool alarm or event off heat cool alarm or event x Indicates Zone Address amp Channel Indicates I O P Status Watlow EZ ZONE PM Integrated Controller 10 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
162. mination resistor B try Do not route network wires Do not connect more than 32 485THR p with power wires Connect EZ ZONE PM controllers on 485 T R network wires in daisy chain any given segment A Maximum EIA 485 network Termination resistor A fashion when connecting multiple devices in a net Profibus Terminal VP Voltage Potential B Line A Line DP GND work A termination resistor should be used if this control is the last one on the network length 1 200 meters 4 000 feet 1 8th unit load on EIA 485 bus Communications instance 2 e If using a 150 Q cable Wat Slot B PM 6 _ 6 ___ low provides internal termi EM nation Place a jumper across Slot E PM 4 8 9 6 pins trB and B and trA and A EIA TIA 485 Name Watlow Terminal Label A wee do c XB 2 o 8 B J T LO 0A A VP A G 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 0 8 Nm 7 0
163. mistor Curve 58 Time Derivative 46 101 07 TRU TUNE Gain 67 101 Time Integral 46 101 107 TRU TUNE Enable 67 01 Valve Travel Time 78 Tuning 33 EUng Tuning 1 or 2 33 m 3 e m 3 e m m rr e fr Lo 3 nr m fr a3 m fr Pr 3 Pr 3 UF AJ User Failure Action 68 U 5 c c User Restore Set 81 100 U 5 7 5 User Save Set 81 100 UJE Wait Event 2 90 Cone Zone 81 gt AC Line Frequency 79 108 e 125 Active Event Output 1 or 2 53 Active Step 51 Active Step Type 51 adaptive tuning 101 Address Modbus 82 Address Standard Bus 82 83 86 Administrator Password 95 Advance Key 32 agency approvals 2 alarm blocking 112 Alarm Menu 47 73 alarms 109 Blocking 74 112 deviation 111 Display 74 Hysteresis 73 111 Latching 74 111 Logic 73 process 111 set points 111 Sides 74 Silencing 74 111 Source 73 Type 73 Altitude Units 55 Analog Input Menu 40 57 Attention Codes 33 35 auto closed loop control 105 Autotune 100 Autotune Aggressiveness 68 Autotune Request 45 Autotune Set Point 44 100 autotuning 100 101 autotuning with TRU TUNE 101 B Barometric Pressure 55 Baud Rate 82 Blocking 74 112 bumpless transfer 105 C calibrating an analog input 102 Calibration Menu 98 Calibration Offset 40 73 102 103 Cascade Control 109 changing the set point 35 Channel 81 chatteri
164. 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 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 instanc
165. n Set this function to operate as an input or output Digital Output 5 to 12 Function Select what func tion will drive this output Note Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Kilofeet 1677 FE Feet 1676 10 0 to 16 0 0 0 to 60 0 seconds DEPE Output 68 1 on Input Dry Contact 44 inj Input Voltage 193 Off 62 Limit 126 Profile Event Out B Profile Event Out A Special Function Out 1533 Special Function Out 1532 Cool Power Control 161 Heat Power Control p 160 Alarm 6 Available with PM4 PM8 and PM9 models only Instance 1 Ox7E 126 Map1 Map2 1to2 Instance 2 Map1 Map2 3406 Instance 1 Ox7E 126 Map1 Map2 1 to 2 meee 3338 Ox1E 30 Instance 2 Mapi1 Map2 3408 Instance 1 Ox7E 126 Map1 Map2 1 to 2 SEM 3330 Ox1A 26 Instance 2 Map1 Map2 3400 Instance 1 0x6A 106 Map 1 Map2 5to12 1000 1120 1 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 0x6A 106 Map1 Map2 5to12 1008 1128 5 Offset to next instance Map 1 amp Map 2 equals 30 Watlow EZ ZONE PM Integrated Controller 63 Chapter 6 Setup Page Note Parameter name Description Digital Output 5 to 12 Function Instance Set the instance of the function selected above Set the output con trol type This pa rameter is on
166. ndard 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 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 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 Quencharc Note Switching pilot duty inductive loads relay coils solenoids etc with the mechanical relay solid st
167. ne 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 on PM6 Auxillary 2nd input Universal Input Auxillary 2nd input Thermistor Inpu
168. ng output 106 chemical compatibility 18 Closed Loop Set Point 45 Closed Loop Working Set Point 44 communications activity light 32 Communications Menu 81 86 89 93 Setup Page 39 55 Compressor Control 109 Control 64 70 Control Loop Menu 67 control methods 105 Chapter 11 Appendix Control Mode 44 106 Control Mode Active 43 Control Module Menus Factory Page Calibration Menu 98 Security Setting Menu 94 96 Operations Page Alarm Menu 47 Analog Input Menu 40 Current Menu 48 Digital Input Output Menu 42 Limit Menu 43 Linearization Menu 40 Loop Menu 44 Math Menu 49 Monitor Menu 43 Process Value Menu 41 Profile Status Menu 51 Special Output Function Menu 50 Setup Page Alarm Menu 73 Analog Input Menu 57 Communications Menu 81 86 89 93 Control Loop Menu 67 Current Menu 75 Digital Input Output Menu 63 Global Menu 79 Limit Menu 66 Linearization Menu 59 Math Menu 76 Output Menu 70 Process Value 62 Cool Algorithm 67 106 Cool Hysteresis 46 106 cool output curve 105 Cool Output Curve 67 105 Cool Power 44 101 Cool Proportional Band 45 101 107 Current Error 49 112 Current Menu 48 75 current sensing 112 Current Sensing 112 D Data Map 83 Date of Manufacture 96 Dead Band 46 107 108 Decimal 59 default Home Page parameters 32 35 deviation alarms 111 Differential Control 110 Digital Input Function 79 Digital Input Output Menu 42 63 dimensions 13 14 15 16 Direction 63 Display 74 Display Pairs
169. nge Control Loop 1 to 2 High Set Point Set the maximum value of the closed loop set point range Setup Page 0 to 3 600 seconds 1 999 000 to 9 999 000 F or 1 110 555 to 5 555 000 C Off 62 Startup 88 Set Point Change Both 13 Hours 39 Minutes 57 0 0 to 9 999 000 F or units 0 0 to 5 555 000 C 1 999 000 to 9 999 000 F or 1 128 000 to 5 537 000 C 1 999 000 to 9 999 000 F or 1 128 000 to 5 537 000 C Default 1 999 F or units 1 128 C 1 999 F or units 1 128 C Parameter Appears in Menu When Open Loop Detect En able is set to Yes Open Loop Detect En able is set to Yes Ramp Ac tion is set to Startup Set Point or Both Ramp Ac tion is set to Startup Set Point 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 Map1 Map2 1924 2404 Instance 2 Map1 Map2 1994 2474 Instance 1 Map1 Map2 1926 2406 Instance 2 Map 2 Instance 1 Map 1 Map2 2186 2666 Instance 2 Map 1 Map2 2266 2746 Instance 1 Map 1 Map2 2188 2668 Instance 2 Map 1 Map2 2268 2748 Instance 1 Map 1 Map2 2192 2672 Instance 2 Map 1 Map2 2272 2752 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 CIP Class In
170. ngham 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 Malaysia Sdn Bhd No 14 3 Jalan 2 114 Kuchai Business Centre Jalan Kuchai Lama 58200 Kuala Lumpur Malaysia Tel 60 3 7980 7741 Fax 60 3 7980 7739 Bisse SRR HAIRS A 80143 BHP BU d Es RE 28 18955 108 2 RA 07 2885168 85 07 2885568 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 Email info watlow cn DRO Vr NVRAAA T 101 0047 RRA 0H X PA t8 FH 1 14 4 Ej E JL 8I SEO Tel 03 3518 6630 Email infoj 9 watlow com Fax 86 21 5080 0906 Website www watlow cn Fax 03 3518 6632 Website www watlow co jp Watlow Japan Ltd 1 14 4 Uchikanda Chiyoda Ku Tokyo 101 0047 Japan Tel 81 3 3518 6630 Email infojfwatlow com Fax 81 3 3518 6632 Website www watlow co jp 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 Fax 82 2 2628 5771 Website www watlow co kr 20090610 Watlow Electric Taiwan Corporation 10F 1 No 189 Chi Shen 2nd Road Kaohsiung 80143 Taiwan Tel 886 7 2885168 Fax 886 7 288556
171. nits Select which scale to use for temperature Global Menu 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 interfaces Setup Page None 61 Profile Start Stop level triggered 208 Pr oF Profile Start Number edge triggered 196 PhoL Profile Hold Resume level triggered 207 Pd 15 Profile Disable level triggered 206 EJA TRU TUNE Dis able level triggered 219 of j Control Outputs Off level triggered 90 Aa Manual Auto Mode level triggered 54 tUnE Tune edge triggered 98 d LE Idle Set Point Enable level triggered 107 AL Force Alarm level triggered 218 Aof Alarm Outputs amp Control Loop Off level trig gered 220 Silence Alarms edge triggered 108 LP Alarm Reset edge triggered 6 PL oC Lock Keypad level triggered 217 uS c Restore User Set tings edge triggered 227 Limit Reset edge triggered 82 F F 30 C C 15 50 50 Hz 3 60 60 Hz 4 Available with PM4 PM8 and PM9 models only Parameter Appears in Menu When Full values can be read with other CIP Modbus Rela Class tive Instance Address Attribute hex dec Instance 1 Ox6E 110 Map1 Map2 1to2 1324 1564 3 Instance 2 Map1 Map2 1344 1584 Instance 1 0x96 110 Map1 Map2 1to2 1326 1566 4 Instance 2 Map1
172. nner 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 be 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 Compressor Control The PM PM8 9 can be configured for Compressor 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 output 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 fo
173. ntegrated Controller e 96 o Chapter 8 Factory Page Factory Page CIP Parameter Modbus Class Parameter name 2 Profibus ER Default Appears in Relative Ad Instance Description Index dress Attribute Diagnostics Menu 0 to 255 169 Always if IP Actual Address Ethernet Part 1 card pres Actual IP address ent see of this module part num Each device on the ber network must have a unique address hex dec Diagnostics Menu 0 to 255 254 Always if IP Actual Address Ethernet Part 2 card pres Actual IP address ent see of this module part num Each device on the ber network must have a unique address Diagnostics Menu 0 to 255 Always if IP Actual Address Ethernet Part 3 card pres Actual IP address ent see of this module part num Each device on the ber network must have a unique address Diagnostics Menu 0 to 255 Always if IP Actual Address Ethernet Part 4 card pres Actual IP address ent see of this module part num Each device on the ber network must have a unique address Diagnostics Menu Always if IP Actual Address Ethernet Part 4 card pres Actual IP address ent see of this module part num Each device on the ber network must have a unique address Diagnostics Menu 0 to 255 Always if IP Actual Address Ethernet Part 5 card pres Actual IP address ent see of this module part num Each device on the ber network must have a unique address Note Some values will be roun
174. ntroller 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 whole 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 e 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 e Increases 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 e 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 e Assures prompt product acceptance Reduces end product documentation costs EZ Key s Programmable EZ Key enables simple one touch operation of repetitive user activities P
175. o if it feels that it will not slide back in do not force it Check the orientation again and reinsert after cor recting 2 Using your thumbs push on either side of the con troller until both latches click Watlow EZ ZONE PM Integrated Controller 17 Chapter 2 Install and Wire Chemical Compatibility 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 AN Warning All electrical power to the controller and controlled circuits must be disconnected before removing the controller from the front panel or disconnecting 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 Watlow EZ ZONE PM Integrated Controller e 18 Chapter 2 Install and Wire Slot A Slot B Slot D Slot E Inputs Terminal Function Configuration 1 2 7 12 Ti ple 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 _ RL R1 R2 S1 RTD thermocouple or
176. o 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 or 1k Potentiometer Digital Input or Output 5 amp 6 optional none switch volts dc EZ Key Programmable Event Ramp Soak max 4 files 40 steps Slot A Optional Output 2 none 15A NO ARC switched dc 5A mechanical relay form A or 0 5A SSR form A EIA 485 Communication wi Standard Bus optional Modbus RTU RUI EZ ZONE Controllers PLC PC or HMI Communications Pal EIA 232 485 Modbus RTU TCP EtherNet IP DeviceNet Profibus Note Modbus Address 1 247 Standard Bus Zone Address 1 16 Supervisory amp Power Board Communication Board Digital Output or Input 5 amp 6 optional none switched dc IS Zone Output Status Address off heat cool alarm event off heat cool alarm event Number of inputs and outputs and various combinations of the same will vary depending upon part number see ordering matrix for more detail 1 2 Ll Indicates Zone Address 3 4 Indicates I O 5 6 g Status Serial Communication Capabilities e Supports network connectivity to a PC or PLC e Available in a wide
177. o 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 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 Time 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 Output Set Point Heafou
178. odel 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 Standard Bus EIA 485 Communications Slot C CF common CD T IR CE 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 controller on the network Do not connect more than 16 EZ ZON
179. oll 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 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 return to the Home Page Using EZ ZONE Configurator Software 1 Make the necessary physical connections between the personal computer and the EZ ZONE PM Set Protocol Setup Page Communications Menu to Standard Bus Run the software and allow it to connect to the controller by directing it or al lowing it to find the appropriate communications port 2 After the software connects to the controller look on the left side of your screen under the Param eters Menus for Function Key under Setup Click on the plus sign to reveal the Function Key 1 sub menu 3 Click on Function Key 1 then select a Digital In put Function and a Function Instance If you want to start and stop a profile with the EZ Key select Profile Start Stop and the number of the profile that you want the EZ Key to control Parameter Menus Parameters Setup Function Key 1 EZZone ST E
180. ommon PL common f B fo B Ag Watlow EZ ZONE PM Integrated Controller e 31 Chapter 2 Install and Wire Chapter 3 Keys and Displays 1 8 DIN PM8 Horizontal Temperature Units WATLOW MN Indicates whether the temperature is displayed in Fahrenheit or Cel sius In the Home Page displays the process value otherwise displays the value of the parameter in the lower display Zone Display Percent Units 1234E2 A 567 8 EZ Indicates the controller zone Lights when the controller is dis playing values as a percentage or 1 to 9 zones 1 to 9 when the open loop set point is dis A zone 10 E zone 14 played b zone 11 F zone 15 1 16 PM6 DIN C zone 12 h zone 16 EXE Output Activity d zone 13 Number LEDs indicate activity of outputs A flashing light indicates Lower Display output activity Indicates the set point or output power value during operation or the param eter whose value appears in the upper display P ss Profile Activity Lights when a profile is running Flashes when a profile is paused EZ Key s p di This key can be programmed to do various tasks such as starting a pro file 1 8 DIN PM9 Vertical Communications Activity WATLOW EZ ZONE Flashes when another device is communicating with this control ler Channel Display er Indicates the channel for any given EZ ZONE module Avail
181. on nected to R1 For best accuracy use a 3 wire RTD to compensate for lead length resistance All three lead wires must have the same resistance 3 wire Input 1 PM _ C R B Input 2 PM _ C R L SI RD TI SI R1 S2 R2 T2 S2 R2 PM 4 8 and 9 only Watlow EZ ZONE PM Integrated Controller 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 locati
182. only 2 000 000 cycle rating for no arc circuit 100 mA minimum load normally open e 2 mA maximum off state leakage Do not use on dc loads Output does not supply power Output 1 L2 K2 PM _ H Output 3 L4 K4 PM 4 8 9 common Watlow EZ ZONE PM Integrated Controller 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 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 CLA
183. ons 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 Input 1 2 Process Slot A B Slot A B e 0 to 20 mA 100 Q input impedance 0 to 10V dc 20 kO input impedance 0 to 50 mV dc 20 kO input impedance scalable Input 1 PM _ GRjB S1 R1 T1 S1 6 Input 2 PM __ _ C R L S2 R2 T2 S2 X 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 Input2 PM _ C R L _____ SURD TUSI RD PM 4 8 and 9 only CW S CCW R Input 1 2 Thermistor Slot A B e gt 20 MO input impedance 3 microampere open sensor detection Input 1 PM Jj WE _ S1 R1 Input 2 PM J P M S2 R2 Shh Input 2 Current Transformer Slot B Input range is 0 to 50 mA current transformer part number 16 0246 e 100 Q inpu
184. ool 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 troubleshooting 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 th
185. op 1 to 2 Autotune Set Point Set the set point that the autotune will use as a percentage of the current set point 0x97 151 1 to 2 0x14 20 Instance 1 Map1 Map2 1918 2398 Instance 2 Map1 Map2 1988 2468 Note Available with PM4 PM8 and PM9 models only Watlow EZ ZONE PM Integrated Controller e 44 e Chapter 5 Operations Page Parameter name IDE Description Loop 1 to 2 AUt Autotune Request Start an autotune While the autotune is active the Home Page will display or Eung When the autotune is complete the message will clear automati cally Loop 1 to 2 Closed Loop Set Point Set the set point that the controller will au tomatically control to Loop 1 to 2 Idle Set Point Set a closed loop set point that can be triggered by an event state Loop 1 to 2 Heat Proportional Band Set the PID propor tional band for the heat outputs Loop 1 to 2 Heat Hysteresis Set the control switching hysteresis for on off control This determines how far into the on region the process value needs to move before the output turns on Loop 1 to 2 C Pb Cool Proportional Band Set the PID propor tional band for the cool outputs Note Operations Page Parameter Default Appears in Menu When no No 59 Heat Al YES Yes 106 gorithm or Cool Algo rithm Set up Page is set to PID Low Set Point to High Set Point Setup Page Low Set Point to
186. ot use on dc loads See Quencharc note ERA Output 1 L2 K2 PM____ K Output 3 L4 K4 PM_____ ___ K _ common K 1 Amp SSR Derating Curve Amps RMS ea1y buneiado ayes 20 10 O 10 20 30 40 50 60 70 Ambient Temperatue C Quencharc Wiring Example In this example the Quencharc circuit Watlow 1 1 User Load part 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 Quencharc Watlow EZ ZONE PM Integrated Controller e 28 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 0 8 Nm 7 0 Ib in torque Note Adjacent terminals may be labeled differently depending on the m
187. ounded 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 CIP Class Instance Attribute hex dec Profibus Index Watlow EZ ZONE PM Integrated Controller e 93 o Chapter 8 Factory Page Factory Page CIP Parameter name LES Modbus wes Profibus ieee Range Default Appears in Relative Ad Instance Description d Index dress Attribute hex dec Custom Setup 1 If there to 20 is only Instance ID one valid Select which instance instance of the for corre parameter will be sponding selected class mem ber then not active otherwise active Security Setting LoC o Operations Page Change the secu rity level of the Operations Page Security Setting Profiling Page Change the secu rity level of the Profiling Page Security Setting Password Enable Turn security fea tures on or off Security Setting rLoC Read Lock Set the read se curity clearance level The user can access the selected level and all lower levels If the Set Lockout Security level is higher than the Read Lockout Se curity the Read Lockout Security level takes prior ity 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 Controlle
188. p2 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 Map1 Map2 890 1010 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 1 Map2 882 1002 Offset to next instance Map 1 amp Map 2 equals 30 CIP Class Instance Attribute hex dec Ox6B 107 1 to 2 5 0x6B 107 1to2 6 0x6A 106 0x6A 106 1to4 6 0x6A 106 1to4 2 Watlow EZ ZONE PM Integrated Controller 70 Chapter 6 Setup Page Parameter name Description Output 1 to 4 Time Base Set the time base for fixed time base control Output 1 to 4 Low Power Scale The power output will never be less than the value speci fied and will rep resent the value at which output scaling begins Output 1 to 4 High Power Scale The power output will never be greater than the value speci fied and will rep resent the value at which output scaling stops Output 1 or 3 pro cess Type Select whether the process output will operate in volts or milliamps Output Process 1 or 3 Function Set the type of func tion that will drive this output Output 1 or 3 pro r Sr cess Retransmit Source Select the value that will be retransmit ted Note Some values will be rounded off to fit in the four character di
189. 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 reaches set point Process doesn t con trol to set point Process value continues to increase or decrease past set point Temperature runway Device Error Controller displays internal malfunction message at power up 4 Heater Error Heater Error Load current incorrect LEr Current Error Unable to access _ SEE GPE FCEY or Pr oF menus or particular prompts in Home Page Menus inaccessible EZ Key s don t work EZ Key s does not activate required function Controller not tuned correctly Control mode is incorrectly set Control set point is incorrect Controller output incorrectly pro grammed 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 Current through load is above current trip set point Current through load is below current
190. 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 EtherNet IP and Modbus TCP Communications SiotB E RJ 45 T568B wire Signal Slot Do not route network unused wires with power wires used Eg pin color B E Connect one Ethernet
191. ped to input 7 Linearization 1 to 2 Input Point 8 Set the value that will be mapped to output 8 Linearization 1 to 2 Output Point 8 Set the value that will be mapped to input 8 Note Range 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 m Parameter Default APPEALS in Menu When Always Instance 1 Map 1 Map2 3582 Instance 2 Map 1 Map2 3652 Always Instance 1 Map 1 Map2 3602 Instance 2 Map 1 Map2 3672 Always Instance 1 Map 1 Map2 3584 Instance 2 Map 1 Map2 3654 Modbus Rela tive Address 4 4 Always Instance 1 Map 1 Map2 3586 Instance 2 Map 1 Map2 3656 Always Instance 1 Map 1 Map2 3606 Instance 2 Map 1 Map2 3676 Always Instance 1 Map 1 Map2 3588 Instance 2 Map 1 Map2 3658 Always Instance 1 Map 1 Map2 3608 Instance 2 Map 1 Map2 3678 Always Instance 1 Map 1 Map2 3604 Instance 2 Map 1 Map2 3674 0 0 5 0 5 0 7 0 7 0 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 OxC 12 0x86 134 1to2 0x16 22 0x86 134 1to2 OxD 13
192. 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 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
193. r Route wires appropriately check for loose connections add line filters Check settings in Factory Page Enter appropriate password in 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 120 Chapter 11 Appendix Specifications LineVoltage Power Minimum Maximum Ratings 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 nonvolatile 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 40t085 C storage temperature 0 to 9096 RH non condensing Accuracy e Calibration accuracy and sensor conformity 0 196 of span 1 C the calibrated ambient temperature and rated line voltage Types R S B 0 2 Type T below 50 C 0 296 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 UL Listed to UL 61010 1 File E185611 UL Reviewed to CSA C22 2 No 61010 1 04 U
194. r a time longer than the Compressor Off Delay Note See Chapter 10 for application examples Set Point Temperature Curve A PID Curve B Cascade Time Curve C Single control Energy Source Control Loop 2 PID Power 0 to 100 gt Cool Output Cascade Cascade Pe ee ee ee ee eee ee ee ee ee ee eee eee eee f 1 amp x 1 Outer Loop RZS Ar ue i PP i o May Con os Og ee 1 I 1 Power gt Source A r Input 1 I SourceA Closed Loop SP gt Source B I Process Part Control Loop 1 PID gio gt Source E Output 1 A cascade disable wan Function 1 Ra me m mm a Ua Um m a m a m m m me m m as m s n n ni ns Rh m a Ga Rm n m m A mm mn d 8 4 0 c uS Cd Inner Loop 100 Range Low 1 1 100 Range High 1 1 gt 1 Remote SP Oto 100 Heat Output 1 gt Source B Heat Power 1 1 1 Input 2 gt Source A Cool Power 1 1 i 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 2 Compressor wy Off Power 0 Compressor On Power Heat 100 2 0 Cool 100 Compressor on isa Time In Seconds Compressor On Delay 45 Seconds EI gt Compressor Off Delay 20 Seconds Watlow EZ ZONE
195. r 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 sc vs 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 f 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 Modbus the reference to Map 1 and Map 2 registers for each of the various parameters If the new functions 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 Several parameters in the control contain more than one instance such as profiles 4 alarms 4 analog inputs 2 etc
196. r display Full values can be read with other interfaces Modbus Relative Ad dress Instance 1 Map 2 Offset to next instance Map 2 equals 100 Instance 1 Map1 Map2 2592 4522 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map1 Map2 2594 4524 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map1 Map2 2596 4526 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map1 Map2 2582 4512 Offset to next instance Map 1 equals 50 Map 2 equals 100 Instance 1 Map1 Map2 2584 4514 Offset to next instance Map 1 equals 50 Map 2 equals 100 CIP Class Instance Attribute hex dec 0x79 121 uint 1to40 RWE 0x29 41 0x79 121 uint 1to40 RWE OxC 12 0x79 121 uint 1to40 RWE OxD 13 0x79 121 uint 1to40 RWE OxE 14 0x79 121 uint 1to40 RWE 7 0x79 121 uint 1to40 RWE 8 R Read W Write E EEPROM S User Set Watlow EZ ZONE PM Integrated Controller e 91 Chapter 7 Profiling Page Chapter 8 Factory Page Navigating the Factory Page To go to the Factory Page from the Home Page e Press the Up O or Down keys to change the press and hold both the Advance and Infinity parameter value keys for six seconds Press the Infinity Key to return to the Home e Press the Advance Key to move through the Page parameter prompts Note Some of these m
197. r e 94 Chapter 8 Factory Page Factory Page CIP Parameter Modbus Class Parameter name 2 Profibus Pipe Range efault Appears in Relative Ad Instance Description Index Menu When dress Attribute hex dec Security Setting 0 to 5 Always Write Security Set the write se curity clearance level The user can access the selected level and all lower levels If the Set Lockout Security level is higher than the Read Lockout Se curity the Read Lockout Security level takes prior ity Security Setting oF FJ Off Rolling Password 55j0n When power is cycled a new Public Key will be Security Setting 1to5 Always Locked Access Level Determines user level menu visibil ity when security is enabled See Features section under Password Security ff Always displayed Security Setting 10 to 999 3 Always User Password Used to acquire access to menus made available through the Locked Access Level setting Security Setting 10 to 999 156 Administrator Password Used to acquire full access to all menus Note Some values will be rounded off to fit in the four character display Full values can be read with W Write other interfaces E EEPROM S User D 5 5 O 6 If there is only one instance of a menu no submenus will appear Watlow EZ ZONE PM Integrated Controller e 95 o Chapter 8 Factory Page Factory Page CIP Parameter Modbus Class DONNE Default Appearsin Relative Ad Instan
198. r is a B or E Watlow EZ ZONE PM Integrated Controller Chapter 6 Setup Page Setup Page Parameter SUE Modbus Rela Class Dis Parameter name Defaul Appears m DUM Range efault in Menu tive Instance P Attribute hex dec Real Time Clock Sunday 1565 Sun Always if 88 136 dow Day of Week Monday 1559 4th digit 1 Tuesday 1560 in part 2 Wednesday 1561 ce is Thursday 1562 M Friday 1563 Saturday 1564 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 87 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 model number information in the Appendix for more information If there is only one instance of a menu no submenus 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 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 Advanc
199. r 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 during 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
200. rall system cost by using a single output to act as two outputs Note See Chapter 10 for application examples ambient air temperature SN _heater Display Case 7 WW glass controlledflow g of pigment flow transmitter motorized valve flow transmitter Y Fluid Sample Container hot water cold water mixed paint temperature transmitter glass temperature sensor uncontrolled flowof unmixed paint Watlow EZ ZONE PM Integrated Controller 110 Chapter 9 Features 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 alar
201. rately 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 1 I I I I i Inner Loop NON i 1 100 Range Low amp Ore 1 1 100 Range High K Outputn LI I 1 Remote SP 0 to 100 Heat l Source B Heat Power Analog Input 2 Source A Cool Power i Energy Source Control Loop 2 0 to 100 Cool 1 Output n 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 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 valu
202. rce 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 Incorrect 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 Incorrect 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 Incorrect 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 Disable alarm blocking if required Set output to correct alarm source instance Set alarm source to correct input in
203. re 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 Electrical 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 Watlow EZ ZONE PM Integrated Controller Chapter 9 Features source signal by this value 9 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 th
204. rement 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 requirements 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 129 Chapter 11 Appendix How to Reach Us Corporate Headquarters Watlow Electric Manufacturing Company 12001 Lackland Road St Louis MO
205. rical 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 Low Power Slot C power m 98 fuse 99 power Minimum Maximum Ratings 12 to 40V dc 20 to 28V ac Semi Sig F47 e 47 to 63 Hz e 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 TEN s 99
206. rogrammable 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 installers and operators P3T Armor Sealing System e NEMA 4X and IP66 offers water and dust resis tance can be cleaned and washed down Backed up by UL 50 independent certification to NEMA 4X specification Removable cage clamp wiring connectors 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 e 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
207. rol Loop 1 to 2 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 En able Enable or disable the TRU TUNE adaptive tuning feature Control Loop 1 to 2 TRU TUNE Band Set the range cen tered on the set point within which TRU TUNE will be in effect Use this function only if the controller is unable to adaptive tune au tomatically Control Loop 1 to 2 t gn Select the respon siveness of the TRU TUNE adaptive tuning calculations More responsiveness may increase over shoot Note TRU TUNE Gain _oFF Off 62 PID 71 On Off 64 of F Off 62 P d PID 71 onoFf On Off 64 Off 62 C A Non linear Curve 1 214 C r b Non linear Curve 2 215 No 59 YES Yes 106 Setup Page Default Parameter Appears in Menu When Cool Algo rithm is set to PID Cool Al gorithm or Heat Algorithm is set to PID Cool Algo rithm or Heat AI gorithm is set to PID and TRU TUNE Enable is set to Yes Cool Algo rithm or Heat Al gorithm is set to PID and TRU TUNE Enable is set to Yes Some values will be rounded off to fit in the four character display Full values can be read with other interfaces
208. s output 3 1 999 000 to 9 999 000 Instance 1 0x76 118 Map1 Map2 730 850 Instance 3 Map1 Map2 810 930 the control ler has process outputs 1 or 3 Calibration Menu 1 or 3 Electrical Output Slope Adjust this value to calibrate the slope of the output value Menu 2 calibrates output 3 ELo S 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 Watlow EZ ZONE PM Integrated Controller e 98 o Chapter 8 Factory Page Chapter 9 Features Saving and Restoring User Settings 0 0000 eee eee 100 Tuning the PID Parameters 2 0 0 c ee eee eee eee 100 Manual Tuning 2 2 red ieee dita donee edad id ance 101 Autotuning with TRU TUNEO occ 101 INPUTS 1 Bede e e E Exec Eia RUE M xxu eS 102 Calibration Offset 00 ccc cece eee ee eens 102 eriluzunp pe T 102 Filter Time Constant 103 Sensor SElECHOM er iios eme brew aoe a owes 103 Sensor BACKUP actes e Batok adt e amines Beh 103 Scale High and Scale Low 0 cc cece 103 Range High and Range Low 0 c cece eee eee 103 Receiving a Remote Set Point 0 cee eee eee es 104 QUI PUTS s s csc ened dace sk oe eee hed adda Seen era 104 DUPLEX PECTUS 104 NO ARC Relay 0 ccc eect cece rn 104 Retransmitting a Process Va
209. s such as Clear or Silence 5 L 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 isplay message and the controller set L tings Some messages such as the message can be cleared when L the condition no longer exists If L an alarm has silencing enabled it can be silenced Push the Advance Key to dis play Sar in the upper display and the message source such as Lah 1 in the lower display Use the Up O and Down Q keys to scroll through possible responses such as Clear or Silence L 5 L Then push the Advance or Infinity key to execute the action Alternatively rather than scrolling through all mes sages simply push the Infinity button to generate a clear Ramping and Tuning indicate Lah that a process is underway If LE the message was generated by a EUn latched alarm or limit condition cP Attention ALL I ALL ALL 3 ALLY Alarm an alarm or er An active message will cause the Low 1 to 4 ror message is display to toggle between the ALA I ALA ALA ALAY Alarm active normal settings and the active High 1 to 4 message in the upper display and ALE T Alarm in the lower display Error 1 to 4 Your response will depend on the Er Error Input 1 or 2 I Limit Low 1 Limit High 1 I Limit Error 1
210. s 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 MI orH Input Sensor Analog Input 1 none Thermocouple RTD 100Q 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 EIA 485 Communication Standard Bus optional Modbus RTU Analog Input 2 none CT Thermocouple RTD 100 gt OQ 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 Output 1 none switched dc open collector 5A mechanical relay form C process V mA or 0 5A SSR form A Output 2 0 5A SSR form A none 15A NO ARC N 5A mechanical relay form A Standard Bus Zone Address 1 16 Supervisory amp Power Board Limit Controller Board optional Address 1 247 Output 3 none switched dc open collector 5A mechanical relay form C process V mA or 0 5A SSR form A be Limit If Limit this output must Output 4 5A mechanical relay form A Output Status
211. sed and all writable parame ters can be written to Pages with security levels greater than 2 will be locked out inaccessible 2 If Set 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 5L o C 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 Lockout Security to 0 4 The operator wants to read and write to the 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 ot
212. sis 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 Algo rithm 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 con trol mode The output goes off 4 The heating action switches off when the process temperature rises above the set point Set Point Temperature Hysteresis 4 NS Process Temperature The heating action switches on when the process temperature drops below the set point minus the hysteresis The heating action switches on at startup Time The cooling action switches on when the process temperature rises above the set point plus the hysteresis n 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 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
213. splay Full values can be read with other interfaces 0 1 to 60 0 seconds solid state relay or switched dc 5 0 to 60 0 seconds mechani cal relay or no arc power control 0 0 to 100 0 100 0 Source is Heat or Cool uo E Volts 104 PTA Milliamps 112 Profile Event Out B Setup Page Parameter Appears in Menu Default When Control is set to Fixed Time Base set to PID Map 1 0 0 to 100 0 0 0 Source is Heat or Cool set to PID Map 1 Off 62 Duplex 212 Cool 20 Heat 36 Retransmit 213 Profile Event Out A Alarm 6 O Always if digit 6 or 10 of part number is an F Analog Always if Input digit 6 or 10 of part number is an F Analog Input 142 Set Point 85 Current 22 Available with PM4 PM8 and PM9 models only Volts Always if digit 6 or 10 of the part number is an F Modbus Rela tive Address Instance 1 Map1 Map2 884 1004 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 2 896 1016 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map 2 898 1018 Offset to next instance Map 1 amp Map 2 equals 30 Instance 1 Map1 Map2 720 840 Instance 3 Map1 Map2 800 920 Instance 1 Map1 Map2 722 842 Instance 3 Map1 Map2 802 922 Instance 1 Map1 Map2 724 844 Instance 3 Map1 Map2 804 924 CIP Class Instance Attribute hex dec 0x6A 106 1to4 3 0x6A 106
214. ss 1 247 TRU TUNE disable Loop amp alarms off Profile disable Digital Output or Input 5 amp 6 optional none switched dc Standard Bus Profile hold resume Profile start Profile start stop Restore user settings Event inputs RUI EZ ZONE Controllers PLC P or HMI Zone Address 1 16 EZ Key Programmable Event Supervisory amp Power Board EIA 485 Communication Standard Bus optional Modbus RTU Slot C Current Transformer Board optional Output 3 none switched dc open collector 5A mechanical relay form C process V mA or 0 5A SSR form A Current gt Transformer Analog Input 2 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 C T P Output 4 Huren Transom none 15A NO ARC switched dc off heat cool alarm event 5A mechanical relay form A or 0 5A SSR form A Output Status Da Um 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 a
215. stance Attribute hex dec 0x97 151 1 to 2 0x17 23 0x97 151 1to2 0x18 24 Ox6B 107 1to2 OxE 14 Ox6B 107 1to2 OxF 15 Ox6B 107 1to2 0x11 17 Ox6B 107 1to2 3 Ox6B 107 1to2 4 Watlow EZ ZONE PM Integrated Controller e 69 o Chapter 6 Setup Page Parameter name Description Control Loop 1 to 2 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 the open loop set point range utput Menu Fn Output Digital 1 to 4 Function Select what func tion will drive this output Output 1 to 4 Function Instance Set the instance of the function selected above Output 1 to 4 Control Set the output con trol type This pa rameter is only used with PID control but can be set anytime Note Setup Page Parameter Appears in Menu When Range Default 100 to 100 100 to 100 oF F Off 62 Limit 126 Profile Event Out B Profile Event Out A Special Function Out 1533 Special Function Out 1532 Cool 20 Heat 36 Alarm 6 Ft b Fixed Time Base 34 Fixed ut b Variable Time Base 108 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 Ma
216. t 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 Process Switched dc cannot use variable time base FJ Universal Process Mechanical rel
217. t Active Temperature Positive Dead Band 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 peau Active Temperature Zero Dead Band gt 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 Watlow EZ ZONE PM Integrated Controller 107 Chapter 9 Features Temperature Negative Dead Band gt Time Adjust the dead band with Dead Band db Operations Page Loop Menu Variable Time Base Variable time base is the preferred method for 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 don
218. t impedance response time 1 second maximum accuracy 1 mA typical T2 PM _IT _____ S2 Watlow EZ ZONE PM Integrated Controller e 24 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 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 suit
219. t 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 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 Turn on power Replace fuse Reset breaker Close interlock switch Reset limit Correct wiring issue Apply correct voltage check
220. t to Off Setup Page Modbus Rela tive Address Instance 1 Map 1 Map2 1906 2386 Instance 2 Map 1 Map2 1976 2456 Instance 1 Map 1 Map2 2172 2652 Instance 2 Map 1 Map2 2252 2732 Instance 1 Map 1 Map2 402 402 Instance 2 CIP Class Instance Attribute hex dec 0x97 151 1to2 OxE 14 Ox6B 107 1to2 7 0x68 104 1 to 2 0x16 22 Profibus Index using the control input Map 1 Map2 482 492 LooP oPEr Loop Menu Loop 1 to 2 Remote Enable Enable this loop to switch control to the remote set point If 9th digit in part number is an R or P no No 59 N YES Yes 106 0x6B 107 1to2 0x15 21 Instance 1 Map1 Map2 2200 2680 Instance 2 Map1 Map2 2280 2760 Instance 1 Mapi1 Map2 2202 2682 Instance 2 Map1 Map2 2282 2762 Instance 1 0x97 151 Map1 Map 2 1to2 1880 2360 1 Instance 2 Map1 Map2 1950 2430 o No Remote en able set to yes 50 0 to 200 0 Heat Al gorithm or Cool Algo rithm Set up Page is set to PID Some values will be rounded off to fit in the four character display Full values can be read with other interfaces Loop 1 to 2 Remote Set Point Type Enable this loop to switch control to the remote set point Auto Auto 10 P 18aj Manual 54 Ox6B 107 1 to 2 0x16 22 Loop 1 to 2 Control Mode Select the method that this loop will use to control oF F Off 62 RUE o Auto 10 PAA Manual 54 Lo
221. tected by double rein 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 0s 2581 LISTED PROC CONT EQ FOR HAZARDOUS LOCATIONS CE APPROVED SP DeviceNet COVORMACE SIED 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 C
222. tem 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 this point the process 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 controlle
223. that are not defective 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 O November 2009 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 llle eee 2 Standard Features and Benefits 0 0 0 cece cece eee 2 Optional Features and Benefits 00 cece cence 2 Chapter 2 Install and Wire llle 13 Chapter 3 Keys and Displays 00 00 cc eee eee eee 32 Attention COd6S eiei coe ts aadedewetaeu reaper edeee PES RES 33 Chapter 4 Home Page 0 cece eee eee 35 Conventions Used in the Menu Pages 00 cee eee es 37 Chapter 5 Operations Page 2 cc eee 39 Chapter 6 Setup Page 2 0 0 2 ee eee 55 Chapter 7 Profiling Page cc cee eee 88 Chapter 8 Factory Page cc cece ee eee 92 Chapter 9 Features 1 0 0 0
224. tices 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 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 Digital Input 7 12 Slot E Common B7 Digital Input Event Conditions DC Input Dry Contact Digital Inputs
225. time power is cycled 3 PR 5 u User Password which is needed for a Us er to acquire access to the control 4 P8 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 default 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 know 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 o C menu Once there follow the steps below Note If Password Security Password Enabled P A 5 E 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 A u or the Administrator Password PA 5 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 ASS prompt will be displayed Proceed to eit
226. tting 33 USE c User sets output power to last open loop set point the user entered 100 Off sets output power 62 Control Loop 1 to 2 Input Error Failure Select what the con troller outputs will do when an input er ror switches control to manual mode Off sets output power 62 Bumpless maintains same output power if it was less than 75 and stable otherwise 096 14 P 18a Manual Fixed sets output power to Manual Power setting 33 USE User sets output power to last open loop set point the user entered 100 Control Loop 1 to 2 Manual Power Set the manual out put power level that will take effect if an input error failure occurs while User Failure Action is set to Manual Fixed Set Point Open Loop Limit Low to Set Point Open Loop Limit High Setup Page Control Loop 1 to 2 Open Loop Detect Enable Turn on the open loop detect feature to monitor a closed loop operation for the ap propriate response no No 59 JE 5 Yes 106 Note Default User CIP Class Instance Attribute hex dec Instance 1 0x97 151 Mapi1 Map2 1to2 1916 2396 0x13 19 Instance 2 Map 1 Map2 1986 2466 Parameter Appears in Menu When Modbus Rela tive Address Cool Al gorithm or Heat Algorithm is set to PID When the Cool and Heat algo rithm are set on Instance 1 0x97 151 Map1 Map2 1to2 1934 2414 0x1C 28 Instance 2 Map1 Map2 2004 2484 0x6
227. ty Setting 94 96 sensor backup 103 Sensor Backup Enable 103 sensor selection 103 Sensor Type 57 101 103 Serial Number 96 Set Lockout Security 113 set point high limit 103 Set Point High Limit Open Loop 70 set point low limit 103 Set Point Low Limit Open Loop 70 Setup Page 55 Sides Alarm 74 e 127 Limit 66 Silencing 74 112 single set point ramping 108 Software Build 96 Software Revision 96 Source 73 Source Function A 56 Source Function E 56 Source Instance A 56 Source Instance E 56 Special Output Function 56 Special Output Function Menu 50 Step Time Remaining 53 System Security 99 113 T Target Set Point 89 temperature units indicator lights 32 Thermistor 57 Time Base 64 71 Time Derivative 46 101 107 Time Integral 46 101 107 TRU TUNE Band 67 101 TRU TUNE Enable 67 101 TRU TUNE Gain 67 101 tuning the PID parameters 100 Type 73 111 U Up Key 32 upper display 32 User Failure Action 68 User Password 95 User Restore Set 81 100 User Save Set 81 100 User Tune Aggressiveness 100 using the software 112 V Valve Travel Time 56 variable time base 108 W Wait Event 1 and 2 90 91 Wait For Process Instance 90 Wait For Time 89 weight 122 wiring digital input or output 5 22 23 digital input or output 6 23 EIA 232 485 Modbus RTU commu nications 29 high power 22 input 1 process 24 input 1 RTD 23 input 1 thermocouple 23 input 2 current transformer 24 input 2 thermocouple 24
228. uctive 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 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 Watlow EZ ZONE PM Integrated Controller 104 Chapter 9 Features 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 9 Select the signal to retransmit with Retransmit Source r 5r Range High Output Scale Range Low Scale Low Scale High Retransmit Source Set the range of the process output with Scale Low _
229. ue needs to move before the output turns on Loop 1 to 2 Time Integral Set the PID integral for the outputs Loop 1 to 2 Time Derivative Set the PID deriva tive time for the out puts 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 Loop 1 to 2 Open Loop Set Point Set a fixed level of output power when in manual open loop mode Note Operations Page Parameter Appears in Menu When Default Cool Al gorithm Setup Page is set to On Off 0 001 to 9 999 000 F or units 1 110 555 to 5 555 000 C Heat Al gorithm or Cool Algo rithm Set up Page is set to PID 0 to 9 999 seconds per repeat 0 to 9 999 seconds 0 0 seconds Heat Al gorithm or Cool Algo rithm Set up Page is set to PID 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 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 1902 CIP Class Instance Attribute hex dec 0x97 151 1to2 OxC 12 Profibus Index Map 2 2382 Instance 2
230. 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 common X Output 1 3 Switched DC Open Collector SlotA B Switched DC e 30 mA dc maximum supply cur rent 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 3 pole up to 2 in series dc open collector WwW dc le Y 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 IC Output 3 X3 W3 Y3 PM __ __I C Switched DC E lg common 7 Iw dc O a 24V e a dc Q boLlscrcn o ctesncond Open Collector
231. uple 0 000 mV 50 000 mV millivolts 0 000 mV 50 000 mV miimps ooma zoom Thermistor 5K 50 00 Q 5000 00 Q Thermistor 10K 50 00 Q 10000 00 Q Thermistor 20K 50 00 Q 20000 00 Q Thermistor 40K 50 00 Q 40000 00 Q 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 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 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 Follow these steps for an RTD input 1 Measure the low source resistance to ensu
232. urrent 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 Current Menu and Heater Error Opera tions Page Current Menu 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 EZ Key to start and stop a profile 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 Level appears in the lower display Use an ar row 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 Pro file Start Stop 4 Press the Advance Key The lower display will show Digital Function Fn Press the Up O or Down Q key to scr
233. usts 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 on Ky i on KA Analog Input 1 Source A Output P OR PV Function
234. ut Control 64 70 Output Function 101 PV Offset 41 Minimum Off Time 78 Output High Power Scale 4 71 Output Low Power Scale 4 71 Minimum On Time 78 Open Loop Set Point 46 Output Point 2 60 Output Point 3 60 Output Point 4 60 Output Point 5 61 Output Point 6 61 Output Point 7 61 Output Point 8 61 Output Point 9 62 Output Point 10 62 Output Time Base 64 71 Output Menu 70 Output Type 71 Output Value 1 50 Output Value 2 50 Output Value 49 Profibus Node Address 83 Administrator Password 95 Password Enable 94 Password 96 User Password 95 Peltier Delay 68 Process Error Enable 58 Process Error Low 58 Pan Part Number 96 Power Off Level A 77 Power Off level B 77 Power On Level A 77 Power On Level B 77 Power Out Time 56 Profile Status Menu 51 Profile Type 80 Pressure Units 62 Process Value Menu 62 Process Value Active 44 Remote Enable 44 104 Software Revision 96 Range High 58 72 103 04 Range Low 58 72 103 04 Read Lockout Security 94 13 Rolling Password 95 Ramp Action 69 108 Ramping 33 J C Rx o o P4 nr o hy 3 Oo mt fr o N fr o J o oo Oo 3 fr o o o Lo fu o Oo EN o o lt o Oo un o O 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
235. utput 1 Source Function A Set the type of func tion that will be used for this source Special Output 1 Source Instance A Set the instance of the function selected above Special Output 1 Source Function B Set the type of func tion that will be used for this source Special Output 1 Source Instance B Set the instance of the function selected above Special Output 1 Power On Level A Compressor 1 power on level Special Output 1 Power Off Level A Compressor 1 power off level Special Output 1 Power On Level B Compressor 2 power on level Special Output 1 Power Off Level B Compressor 1 power off level Note Setup Page idi Special Output Function Menu oF F Off 62 u RC Motorized Valve 1508 Compressor Control None 61 Power Control Loop 73 amp P c Heat Power Control Loop 160 P Cool Power Control Loop 161 None 61 Power Control Loop 73 h P c Heat Power Control Loop 160 Cool Power Control Loop 161 100 00 to 100 0046 100 00 to 100 0046 100 00 to 100 0096 100 00 to 100 0046 Parameter Appears in Menu When Always if 12th digit of part num ber is a C PMA 8 and 9 only Function is not set to Off Function is not set to Off Function is set to Compres Sor Function is set to Compres Sor Function is set to Compres sor Function is set to Compres sor
236. 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 Source A Analog Input 1 Analog Input 2 Source B Output Cp PV Function Soy A fo Or Qv Ing 5 Output n 0 to 100 Heat Source A Heat Power Cool Power Control L 1 eon OTEA TROR 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 the heater Systems with long lag times be tween the energy source heater steam etc and the measured process value cannot be controlled accu
237. yed value Analog Input 1 to 2 Sensor Backup En able Enable sensor Linearization 1 to 2 Function Set how this function will linearize Source A which is Analog Input 1 Source A of Linearization 2 is Analog Input 2 Un t Linearization 1 to 2 Unit Units Set the units of Source A or Analog Input 1 Source A of Linearization 2 is Analog Input 2 Note oF F Off 62 on On 63 Whole 105 Tenths 94 Hundredths 40 Thousandths 96 oF F Off 62 Interpolated 1482 Source 1539 Relative Humidty Process 75 Power 73 Relative Tempera 1541 Absolute Tempera 1540 ponE None 61 Setup Page Default Off Parameter Appears in Menu When Always Instance 1 Map1 Map2 414 414 Instance 2 Map1 Map2 494 504 Always Instance 1 Map1 Map2 398 398 Instance 2 Map1 Map2 478 488 Always Instance 1 Map1 Map2 410 410 Instance 2 Map1 Map2 490 500 Modbus Rela tive Address Instance 1 Map1 Map2 3568 Instance 2 Map 1 Map2 3638 Always if part num ber digit 4 is C R J B E or N PMS8 and 9 only Instance 1 Map1 Map2 3616 Instance 2 Map 1 Map2 3686 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 0x1C 28 0x68 104 1 to 2 0x14 20

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