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

Watlow ez-zone pm integrated controller user manual
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Integrated Controller Models
0600-0059-0000 Rev. C
March 2008
EZ-ZONE
User's Manual
1241 Bundy Boulevard., Winona, Minnesota USA 55987
Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watlow.com
®
PM
TOTAL
CUST T O O M M ER
CUS
ER
S S A A TISF
TISFA A CTI
CTIO O N N
3 Year Warranty
ISO 9001
ISO 9001
Registered Company
Winona, Minnesota USA
Made in the U.S.A.
$15.00

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  • Page 1 Integrated Controller Models Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watlow.com 0600-0059-0000 Rev. C March 2008 ® EZ-ZONE User’s Manual 1241 Bundy Boulevard., Winona, Minnesota USA 55987 TOTAL CUST T O O M M ER S S A A TISF TISFA A CTI CTIO O N N 3 Year Warranty...

  • Page 2: Safety Information

    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.

  • Page 3: Table Of Contents

    Table of Contents Chapter 1: Overview ........2 Standard Features and Benefits .

  • Page 4: Chapter 1: Overview

    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 a PID controller or an over-under limit controller, or you can combine both functions in the PM Integrat- ed Limit Controller.

  • Page 5: A Conceptual View Of The Pm

    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.
  • Page 6 ® EZ-ZONE PM Integrated Model 1/16 DIN with a Current Transformer — Input/Output Universal Sensor Input, Configuration Communications, Input Functions Analog Input 1 thermocouple, input sensor RTD, process (V, mV, mA, 1k po- tentiometer) none, idle set point, alarm reset, tune, silence alarm, manual/auto mode,...
  • Page 7 ® EZ-ZONE PM Integrated Model 1/16 DIN with Remote Set Point — Input/Output Universal Sensor Input, Configuration Communications, Input Functions Analog Input 1 thermocouple, input sensor RTD, process (V, mV, mA, 1k po- tentiometer) none, idle set point, alarm reset, tune, silence alarm, manual/auto mode,...
  • Page 8 ® EZ-ZONE PM Integrated Model 1/16 DIN with a Limit — Input/Output Universal Sensor Input, Configuration Communications, Input Functions Analog Input 1 thermocouple, input sensor RTD, process (V, mV, mA, 1k po- tentiometer) none, limit reset, idle set point, tune, alarm reset, silence alarm, manual/auto mode,...
  • Page 9 ® EZ-ZONE PM Integrated Model 1/16 DIN with Expanded Communications Universal Sensor Input, Configuration Communications, Input Functions Analog Input 1 thermocouple, input sensor RTD, process (V, mV, mA, 1k po- tentiometer) none, idle set point, tune, alarm reset, silence alarm, manual/auto mode, Digital Input (or Output) 5 control outputs off,...

  • Page 10: Chapter 2: Install And Wire

    Chapter 2: Install and Wire Dimensions 15.8 mm (0.62 in) Side 45.2 mm (1.78 in) ® Wat lo w EZ-ZO NE P M I n te g r at e d C o n tr o lle r 101.6 mm (4.00 in) 51.2 mm (2.02 in)

  • Page 11: Installation

    Installation retention collar case 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.

  • Page 12: Chemical Compatibility

    Returning the Controller to its Case 1. Ensure that the orientation of the controller is correct and slide it back into the housing. Note: The controller is keyed so if it feels that it will not slide back in do not force it. Check the orientation again and reinsert after correcting.
  • Page 13 Slot A Slot B Output Terminal Function common (Any switched dc output can use this common.) dc- (open collector) voltage or current - voltage + current + normally open common normally closed normally open common normally open common normally open common Communications Modbus RTU EIA-485 T+/R+...
  • Page 14 Slot C Terminal Function power input: ac or dc+ power input: ac or dc- Standard Bus or Modbus RTU EIA-485 common Standard Bus or Modbus RTU EIA-485 T-/R- Standard Bus or Modbus RTU EIA-485 T+/R+ Standard Bus EIA-485 common Standard Bus EIA-485 T-/R- Standard Bus EIA-485 T+/R+ digital input-output common digital input or output 6...

  • Page 15: Low Power

    Low Power Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.
  • Page 16 Input 1 Thermocouple Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.
  • Page 17 Input 2 Thermocouple Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.
  • Page 18 Input 2 Current Transformer Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.
  • Page 19 Output 1 Switched DC/Open Collector Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.
  • Page 20 Output 1 Solid-state Relay, Form A Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.
  • Page 21 Output 2 Solid-state Relay, Form A Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.
  • Page 22 Output 3 Universal Process Ó volts or current - Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.
  • Page 23 Output 4 Solid-state Relay, Form A Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.
  • Page 24 Standard Bus EIA-485 Communications Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.

  • Page 25: Devicenet™ Communications

    EtherNet/IP™ and Modbus TCP Communications Ó Warning: 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 elec- trical sensors or peripheral devices. Failure to do so may result in damage to equip- ment and property, and/or injury or loss of life.

  • Page 26: Chapter 3: Keys And Displays

    Chapter 3: Keys and Displays Upper Display: In the Home Page, displays the process value, otherwise displays the value of the pa- rameter in the lower display. Zone Display: Indicates the controller zone that the remote user interface (RUI) is currently communi- cating with.

  • Page 27: Navigating The Ez-Zone

    Navigating the EZ-ZONE EZ-ZONE WATLOW ® WATLOW [``Ai] [``70] [`Set] Home Page from anywhere: Press the Infinity Key EZ-ZONE ® WATLOW WATLOW [``70] [``Ai] [``72] Operations Page from Home Page: Press both the Up EZ-ZONE WATLOW ® WATLOW [``Ai] [``70] [``72] Setup Page from Home Page: Press both the Up ¿...

  • Page 28: Chapter 4: Home Page

    Chapter 4: Home Page Default Home Page Parameters The Home Page is a customized list of as many as 20 parameters that can be configured and changed in the Custom Menu [ CUSt] (Factory Page). The default list of nine parameters below includes the Active Process Value (value in upper display) and Active Set Point (value in lower display).
  • Page 29 Display Parameter Name Description [Attn] Attention An active message will cause the display to toggle between the normal settings and the active message in the upper display and [Attn] in the lower display. Your response will depend on the message and the controller set- tings.

  • Page 30: Chapter 5: Operations Page

    Chapter 5: Operations Page To go to the Operations Page from the Home Page, press both the Up ¿ and Down ¯ keys for three sec- onds. [``Ai] will appear in the upper display and [oPEr] will appear in the lower display. •...
  • Page 31 Display Parameter name Description [``Ai] [```1] [oPEr] [``Ai] Analog Input Menu Analog Input 1 or [`Ain] Analog Input (1 or 2) [ Ain] Process Value View the process value. [`i; E r] Analog Input (1 or 2) [ i.Er] Error Status View the cause of the most recent error.
  • Page 32 Display Parameter name Description [Loop] [oPEr] Loop Menu [`r; E n] Loop Remote Enable [ r;En] Switch control to the remote set point. [`r; t y] Loop [ r.ty] Remote Set Point Type Select how the remote set point will be deter- mined.
  • Page 33 Display Parameter name Description [``dB] Loop [ db] 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.
  • Page 34 Display Parameter name Description [P; S tr] Profile Status {P.Str] Profile Start Select a step or profile to load. [P; A Cr] Profile Status {P.ACr] Profile Action Request Select what action to apply to the currently loaded profile. [`StP] Profile Status [ StP] Active Step View the currently running step.

  • Page 35: Chapter 6: Setup Page

    Chapter 6: Setup Page Home Page Setup Page Parameters [~~~1] [~~p~] ˆ ˆ [~`A1] ˆ [~~AI] [~~Sp] <> [~set] ‰ [~sen] [~lin] ‰ ‰ ‰ Analog Input Input 1 Sensor Type Linearization RTD Leads Hold both keys for 6 seconds. Menu Submenu <...
  • Page 36 To go to the Setup Page from the Home Page, press both the Up ¿ and Down ¯ keys for six seconds. [``Ai] will appear in the upper display and [`Set] will appear in the lower display. • Press the Up ¿ or Down ¯ key to move through the menus.
  • Page 37 Dis- Parameter Name play Description [`P; E L] Input (1 or 2) [ P.EL] Process Error Low If the process value drops below this value, it will trigger an input error. [`FiL] Input (1 or 2) [ FiL] Filter Time Filtering smooths out the process signal to both the display and the input.
  • Page 38 Dis- Parameter Name play Description [`leu] Digital Input (5 or 6) [ LEu] Level Select what action will be interpreted as a true state. [``Fn] Digital Input (5 or 6) [ Fn] Function Select the function that will be triggered by a true state.
  • Page 39 Dis- Parameter Name play Description sp; l l Limit [SP.LL] Set Point Limit Low Clamp the operational limit low maximum setting to this value. [`L; i t] Limit [ L.it] Integrate In a limit state the controller will turn off the outputs, terminate an active profile and freeze PID and TRU-TUNE+ tions.
  • Page 40 Dis- Parameter Name play Description [FAiL] Loop [FAiL] Input Error Failure Select what the controller outputs will do when an input error switches control to manual mode. [MAn] Loop [MAn] Manual Power Set the manual output power level that will take effect if an input error failure occurs.
  • Page 41 Dis- Parameter Name play Description [otpt] [```1] [```2] [`Set] [otpt] [otPt] Output Menu Output 1 Output 2 [`o; t y] Output (1 or 3) Type [ o.ty] Select whether the process output will op- erate in volts or milliamps. [``Fn] Output (1 or 3) [ Fn] Function...
  • Page 42 Dis- Parameter Name play Description [``Fn] Output (1 to 4) [ Fn] Function Select what function will drive this output. [``Fi] Output (1 to 4) [ Fi] Function Instance Select which source instance will drive the output. [`o; C t] Output (1 to 4) [ o.Ct] Control...
  • Page 43 Dis- Parameter Name play Description [`A; h y] Alarm (1 to 4) [ A.hy] Hysteresis Set the hysteresis for an alarm. This de- termines how far into the safe region the process value needs to move before the alarm can be cleared. [`A;...
  • Page 44 Dis- Parameter Name play Description [`C; S i] Current [ C.Si] Source Output Instance Select which output instance the current transformer will monitor. [`FUn] [`Set] Function Key Menu [`Leu] Function Key [ LEv] Level Select what state the Function Key will be in at startup.
  • Page 45 Dis- Parameter Name play Description [P; t yp] Global [P.tyP] Profile Type Set the profile startup to be based on a set point or a process value. [`GSE] Global [ gSE] Guaranteed Soak Enable Enables the guaranteed soak deviation function in profiles. [`GSd] Global Guaranteed Soak Deviation...
  • Page 46 Dis- Parameter Name play Description [iP; F 3] Communications 2 IP Fixed Address Part 3 [ip.F3] Set the IP address of this controller. Each device on the network must have a unique address. [iP; F 4] Communications 2 IP Fixed Address Part 4 [ip.F4] Set the IP address of this controller.

  • Page 47: Chapter 7: Profiling Page

    Chapter 7: Profiling Page Navigating the Profiling Page Profi ling Home Page Page Steps ˆ [~~p~] ˆ [~~p1] [~~`1] ‰ [~~Sp] ‰ [FiLe] [``P1] Profi le 1 < Hold key for 3 seconds. < > > Steps 1 to 10 Profi...
  • Page 48 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 [ProF] appears in the lower display and the pro- file number appears in the upper display.
  • Page 49 Display Parameter name Description [hoUr] Step Type Parameters [hoUr] Hours Select the hours (plus Minutes and Seconds) for a timed step. [Min] Step Type Parameters [Min] Minutes Select the minutes (plus Hours and Seconds) for a timed step. [~SEC] Step Type Parameters [ SEC] Seconds Select the seconds (plus Hours and Minutes) for...
  • Page 50 Display Profiling parameters appear if the controller includes profiling (PM6 R _ _ _-_ _ _ _ A _ _). [``ti] Step Types Time [ ti] A Time Step controls at the Target Set Point and maintains two event output states for the designated time. [rAtE] Step Types Rate...

  • Page 51: Chapter 8: Factory Page

    Chapter 8: Factory Page To go to the Factory Page from the Home Page, press and hold both the Advance ‰ and Infinity ˆ keys for six seconds. • Press the Advance Key ‰ to move through the parameter prompts. •...
  • Page 52 Dis- Parameter Name play Description [CUSt] [```1] [FCty] [CUSt] Custom Menu Custom 1 [`PAr] Custom Menu [ PAr] Parameter 1 to 20 Select the parameters that will appear in the Home Page. The Parameter 1 value will ap- pear in the upper display of the Home Page.
  • Page 53 Dis- Parameter Name play Description [rLoC] Lockout Menu [rLoC] Read Lockout Security Set the read security clearance level. The user can access the se- lected level and all lower levels. If the Set Lockout Security level is higher than the Read Lockout Security, the Read Lockout Secu- rity level takes priority.
  • Page 54 Dis- Parameter Name play Description [iP; A 3] Diagnostics Menu [iP.A3] IP Actual Address Part 3 Display the third part of this controller's IP address. [iP; A 4] Diagnostics Menu IP Actual Address Part 4 [iP.A4] Display the fourth part of this controller's IP address.

  • Page 55: Chapter 9 Fea Tur Es

    Chapter 9: Features Saving and Restoring User Settings ......54 Programming the Home Page ......54 Tuning the PID Parameters .

  • Page 56: Saving And Restoring User Settings

    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 [USr;...
  • Page 57 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.

  • Page 58: Calibration Offset

    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+ ously tunes to provide the best possible PID control for the process.

  • Page 59: Receiving A Remote Set Point

    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.
  • Page 60 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 The controller must have two process inputs to use the remote set point feature.

  • Page 61: Control Methods

    Range High Range Low Scale Low Retransmit Source Set the range of the process output with Scale Low [`S; L o] and Scale High [`S; h i]. Scale the re- transmit source to the process output with Range Low [`r; L o] and Range High [`r; h i]. When the retransmit source is at the Range Low value, the retransmit output will be at its Scale Low value.

  • Page 62: Proportional Control

    Set Point Actual Temperature 100% Output Power Time Input Error Latching [`i; E r] (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.

  • Page 63: Proportional Plus Integral (Pi) Control

    In an application with one output assigned to heating and another assigned to cooling, each will have a separate proportional parameter. The heating parameter takes 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.

  • Page 64: Single Set Point Ramping

    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. Cool Output Active Set Point Heat Output Active Negative Dead Band Time Adjust the dead band with Dead Band [``db] (Operations Page, Loop Menu).

  • Page 65: Process And Deviation Alarms

    Set Point degrees per minute Temperature ramps to Set Point at a set rate Time 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.

  • Page 66: Programming The Ez Key

    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. 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...

  • Page 67: Using Lockout To Secure Settings

    Using Lockout to Secure Settings 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.

  • Page 68: Chapter 10: Appendix

    Chapter 10: Appendix Troubleshooting Alarms, Errors and Control Issues Indication Description Alarm won’t clear or Alarm will not clear or reset reset with keypad or digital input Alarm won’t occur Alarm will not activate output • Alarm silencing is active [AL;...
  • Page 69 Indication Description [Li; h 1] Limit High Sensor input above high limit set point [Li; h 2] [LP; o 1] Open Loop Detect is active and the process value did Loop Open Error not deviate by a user-select- ed value in a user specified period.
  • Page 70 Indication Description Process doesn’t con- Process is unstable or never trol to set point reaches set point Temperature runway Process value continues to increase or decrease past set point. [`100] Device Error Controller displays internal malfunction message at [rEtn] power up. [`h;...

  • Page 71: Specifications

    Specifications Line Voltage/Power • 85 to 264VÅ (ac), 47 to 63 Hz • 12 to 40VÎ (dc); 20 to 28VÅ (ac), 47 to 63 Hz • 10VA maximum power consumption • Data retention upon power failure via nonvolatile memory • Compliant with Semi F47-0200, Figure R1-1 voltage sag require- ments @ 24Å...
  • Page 72 Solid-State Relay • 0.5 A @ 24 to 264VÅ (ac) maximum, opto-isolated, without con- tact suppression; maximum off-state leakage current: 105 micro- amperes Electromechanical Relay, Form A • 5 A, 24 to 240VÅ (ac) or 30VÎ (dc) maximum, resistive load, 100,000 cycles at rated load, 125 VA pilot duty •...

  • Page 73: Ordering Information For Integrated Controller Models

    Ordering Information for Integrated Controller Models Controller ® EZ-ZONE Integrated Controller Models Universal Sensor Input, configuration communications ® TRU-TUNE+ Adaptive Tune, red-green 7-segment displays Package Size 1⁄16 DIN Primary Function PID Controller Ramp and Soak Custom Firmware Power Supply, Digital Input/Output 100 to 240VÅ...

  • Page 74: Index

    Index [`A; b L] Alarm Blocking 41, 64 [AC; L F] AC Line Frequency 42, 62 [AC; S P] Active Set Point 32 [Ad; M ] Address Modbus 43 [`Ad; s ] Address Standard Bus 43 [A; d SP] Alarm Display 41 [`A;...
  • Page 75 35, 39, 40 [``oP] Open Loop Set Point 31 [`o; t b] Output Time Base 35, 40 [otPt] Output Menu 39 [`o; t y] Output Type 39 [P; A C1] Profi le Action Request 27 [P; A C1] Profi le Action Request, Home Page 26 [P;...
  • Page 76 deviation alarms 63 Diagnostics Menu 51 Factory Page 49 Digital Input/Output Menu 29, 35 Operations Page 28 Setup Page 33 digital inputs 3 Digital Input Function 3, 42 digital input specifi cations 69 digital output specifi cations 69 dimensions 8, 70 Direction 35 Display 41 displays 24...
  • Page 77 Output Menu 39 Setup Page 33 output power scaling 59 Output State 29 Output Type 39 P, Q P3T armor sealing system 2 Parameter 1 to 20 50 Parity 43 Part Number 51 percent units indicator light 24 process alarms 63 Process Error Enable 34 Process Error Low 35 Process Value 29...

  • Page 78: Declaration Of Conformity

    Series EZ Zone PM Watlow Winona, Inc. 1241 Bundy Blvd. Winona, MN 55987 USA Declares that the following product: Designation: Model Numbers: Classification: Rated Voltage and Frequency: Rated Power Consumption: Environmental Rating: Meets the essential requirements of the following European Union Directives by using the relevant standards show below to indicate compliance.
  • Page 80 传真: 86 21 5080-0902 86 21 5080-0906 电子邮箱: info@watlow.cn Website: www.watlow.cn Watlow Electric Manufacturing (Shanghai) Company 115-22#, 572nd Lane, Bibo Road, Zhangjiang High-Tech Park, Shanghai, PRC 201203 People’s Republic of China Tel: +86 21 5080-0902 Fax: +86 21 5080-0906 Email: info@watlow.cn Website: www.watlow.cn...

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