Watlow F4T Installation And Troubleshooting User’s Manual
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Watlow F4T Installation And Troubleshooting User’s Manual

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Installation and Troubleshooting
1720-6742 Rev. A
January 2019
Anderson-Bolds ~ 216-360-9800
F4T Controller
User's Guide
1241 Bundy Boulevard., Winona, Minnesota USA 55987
Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507
http://www.watlow.com/F4T
www.anderson-bolds.com
TOTAL
CUSTOMER
SATISFACTION
3 Y ear Warranty
ISO 9001
Registered Company
Winona, Minnesota USA
Made in the U.S.A.

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  • Page 1 Anderson-Bolds ~ 216-360-9800 F4T Controller Installation and Troubleshooting User’s Guide TOTAL CUSTOMER SATISFACTION 3 Y ear Warranty ISO 9001 Registered Company 1241 Bundy Boulevard., Winona, Minnesota USA 55987 Winona, Minnesota USA Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watlow.com/F4T 1720-6742 Rev.
  • Page 2 Anderson-Bolds ~ 216-360-9800 Safety Information We use note, caution and warning symbols throughout this document 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 information that is important for protecting your equipment and performance.
  • Page 3 Temperature Indicating-Regulating Equipment per CSA C22.2 No. 24. See: www.csagroup.org This F4T User’s Guide is copyrighted by Watlow Electric Manufacturing Company, © May 2016 with all rights reserved. • © 2010-2012, QNX Software Systems Limited. All rights reserved. • © 2008 -2014, Crank Software Inc. All rights reserved.

  • Page 4: Table Of Contents

    Available F4T Literature and Resources . . . . . . . . . . . . . . . . . .

  • Page 5: Chapter 1: Overview

    0601-0001-0000 guide described above. To acquire one or more of these documents navigate to the Watlow website where you will have a choice to download free copies or purchase printed versions. Click on the link below to find your document of choice: http://www.watlow.com/F4T.
  • Page 6 Anderson-Bolds ~ 216-360-9800 Warranty This product is warranted by Watlow for a period of 36 months in accordance with the terms and conditions set forth on Watlow's website which can be accessed at www.watlow.com/terms. 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.

  • Page 7: Chapter 2: Install And Wire

    6. Insert all wired I/O connectors onto the applicable modules and apply power to the base. 7. Connect the controller to a computer running Composer™ software using an Ethernet cable (see section "Connecting the F4T Base to a PC"). Dimensions Panel Mount...

  • Page 8: Installing The F4T

    Anderson-Bolds ~ 216-360-9800 Dimensions (cont .) Installing the F4T Panel Mounting the Base 1. Make the panel cutout using the mounting template dimensions above and insert the case assembly into the panel cutout. 2. While pressing the case assembly firmly against the panel, slide the Retention Collar over the back of the controller until the gasket is compressed.

  • Page 9: Flush Mounting The Base

    Anderson-Bolds ~ 216-360-9800 Dimensions (cont .) Flush Mounting the Base 1. Fabricate the mounting panel per the flush mount vertical or horizontal panel template (shown below). 2. Press PEM standoffs (based on panel material) into mounting panel per supplier recom- mendations.
  • Page 10 Anderson-Bolds ~ 216-360-9800 Dimensions (cont .) Wat l ow F 4T I ns t al l & Tr ou b le s h o o tin g Chapter 2 I nst al l and W i r e • • www.anderson-bolds.com...

  • Page 11: Electrical Isolation

    USB Device Isolation Low-voltage Ethernet Port Isolation Low-voltage Isolation: 42V peak Safety Isolation: 2300VÅ (ac) Wiring the F4T Base Identify Connector Pinout Power and Communications Óç Terminal Function Warning: Power input: ac or dc+ Use National Electric (NEC) or other country-...

  • Page 12: Power Requirements

    (ac), (Models F4T _ _ [1, 2, 3, 4]) • 85 to 264V Å • 20.4 to 30.8VÅ (ac) or Î (dc), (Models F4T _ _ [5, 6, 7, 8]) • 50 to 60 Hz • Power consumption 23W, 54VA •...

  • Page 13: Wiring The Modules

    Anderson-Bolds ~ 216-360-9800 5. With the component side of the module facing right (viewing the controller from the rear) insert the module in to the slot until it latches. 6. Remove the screw terminal block from the module. 7. Wire field devices to the appropriate terminals (see. Wiring details for each input and output are provided in the following sections.
  • Page 14 Maintain electrical isolation between the analog input, digital input-outputs, switched dc/ open collector outputs and process outputs to prevent ground loops. Note: The F4T meets IP10 requirements when the empty slots have slot caps installed. Note: Maximum wire size and torque for screw terminations: •...
  • Page 15 Anderson-Bolds ~ 216-360-9800 FM [M, L] A - [L, U, Y*] _ _ A - A _ _ _ • 2 or 3-wire platinum, 100 Lead Wire Resistance and 1,000 Ω @ 32°F (0°C) Each wire for 2-Wire calibration to DIN curve RTDs, not to exceed 10 (0.00385 Ω/Ω/°C) ohms maximum.
  • Page 16 Anderson-Bolds ~ 216-360-9800 Input Connections (cont .) Process (High Density) FMHA - RAAA - A _ _ _ • 0 to 20 mA @ 100 Ω input impedance Volts Amps • 0 to 10VÎ (dc) @ 20 kΩ input impedance •...
  • Page 17 Anderson-Bolds ~ 216-360-9800 Input Connections (cont .) Thermistor FM [M, L] A - [M, T] AAA - A _ _ _ • >20 MΩ input impedance • 0 to 40kΩ, 0 to 20kΩ, 0 to 10kΩ, 0 to 5kΩ • 2.252kΩ and 10kΩ base at 77°F (25°C) •...
  • Page 18 Anderson-Bolds ~ 216-360-9800 Input Connections (cont .) Digital Input FMLA - YEBA - A _ _ _ Voltage Input Dry Contact • Update rate 10Hz • Voltage - Max. input 36V at 3mA common - Input inactive when =< common - Input active when =>...
  • Page 19 Anderson-Bolds ~ 216-360-9800 Example: Using a Current Transformer T/R = 50mA ISC = I = 50mA(R)/T p(full scale) CSI = Output N = Current in secondary of current transformer = Current in primary of current transformer = Number of turns through the primary of the transformer Fuse R = Number of turns in the secondary of the current transformer (Turns ratio, assuming one primary turn)
  • Page 20 Anderson-Bolds ~ 216-360-9800 Output Connections Mechanical Relay Form A FM [M, L]A - _ _ JA - A _ _ _ • 5 A at 240VÅ (ac) or 30VÎ (dc) maxi- mum resistive load • 20 mA at 24V minimum inductive load normally open common...
  • Page 21 Anderson-Bolds ~ 216-360-9800 Output Connections (cont .) Four Mechanical Relays Form A (High Density) FMHA - JAAA - A _ _ _ • 5 A at 240VÅ (ac) or 30VÎ (dc) maxi- mum resistive load normally open normally open • 20 mA at 24V minimum load common normally open common...
  • Page 22 Common put. Normally Open Quad 2 Amp SSR Derating Curve All Outputs 100% Duty Cycle F4T with 2 FMs: 1 quad input and 1 quad 2A SSR FM. Outputs 1 and 3 on. F4T with 2 FMs: 1 quad input and 1 quad 2A SSR FM.
  • Page 23 Anderson-Bolds ~ 216-360-9800 Output Connections (cont .) 3 Mechanical Relays, 2 Form C, 1 Form A (High Density) FMHA - BAAA - A _ _ _ • 5A at 24 to 240VÅ (ac) or 30V Î (dc) maximum resistive load normally open common normally open...
  • Page 24 Anderson-Bolds ~ 216-360-9800 Output Connections (cont .) Tri-Process/Retransmit (High Density) FMHA - FAAA - A _ _ _ • 0 to 20 mA into 400Ω maximum load volts - / current - negative • 0 to 10VÎ (dc) into 4 kΩ minimum volts + / current + 0 to 10 V load...
  • Page 25 Anderson-Bolds ~ 216-360-9800 Output Connections (cont .) Six Digital Outputs (High Density) FMHA - CAAA - A _ _ _ Open Collector Open Collector Outputs Common open collector/switched dc • Maximum switched voltage is 32VÎ open collector/switched dc (dc) open collector/switched dc •...
  • Page 26 Anderson-Bolds ~ 216-360-9800 Output Connections (cont .) relays. As an open collector output, use an external power supply with the negative wired to B1, the positive to the coil of a pilot mechanical relay and the other side of the coil wired to D_.

  • Page 27: Communications Connections

    • 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. Modbus-IDA EIA/TIA-485 Watlow Terminal Function Terminal Name Label CA or CD T-/R- CB or CE...

  • Page 28: Chapter 3: Connecting A Pc

    Understanding the Front Panel Navigational Buttons When looking at the front panel of the F4T, at the bottom of the display, four push buttons are displayed as icons shown below. The text in this graphic was placed there for clarity only and is not present on the front panel.
  • Page 29 • Data Map: [1], 2 - Data Map, the user can switch Modbus registers from the comprehensive listing of F4T registers to a limited set of the legacy F4 controller registers (1 = F4T, 2 = F4 compatibil- ity). To change Ethernet parameters: 1.

  • Page 30: Connecting The F4T Base To A Pc

    Fixed IP Connection If it is desired to connect the F4T directly to a PC as shown in the graphic below follow the steps below to do so. It should be noted too that there are alternatives to the steps defined below, this is one way to do this.

  • Page 31: Composer Software

    Anderson-Bolds ~ 216-360-9800 Composer Software Composer™ is the PC-based software used to configure an F4T controller for a specific ap- plication. Use Composer to configure which flex modules the controller expects to find in each of its slots and to customize the controllers functions for your application. To acquire Composer software free of charge, point your browser to: http://www.watlow.com/F4T.cfm.
  • Page 32 Anderson-Bolds ~ 216-360-9800 Symbols Related to Pluggable Modules As viewed from the Menu bar, the symbol that will be displayed to the left of the Pluggable Modules button will be of the most significance. The red exclamation will always take prece- dence.

  • Page 33: Chapter 4: Calibration

    Anderson-Bolds ~ 216-360-9800 Chapter 4: Calibration Calibrating the F4T Inputs All controllers are calibrated and are accurate to the specified specifications (see Appendix for specifications) when they ship from the manufacturing facility. If an input is suspect as being out of calibration it is recommended that prior to perform- ing any calibration procedure that the user verify that the displayed readings are not within published specifications.

  • Page 34: Calibration Of Analog Inputs

    Note: There are three security settings that can be applied to the calibration screens through the Diagnostics and Troubleshooting (see the System Overview section of the F4T Setup and Operation User's Guide for more information) access point: 1. Full Access - full capabilities to calibrate available 2.

  • Page 35: Using Composer Software To Calibrate Analog Inputs

    6. Follow instructions on the screen. Using the User Interface to Calibrate Analog Inputs To calibrate from the F4T front panel: 1. Push the Menu, Service and Calibration buttons, in that order. 2. Select the desired module and input and then push Perform Field Calibration.

  • Page 36: Chapter 5: Troubleshooting

    Anderson-Bolds ~ 216-360-9800 Chapter 5: Troubleshooting Indication Description Possible Cause(s) Corrective Action Alarm won’t Alarm will not clear • Alarm latching is active • Reset alarm when pro- clear or reset or reset with key- cess is within range or pad or digital input disable latching •...
  • Page 37 Anderson-Bolds ~ 216-360-9800 Indication Description Possible Cause(s) Corrective Action Alarm Low Sensor input below • Temperature is less than • Check cause of under low alarm set point alarm set point temperature • Alarm is set to latching • Clear latched alarm and an alarm occurred in the past •...
  • Page 38 Anderson-Bolds ~ 216-360-9800 Indication Description Possible Cause(s) Corrective Action Limit High Sensor input above • Temperature is greater • Check cause of over high limit set point than limit set point temperature • Limit outputs latch and • Clear limit require reset •...
  • Page 39 Anderson-Bolds ~ 216-360-9800 Indication Description Possible Cause(s) Corrective Action No heat/cool Output does not • Output function is incor- • Set output function cor- action activate load rectly set rectly • Control mode is incor- • Set control mode appro- rectly set priately (Open vs Closed Loop)
  • Page 40 Anderson-Bolds ~ 216-360-9800 Indication Description Possible Cause(s) Corrective Action No Serial Cannot establish se- • Address parameter incor- • Set unique addresses on Communica- rial communications rect network tion with the controller • Incorrect protocol se- • Match protocol between lected devices •...
  • Page 41 Anderson-Bolds ~ 216-360-9800 Indication Description Possible Cause(s) Corrective Action Heater Error Heater Error • Current through load is • Check that the load cur- above current trip set rent is proper. Correct point cause of over current and/or ensure current trip set point is correct.

  • Page 42: Replacing The Battery

    Anderson-Bolds ~ 216-360-9800 Replacing the Battery All F4T controllers are equipped with a field replaceable battery. In a worse case scenario, the battery should be replaced every 7.5 years. If a replacement is required, the part num- ber for the battery is BR 2032. The Watlow part number for the battery is: 0830-0858-0000 Identifying the battery location: 1.
  • Page 43 Because there will always be some residual metals remaining in the battery Watlow recommends that this battery be recycled. Watl o w F 4T I nst al l & Tr o u bl es h o o tin g Chapter 5 Troubl eshooti ng •...

  • Page 44: Chapter 6: Appendix

    • FM Class 3545 (configurations with limit modules) • AMS 2750 E compliant: Analog input process values. Tip: Maximize field calibration accu- racy and uniformity by using advanced F4T features such as Calibration Offset and Linear- ization Function Blocks. Refer to user manual for details.
  • Page 45 • Program the bar code scanner to add an enter key (carriage return feed) at the end of each bar code data field sent to F4T/D4T. Refer to USB scanner user manual. Trending •...
  • Page 46 Anderson-Bolds ~ 216-360-9800 Number of Function Blocks by Ordering Option Function Block Basic Set 1 Set 2 Alarm Compare None Counter None Linearization Logic None Math None Process Value Special Output None Function Timer None Variable Real Time Clock with Battery Backup •...

  • Page 47: F4T Base Ordering Information

    Base includes: Battery Backup, Real-Time Clock, 4.3 inch color graphical touch panel, 2 USB ® host, USB configuration port, standard bus, wired Ethernet Modbus TCP. SCPI protocol and ® backwards compatible Modbus for select key SERIES F4D/P/S parameters (see the F4T Setup and Operation User's Guide) Part Number ① ② ③ ④...

  • Page 48: Flex Modules And Limit I/O Specifications

    Anderson-Bolds ~ 216-360-9800 Flex Modules and Limit I/O Specifications 1 Universal Input • Thermocouple, grounded or ungrounded sensors - >20MΩ input impedance • Max. of 2KΩ source resistance • RTD 2 or 3 wire, platinum, 100Ω and 1000Ω @ 32°F (0°C) calibration to DIN curve (0.00385Ω/Ω/°C) - Maximum lead resistance 10Ω...
  • Page 49 Anderson-Bolds ~ 216-360-9800 Operating Range Input Type Range Low Range High -210 °C 1200 °C -270 °C 1371 °C -270 °C 400 °C -270 °C 1300 °C -270 °C 1000 °C -50 °C 1767 °C -50 °C 1767 °C -50 °C 1816 °C 0 °C 2315 °C...
  • Page 50 • Current input range: 0 to 50mA ac, 100Ω input impedance • Response time: 1 second max., accuracy ±1mA typical • Requires optional current transformer, Watlow part number: 16-0246 Switched DC Output • Switched dc = 22 to 32VÎ (dc) @ 30mA per output, 40mA per pair (option CC) Open Collector Output •...

  • Page 51: Flex Module - Mixed I/O Ordering Information

    Anderson-Bolds ~ 216-360-9800 Universal Process/Retransmit Output • Universal process/retransmit, Output range selectable: - 0 to 10V Î(dc) into a min. 1,000Ω load - 0 to 20mA into max. 800Ω load Resolution - dc ranges: 2.5mV nominal resolution - mA ranges: 5 µA nominal resolution Calibration Accuracy - dc ranges: ±15 mV - mA ranges: ±30 µA...

  • Page 52: Flex Module - Limit Ordering Information

    Anderson-Bolds ~ 216-360-9800 Flex Module - Limit Ordering Information Part Number ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ d Module Future Input and Future Future Custom Custom Options - Firmware, ID Type Option Output Option Options Options and Overlay, Preset Parameters, Hardware...
  • Page 53 Anderson-Bolds ~ 216-360-9800 • Max Error @ Accuracy Accuracy Input Type Units 25 Deg C Range Low Range High ±1.75 Deg C ±2.45 -200 1250 Deg C T (-200 to 350) ±1.55 -200 Deg C ±2.25 1250 Deg C ±2.10 -200 Deg C ±3.9...
  • Page 54 Anderson-Bolds ~ 216-360-9800 Operating Range (cont.) Input Type Range Low Range High mAdc mAac Potentiometer, 1K 1200 range Resistance, 5K range 5000 Resistance, 10K range 10000 Resistance, 20K range 20000 Resistance, 40K range 40000 4 Thermistor Inputs Max Error @ Accuracy Accuracy Input Type...
  • Page 55 2A per output at 240VÅ (ac), max. See table for max. current per output • 50 VA pilot duty at 120/240 VÅ (ac) Quad 2 Amp SSR Derating Curve All Outputs 100% Duty Cycle F4T with 2 FMs: 1 quad input and 1 quad 2A SSR FM. Outputs 1 and 3 on.

  • Page 56: Flex Module - High Density Ordering Information

    Anderson-Bolds ~ 216-360-9800 Flex Module - High Density Ordering Information Part Number ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ d Module Future Input and Future Future Custom Custom Options - Firmware, ID Type Option Output Option Options Options and Overlay, Preset Parameters,...
  • Page 57 Watlow EZ-ZONE FM “Flex Module” to have a ® useful function. All Flex Modules were tested as part of F4T system for compliance with the following directives. 2004/108/EC Electromagnetic Compatibility Directive EN 61326-1 2013 Electrical equipment for measurement, control and laboratory use –...
  • Page 58 Flex Modules are considered components and have no function in and of themselves, it is only when installed in a Watlow EZ-ZONE CC or F4T Base enclosure that they have useful function. Modules were tested as part of these ®...

  • Page 59: How To Reach Us

    Fax: +65 6778 0323 Website: www.watlow.co.k Email: info@watlow.com.sg Website: www.watlow.com.sg 瓦特龍電機股份有限公司 Watlow Electric Manufacturing Company (Shanghai) Co. Ltd. 80143 高雄市前金區七賢二路189號 10樓之一 Greenland International Plaza Room 1306 電話: 07-2885168 傳真: 07-2885568 275-8 East Guoding Road, Yangpu District Shanghai 200433 Watlow Electric Taiwan Corporation China 10F-1 No.189 Chi-Shen 2nd Road Kaohsiung 80143...

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