Watlow ez-zone pm User manual

0600-0059-0000 Rev. P Made in the U.S.A.
August 2016
User’s Guide
EZ-ZONE®PM
Integrated Controller Models
1241 Bundy Boulevard., Winona, Minnesota USA 55987
Phone: [phone], Fax: [phone]
http://www.watlow.com
TOTAL
3 Year Warranty
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 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 WARNING safety statement. Further explanations follow:
Symbol Explanation
CAUTION – Warning or Hazard that needs further explanation than
label on unit can provide. Consult User's Guide for further informa-
tion.
ESD Sensitive product, use proper grounding and handling techniques
when installing or servicing product.
Unit protected by double/reinforced insulation for shock hazard pre-
vention.
Do not throw in trash, use proper recycling techniques or consult
manufacturer for proper disposal.
Enclosure made of Polycarbonate material. Use proper recycling
techniques 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
evaluated 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
evaluated 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 cannot
guarantee against failure. Watlow's obligations hereunder, at Watlow's option, are limited 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 [phone] 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, [phone], 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 evalua-
tion. Make sure the Return Merchandise Authorization number is on the outside of the car-
ton 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
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 all
rights reserved.
EZ-ZONE PM is covered by U.S. Patent Numbers: 6005577; D553095; D553096; D553097;
D560175; D55766; and OTHER PATENTS PENDING

Watlow EZ-ZONE®PMI Controller •1 • Table of Contents
Table of Contents
TC
Table of Contents ..................................1
Chapter 1: Overview ................................6
Available EZ-ZONE PM Literature and Resources ...................6
Introduction ...............................................7
Getting Started Quickly .......................................9
A Conceptual View of the PM .................................10
Inputs .................................................10
Internal Functions ........................................11
Outputs ................................................11
Input Events and Output Events .............................11
What is a Profile .........................................11
Chapter 2: Install and Wire...........................20
Dimensions...............................................20
1/16 DIN (PM6) Dimensions ...............................20
1/16 DIN (PM6) Recommended Panel Spacing .................20
1/8 DIN (PM8) Vertical Dimensions ..........................21
1/8 DIN (PM8) Vertical Recommended Panel Spacing............21
1/8 DIN (PM9) Horizontal Recommended Panel Spacing..........22
1/4 DIN (PM4) Dimensions ................................23
1/4 DIN (PM4) Recommended Panel Spacing ..................23
Installation ...............................................24
Wiring ...................................................26
PM Integrated Isolation Block.................................30
Chapter 3: Keys and Displays .........................55
Responding to a Displayed Message .........................56
Default Home Page Parameters ...............................57
Chapter 4: Home Page..............................57
Changing the Set Point ....................................59
Starting a Profile from the Home Page........................59
Ending a Profile from the Home Page ........................59
Modifying the Home Page .................................59
Conventions Used in the Menu Pages ........................63
Display ................................................64
Communication Protocols .................................64
Modbus Introduction to the Modbus Protocol ..................64
J1939 CAN .............................................65
Profibus DP ............................................66
Chapter 5: Operations Page ..........................67
Analog Input Menu .........................................70
Digital Bus Menu (J1939 CAN)................................71
Linearization Menu .........................................72

Watlow EZ-ZONE®PMI Controller •2 • Table of Contents
TC Table of Contents (cont.)
Process Value Menu ........................................73
Digital Input/Output Menu ...................................74
Limit Menu ...............................................75
Monitor Menu .............................................76
Control Loop Menu.........................................77
Alarm Menu ..............................................81
Current Menu .............................................83
Timer Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Math Menu ...............................................87
Special Output Function Menu ................................87
Profile Status Menu ........................................89
Chapter 6: Setup Page ..............................92
Analog Input Menu .........................................96
Digital Bus Menu (J1939 CAN)................................99
Linearization Menu ........................................103
Process Value Menu .......................................107
Digital Input/Output Menu ..................................108
Limit Menu ..............................................114
Control Loop Menu........................................116
Output Menu.............................................125
Alarm Menu .............................................128
Current Menu ............................................133
Timer Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Math Menu ..............................................137
Special Output Function Menu ...............................138
Function Key .............................................140
Global Menu .............................................142
Communications Menu.....................................145
Standard Bus ..........................................146
Modbus RTU...........................................146
DeviceNet .............................................148
J1939 CAN bus (Digital Input Bus)..........................149
Profibus DP ...........................................150
Modbus TCP or EtherNet/IP ...............................151
Real Time Clock Menu .....................................155
Chapter 7: Profiling Page ...........................156
Profile Setup .............................................156
Starting a Profile..........................................157
Profiling Menu ...........................................161
Chapter 8: Factory Page............................168
Custom ................................................170

Watlow EZ-ZONE®PMI Controller •3 • Table of Contents
Lock Menu ..............................................171
Unlock Menu.............................................173
Diagnostics Menu .........................................174
Calibration Menu..........................................176
Chapter 9: Features...............................179
Changing PM Integrated Model Number to PM Express ..........181
Saving and Restoring Settings..............................182
Tuning the PID Parameters ................................183
Autotune .............................................183
Manual Tuning ........................................184
Autotuning with TRU-TUNE+®..................................184
Inputs.................................................185
Calibration Offset ......................................185
Calibration............................................186
Filter Time Constant ....................................188
Sensor Selection.......................................188
Sensor Backup ........................................188
Set Point Minimum and Maximum .........................188
Scale High and Scale Low ...............................188
Range High and Range Low ..............................189
Receiving a Remote Set Point ............................189
Ten Point Linearization ..................................190
Outputs ...............................................190
Duplex...............................................190
NO-ARC Relay.........................................190
Retransmitting a Process Value or Set Point .................191
Cool Output Curve .....................................192
Resetting a Tripped Limit..................................192
Control Methods ........................................193
Output Configuration ...................................193
Auto (closed loop) and Manual (open loop) Control. . . . . . . . . . . . 193
On-Off Control ........................................194
Proportional and (P) Control .............................195
Proportional and Integral (PI) Control ......................195
Proportional, Integral and Derivative (PID) Control ............196
Dead Band ...........................................196
Variable Time Base .....................................197
TC Table of Contents (cont.)

Watlow EZ-ZONE®PMI Controller •4 • Table of Contents
Table of Contents (cont.)
Single Set Point Ramping................................198
Cascade Control .......................................198
Compressor Control ....................................198
Differential Control .....................................199
Ratio Control..........................................199
Duplex Control ........................................199
Motorized Valve Control .................................199
Timer Function..........................................200
Setting up the timer function .............................200
Alarms ................................................202
Process and Deviation Alarms ............................203
Set Points ............................................203
Hysteresis ............................................203
Latching .............................................203
Silencing .............................................204
Blocking .............................................204
Current Sensing.........................................204
Open and Shorted Load Circuit Detection....................204
Open Loop Detection ...................................205
Programming the EZ Key/s ................................205
Using Lockout and Password Security .......................206
Using Lockout Method 1 (Read and Set Lock)................206
Using Lockout Method 2 (Password Enable) .................208
Modbus - Using Programmable Memory Blocks................210
CIP - Communications Capabilities ..........................210
CIP Implicit Assemblies .................................211
PCCC - (Programmable Controller Communications Commands) ..212
Profibus DP - (Decentralized Peripherals) ....................213
Software Configuration ...................................213
Using EZ-ZONE Configurator Software ......................213
Chapter 10: Applications ...........................217
Example 1: Single Loop Control ..............................217
Example 2: Sensor Backup ..................................217
Example 3: Square Root ....................................218
Example 4: Ratio..........................................218
Example 5: Differential .....................................219
Example 6: Cascade .......................................219
Example 7: Wet Bulb / Dry Bulb ..............................221
TC

Watlow EZ-ZONE®PMI Controller •5 • Table of Contents
Table of Contents (cont.)
TC
Example 8: Vaisala ........................................222
Example 9: Motorized Valve Control ...........................223
Chapter 11: Appendix .............................225
Troubleshooting Alarms, Errors and Control Issues ...............225
Modbus - Programmable Memory Blocks ......................232
CIP Implicit Assembly Structures .............................235
CIP Implicit Assembly....................................235
Originator (Master) to Target (PM)..........................235
CIP Implicit Assembly....................................236
Target (PM) to Originator (Master) ..........................236
Compact Class Assembly Structure ...........................237
PM Specifications .........................................244
Ordering Information for PM Integrated Controller Models .........250
How to Reach Us .........................................252

Watlow EZ-ZONE®PMI Controller •6 •Chapter 1 Overview
Chapter 1: Overview
1
Available EZ-ZONE PM Literature and Resources
Document Title and Part Number Description
EZ-ZONE PM PID Controller Us-
er's Guide, part number: 0600-
0058-0000
Describes how to connect and use an advanced PID loop
controller. This particular model is limited to one con-
trol loop and 2 outputs. Like all PM controllers, it comes
with Standard Bus communications. As an additional
option, it can also be ordered with Modbus®RTU com-
munications.
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/en/resources-and-support/Technical-Library/User-Manuals. 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:
[e-mail]