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ZESTA ZEL-L Series User Manual

Temperature limit controller
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User's Manual
ZEL-L62 / ZEL-L42 / ZEL-L22
Temperature Limit Controller
English
UM0L621B-0922
September 2022
Zesta Engineering Ltd. ● 212 Watline Avenue, Mississauga, ON L4Z 1P4
(905) 568-3100 ● www.zesta.com

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  • Page 1 User’s Manual ZEL-L62 / ZEL-L42 / ZEL-L22 Temperature Limit Controller English Zesta Engineering Ltd. ● 212 Watline Avenue, Mississauga, ON L4Z 1P4 UM0L621B-0922 (905) 568-3100 ● www.zesta.com September 2022...
  • Page 2 The documentation and the software included with this product are copyrighted 2020 by Zesta Engineering Ltd. All rights are reserved. Zesta Engineering Ltd. reserves the right to make improvements in the products described in this manual at any time without notice.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1 INTRODUCTION ..............................7 1.1 Introduction ......................................7 1.2 Features ........................................ 7 1.3 Limit Control Function ..................................9 1.3.1 High Limit Control ..................................9 1.3.2 Low Limit Control ................................... 9 1.3.3 High / Low Limit Control ................................. 9 1.3.4 Using Limit control Function ................................
  • Page 4 2.9 Event Input Wiring ..................................... 50 2.10 Retransmission Wiring ..................................50 2.11 RS-485 Data Communication ................................51 3 PROGRAMMING .............................. 52 3.1 User Security ...................................... 52 3.2 Calibration Security ................................... 52 3.3 Signal Input ......................................52 3.4 Limit Control Output ..................................53 3.5 Set Point Range ....................................
  • Page 5 6.1.2 Function Code 06: Pre-set Single Register ..........................68 6.1.3 Function Code 16: Pre-set Multiple Register ..........................68 6.2 Exception Responses ..................................69 6.3 Parameter Mapping .................................... 69 6.4 Error Code ......................................69 6.5 Mode ........................................69 6.6 PROG Code ......................................70 6.7 Scaling ........................................
  • Page 6 ZEL-L22 TERMINAL CONNECTION– LOW VOLTAGE INPUT POWER ....................46 POWER WIRING ....................................... 47 ZEL-L42 SENSOR INPUT WIRING ................................48 ZEL-L62 SENSOR INPUT WIRING ................................48 ZEL-L22 SENSOR INPUT WIRING ................................48 OUTPUT 1 RELAY TO DRIVE LOAD ................................ 48 OUTPUT 1 RELAY TO DRIVE CONTACTOR ............................49 OUTPUT1 PULSED VOLTAGE TO DRIVE SSR ............................

  • Page 7: Introduction

    1 Introduction 1.1 Introduction The ZEL-L22, ZEL-L62 & ZEL-L42 are FM approved limit controllers that can be configured either as a high limit or as a low limit controller by the user. These limit controllers are powered by an 11-26 or 90-250 VDC / VAC supply, incorporating a 2 Amp relay output as a standard.
  • Page 8 High Accuracy This series of limit controllers are manufactured using an innovative technology which contains an 18-bit A to D converter for high-resolution measurement (true 0.1°F resolution for thermocouple and PT100 sensors). Fast Sampling Rate The sampling rate of the input A to D converter reaches 200 msec. This fast sampling rate allows the limit controller to protect fast processes.

  • Page 9: Limit Control Function

    1.3 Limit Control Function When a temperature controller is controlling the temperature of a furnace or other heating device, a malfunction in the temperature controller may cause the furnace temperature to rise, resulting in damage to the heated product or the furnace itself. When this situation occurs with the Limit controller, if the temperature rises above the pre-set limit temperature (Heating Application), the limit output will open and the heater system circuit can be shut down to stop the heat source.

  • Page 10: Specifications

    1.4 Specifications Specification ZEL-L22 ZEL-L62 ZEL-L42 Power Supply 90 to 250VAC, 47 to63Hz, 20 to 28 VAC,47-63Hz / 11 to 40 VDC Power 8VA, 4W Maximum 10VA, 5W Maximum., 12VA,6W Maximum Consumption Over Voltage Category Signal Input Type Thermocouple (J, K, T, E, B, R, S, N, L, U, P, C, D), RTD(PT100(DIN), PT100(JIS)), Current(mA), Voltage (V, mV) Resolution 18 Bits Sampling Rate...
  • Page 11 Specification ZEL-L22 ZEL-L62 ZEL-L42 Remote Lock, Remote Reset Output1, HSP2, LSP2, HLS2, HSP3, LSP3, HLS3, Reset Alarm1, Reset Alarm2, Reset Alarm 3, Reset Functions All Alarms, Cancel Latch, Reset Reference data Output 1 /Output 2 Limit Control High Limit, Low Limit and High / Low Limit Function Type Relay, Pulsed Voltage...
  • Page 12 Specification ZEL-L22 ZEL-L62 ZEL-L42 Lower Display 0.25” (6.5mm) 0.3” (7.8mm) 0.55” (14mm) Size Programming Port Interface Micro USB Communication Firmware upgrade Function Environmental and Physical Specifications Operating -10°C to 50°C Temperature Storage -40°C to 60°C Temperature Humidity 0 to 90 % RH (Non-Condensing) Altitude 2000 Meters Maximum Pollution...

  • Page 13: Ordering Code

    1.5 Ordering Code 1.5.1 ZEL-L42 Ordering Code ZEL-L42 – Power Input 4: 90 to 250 VAC, 47-63Hz 5: 20 to 28 VAC, 47-63Hz / 11 to 40 VDC Output 1 1: Form A Relay (2A, 250V) 2: SSRD, 5VDC/30mA (33Ω, ¼W *2) C: SSRD, 14VDC/40mA (OM94-7) Output 2 / Alarm 1 0: None...

  • Page 14: Zel-L62 Ordering Code

    1.5.2 L62 Ordering Code ZEL-L62 – Power Input 4: 90 to 250 VAC, 47-63Hz 5: 20 to 28 VAC, 47-63Hz / 11 to 40 VDC Output 1 1: Form A Relay (2A, 250V) 2: SSRD, 5VDC/30mA (33Ω, ¼W *2) C: SSRD, 14VDC/40mA (OM94-7) Output 2 / Alarm 1 0: None 1: Form A Relay (2A, 250V)

  • Page 15: Zel-L22 Ordering Code

    1.5.3 L22 Ordering Code ZEL-L22 – Power Input 4: 90 to 250 VAC, 47-63Hz 5: 20 to 28 VAC,47-63Hz / 11 to 40 VDC Output 1 1: Form A Relay (2A, 250V) 2: SSRD, 5VDC/30mA (33Ω, ¼W *2) C: SSRD, 14VDC/40mA (OM94-7) Output 2 / Alarm 1 0: None 1: Form A Relay (2A, 250V)

  • Page 16: Programming Port

    1.6 Programming Port A Micro USB Port provided on the limit controller can be used to connect to a PC by using a programming port cable (CC98-1) and a programming adapter (PA98-1) for firmware upgrades. The limit controller can also be connected to an ATE system for automatic calibration and testing using the micro-USB port.

  • Page 17: Keys And Displays

    1.7 Keys and Displays KEYPAD OPERATION SCROLL KEY: This key is used to select a parameter to be viewed or adjusted and navigate to the next parameter. ENTER KEY: Press and hold for 5 seconds or longer to: 1. Enter the setup menu. The display will show. Press and hold for 8.6 seconds, then let go to select calibration mode.

  • Page 18: Zel-L42 Front Panel Keys And Display

    1-3 ZEL-L42 Front Panel Keys and Display 1-4 ZEL-L62 Front Panel Keys and Display Page 18 of 71...

  • Page 19: Menu Flowchart

    1-5 ZEL-L22 Front Panel Keys and Display 1-6 How Characters are Displayed on the LCD screen 1.8 Menu Flowchart The Menu has been divided into 3 groups. They are as follows: User Menu Setup Menu Calibration Mode Menu Page 19 of 71...

  • Page 20: User Access Menu

    User Menu Setup Menu Calibration Menu User Menu 5 Sec 6.2 Sec 7.4 Sec PV,SV CALI 2 Sec Min 3 Sec Max To access parameters refer To access parameters refer To access parameters refer Section 1.8.3 Section 1.8.2 Section 1.8.1 Press for the next parameter Press...

  • Page 21: Setup Menu

    Note: ❖ Calibration modes will break the limit loop and change some of the previous setting data. Make sure that the system is allowable to apply these modes. ❖ The flow chart shows a complete list of all parameters. For actual application, the number of available parameters will vary depending on the setup and model of the limit controller and will be less than that shown in the flow chart.

  • Page 22: Basic Menu (Base)

    1.8.3.1 Basic Menu (bASE) Once SET is displayed in the upper display, use key until bASE is displayed in the lower display. Then use key to access to basic menu parameters. The upper display will show the parameters and the lower display will show its selection. 1-9 Basic Menu Page 22 of 71...

  • Page 23: Output Menu (Out)

    1.8.3.2 Output Menu (OUT) Once SET is displayed in the upper display, use key until OUT is displayed in the lower display. Then use key to access to output parameters. The upper display will show the parameters and the lower display will show its selection. 5 Sec PV,SV OUT1...

  • Page 24: Alarm Menu (Alrm)

    1.8.3.4 Alarm Menu (ALRM) Once SET is displayed in the upper display, use key until ALRM is displayed in the lower display. Then use key to access to alarm parameters. The upper display will show the parameters and the lower display will show its selection. 5 Sec ALRM PV,SV...

  • Page 25: User Menu (Sel)

    1.8.3.6 User Menu (SEL) Once SET is displayed in the upper display, use key until SEL is displayed in the lower display. Then use key to access to user menu parameters. The upper display will show the parameters and the lower display will show its selection. 1-14 User Menu (SEL) 1.9 Parameter Availability Table Register...
  • Page 26 Register Parameter Existence Conditions Address Notation A1MD ✓ ✓ ✓ Exists if OUT2 selects AL1 and A1FN selects PVHI or PVLO A1HY Exists if OUT2 selects AL1 and A1FN selects PVHI or PVLO ✓ ✓ ✓ A1FT Exists if OUT2 selects AL1 and A1FN selects PVHI or PVLO ✓...

  • Page 27: Parameter Availability Table

    Register Parameter Existence Conditions Address Notation CJCL ✓ ✓ ✓ Exists unconditionally CJCT Exists unconditionally ✓ ✓ ✓ T.ABN Exists unconditionally ✓ ✓ ✓ ✓ ✓ ✓ Exists unconditionally HSV1 ✓ ✓ ✓ Exists unconditionally LSV1 Exists unconditionally ✓ ✓ ✓...

  • Page 28: Parameters Description

    1.10 Parameters Description Modbus Data Scale Parameter Parameter Default Register Range Access Notation Description Value High Address Type High Limit Set Low: HSP.L 100.0°C HSP1 -19999 45536 Point1 High: HSP.H (212.0°F) Low Limit Set Low: LSP.L 0.0°C LSP1 -19999 45536 Point1 High: LSP.H (32.0°F)
  • Page 29 Modbus Data Scale Parameter Parameter Default Register Range Access Notation Description Value High Address Type High limit of Low: HSPL 500.0°C HSPH high limit set -19999 45536 High: 45536 (932.0°F) point value Low limit of low -100.0°C Low: -19999 LSPL limit set point (-148.0°...
  • Page 30 Modbus Data Scale Parameter Parameter Default Register Range Access Notation Description Value High Address Type Alarm 2 A2FN functions for Same as A1FN 65535 alarm 2 output Alarm 2 A2MD Same as A1MD 65535 operation mode Alarm 2 Low: 0.1°C 0.1°...
  • Page 31 Modbus Data Scale Parameter Parameter Default Register Range Access Notation Description Value High Address Type L42: NoNE: Not selected L62: NoNE: Not selected EI1.2: Event input 1 and Event input 2 L22: 0. NoNE: No selected 1. 4-20: 4-20mA retransmission output OFS2 Option 2 65535...
  • Page 32 Modbus Data Scale Parameter Parameter Default Register Range Access Notation Description Value High Address Type NoNE: none LOCK: Remote Lock RRST: Remote Reset HSP2: HSP2 activated to replace HSP1 LSP2: LSP2 activated to replace LSP1 HLS2: HSP2 & LSP2 activated to replace HSP1 & LSP1 HSP3: HSP3 activated to replace HSP1...
  • Page 33 Modbus Data Scale Parameter Parameter Default Register Range Access Notation Description Value High Address Type 2K4: 2.4 Kbits/s baud rate 4K8: 4.8 Kbits/s baud rate 9K6: 9.6 Kbits/s baud rate 14K4: 14.4 Kbits/s baud rate 19K2: 19.2 Kbits/s baud Baud rate of rate BAUD digital...
  • Page 34 Modbus Data Scale Parameter Parameter Default Register Range Access Notation Description Value High Address Type MA1 calibration Low: -1999 MA1G ------ -19999 45536 high coefficient High: 1999 Sensor voltage during cold Low: 0 CJCL ------ 65535 junction High: 7552 calibration low Cold Junction Low: -4000 CJCT...
  • Page 35 Modbus Data Scale Parameter Parameter Default Register Range Access Notation Description Value High Address Type NoNE: No Parameter dISP: DISP o1HY: O1HY A1HY: A1HY A1SP: A1SP A2HY: A2HY 1'st parameter A2SP: A2SP SEL1 for the user OFTL: OFTL 65535 menu OFTH: OFTH CALO: CALO CAHI: CAHI...
  • Page 36 Modbus Data Scale Parameter Parameter Default Register Range Access Notation Description Value High Address Type Current Low Low: SP1L LSV1 Limit Set point ------ -19999 45536 High: SP1H value Accumulated time during Low: 0.0 T.ABN ------ 65535 abnormal High: 6553.5 Minutes condition Operation Low: 0...

  • Page 37: Installation And Wiring

    2 Installation and Wiring Sometimes dangerous voltages capable of causing death are present in this instrument. Before doing the installation or any troubleshooting procedures, the power to the equipment must be switched off and isolated. Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair.

  • Page 38: Zel-L42 Dimension With Clamps

    2-1 L42 Dimension with Clamps Page 38 of 71...

  • Page 39: Zel-L42 Dimension Without Clamp

    2-2 L42 Dimension without Clamp Page 39 of 71...

  • Page 40: Zel-L62 Dimension

    2.2.2 L62 Dimension 2-3 L62 Dimension with clamp Page 40 of 71...

  • Page 41: Zel-L62 Dimension Without Clamp

    2-4 L62 Dimension without Clamp Page 41 of 71...

  • Page 42: Zel-L22 Dimension

    2.2.3 L22 Dimension 2-5 L22 Dimension Page 42 of 71...

  • Page 43: Wiring Precautions

    2.3 Wiring Precautions Before wiring, verify the label for correct model number and options. Switch off the power when checking. The utmost care must be taken to ensure that maximum voltage rating specified on the label are not exceeded. All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools.

  • Page 44: Zel-L42 Terminal Connection

    2.3.1 ZEL-L42 Terminal Connection 2-7 ZEL-L42 Rear Terminal Connection – High Voltage Input Power 2-8 ZEL-L42 Rear Terminal Connection – Low Voltage Input Power Page 44 of 71...

  • Page 45: Zel-L62 Terminal Connection

    2.3.2 ZEL-L62 Terminal Connection 2-9 ZEL-L62 Rear Terminal Connection – High Voltage Input Power 2-10 ZEL-L62 Rear Terminal Connection – Low Voltage Input Power Page 45 of 71...

  • Page 46: Zel-L22 Terminal Connection

    2.3.3 ZEL-L22 Terminal Connection 2-11 ZEL-L22 Terminal Connection– High Voltage Input Power 2-12 ZEL-L22 Terminal Connection– Low Voltage Input Power Page 46 of 71...

  • Page 47: Power Wiring

    2.4 Power Wiring The limit controller is designed to operate at either 11-26VAC/VDC or 90-250VAC depending on power input option ordered. Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the limit controller. Near the limit controller, a fuse and a switch rated at 2A/250VAC should be equipped as shown below.

  • Page 48: Limit Control Output Wiring

    2-14 L42 Sensor Input Wiring 2-15 L62 Sensor Input Wiring 2-16 L22 Sensor Input Wiring 2.7 Limit Control Output Wiring 2.7.1 Output 1 2-17 Output 1 Relay to Drive Load Page 48 of 71...

  • Page 49: Alarm Wiring

    2-18 Output 1 Relay to Drive Contactor 2-19 Output1 Pulsed voltage to Drive SSR 2.8 Alarm Wiring 2.8.1 Alarm 1(Output 2) 2-20 Alarm 1 Output to Drive Load Page 49 of 71...

  • Page 50: Alarm 2

    2.8.2 Alarm 2 2-21 Alarm 2 Output to Drive Load 2.8.3 Alarm 3 2-22 Alarm 3 Output to Drive Load 2.9 Event Input Wiring The event input can accept a switch (dry contact) or an open collector signal. The event input function (EIFN) is activated as the switch is closed or an open collector (or a logic signal) is pulled down.

  • Page 51: Rs-485 Data Communication

    2-25 Retransmission Wiring - Voltage 2.11 RS-485 Data Communication 2-26 RS-485 Wiring Page 51 of 71...

  • Page 52: Programming

    3 Programming Press for 5 seconds and release to enter the setup menu. Press and release to select the desired parameter. The upper display indicates the parameter symbol, and the lower display indicates the value of the selected parameter. 3.1 User Security There are two parameters PASS (password) and CODE (security code) which will control the data security function.

  • Page 53: Limit Control Output

    (RTD) PT. DN, PT.JS (Linear) 4-20mA, 0-20mA, 0-5V, 1-5V, 0-10V, 0-50mV UNIT: Select the processing unit Range: °C, °F, PU (Process unit). If the unit is neither °C nor °F, then selects PU. DP: Select the resolution of the process value. Range: For Thermocouple and RTD Signal NO.

  • Page 54: Alarm Types

    3.6.1 Alarm Types There are two different types of alarms as listed below that the user can assign to different alarm outputs. 1. PV. HI: Process value high alarm 2. PV. Lo: Process value low alarm A process alarm can set two absolute trigger levels. When the process value is higher than AxSP, a process high alarm (PV.

  • Page 55: Alarm Modes

    3-3 Process Value Low (PV.Lo) 3.6.2 Alarm Modes There are six types of alarm modes available for each alarm function. 1. Normal alarm 2. Latching alarm 3. Normal Alarm Reverse Output 4. Latching Alarm Reverse Output 3.6.2.1 Normal Alarm: ALMD = NoRM When a normal alarm is selected, the alarm output is de-energized in the non-alarm condition and energized in an alarm condition.

  • Page 56: Alarm Failure Transfer

    3-4 Process Value High- Normal Alarm 3-5 Process Value High- Latching Alarm 3.6.3 Alarm Failure Transfer Alarm Failure transfer is activated as the unit enters failure mode. The respective Alarm will go on if ON is set for A1FT, A2FT or A3FT and will go off if OFF is set for A1FT, A2FT or A3FT. The unit will enter failure mode if a sensor break occurs or if the A-D converter fails.

  • Page 57: User Select Menu Configuration

    3.7 User Select Menu Configuration Conventional limit controllers are designed with parameters in a fixed order. If the user needs a friendlier menu operation to suit their application, most conventional limit controllers do not offer a solution. This series limit controllers have the flexibility for the user to select those parameters which are most significant and put these parameters in an easy access USER menu.

  • Page 58: Digital Filter

    3-6 Two Point User Calibration 3.9 Digital Filter In certain applications, the process value is too unstable to be read. To improve this, a programmable low pass filter incorporated in the limit controller can be used. This is a first-order filter with a time constant specified by the FILT parameter.

  • Page 59: Remote Lock

    3.12 Remote Lock If LOCK is selected for E1FN or E2FN, the event input terminals will act as remote lock input. Turning the remote lock switch on will keep all the parameter setting from been changed. If the switch is opened the lock indicator is extinguished and the up/down key is enabled. Depends on the user security configuration, the parameters can be changed.

  • Page 60: Output 1 Failure Transfer

    3.15.1 Output 1 Failure Transfer If Output 1 Failure Transfer is activated, it will perform like the limit controller is in abnormal condition. 3.15.2 Alarm Failure Transfer An alarm failure transfer is activated as the limit controller enters failure mode. After that, the alarm output will transfer to the ON or OFF state which is determined by the set value of A1FT, A2FT and A3FT.

  • Page 61: Event Input Functions

    3.18.1 Event Input Functions ❖ NoNE: none ❖ LOCK: Remote Lock. If LOCK is selected for E1FN or E2FN, the event input terminals will act as remote lock input. Turning the remote lock switch on will keep all the parameter setting from been changed depends on the user security configuration.

  • Page 62: Applications

    4 Applications 4.1 Limit Controller Application Wiring 4-1 Limit Controller Application Wiring Page 62 of 71...

  • Page 63: High Temperature Protection With Remote Reset

    4.2 High Temperature Protection with Remote Reset An oven uses a single-phase heater to heat the process. A single loop temperature control ZEL-C62 is used to regulate the temperature. A limit control ZEL-L62 is used to protect the process from being over heated. The wiring diagram is shown below.

  • Page 64: Calibration

    5 Calibration Do not proceed through this section unless there is a definite need to re-calibrate the limit controller. All previous calibration data will be lost. Do not attempt recalibration unless you have appropriate calibration equipment. If calibration data is lost, you will need to return the limit controller to your supplier who may charge you a service fee to re-calibrate the limit controller.

  • Page 65: Calibrate Gain Of Cold Junction Compensation

    5-1 Cold Junction calibration Setup Let limit controller sit at least 20 minutes in a room temperature of 25±3°C. The 5520A calibrator is to be configured as a K type thermocouple output with internal compensation. Send a 0.00°C signal to the limit controller.

  • Page 66: Calibrate Linear Input

    5.1.1.6 Calibrate Linear Input Select the input type as 0 to 10V in the INPT parameter in bASE menu configuration. Press and hold the scroll key until appears on the display, then release the scroll key. Press the scroll key for 2-3 seconds then release, the display will show and the unit will enter the calibration mode.

  • Page 67: Communication

    6 Communication This chapter explains the Modbus Communication protocol of the limit controller using RS-485 communication. This supports only RTU mode. Data is transmitted as 8-bit binary bytes with 1 start bit,1 stop bit and optional parity checking (None, Odd, Even). Baud rate may be set to 2400, 4800, 9600, 14400, 19200, 28800, 38400, 57600 and 115200 BPS.

  • Page 68: Function Code 06: Pre-Set Single Register

    6.1.2 Function Code 06: Pre-set Single Register Slave Address (1~247) Slave Address (1~247) Function Code (06) Function Code (06) Starting Address of Register Hi (00) Starting Address of Register Hi (00) Starting Address of Register Lo Starting Address of Register Lo Query (From Response (00~49,51~88,128~132,139,140,142,143)

  • Page 69: Exception Responses

    6-3 Function Code 16 6.2 Exception Responses If the limit controller receives a message which contains a corrupted character (parity check error, framing error etc.), or if the CRC16 check fails, the limit controller ignores the message. However, if the limit controller receives a syntactically correct message which contains an illegal value, it will send an exception response, consisting of five bytes as follows: Slave address +offset function code + exception code + CRC16 Hi +CRC16 Lo...

  • Page 70: Prog Code

    6-6 Operation Mode Bit wise description of Mode register value as below. Operation Mode: Event Input: Alarm: Event Input: All Bit OFF: Normal Bit 4: EI1(0x0001) Bit 0: Alarm1(0x0001) Bit 12: N.A. Mode (0x0000) Bit 5: EI2(0x0010) Bit 1: Alarm2(0x0010) Bit 13: N.A.

  • Page 71: Read All Parameters

    Calibrate MA1G MA1G 003C ✓ 26661 6825 Reset Do same action as Reset Key … … … ✓ ✓ 6-9 Command Register ZESTA ENGINEERING LTD. 212 Watline Avenue Mississauga, ON L4Z 1P4 Canada (905) 568-3100 www.zesta.com Page 71 of 71...

This manual is also suitable for:

Zel-l62Zel-l42Zel-l22

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