1、0600-0059-0000 Rev. B Made in the U.S.A. July 2007 $15.00 Users Manual Registered Company Winona, Minnesota USA ISO 9001 ISO 9001 TOTAL 3 Y ear Warranty CUS CUST TO OM MER ER S SA ATISF TISFA ACTI CTIO ON N EZ-ZONE PM Integrated Controller Models 1241 Bundy Boulevard., Winona, Minnesota USA 55987 Ph
2、one: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http:/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
3、 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 dam
4、age. Pay very close attention to all warnings that apply to your application. The safety alert symbol, (an exclamation point in a triangle) precedes a general CAUTION or WARNING statement. The electrical hazard symbol, (a lightning bolt in a triangle) precedes an electric shock hazard CAUTION or WAR
5、NING safety statement. CAUTION or WARNING Electrical Shock HazardCAUTION or WARNING 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 n
6、o control over their use, and some- times misuse, we cannot guarantee against failure. Watlows obligations hereunder, at Watlows 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
7、 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
8、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 wintechsupportwatlow. com or by dialing +1 (507) 494-5656 betwee
9、n 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 Users Manual Factory Page Return Material Authorization (RMA) 1. Call Watlow Customer Service, (50
10、7) 454-5300, for a Return Material Authorization (RMA) num- ber before returning any item for repair. If you do not know why the product failed, contact an Application Engineer or Product Manager. All RMAs require: Ship-to address Bill-to address Contact name Phone number Method of return shipment Y
11、our 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 RMA number from the Customer Service Department is required when returning any product for credit, repair or evalu- ation. Make sure the RMA nu
12、mber is on the out- side 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 returning it. 4. In cases of manufacturing defect, we will enter a repair order, replacement order or issue cred
13、it for material returned. In cases of customer mis-use, we will provide repair costs and request a pur- chase order to proceed with the repair work. 5. To return products that are not defective, goods must be be in new condition, in the original boxes and they must be returned within 120 days of rec
14、eipt. A 20 percent restocking charge is applied for all returned stock controls and accessories. 6. If the unit is unrepairable, you will receive a let- ter 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 r
15、ight to charge for no trouble found (NTF) returns. The EZ-ZONE PM Users Manual is copyrighted by Watlow Winona, Inc., July 2007 with all rights reserved. EZ-ZONE PM is covered by U.S. Patent No. 6,005,577 and Patents PendingWatlow EZ-ZONE PM Integrated Controller 1 Table of Contents TC Table of Cont
16、ents Chapter 1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Standard Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Chapter 2: Install and Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Chapter 3:
17、 Keys and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Attention Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Chapter 4: Home Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Chapter 5: Operations P
18、age . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Chapter 6: Setup Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Chapter 7: Profiling Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Chapter 8: Factory Page . . . . . . . . . .
19、. . . . . . . . . . . . . . . . . . . . . . . .49 Chapter 9: Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Chapter 10: Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Troubleshooting Alarms, Errors and Control Issues . . . . . .
20、 . . . . . . . . 66 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Ordering Information for Integrated Controller Models . . . . . . . . . . . . 71 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21、 . . . . . . . 72 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Watlow EZ-ZONE PM Integrated Controller 2 Chapter 1 Overview Chapter 1: Overview 1 The EZ-ZONE PM takes the pain out of solving your thermal loop requirements. Watlows EZ-ZONE PM contr
22、ollers 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 Inte- grated Limit Controller. You now have the option to integrate a high-amperag
23、e power controller output, an over-under limit controller and a high-perfor- mance PID controller all in space-saving, panel- mount packages. You can also select from a number of serial communications options to help you manage system performance. It just got a whole lot easier to solve the ther- ma
24、l 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 controller, an over-under limit controller or an integrated controller, the EZ-ZONE PM is the an- swer. Standard Features and Benefits Advanced PID
25、Control Algorithm TRU-TUNE+ Adaptive tune provides tighter con- trol 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 owner
26、ship EZ-Zone configuration communications and software Saves time and improves the reliability of control- ler set up FM Approved Over-under Limit with Auxiliary Outputs Increases user and equipment safety for over-un- der temperature conditions Parameter Save procedures; and outputs. Information fl
27、ows from an input to a procedure to an output when the controller is properly configured. A single PM controller can carry out several procedures at the same time, for instance closed-loop control, monitor- ing for several different alarm situations and oper- ating switched devices, such as lights a
28、nd motors. Each process needs to be thought out carefully and the controllers inputs, procedures and outputs set up properly. Inputs 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 a
29、s 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 or RTD to read the temperature of something. It can also read volts, current or resistance, allowing it to use various devices to read hu
30、midity, air pressure, operator inputs and others values. The settings in the Analog Input Menu (Setup Page) for each analog input must be configured to match the device con- nected to that input. Each digital input reads whether a device is active or inactive. A PM with digital input-output hardware
31、 includes two sets of terminals each of which can be used as either an input or an output. Each pair of terminals must be configured to function as either an input 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 P
32、M 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). 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
33、, 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 a function, its important to tell it what source, or instance, to use. For example, an alarm may be set to respo
34、nd to either analog input 1 or 2 (instance 1 or 2, respectively). Keep in mind that a function is a user-pro- grammed internal process that does not execute any action outside of the controller. To have any effect outside of the controller, an output must be config- ured to respond to a function. Ou
35、tputsOutputs can perform various functions or actions in response to information provided by a function, such as operating a heater; turning a light on or off; un- locking a door; or turning on a buzzer. Assign an output to a Function in the Output Menu or Digital Input/Output Menu. Then select whic
36、h 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 instance of a function. For example, alarm 2
37、could be used to trigger a light connected to output 1 and a siren connected to digital output 5. Input Events and Output EventsInput events are internal states that are set by the digital inputs. Digital input 5 provides the state of input event 1, and digital input 6 provides the state of input ev
38、ent 2. Wait for Event steps in profiles are triggered by these events. The setting of Digital Input Function (Setup Page, Digital Input/Output Menu) does not change the relationship between the input and the event, so take care not to configure the function in a way that would conflict with a profil
39、e that uses and input event. An input will still control the input event state, even if Digital Input Function is set to None. Output events are internal states that can only be set by profile steps. Outputs 1 through 4 can be con- figured to respond to output events.Watlow EZ-ZONE PM Integrated Con
40、troller 4 Chapter 1 Overview EZ-ZONE PM Integrated Model 1/16 DIN with a Current Transformer Input/Output (no communications options 2 to 3) Universal Sensor Input, Configuration Communications, Red/Green 7-Segment Display Supervisory & Power Board Slot C PID Controller Board Slot A ramp-soak with 4
41、 les (optional) Output 4 none, switched dc, form A mechanical (5 A) or solid-state (0.5 A) relay Output 3 none, switched dc/open collector, form C mechanical (5 A) or solid-state (0.5 A) relay, process (V, mA) Output 2 none, switched dc, no-arc power control (15 A), form A mechanical (5 A) or solid-
42、state (0.5 A) relay Output 1 none, switched dc/open collector, form C mechanical (5 A) or solid-state (0.5 A) relay, process (V, mA) off, heat, cool, duplex, alarm, retransmit, event off, heat, cool, alarm, event off, heat, cool, alarm, event, retransmit off, heat, cool, alarm, event EZ Key programm
43、able event Digital Output (or Input) 5 (optional) none, switched dc Digital Output (or Input) 6 (optional) none, switched dc off, heat, cool, alarm, event off, heat, cool, alarm, event Network remote user interface, personal computer, programmable logic controller, human- machine interface EIA 485 C
44、ommunications Standard Bus, Modbus RTU (optional) Current Transformer Board (optional) Slot B Analog Input 1 thermocouple, RTD, process (V, mV, mA, 1k po- tentiometer) Digital Input (or Output) 5 (optional) none, switch, volts dc Digital Input (or Output) 6 (optional) none, switch, volts dc Analog I
45、nput 2 current transformer none, idle set point, alarm reset, tune, silence alarm, manual/auto mode, control outputs off, lock keypad, force alarm, TRU-TUNE+ disable loop & alarms off, prole disable, prole hold/resume, prole start, prole start/stop, restore user settings current transformer input sensor Input Functions Output Functions Current Monitoring detects heater current flow provides an alarm indication of a failed-load issue.
