Watlow F4P Series User manual

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User’s Manual
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1241 Bundy Boulevard, Winona, Minnesota USA
Phone: [phone], Fax: [phone] http://www.watlow.com
English

Safety Information
We use note, caution and warning symbols throughout this book to draw your
attention to important operational and safety information.
A“N OTE ” m a r k s a s h or t m es s a ge t o a ler t you t o a n im por t a n t d e t a il.
A“CAU TI ON ” s a fe t y a ler t a pp ea r s wit h in for m a t ion t h a t is im p or t a n t for p r ot e ct in g
your equipment and performance. Be especially careful to read and follow all
cau t ion s that a pply t o you r applica t ion .
A“WARNING” safety alert appear s with infor m at ion t h at is im por ta n t for pr otect in g
you, others and equipment from damage. Pay very close attention to all warnings
that apply to your application.
The safety alert symbol, ç(an excla ma t ion poin t in a t r ia n gle) precedes a gener al
CAUTION or WARNING statement.
The electrical hazard symbol, Ó(a ligh t nin g bolt in a tr ia n gle) precedes an elect ric
shock hazard CAUTION or WARNING safety statement.
Technical Assistance
If you encounter a problem with your Watlow controller, review your configuration
information to verify that your selections are consistent with your application:
inputs; outputs; alarms; limits; etc. If the problem persists after checking the
configu r at ion of t he con t roller, you ca n get t echn ica l a ssistance fr om you r local
Watlow representative (see back cover), or in the U.S., dial [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:
• Completemodelnumber • Allconfiguration information
• User’sManual • Diagnosticmenu readings
Your Comments
We welcome your comments or suggestions on this user ’s manual. Please send them
to: Technical Writer, Watlow Winona, 1241 Bundy Blvd., P.O. Box 5580, Winona,
Minnesota, USA 55987-5580; telephone: [phone]; fax: [phone].
© Copyr igh t 2003 by Wa t low Win on a , I n c. All r igh t s r es er ved . (2328)
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Wat l ow Ser i es F4P Tabl e of Cont ent s ■i
Operati ng the Control l e r
Chapter 1: Introduction . . . . . . . . . . . . . . . . . 1.1
Setup Steps . . . . . . . . . . . . . . . . . . . . . . . .1.2
Chapter 2: Operating from the Front Panel . .2.1
Keys, Displays and Lights . . . . . . . . . . . . .2.2
Guided Programming . . . . . . . . . . . . . . . .2.3
Custom Main Page . . . . . . . . . . . . . . . . . .2.3
Auto and Manual Operation . . . . . . . . . . .2.3
Troubleshooting, Alarms and Errors . . . . .2.4
Programming the Controll er
Chapter 3: Operations Page . . . . . . . . . . . . . .3.1
Alarm Set Points . . . . . . . . . . . . . . . . . . . .3.1
To Clear an Alarm or Error . . . . . . . . . . . .3.1
Autotune PID . . . . . . . . . . . . . . . . . . . . . . .3.2
Edit PID . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2
Multiple PID Sets . . . . . . . . . . . . . . . . . . . .3.3
Cascade . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
Chapter 4: Setup Page . . . . . . . . . . . . . . . . . .4.1
Parameter Setup Order . . . . . . . . . . . . . . .4.1
Customizing the Main Page . . . . . . . . . . .4.2
Static Messages . . . . . . . . . . . . . . . . . . . .4.2
Chapter 5: Factory Page . . . . . . . . . . . . . . . .5.1
Security . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . .5.3
Calibration . . . . . . . . . . . . . . . . . . . . . . . . .5.3
Chapter 6: Parameters . . . . . . . . . . . . . . . . . .6.1
Pages, Menus and Parameters . . . . . . . . .6.1
Main Page . . . . . . . . . . . . . . . . . . . . . . . . .6.2
Operations Page Parameter Table . . . . . .6.4
Setup Page Parameter Table . . . . . . . . . .6.11
Factory Page Parameter Table . . . . . . . . .6.26
Chapter 7: Features . . . . . . . . . . . . . . . . . . . .7.1
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2
Control Methods . . . . . . . . . . . . . . . . . . . .7.5
Other Features . . . . . . . . . . . . . . . . . . . . .7.9
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
Advanced Features . . . . . . . . . . . . . . . . . .7.12
Features in Enhanced Series F4P Controller
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
Installation and Wiring
Chapter 8: Installation and Wiring . . . . . . . . .8.1
Wiring the F4P Controller . . . . . . . . . . . . .8.5
Communi cati ons
Chapter 9: Communications . . . . . . . . . . . . . .9.1
Exception Responses . . . . . . . . . . . . . . . .9.1
Modbus Registers (Alphabetical) . . . . . . .9.2
Modbus Registers (Numerical) . . . . . . . . .9.11
Appendi x
Specifications . . . . . . . . . . . . . . . . . . . . . .A.2
Ordering Information . . . . . . . . . . . . . . . . .A.3
Declaration of Conformity . . . . . . . . . . . . .A.4
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . .A.5
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.8
Software Map . . . . . . . . . . . . . . . . . . . . . .A.13
About Watlow and Warranty Information
. . . . . . . . . . . . . . . . . . . . . . Inside Back Cover
Series F4P: Table of Contents
T
Adownloadable electronic copy of this user manual is available free of charge through Watlow's web
site: http://www.watlow.com/literature/prodtechinfo

ii ■Tabl e of Cont ent s Wat l ow Ser i es F4P
Notes

Wat l ow Ser i es F4P Introduction ■1.1
1
Chapt er One: Introduction
Inputs and Outputs
Figure 1. 1 — Series F4P I nputs and Outputs ( Standard, 1 i nput, F4P _ - _ _ AA - _ _ _ _; and Enhanced, 3 i nputs, F4P _ -
_ _ AB - _ _ _ _ ).
2 Control Outputs
2 Alarm Outputs
2 Retransmit Outputs
(optional)
F
1
2
ˆ
1B
1B
1A
1A
…Alarm1 Lo Deviation
Adjusts Value
Back Next
–1 F
1 or 3 Universal Analog Inputs
1 Communication Input/Output
4 Digital Inputs
å
Watlow’s Series F4P, 96mm by 96mm (1/4 DIN)
Temperature/Process controllers are easy to set up, pro-
gram and operate in the most demanding applications.
The F4P Temperature/Process controller includes:
•four -lin e, high r esolu t ion LCD displa y;
•guided setup software;
•cont ext -sen sit ive in for m a t ion key;
•16-bit microprocessor;
•universal and digital inputs.

1.2 ■Introduction Watlow Series F4P
Setup Steps
The ˆˆKey
During all these steps, the Information Key will summon
helpful definitions and setup tips. Just position the cur-
sor next to the item you want to know more about, then
press the key. Press it again to return to your task.
See Chapter 3, Operations Page.
4 Establish a set point for static set point
control.
See Chapter 3, Operations Page.
3 Tune the system and set alarm set points.
Learn to navigate the software in Chapter 2,
Operating from the Front Panel, and then go to
Chapter 4, S etup Page. For background, you m ay
also want to refer to Chapter 7, Features. (Th is
step may not be necessary if the Series F4P is
already installed in the equipment.)
2 Configure the controller to suit your
application.
See Chapter 8, Installation and Wiring. (This
step will not be necessary if the Series F4P is
already installed in equipment.)
1 Install and wire the controller.
How to do itWhat to do
Your Ser ies F4P ma y a r rive a s an in dependen t u n it or
already installed in other equipment. The steps below
may or may not apply to all units. The Series F4P soft-
ware can be locked with different types of security. See
Chapter 5, Factory Page.

Wat l ow Ser i es F4P Oper at i ng f r om t he Fr ont Panel ■2.1
Chapt er Two: Navigation and
Operati ng from the Front Panel
Displays and Indicator Lights . . . . . . . . . . . . . . . . .2.2
Guided Programming . . . . . . . . . . . . . . . . . . . . . . .2.3
Custom Main Page . . . . . . . . . . . . . . . . . . . . . . . . .2.3
Auto and Manual Operation . . . . . . . . . . . . . . . . . .2.3
Troubleshooting Alarms and Errors . . . . . . . . . . . . .2.4
Figure 2. 1 — Page Navi gati on.
Main Page_____
Input 1 Error
Input 2 Error
Input 3 Error
Alarm 1 Condition
Alarm 2 Condition
Tune Status 1
Input 1 Value
In 1 ■■■■
Input 2 Value
Set Point 1
Set Point 2
Digital Set Point
Power 1A
1A% ■■
Power 1B
1B% ■■■
Digital Ins 1234
Active PID Set
Message 1
Message 2
Message 3
>Go to Operations
Go to Setup
Go to Factory
Operations Page
Autotune PID
Edit PID
Alarm Set Point
PID Crossover
Ramp to Set Point
Control Set Points
Setup Page
System
Analog Inputs
Digital Inputs
Control Outputs
Alarm Outputs
Retransmit Outputs
Communications
Custom Main Page
Static Message
Factory Page
Set Lockout
Diagnostic
Test
Calibration
The Main Page presents
error messages, static
messages and the status
of inputs, outputs and
depending on the Custom
Main Page, parameter
settings in the Setup
Page.
Scroll to the bottom of the
Main Page to reach the
other pages.
When you exit the Setup
or Factory Page, the
controller prompts you to
restore the old settings or
save the new ones.
Series F4P software is organized into four sections called
“p a ge s .” T h e Ma in P a ge is t h e ce n t r a l, d efa u lt p a ge t h a t
displays status information on the lower display. To get
to the other pages, you must begin in the Main Page.
✔Note: Access to th e soft wa r e is lim ited wh ile t h e con -
troller is autotuning (Setup and Factory pages are not
accessible).
2

Keys, Di spl ays and Li ghts
Figure 2. 2 — Seri es F4P Displ ays and Indi cator Li ghts.
F
1
2
i
1B
1B
1A
1A
Main Page___________
Go to Operations
Go to Setup
Go to Factory
5PPER$ISPLAY
Displays Channel 1 actual
process values during
operation. Displays error
information if errors occur.
#OMMUNICATIONS3TATUS
,IGHT
Blinks when the controller
sends or receives data.
!LARM/UTPUT3TATUS,IGHTS
Lit during an alarm state.
3CROLL"AR
Indicates that more informa-
tion exists above or below.
Use Up and Down keys.
!CTIVE/UTPUT3TATUS,IGHTS
Lit when the corresponding
controller channel output is
active.
,OWER$ISPLAY
Guides setup and operation, displays
status information.
#URSOR
Points to the selected
parameter or present value.
Moves via the Up, Down,
Right and Left keys.
!UTO-ANUAL3TATUS,IGHT
)NDICATESMODESTATUS
• Lit when in manual mode.
• Blinks for 10 seconds after
key pressed, while user
can change mode.
• Not lit during automatic
mode.
!UTO-ANUAL+EY
Press to toggle between auto
(closed-loop) and manual
(open-loop) control. )NFORMATION+EY
Press for tips and definitions,
press again to return to the
original task.
,EFTAND2IGHT+EYS
Press Right key to select the
item to the right of the cursor
(>) and proceed to the next
screen. Press Left key to
move left or exit.
5PAND$OWN+EYS
Press to move the cursor (>),
increase or decrease a value
or change a letter in a name.
4O#LEARAN!LARMOR%RROR
In an alarm condition, the alarm
status light will be lit. An alarm
message will appear on the Main
Page if configured to do so. To
silence the alarm, move the cursor
to the alarm message and press the
Right key. A message will confirm
the alarm silencing, and the alarm
status light will turn off.
After correcting the condition that
caused the error or alarm, return to
the error or alarm message on the
Main Page, and press the Right key
again. A message will confirm that
the alarm is unlatched.
2.2 ■Oper at i n g f r o m t he Fr on t Pan el Wat l o w Ser i es F4 P

Wat l ow Ser i es F4P Oper at i ng f r om t he Fr ont Panel ■2.3
Gui ded Progr a mmi ng
The Series F4P software guides users through most
tasks. To accomplish a task, simply proceed through the
sequence of parameters. For each parameter, choose the
appropriate option or establish the value, then press the
Right key to proceed to the parameter on the next
screen. The task is complete when you return to the ini-
tial menu.
1. Use >or <to move the cursor to select an item
in a list.
2. Press the Right key ...
3. Enter the value and make a choice.
4. Press .again.
5. Repeat until you return to the original list.
To cha n ge a specific, sin gle para m et er, pr oceed throu gh
the parameter sequence without changing values until
you reach that parameter, then make your change. After
cha n gin g th e valu e, you ma y ba ck ou t of th e sequ en ce by
pressing the Left key or continue on through the
sequence by pressing the Right key. When you exit the
page, you must choose to Save Changes or Restore
Values.
.
.
.
Choose Cycle Time:__
>Variable Burst
Fixed Time
Choose Function:____
>Heat
Cool
Choose to Setup:____
>Control Output 1A
Control Output 2A
Main Page___________
Go to Operations
>Go to Setup
Go to Factory
Cust om Mai n Page
The Main Page shows error messages; input and output
status; and allows access to controller software. You can
cust om ize the Main P a ge t o display chosen in for m a t ion
by going to the Setup Page, Custom Main Page Menu.
(See Ch a pt er 4, Set u p P a ge, for inst r u ct ion s.)
Aut o a nd Manua l Ope rati on
The Series F4P controller can function as a static set
point cont r oller (a u t o m ode); or t h e u ser ca n dir ect ly
cont r ol t h e ou t pu t s (m a n u a l m ode).
In the static set point mode, the Series F4P can only be
oper a t ed in a closed-loop con figu r a t ion.
The Auto/Manual Indicator Light is on when the con-
troller is in manual mode. To toggle between manual and
auto mode, first press the Auto/Manual key å, then con-
fir m you r select ion in the lower displa y. Th e indicator
light will flash after you press åuntil you confirm your
choice or 10 secon ds h a ve ela psed. Wh ile in ma n u a l mode
you can adjust the output power level for process outputs
or tu r n r ela y or open collector ou t pu t s on or off.
çWARNING: Only auth or ized a n d qu a lified person n el
should change the set point on the controller. Failure to
comply wit h t h ese recommenda t ion s ma y resu lt in da m -
age to equipment and property and injury to personnel.
Static Set Point Control
When the Series F4P is in static set point mode:
•The Upper Display shows the actual process temper-
ature of input 1.
•The Lower Display shows the default or user-config-
ured Main Page.
To oper a t e t h e Series F4P a s a static set poin t cont r oller,
select SP1 in the Main Page then use the Up and Down
keys to adjust the set point.
Limits may be placed on the set point in the Set Point
Low Limit and Set Point High Limit parameters (Setup
Page > Analog Input 1).
✔Note:All con t r ol a ct ivit y st ops wh en you en t er th e
Setup Page, Analog Input, Digital Input, Control Output,
Ala r m Ou t pu t a n d Ret r a n sm it m en us.
✔Note: See also differential set point and ratio set
point.

2.4 ■Oper at i n g f r o m t he Fr on t Pan el Wat l o w Ser i es F4 P
• Process value must return tonormalby
more than the hysteresis value to be
clea r ed.
• Configurealarm type,sides,hysteresis,
logic and set points.
• Correct cause ofinput error.
• Check the alarm output function.
• Alarm latched.
• Alarm output not configured cor-
rectly.
• Analoginput(s)in error condi-
tion.
• Input maybein error condition.
• Alarm won’t clear.
(To clea r t h e a larm, cor r ect t he
alarm condition. If the alarm
is latched, press
.with the
cur sor a t t h e a la r m m essa ge on
the Main Page.)
• Turn on alarm annunciation.• Alarm annunciation is set tooff.
• Exit Diagnosticmode.• Controller in Diagnosticmode.
• Configurealarm type,sides,hysteresis,logic
and set points.
• Alarm output not configured.
• Verifythat silencingfunction is required.
Disable if not required.
• Alarm silencingis enabled.
Alarms
• Alarm won’t occur.
• Return controller tofactoryfor repair.• Serialport ofcontroller is defective.
• Verifyor replace serialcable.• Serialcableis open or not wired correctly.
• Check converter box wiringand its docu-
mentation.
• Termination and/or pull up ofbus required.
• Check computer communications port set-
tings and verify PC communications.
• Computer communications port incorrectly
set up or defective.
•Converter must be half duplex.
• Check converter box wiringand settings.
• EIA-232toEIA-485 converter incorrectly
set or wired.
• Verifycorrect connections and test wiring
paths.
•Communications wiring reversed, shorted
or open .
• Look for a break in thedaisychain.• Unit-to-unit daisychain disconnected.
• Check Communications Setup Menu and set
to correct baud rate. Be sure it is Modbus
RTU protocol.
• Baud rate parameter incorrectlyset or
incorrect protocol. Use Modbus RTU, 8 data
bits, no parity and 1 stop bit.
• Check Communications Setup Menu and set
to correct address.
•Addr ess pa r a m et er in cor r ect ly set .
Communications
• Unit willnot
comm u n ica te.
• Measurepower for requiredlevel.Check
part number for input power required.
• Check wire size.
• Check for bad connections.
• Input power incorrect.
• Check switches,fuses,breakers,interlocks,
limits, connectors, etc. for energized condi-
tions and proper connection.
• Power tounit off.
• Fuseblown.
• Breaker tripped.
• SafetyInterlock door switch,etc.,activated.
• Separatesystem limit controllatched.
• Wiringopen.
Power
• Nodisplays.
Corrective ActionProbable Cause(s)Indication
Tr oubleshooting