Watlow Ez-zone pm User manual

0600-0058-0000 Rev. P Made in the U.S.A.

August 2016

User’s Guide

EZ-ZONE®PM

PID Controller Models

1241 Bundy Boulevard., Winona, Minnesota USA 55987

Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507

http://www.watlow.com

TOTAL

3 Year W arranty

CUSTOMER

SATISFACTION

Registered Company

Winona, Minnesota USA

ISO 9001

Safety Information

We use note, caution and warning symbols throughout 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 information that is important for protecting your

equipment and performance. Be especially careful to read and follow all cautions that

apply to your application.

• A “WARNING” safety alert appears with information 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, Ó(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 User's Guide for further information.

ESD Sensitive product, use proper grounding and handling techniques

when installing or servicing product.

Unit protected by double/reinforced insulation for shock hazard preven-

tion.

Do not throw in trash, use proper recycling techniques or consult manu-

facturer for proper disposal.

Enclosure made of Polycarbonate material. Use proper recycling tech-

niques or consult manufacturer for proper disposal.

Unit can be powered with either alternating current (ac) voltage or direct

current (dc) voltage.

Unit is a Listed device per Underwriters Laboratories®. It has been evalu-

ated 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

Unit is a Listed device per Underwriters Laboratories®. It has been evalu-

ated 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

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 approved by Factory Mutual as a Temperature

Limit Device per FM Class 3545 standard. See: www.fmglobal.com

Unit has been reviewed and approved by CSA International for use as

Temperature Indicating-Regulating Equipment per CSA C22.2 No. 24. See:

www.csa-international.org

Unit has been reviewed and approved by ODVA for compliance with

DeviceNet communications protocol. See: www.odva.org

Unit has been reviewed and approved 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, providing that the units have not been

misapplied. Since Watlow has no control over their use, and sometimes misuse, we can-

not guarantee against failure. Watlow’s obligations hereunder, at Watlow’s option, are lim-

ited to replacement, repair or refund of purchase 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 controller, review your configuration infor-

mation to verify that your selections are consistent with your application: inputs, outputs,

alarms, limits, etc. If the problem persists, you can get technical assistance from your local

Watlow representative (see back cover), by e-mailing your questions to wintechsupport@wat-

low.com or 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

• All configuration information

• User's Guide

• 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:

• Ship-to address

• Bill-to address

• Contact name

• Phone number

• Method of return shipment

• Your P.O. number

• Detailed description of the problem

• Any special instructions

• Name and phone number of person returning the product.

2. Prior approval and an Return Merchandise Authorization number from the Customer

Service Department is required when returning any product for credit, repair or evalu-

ation. Make sure the Return Merchandise Authorization number is on the outside of the

carton and on all paperwork returned. Ship on a Freight Prepaid basis.

3. After we receive your return, we will examine it and try to verify the reason for return-

ing it.

4. In cases of manufacturing defect, we will enter a repair order, replacement order or

issue credit for material returned. In cases of customer misuse, we will provide repair

costs and request a purchase order to proceed with the repair work.

5. To return products that are not defective, goods must be in new condition, in the origi-

nal boxes and they must be returned within 120 days of receipt. A 20 percent restocking

charge is applied for all returned stock controls and accessories.

6. If the unit cannot be repaired, 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.

7. Watlow reserves the right to charge for no trouble found (NTF) returns.

This EZ-ZONE®PM User’s Guide is copyrighted by Watlow Electric, Inc., © August 2016 with

EZ-ZONE PM is covered by U.S. Patent Numbers: 6005577; D553095; D553096; D553097;

D560175; D55766; and OTHER PATENTS PENDING

Watlow EZ-ZONE®PM PID Controller •1 • Table of Contents

Table of Contents ..................................1

Chapter 1: Overview ................................5

Available EZ-ZONE PM Literature and Resources .................5

Introduction ..............................................6

Getting Started Quickly .....................................7

A Conceptual View of the PM ................................8

Inputs .................................................8

Internal Functions........................................9

Outputs................................................9

Input Events and Output Events .............................9

What is a Profile.........................................9

Chapter 2: Install and Wire...........................11

Dimensions .............................................11

1/32 DIN..............................................11

1/16 DIN..............................................12

1/8 DIN (PM8) Vertical...................................13

1/8 DIN (PM8) Vertical Recommended Panel Spacing...........13

1/8 DIN (PM9) Horizontal.................................14

1/8 DIN (PM9) Horizontal Recommended Panel Spacing ........14

1/4 DIN (PM4) .........................................15

1/4 DIN (PM4) Recommended Panel Spacing .................15

Installation ..............................................16

Wiring .................................................18

EZ-ZONE PM Isolation Blocks ...............................20

Chapter 3: Keys and Displays .........................34

Responding to a Displayed Message ..........................35

Chapter 4: Home Page..............................36

Default Home Page Parameters ..............................36

Navigating the EZ-ZONE®PM PID Controller ..................37

Changing the Set Point...................................37

Starting a Profile from the Home Page.......................38

Modifying the Display Pairs ...............................40

Conventions Used in the Menu Pages .......................41

Display ...............................................42

Range ................................................42

Modbus RTU Protocols ..................................42

Table of Contents

Watlow EZ-ZONE®PM PID Controller •2 • Table of Contents

TC Table of Contents (cont.)

Chapter 5: Operations Page ..........................44

Analog Input Menu......................................46

Linearization Menu ......................................47

Process Value Menu.....................................48

Digital Input/Output Menu ................................48

Monitor Menu..........................................49

Control Loop Menu......................................50

Alarm Menu ...........................................53

Timer Menu ...........................................55

Profile Status Menu .....................................57

Chapter 6: Setup Page ..............................60

Analog Input Menu......................................63

Linearization Menu ......................................66

Process Value Menu.....................................69

Digital Input/Output Menu ................................70

Control Loop Menu......................................74

Output Menu...........................................81

Alarm Menu ...........................................84

Timer Menu ...........................................89

Function Key...........................................91

Global Menu ...........................................93

Communications Menu...................................96

Real Time Clock Menu ...................................98

Chapter 7: Profiling Page ............................99

Profile Setup ............................................99

Profiling Menu ........................................104

Chapter 8: Factory Page............................110

Custom .............................................111

Lock Menu ...........................................112

Unlock Menu .........................................114

Diagnostics Menu......................................115

Calibration Menu ......................................116

Chapter 9: Features...............................119

Changing PM Integrated Model Number to PM Express ..........121

Saving and Restoring Settings..............................122

Programming the Home Page ..............................123

Watlow EZ-ZONE®PM PID Controller •3 • Table of Contents

TC Table of Contents (cont.)

Tuning the PID Parameters ................................123

Autotune.............................................123

Manual Tuning ........................................124

Autotuning with TRU-TUNE+®..................................125

Inputs.................................................126

Calibration Offset ......................................126

Calibration ...........................................126

Filter Time Constant ....................................128

Sensor Selection.......................................128

Set Point Minimum and Maximum.........................128

Scale High and Scale Low ...............................128

Range High and Range Low ..............................129

Ten Point Linearization ..................................129

Outputs ...............................................129

Duplex ..............................................129

NO-ARC Relay ........................................130

Retransmitting a Process Value or Set Point .................130

Cool Output Curve .....................................131

Control Methods ........................................131

Output Configuration ...................................131

Auto (closed loop) and Manual (open loop) Control ...........132

On-Off Control ........................................133

Proportional and (P) Control .............................133

Proportional and Integral (PI) Control ......................134

Proportional, Integral and Derivative (PID) Control ............134

Dead Band ...........................................134

Variable Time Base .....................................135

Single Set Point Ramping................................136

Timer Function..........................................137

Setting Up the Timer Function ............................138

Alarms ................................................140

Process and Deviation Alarms ............................140

Set Points............................................140

Hysteresis............................................140

Latching .............................................141

Silencing.............................................141

Blocking .............................................141

Watlow EZ-ZONE®PM PID Controller •4 • Table of Contents

TC Table of Contents (cont.)

Open Loop Detection ...................................141

Using Lockout and Password Security .......................142

Using Lockout Method 2 (Password Enable) .................144

Modbus - Using Programmable Memory Blocks................146

Software Configuration ...................................147

Using EZ-ZONE Configurator Software......................147

Chapter 10: Appendix .............................151

Troubleshooting Alarms, Errors and Control Issues .............151

Modbus - Programmable Memory Blocks .....................157

PM Specifications .......................................160

Ordering Information for PID Controller Models ................166

How to Reach Us........................................168

Watlow EZ-ZONE®PM PID Controller •5 •Chapter 1 Overview

Chapter 1: Overview

Available EZ-ZONE PM Literature and Resources

Document Title and Part Number Description

EZ-ZONE PM Integrated PID

Controller User's Guide, part

number: 0600-0059-0000

Describes how to connect and use an advanced PID loop

controller. This particular model can be ordered with

two loops of PID control and integrated limit controller

with up to 4 outputs. Like all PM controllers, it comes

with Standard Bus communications while also offering

as an option many of the most popular industrial proto-

cols available today.

EZ-ZONE PM Limit (PML) User's

Guide, part number: 0600-

0057-0000

This document describes how to protect against un-

wanted thermal runaway and over temperature condi-

tions through proper configuration, programming. Like

all PM controllers, it comes with Standard Bus communi-

cations. As an additional option, it can also be ordered

with various fieldbus communications protocols.

EZ-ZONE Remote User Interface

(RUI) User's Guide, part num-

ber: 0600-0060-0000

The RUI provides a visual remote LED display for the

PM/RM configuration and setup menus. This document

illustrates and describes connections and also describes

the Home Page for each EZ-ZONE device as viewed from

the RUI.

EZ-ZONE PM Specification

Sheet, part number: wine-

zpm0516

Describes the PM family hardware options, features,

benefits and technical specifications.

Watlow Support Tools DVD,

part number: 0601-0001-0000

Contains all related user documents, tutorial videos, ap-

plication notes, utility tools, etc...

The DVD described above ships with the product and as stated contains all of the literature

above as well as much more. If the DVD is not available one can be acquired by contacting

Watlow Customer Service at 1-507-454-5300.

As an alternative to the DVD, all of the user documentation described above can also be

found on the Watlow website. Click on the following link to nd your document of choice:

http://www.watlow.com/literature/index.cfm. Once there, simply type in the desired part

number (or name) into the search box and download free copies. Printed versions of all user

documents can also be purchased here as well.

Your Comments are Appreciated

In an effort to continually improve our technical literature and ensure that we are providing

information that is useful to you, we would very much appreciate your comments and sug-

gestions. Please send any comments you may have to the following e-mail address:

TechlitComments@watlow.com

Watlow EZ-ZONE®PM PID Controller •6 •Chapter 1 Overview

Introduction

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 Integrated Controller. You now have

the option to integrate a high-amperage power controller output, an over-under limit con-

troller and a high-performance PID controller all in space saving, panel-mount packages. You

can also select from a number of industrial serial communications options to help you man-

age system performance.

Standard Features and Benefits

Advanced PID Control Algorithm

• TRU-T UNE+

Adaptive tune provides tighter control for demanding applications.

• Auto Tune for fast, efficient start ups

High-amperage Power Control Output

• Drives 15 amp resistive loads directly

• Reduces component count

• Saves panel space and simplifies wiring

• Reduces the cost of ownership

EZ-ZONE configuration communications and software

• Saves time and improves the reliability of controller set up

Parameter Save & Restore Memory

• Reduces service calls and down time

Agency approvals: UL Listed, CSA, CE, RoHS, W.E.E.E. FM

• Assures prompt product acceptance

• Reduces end product documentation costs

• Semi F47-0200

P3T Armor Sealing System

• NEMA 4X and IP65 offers water and dust resistance, can be cleaned and washed down (in-

door use only)

• Backed up by UL 50 independent certification to NEMA 4X specification

Three-year warranty

• Demonstrates Watlow’s reliability and product support

Touch-safe Package

• IP2X increased safety for installers and operators

Removable cage clamp wiring connectors

• Reliable wiring, reduced service calls

• Simplified installation

EZ-Key/s

• Programmable EZ-Key enables simple one-touch operation of repetitive user activities

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