EZ-ZONE® ST User’s Manual Integrated Control Loop TOTAL CUSTOMER SATISFACTION 3 Year Warranty ISO 9001 Registered Company 1241 Bundy Boulevard., Winona, Minnesota USA 55987 Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507 http://www.watlow.com 0600-0052-0000 Rev. F January 2010 Winona, Minnesota USA Made in the U.S.A.
Safety Information Warranty We use note, caution and warning symbols throughout this book to draw your attention to important operational and safety information. The EZ-ZONE® ST 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 cannot guarantee against failure.
TC Table of Contents Chapter 1: Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The EZ-ZONE® ST Provides Total Thermal System Control . . . . . . . . . . . . . . A Conceptual View of the ST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Getting Started Quickly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TC Table of Contents (cont.) Modbus - Using Programmable Memory Blocks. . . . . . . . . . . . . . . . . . . . . . 75 CIP - Communications Capabilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Software Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Chapter 8: Appendix . . . . . . . . . . . . . . . . . . . . . . . . . .
1 Chapter 1: Overview The EZ-ZONE® ST Provides Total Thermal System Control • When used with the optional Remote User Inter face/Gateway (RUI/GTW) the following protocols are available: - EIA 232/485 Modbus RTU - Modbus TCP - EtherNet/IP - DeviceNet - Profibus DP The EZ-ZONE ST solid-state controller offers complete thermal system control in a single package while reducing system complexity and the cost of control-loop ownership.
A Conceptual View of the ST set a state to true or false, or reading a temperature 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, it’s important to tell it what source, or instance, to use. For example, an alarm may be set to respond to either analog input 1 or 2 (instance 1 or 2, respectively). The flexibility of the ST software and hardware allows a large range of configurations.
Note: The output cycle time will have a bearing on the life of mechanical relay outputs and can be different based on the type of output ordered. The output cycle time can be changed in the Setup Page under the Output Menu. Getting Started Quickly The ST control has a page and menu structure that is listed below along with a brief description of its purpose. Setup Page Push and hold the up and down keys (¿ ¯) for 6 seconds to enter.
EZ-ZONE® ST System Diagram Output Functions Input Functions Input Sensor Analog Input 1 none, Thermocouple, RTD (100Ω, 1kΩ), Process (V, mV, mA) PID Controller Output 1 Solid State Relay (form A) off, heat, cool (Optional Ramp/Soak max 4 Output 2 files, 40 steps) 5A Mechanical Relay (form A), or off, heat, cool alarm, event 0.
2 Chapter 2: Install, Wire and Set Address EZ-ZONE® ST with 25A or 40A Contactor 36.2 mm (1.43 in) Front View 156 mm (6.14 in) 25 A heatsink (shown) This dimension same for 40 A heatsink. 41.9 mm (1.65 in) 4 1 35 mm (1.38 in) EZ-ZONE™ ST Patent Pending WARNING: The heat sink can become hot during operation. Integrated Control Loop 177.8 mm (7.00 in) 2 CAUTION: The EZ-ZONE ST must be mounted vertically (as shown) to meet the ampere/ambient-temperature performance curve.
EZ-ZONE ST Without a Contactor Front View 215.1 mm (8.47 in) 51.6 mm (2.03 in) WARNING: The heat sink can become hot during operation. CAUTION: The EZ-ZONE ST must be mounted vertically (as shown) to meet the ampere/ ambient-temperature performance curve. Side View 46 mm (1.18 in) 39.9 mm (1.57 in) 35 mm (1.38 in) 87 mm (3.43 in) 197.1 mm (7.76 in) with 120 and 240Vac fan (shown) 138.5 mm (5.45 in) 184.4 mm (7.26 in) with 24 Vdc fan 28.1 mm (1.11 in) 126.5 mm (4.98 in) 48 mm (1.89 in) 89.
Wiring with a contactor (ST _ _ - (B or F) _ _ _ - _ _ _ _) Ó L3 K3 J3 A1 L4 T2 T2 L4 A1 J3 K3 L3 T2 L4 A1 J3 K3 L3 S2 S2 S1 EZ-ZONE™ ST S2 Patent Pending L3 K3 J3 A1 L4 T2 ST_ L - _ _ _ _ - _ _ _ _ (with limit) OUT 3 LIMIT SSR ON OUT 2 STATUS common (RUI) OUT 2 CF T+/R+ (RUI) T-/R- (RUI) ON 1234 98 99 3 6 fuse Output 1 (SSR) Power Supply ST_ _ - _ _ A _ - _ _ _ _ Remote User Interface (RUI) earth ground 98 99 CC CA CB B5 T-/R- (Modbus RTU) common (M
Wiring without a contactor (ST _ _ - A _ _ _ _ - _ _ _ _ ) hot Ó hot fuse fuse WARNING: Use National Electric (NEC) or other countryspecific standard wiring and safety practices when wiring and connecting this controller to a power source and to electrical sensors or peripheral devices. Failure to do so may result in damage to equipment and property, and/or injury or loss of life.
hot hot fuse fuse load Output 1 (SSR) neutral Ground Connection hot Connect the ground to the heat sink. There is no ground connection on models without a heat sink. fuse load Output 1 (SSR) 1 2 EZ-ZONE™ ST Integrated Control Loop Patent Pending Indicator Lights SSR LIMIT STATUS OUT 3 Limit Address Selection 1234 L3 ON N.O. (Output 3) OUT 2 98 Power 98 Power Power 99 Power CC common (Modbus RTU) CA T-/R- (Modbus RTU) CB T+/R+ (Modbus RTU) ommon (Output 3) K3 N.C.
1 Internal wiring in an ST with a single-pole contactor without a limit (ST _ B - B _ _ _ - _ _ _ _). 4 Use single-pole contactors for hot-to-neutral loads. NEC does not permit neutral to be switched. contactor contact 2 SSR 4 contactor contacts Use double-pole contactors for hot-to-hot loads. Both hot legs must be opened together on limit conditions to remove power from circuit.
1 2 hot 120VÅ (ac) EZ-ZONE™ ST Integrated Control Loop neutral Patent Pending fuse Do not switch or fuse neutral wire! fuse SSR LIMIT STATUS OUT 3 ON 98 1234 L3 K3 99 J3 N.O.
Installation Mounting and Dismounting the Controller from a DIN Rail To mount the controller on a DIN rail, first hook the top flange on the back of the heat sink on to the top of the DIN rail. Then rotate the controller to an upright position until the lower flange snaps into place. To dismount the controller, first use a screwdriver to pull down the small lever on the bottom of the heat sink and rotate the bottom of the controller forward. Then lift the the controller off of the rail.
Replacing the Solid-State Relay on a Controller without a Contactor (ST _ _-A _ _ _-_ _ _ _) 1. Pinch the release levers on the top and bottom of the control module and lift the bottom edge forward to detach the unit. 2. With a Phillips screwdriver, remove 3. Lift the controller body, exposing the four nearest screws that were un- the solid-state relay. der the module. Replacing the Solid-State Relay 1. Using a Phillips screwdriver, replace the two screws connecting the solidstate relay to the heat sink.
Replacing the Solid-State Relay on a Controller with a Contactor (ST _ _ - (B or F) _ _ _ - _ _ _ _) 1. Pinch the release levers on the top and bottom of the control module and lift the right edge forward to detach the unit. 3. With a Phillips screwdriver, remove the two screws at the top corners of the controller. 2. With a Phillips screwdriver, remove the four nearest screws that were under the module. 4. Lift the controller body, exposing the solid-state relay. 5.
Indicator Lights and Slot Identification 1 2 EZ-ZONE™ ST Integrated Control Loop Patent Pending Solid-State Relay: Indicates that the solid-state relay is in an on state. SSR LIMIT STATUS Limit: OUT 3 Indicates that the controller is in a limit state. L3 Indicates that output 3 is in an on state. K3 Address Selection 1234 ON Output 3: Status: OUT 2 98 99 Flashing green indicates the controller is running with no input errors. Flashing red indicates an input error.
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 electrical sensors or peripheral devices. Failure to do so may result in damage to equipment and property, and/or injury or loss of life. Power Slot C 98 99 power power fuse CF CD CE B5 D6 • • • • • Minimum/Maximum Ratings 85 to 264VÅ (ac) 20.4 to 26.
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 electrical sensors or peripheral devices. Failure to do so may result in damage to equipment and property, and/or injury or loss of life. Input 2 Thermocouple Slot A • • • • - 20 kΩ maximum source resistance >20 MΩ input impedance 3 microampere open-sensor detection Thermocouples are polarity sensitive.
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 electrical sensors or peripheral devices. Failure to do so may result in damage to equipment and property, and/or injury or loss of life.
Selection ON 1234 ON 1234 98 common (RUI) 99 CF 6 See Quencharc note.
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 electrical sensors or peripheral devices. Failure to do so may result in damage to equipment and property, and/or injury or loss of life. NOTE: To prevent ground loops, isolation needs to be maintained from input to output when using switched DC or analog process outputs.
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 electrical sensors or peripheral devices. Failure to do so may result in damage to equipment and property, and/or injury or loss of life. Digital Output 5 - 6 • Internal supply provides a constant power output of 750mW • Maximum output sink current per output is 1.
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 electrical sensors or peripheral devices. Failure to do so may result in damage to equipment and property, and/or injury or loss of life. NOTE: To prevent ground loops, isolation needs to be maintained from input to output when using switched DC or analog process outputs.
Ó T+/R+ and T-/R- of the last controller Do not route network wires with pow- on a network. er wires. Connect network wires in Only one protocol per port is availdaisy-chain fashion when connecting able at a time: either Modbus RTU or multiple devices in a network. Standard Bus. Note: A termination resistor may be reDo not route network wires with power quired. Place a 120 Ω resistor across wires. A network using Watlow's Standard Bus and an RUI/Gateway.
Setting the Address Communications Parameter Name Modbus Controller Address The address of an EZ-ZONE® ST controller with the Modbus option (ST _ _-_ _ M _-_ _ _ _) can be set to ranges from 1 to 8 using the DIP switch and ranges 1 to 247 using software. Set switch 4 to on to use Modbus communications. Modbus™ RTU addresses from 1 to 247 can be programmed into the controller using Standard bus communications.
Watlow Standard Bus Controller Address The address of an EZ-ZONE ST controller using Standard Bus exclusively (ST_ _ - _ _ A _ - _ _ _ _ ) ranges from 1 to 16, where up to 16 controllers can be connected on the Standard Bus network.
that value to the control. Communication Protocols All EZ-ZONE ST controllers come standard with the Standard Bus protocol. As a option it can also be delivered with the Modbus protocol as well. The Standard Bus protocol is used primarily for communications to other EZ-ZONE products to include the RUI and EZ-ZONE Configurator software (free download from Watlow's web site (http://www.watlow.com).
Data Types Used with CIP uint = Unsigned 16 bit integer int = Signed 16-bit dint = Signed 32-bits, long real = Float, IEEE 754 32-bit string = ASCII, 8 bits per character sint = Signed 8 bits , byte To learn more about the DeviceNet and EtherNet/IP protocol point your browser to http://www.odva.org. Profibus DP To accommodate for Profibus DP addressing the following menus contain a column identified as Profibus Index.
3 Chapter 3: Operations Pages Control Module Operation Page Parameters To go to the Operations Page from the Home Page, press both the Up ¿ and Down ¯ keys for three seconds. [``Ai] will appear in the upper display and [oPEr] will appear in the lower display. press the Up ¿ or Down ¯ key to select and then press the Advance Key ‰ to enter. • Press the Up ¿ or Down ¯ key to move through available menu prompts.
Operations Page Display Parameter Name Description Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID RUI/ Data GTW Type Mod- & Read/ bus Write [``Ai] [oPEr] Analog Input Menu Inst. 1 float 360 R [``Ain] Analog Input (1 to 2) Process Value [ Ain] View the process value. -1,999.000 to 9,999.000°F or units -1,128.000 to 5,537.
Operations Page Parameter Name Description Display Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID RUI/ Data GTW Type Mod- & Read/ bus Write `dio] [oPEr] Digital Input/Output Menu [`do;S] [ do.S] [`ei;S] [ Ei.S] Digital Output (5 to 6) Output State View the state of this output. [`off] Off (62) [``on] On (63) Digital Input (5 to 6) Event Status View this event input state. [`off] Off (62) [``on] On (63) Inst.
Operations Page Parameter Name Description Display Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID RUI/ Data GTW Type Mod- & Read/ bus Write [`h;Pr] [ h.Pr] Monitor (1) Heat Power View the current heat output level. 0.0 to 100.0% 0.0 Instance 1 0x97 (151) 1 Map 1 Map 2 0xD (13) 236 1774 ---- 8011 Inst. 1 float 1900 R [`C;Pr] [ C.Pr] Monitor (1) Cool Power View the current cool output level. -100.0 to 0.0% 0.
Operations Page Display Parameter Name Description Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID RUI/ Data GTW Type Mod- & Read/ bus Write [`h;Pb] [ h.Pb] Control Loop (1) Heat Proportional Band Set the PID proportional band for the heat outputs. 0.001 to 9,999.000°F or units -1,110.555 to 5,555.000°C 25.0°F or units 14.0°C Instance 1 Map 1 Map 2 232 1760 0x97 (151) 1 6 65 8009 Inst. 1 float 1896 RWES [`h;hy] [ h.
Operations Page Parameter Name Description Display Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID RUI/ Data GTW Type Mod- & Read/ bus Write [ALM] [oPEr] Alarm Menu [`A;Lo] [ A.Lo] [`A;hi] [ A.hi] No Display No Display No Display No Display Alarm (1 to 2) Low Set Point If Alarm Type (Setup Page, Alarm Menu) is set to: process - set the process value that will trigger a low alarm.
Operations Page Parameter Name Description Display No Display No Display Range Alarm (1 to 2) Alarm Silenced Indicates if alarm can be silenced. Yes (106) No (59) Alarm (1 to 2) Alarm Latched Indicates if alarm is latched. Yes (106) No (59) Default ---- ---- Current (1) High Set Point Set the current value that will trigger a high heater error state. -1,999.000 to 9,999.000 50.0 [`C;Lo] [ C.Lo] Current (1) Low Set Point Set the current value that will trigger a low heater error state.
Operations Page Display Parameter Name Description [P;Sta] [oPEr] Profile Status Menu [P;Str] [P.Str] Profile Status Profile Start Range Default Modbus Relative Address [nonE] None (61) [ProF] Profile (77) [PAUS] Pause (146) [rESU] Resume (147) [`End] Terminate (148) [step] Step (89) None Profile Status Active Step View the currently running step. 1 to 40 0 (none) Profile Status Active Step Type View the currently running step type.
Operations Page Display Parameter Name Description Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID RUI/ Data GTW Type Mod- & Read/ bus Write ---- ---- [sec] [ Sec] Profile Status Seconds Remaining 0 to 59 0.0 Instance 1 Map 1 Map 2 ---- ---- ---- ---- 22076 No Display Profile Status Profile State Off (62) Running (149) Pause (146) Off Instance 1 Map 1 Map 2 294 3802 0x7A (122) 1 2 ---- 22002 Inst.
4 Chapter 4: Setup Pages Control Module Setup Page Parameters 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 view available menus.
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. • Press the Advance Key ‰ to move to a submenu. • Press the Up ¿ or Down ¯ key to move through the submenus. • Press the Advance Key ‰ to move through the parameters of the menu or submenu.
Setup Page Display [`S;Lo] [ S.Lo] [`S;hi] [ S.hi] [`r;Lo] [ r.Lo] Parameter Name Description Analog Input (1 to 2) Scale Low Set the low scale for process inputs. This value, in millivolts, volts or milliamps, will correspond to the Range Low output of this function block. Range Default -100.0 to 1,000.0 0.0 Analog Input (1 to 2) -100.0 to 1,000.0 Scale High Set the high scale for process inputs.
Setup Page Display [`i;Er] [ i.Er] [`dEC] [ dEC] [`s;ba] [ S.bA] Parameter Name Description Range Default Analog Input (1 to 2) [`off] Off (62) Error Latching [``on] On (63) Turn input error latching on or off. If latching is on, errors must be manually cleared. Off Analog Input (1 to 2) Display Precision Set the precision of the displayed value.
Setup Page Display [`o;tb] [ o.tb] [`o;Lo] [ o.Lo] [`o;hi] [ o.hi] [`leu] [ LEv] [``Fn] [ Fn] Parameter Name Description Range Default Digital Output (5 or 6) Time Base Set the time base for fixed-time-base control. 0.1 for Fast and Bi-Directional outputs, 5.0 for Slow outputs] to 60 Digital Output (5 or 6) Low Power Scale The power output will never be less than the value specified and will represent the value at which output scaling begins. 0.0 to 100.
Setup Page Parameter Name Description Display [``Fi] [ Fi] Range Default Digital Input (5) 0 to 4 Function Instance Select which instance of the Event Function that will be triggered by a true state. Modbus Relative Address Instance 1 Map 1 Map 2 267 1296 Instance 2 Map 1 Map 2 271 1316 0 CIP Class Pro DP Instance Index Attribute hex (dec) 0x6E (110) 1 4 139 Par ID Data RUI/ Type GTW & ModRead/ bus Write 10004 Inst. 5 uint 1406 RWES Inst. 6 1426 [Lim] [`Set] Limit Menu [`L;Sd] [ L.
Setup Page Display Parameter Name Description Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID Data RUI/ Type GTW & ModRead/ bus Write No Instance 1 0x97 (151) 1 Map 1 Map 2 10 (16) 257 1780 ---- 8022 Inst. 1 uint 1922 RWES Control Loop (1) 0 to 100 TRU-TUNE+™ Band Set the range, centered on the set point, within which TRU-TUNE+™ will be in effect. Use this function only if the controller is unable to adaptive tune automatically.
Setup Page Display Parameter Name Description Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID Data RUI/ Type GTW & ModRead/ bus Write [MAn] [MAn] Control Loop (1) Set Point Open Loop Limit Manual Power Low to Set Point Open Loop Set the manual output Limit High (Setup Page) power level that will take effect if an input error failure occurs while User Failure Action is set to Manual Fixed. 0.0 Instance 1 Map 1 Map 2 211 1910 [`L;dE] [ L.
Setup Page Display Parameter Name Description Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID Data RUI/ Type GTW & ModRead/ bus Write 9,999°F or Instance 1 units Map 1 Map 2 5,537°C 197 1896 0x6B (107) 1 4 53 7004 Inst. 1 float 2166 RWES -100 Instance 1 Map 1 Map 2 199 1898 0x6B (107) 1 5 54 7005 Inst. 1 float 2168 RWES 100 Instance 1 Map 1 Map 2 201 1900 0x6B (107) 1 6 55 7006 Inst.
Setup Page Parameter Name Description Display Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) 0.1 to 60.0 seconds (solid-state 0.1 sec. relay or switched dc) [SSR & sw dc] 5.0 to 60.0 seconds (mechanical relay or no-arc power 20.0 sec. control) [mech, relay, noarc] Instance 1 Map 1 Map 2 132 944 Output (1 to 4) Low Power Scale The power output will never be less than the value specified and will represent the value at which output scaling begins. 0.
Setup Page Display [`is;a] [ iS.A] [`A;hy] [ A.hy] [`A;Lg] [ A.Lg] [`A;Sd] [ A.Sd] [`A;LA] [ A.LA] [`A;bL] [ A.bL] [`A;Si] [ A.Si] Parameter Name Description Range Default Alarm (1 to 2) Source Instance A Set the instance of the function selected above. 1 or 2 Alarm (1 to 2) Hysteresis Set the hysteresis for an alarm. This determines how far into the safe region the process value needs to move before the alarm can be cleared. 0.001 to 9,999.000°F or units 0.001 to 5,555.
Setup Page Display Parameter Name Description Range Default [`A;dL] [ A.dL] Alarm (1 to 2) 0 to 9,999 seconds Delay Set the span of time that the alarm will be delayed after the process value exceeds the alarm set point.
Setup Page Display Parameter Name Description Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID Data RUI/ Type GTW & ModRead/ bus Write [`FUn] [`Set] Function Key [``Fn] [ Fn] Function Key (1 to 2) Digital Input Function Program the EZ Key to trigger an action. Functions respond to a level state change or an edge level change.
Setup Page Parameter Name Description Display Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID Data RUI/ Type GTW & ModRead/ bus Write [gLbL] [`Set] Global Menu [`C_F] [ C_F] Global Display Units Select which scale to use for temperature. [AC;LF] Global [AC.LF] AC Line Frequency Set the frequency to the applied ac line power source.
Setup Page Display Parameter Name Description Range Default Modbus Relative Address CIP Class Pro DP Instance Index Attribute hex (dec) Par ID Data RUI/ Type GTW & ModRead/ bus Write [CoM] [`SEt] Communications Menu 1 Instance 1 0x96 (150) 1 Map 1 Map 2 2 313 2052 ---- 17007 Inst. 1 uint 2320 RWE 9,600 Instance 1 0x96 (150) 1 Map 1 Map 2 3 314 2054 ---- 17002 Inst. 1 uint 2322 RWE None Instance 1 0x96 (150) 1 Map 1 Map 2 4 315 2056 ---- 17003 Inst.
5 Chapter 5: Profiling Page The Profiling Page allows you to enter your ramp and soak profile information. propriate action. • [none] No action • [ProF] Begin execution from first step of the specified profile number, whether it exists or not. • [PAUS] Pause the currently running profile. • [rESU] Resume running the profile from the previously paused step. • [`End] End the profile. • [StEP] Begin running the profile from the specified step number.
Profile Page Display Parameter Name Description Range Default [S;typ] [S.typ] Step (1 to 40) Step Type Select a step type. Time or rate depending on setting of profile type found on the Setup Page in the the Global menu. [UStP] Unused Step (50) [``ti] Time (143) [`End] End [``JL] Jump Loop (116) [w;bo] Wait For Both (210) [w;pr] Wait For Process (209) [`w;E] Wait For Event (144) [SoAH] Soak (87) [rAtE] Rate (81) Unused [t;SP1] [t.
Profile Page Display Parameter Name Description Range Default [W;P1] [W.P1] Step (1 to 40) Wait For Process 1 -1,999.000 to 9,999.000°F or units -1,128.000 to 5,537.000°C 0.0°F or units -18.0°C [WE;1] [WE.1] Step (1 to 40) Wait Event 1 [nonE] None (61) [``on] On (63) [`oFF] Off (62) None CIP Data RUI/ Class Type Pro DP GTW Instance & Index Par ID ModAttribute Read/ bus hex (dec) Write Instance 1 0x79 21011 Inst.
Profile Page Parameter Name Description Display Range Default CIP Data RUI/ Class Type Pro DP GTW Instance & Index Par ID ModAttribute Read/ bus hex (dec) Write Instance 1 0x79 21007 Inst. 1 uint (121) 2882 RWE Map 1 Map 2 1 to (40) 508 4012 7 Offset +80 [Map1 Offset + 20] [Map2 Offset + 100] - - - - 21008 Inst. 1 uint Instance 1 0x79 Modbus Relative Address [Ent1] [Ent1] Step (1 to 40) Event 1 Select whether Event Output 1 is on, unchanged or off during this step.
Display Step Type Description Parameters in Step Type [``jl] [ JL] Step Types Jump Loop A Jump Loop step will jump to the Jump Step the number of times designated in Jump Count. Loops can be nested up to four deep. [``JS] [``JC] [Ent1] [Ent2] [`End] [ End] Step Types End An End Step will end the profile. If a profile doesn't include an End Step, control will move to the next step. If no End Step is confronted, after step 40 control will default to the set point in effect before the profile started.
6 Chapter 6: Factory Pages Control Module Factory Page Parameters Note: To go to the Factory Page from the Home Page, press and hold both the Advance ‰ and Infinity ˆ keys for six seconds. Some of these menus and parameters may not appear, depending on the modules options. See model number information in the Appendix for more information. If there is only one instance of a menu, no submenus will appear. • Press the Advance Key ‰ to move through the parameter prompts.
Control Module Display Parameter Name Description • Range Factory Page Default Modbus Relative Address CIP Class Pro DP Par Instance Index ID Attribute hex (dec) RUI/ GTW Modbus Data Type & Read/ Write [CUSt] [FCty] Custom Setup Menu [`par] [ Par] Custom Parameter 1 to 20 Select the parameters that will appear in the Home Page. The Parameter 1 value will appear in the upper display of the Home Page. It cannot be changed with the Up and Down Keys in the Home Page.
Control Module Display Parameter Name Description • Range Factory Page Default Modbus Relative Address CIP Class Pro DP Par Instance Index ID Attribute hex (dec) Data Type & Read/ Write uint ---RWE RUI/ GTW Modbus [LoC;P] [LoC.P] Security Setting Profiling Page Change the security level of the Profiling Page. 1 to 3 3 Instance 1 Map 1 Map 2 - - - - 1704 ---- ---- 3008 [pas;e] [LoC.P] Security Setting Password Enable Turn security features on or off.
Control Module Display [pas;a] [PAS.A] Parameter Name Description Security Setting Administrator Password Used to acquire full access to all menus.
Control Module Display Parameter Name Description • Range No Display Diagnostics Hardware ID Display hardware ID. 17 or 31 No Display Diagnostics Software ID Display software ID. 0 to 2147483647 No Display Diagnostics Device Name 0 or 32 No Display Diagnostics Device Status OK (138) FAIL (32) Factory Page Default Modbus Relative Address CIP Class Pro DP Par Instance Index ID Attribute hex (dec) Data Type & Read/ Write dint 1001 Inst.
7 Chapter 7: Features Saving and Restoring User Settings. . . . . . . . . . . . . . . . . . . . . . . . . . 65 Tuning the PID Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Manual Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Autotuning with TRU‑TUNE+® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Saving and Restoring User Settings Recording setup and operations parameter settings for future reference is very important. If you unintentionally 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;S] (Setup Page, Global Menu) to save the settings into either of two files in a special section of memory.
the set point. If it has not, reduce the setting by half and wait another 10 minutes. Continue reducing the setting by half every 10 minutes until the process value equals the set point. If the process becomes unstable, the Integral value is too small. Increase the value until the process stabilizes. 6. Increase Derivative to 0.1. Then increase the set point by 11° to 17°C. Monitor the system’s approach to the set point. If the process value overshoots the set point, increase Derivative to 0.2.
Negative Calibration Offset will compensate for the difference between the Sensor Reading and the Actual Temperature Temperature Actual Process Temperature Time Calibration To calibrate an analog input, you will need to provide two electrical signals or resistance loads near the extremes of the range that the application is likely to utilize. See recommended values below: Low Source High Source thermocouple 0.000 mV 50.000 mV millivolts 0.000 mV 50.000 mV volts 0.000V 10.000V milliamps 0.
Select the sensor type with Sensor Type [`Sen] (Setup Page, Analog Input Menu). Select the low and high values with Range Low [`r;Lo] and Range High [`r;hi] (Setup Page, Analog Input Menu). Set Point Low Limit and High Limit The controller constrains the set point to a value between a set point low limit and a set point high limit. Set the set point limits with Low Set Point [`L;SP] and High Set Point [`h;SP] (Setup Page, Loop Menu).
prior to sensor failure, and that power level is less than 75 percent. Actual Temperature Temperature Set Point On-off control can be selected with Heat Algorithm [`h;Ag] or Cool Algorithm [`C;Ag] (Setup Page, Loop Menu). On-off hysteresis can be set with Heat Hysteresis [`h;hY] or Cool Hysteresis [`C;hY] (Operations Page, Loop Menu). Sensor Break Note: Input Error Failure Mode [faIl] does not function in on-off control mode. The output goes off.
Adjust the proportional band with Heat Proportional Band [`h;Pb] or Cool Proportional Band [`C;Pb] (Operations Page, Loop Menu). Set Point Overshoot Temperature Proportional Band Droop Dead Band In a PID application the dead bands above and below the set point can save an application’s energy and wear by maintaining process temperature within acceptable ranges. Proportional action ceases when the process value is within the dead band.
Variable Time Base Variable time base is the preferred method for controlling a resistive load, providing a very short time base for longer heater life. Unlike phase-angle firing, variable-time-base switching does not limit the current and voltage applied to the heater. With variable time base outputs, the PID algorithm calculates an output between 0 and 100%, but the output is distributed in groupings of three ac line cycles.
hysteresis value from the alarm high set point. View or change alarm hysteresis with Hysteresis [`A;hy] (Setup Page, Alarm Menu). Temperature Set Point degrees High Side Alarm Range per minute Alarm High Set Point Alarm Hysteresis Temperature ramps to Set Point at a set rate Heating System with Ramping Alarms are activated when the output level, process value or temperature leaves a defined range.
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 and [Attn] in the lower display.
Lockout Security [rLoC] to 5 and Set Lockout Security [SLoC] to 0. 4. The operator wants to read and write to the Home Page and Profiling Page, and lock all other pages and menus. In the Factory Page, Lockout Menu, set Read Lockout Security [rLoC] to 2 and Set Lockout Security [SLoC] to 2. In the Factory Page, Lockout Menu, set Lock Operations Page [LoC;O] to 3 and Lock Profiling Page [LoC;P] to 2. 5.
b. If Rolling Password [roll] is On, Password [pass] equals: ([pas;u] x code) Mod 929 + 70 8. Administrator a. If Rolling Password [roll] is Off, Password [pass] equals User Password [pas;a]. b. If Rolling Password [roll] is On, Password [pass] equals: ([pas;a] x code) Mod 997 + 1000 Differences Between a User Without Password, User With Password and Administrator - User without a password is restricted by the Locked Access Level [loC;l]. eter’s actual value.
Software Configuration define the communications port on the PC to use. Using EZ-ZONE® Configurator Software To enable a user to configure the ST control using a personal computer (PC), Watlow has provided free software for your use. If you have not yet obtained a copy of this software insert the CD (Controller Support Tools) into your CD drive and install the software.
In the previous screen shot the ST is shown highlighted to bring greater clarity to the control in focus. Any EZ-ZONE device on the network will appear in this window and would be available for the purpose of configuration. After clicking on the control of choice simply click the next button once again. The next screen appears below. to display the menu and parameter of choice.
Lastly, when the configuration is complete click the "Finish" button at the bottom right of the previous screen shot. The screen that follows this action can be seen below. Although the ST control now contains the configuration (because the previous discussion focused on doing the configuration on-line) it is suggested that after the configuration process is completed that the user save this file on the PC for future use.
8 Chapter 8: Appendix Troubleshooting Indication Description Possible Cause(s) Alarm won’t clear or reset Alarm will not clear or reset • Alarm latching is active with keypad or digital input • Alarm set to incorrect output Alarm won’t occur Alarm will not activate output • Alarm silencing is active • Alarm blocking is active • Alarm is set to incorrect output • Reset alarm when process is within range or disable latching. • Set output to correct alarm source instance.
Indication Description Possible Cause(s) Corrective Action [Li;L1] Limit Low [Li;L2] Sensor input below low limit set point • Temperature is less than limit set • Check cause of under temperature. point • Limit outputs latch and require reset • Clear limit. • Incorrect alarm set point • Establish correct limit set point. [Li;h1] Limit High [Li;h2] Sensor input above high limit • Temperature is greater than limit set • Check cause of over temperature.
Indication Process doesn’t control to set point Description Process is unstable or never reaches set point Possible Cause(s) • Controller not tuned correctly • Perform autotune or manually tune system. • Control mode is incorrectly set • Set control mode appropriately (Open vs Closed Loop). • Control set point is incorrect • Set control set point in appropriate control mode and check source of set point: remote, idle, profile, closed loop, open loop.
Modbus - Programmable Memory Blocks Assembly Definition Addresses and Assembly Working Addresses Assembly Definition Addresses 40 & 41 42 & 43 44 & 45 46 & 47 48 & 49 50 & 51 52 & 53 54 & 55 56 & 57 58 & 59 60 & 61 62 & 63 64 & 65 66 & 67 68 & 69 70 & 71 72 & 73 74 & 75 76 & 77 78 & 79 Assembly Working Addresses 200 & 201 202 & 203 204 & 205 206 & 207 208 & 209 210 & 211 212 & 213 214 & 215 216 & 217 218 & 219 220 & 221 222 & 223 224 & 225 226 & 227 228 & 229 230 & 231 232 & 233 234 & 235 236 & 237 238 & 2
Modbus Default Assembly Structure 80-119 Assembly Definition Addresses Default Pointers Assembly Working Addresses Assembly Definition Registers Default Pointers Assembly Working Registers Registers 80 & 81 Registers 240 & 241 Registers 100 & 101 Registers 260 & 261 Pointer 21 = 360 & 361 Analog Input 1 Process Value Registers 82 & 83 Pointer 22 = 362 & 363 Analog Input 1 Error Status Registers 84 & 85 Pointer 23 = 440 & 441 Analog Input 2 Process Value Registers 86 & 87 Pointer 24 = 442 & 443 Anal
CIP Implicit O to T (Originator to Target) Assembly Structure CIP Implicit Assembly Originator (Master) to Target (ST) Assembly Members ST Assembly Class, Instance, Attritbute ST Data Type 1 0x77, 0x01, 0x01 DINT Loop Control Mode 0x97, 0x01, 0x01 DINT 2 0x77, 0x01, 0x02 DINT Closed Loop Set Point 0x6B, 0x01, 0x01 REAL 3 0x77, 0x01, 0x03 DINT Open Loop Set Point 0x6B, 0x01, 0x02 REAL 4 0x77, 0x01, 0x04 DINT Alarm 1 - Alarm High Set Point 0x6D, 0x01, 0x01 REAL 5 0x77, 0x01, 0x05
Specifications Line Voltage/Power • 85 to 264VÅ (ac), 47 to 63Hz • 20 to 26Vı (ac/dc), 47 to 63Hz • 12VA maximum power consumption without mechanical contactor in system • 50VA maximum power consumption with mechanical contactor in system • 140VA maximum power consumption with external contactor • Data retention upon power failure via nonvolatile memory • Maximum closed resistance 100 Ω Current Measurement • Nominal operating frequency 50 to 60 Hz.
Ordering Information Model Numbers for EZ-ZONE® ST S T __ __ EZ-ZONE ST Integrated Control Loop - __ __ __ __ - __ __ __ __ - Output 1 is dedicated to controlling the internal SSR. - If 75A heat sink is selected below 1 Digital Input (6) will be factory set and fixed as the SSR over temperature Digital Input. Output 2, Digital I/O and Current Measurement K B P E H D J C 0.5 A solid-state relay 0.5 A solid-state relay with 2 digital i/o points 0.5 A solid-state relay with current measurement 0.
ST R C EZ-ZONE ST Replacement Modules - 0 __ __ __ - __ __ __ __ STRC-0 (Series ST Replacement Control Module) - Output 1 is dedicated to controlling the internal Solid-State Relay. - Includes 1 universal input and 2 outputs for heat, cool or alarm Output 2, Digital I/O and Current Measurement K B P E H D J C 0.5 A solid-state relay 0.5 A solid-state relay with 2 digital i/o points 0.5 A solid-state relay with current measurement 0.
Ordering Information for EZ-ZONE ST Replacement Base Code Number S T R T - B A S E - __ __ __ __ Series ST Replacement Base Integrated Mechanical Controller 0000 Compact base version (no space for mechanical contactor) DPB1 Base housing with single-pole, 40 A Watlow contactor, 24VÅ (ac) power supply DPB2 Base housing with single-pole, 40 A Watlow contactor, 110/120VÅ (ac) power supply DPB3 Base housing with single-pole, 40 A Watlow contactor, 208/240VÅ (ac) power supply DPF1 Base housing wi
Index [`A;bL] Alarm Blocking 49, 73 [AC;LF] AC Line Frequency 52, 71 [A;dSP] Alarm Display 50 [`A;hi] Alarm High Set Point 35, 72 [`A;hy] Alarm Hysteresis 49, 72 [``Ai] Analog Input Menu 31, 40 [`A;iS] Alarm Source Instance 49 [`A;LA] Alarm Latching 49, 72 [`A;Lg] Alarm Logic 49 [ALM] Alarm Menu 35, 48 [`A;Lo] Alarm Low Set Point 35, 72 [`A;Sd] Alarm Sides 49 [`A;Si] Alarm Silencing 49, 73 [A;tSP] Autotune Set Point 33, 65 [Attn] Attention 72, 73 [`A;ty] Alarm Type 48, 72 [`AUt] Autotune 33, 65 [bAUd] Baud
[`S;ti] Step Time Remaining 37, 38 [`StP] Active Step 37 [S;tyP] Active Step Type 37 [S;tyP] Step Type 55 [t;Agr] User Tune Aggressiveness 45, 65 [t;bnd] TRU-TUNE+™ Band 45, 66 [``td] Time Derivative 34, 65, 70 [`t;gn] TRU-TUNE+™ Gain 45, 66 [``ti] Time 57 [``ti] Time Integral 34, 65, 70 [t;tUn] TRU-TUNE+™ Enable 45, 66 [`UFA] User Failure Action 45 [UloC] Unlock 74 [ULoC] Unlock 59 [UloC] Unlock Menu 74 [USr;r] User Restore Set 52, 65 [USr;S] User Save Set 52, 65 [UStP] Unused Step 58 [`W;E] Wait For Event
EZ Key 4 F Factory Page Control Module 59 features and benefits 3 Filter Time 41, 67 filter time constant 67 Function 66 Function Instance 42, 44 functions 4 G Global Menu 52 Guaranteed Soak Deviation 52 Guaranteed Soak Enable 52 H Heat Algorithm 44, 69 Heater Error 36 Heat Hysteresis 34, 69 Heat Power 33, 65 Heat Proportional Band 34, 65, 70 High Power Scale 43, 48 high range 68 high scale 68 High Set Point Alarm 35, 36, 72 Current 36 Loop 47, 68 Hours 55 Hysteresis 44, 49, 72 I Idle Set Point 33 Input
Setup Page Control Module 39 Sides Alarm 49 Limit 44 Silencing 49, 73 single set point ramping 71 Soft Start 71 Soft Start Time 71 Software Build 62 Software Configuration 76 Software ID 62 Software Release 62 Source 48 specifications 85 status indicator light 9 Step Type 55 sub-assembly labels 13 System Security 74 T thermal system control 3 Time 57 Time Base 43, 48 Time Derivative 34, 65, 70 Time Integral 34, 65, 70 troubleshooting 79 TRU-TUNE+™ Band 45, 66 TRU-TUNE+™ Enable 45, 66 TRU-TUNE+™ Gain 45, 66
Declaration Conformity Declaration of of Conformity Series EZ-ZONE® ST Tower WATLOW an ISO 1241 Bundy Blvd. Winona, MN 55987 USA 9001 approved facility since 1996.
Declaration of Conformity (cont.) Declaration of Conformity NOTE 3: For Phase Angle control models, filtering in addition to that recommended in NOTE 1 will be needed to comply with conducted emissions requirements, consult factory for details. 3 NOTE 4: Phase angle models will need power factor correction to pass harmonic current standard. 4 2006/95/EC Low-Voltage Directive EN 61010-1 2001 Safety Requirements of electrical equipment for measurement, control and laboratory use.
How to Reach Us Corporate Headquarters Watlow Electric Manufacturing Company 12001 Lackland Road St. Louis, MO 63146 Sales: 1-800-WATLOW2 Manufacturing Support: 1-800-4WATLOW Email: info@watlow.com Website: www.watlow.com From outside the USA and Canada: Tel: +1 (314) 878-4600 Fax: +1 (314) 878-6814 Latin America Watlow de México S.A. de C.V. Av. Fundición No. 5 Col. Parques Industriales Querétaro, Qro. CP-76130 Mexico Tel: +52 442 217-6235 Fax: +52 442 217-6403 Europe Watlow France Tour d'Asnières.
