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

Wat l ow Ser i es F4P Oper at i ng f r om t he Fr ont Panel ■2.5
• Return tofactoryfor evaluation.• Component failure.
Upper [Atod`]
Lower !Tim eou t x
(x is 1 to 3)
• Repair or replace sensor.
• Reversesensor wiringconnections.
Red lead is usually negative for tc.
• Set analoginput tomatch sensor.
• Check sensor isolation. Inputs 2 and
3 are not isolated from each other.
• Sensor open.
• Sensor wired backwards.Display
decreases as process increases.
• Input typeset towrongsensor.
• Ground loop
Upper [SEnhi]
Lower !I n pu t S en s or x+
(x is 1 to 3)
• Repair or replace sensor.
• Reversesensor wiringconnections.
Red lead is usually negative for tc.
• Set analoginput tomatch sensor.
• Check sensor isolation. Inputs 2 and
3 are not isolated from each other.
• Sensor shorted (RTD).
• Sensor wired backwards.Display
decreases as process increases.
• Input typeset towrongsensor.
• Ground loop
Upper [SEnLo]
Lower !I n pu t S en s or x-
(x is 1 to 3)
• Repair or replace sensor.
• Reversesensor wiringconnections.
Red lead is usually negative for tc.
• Set analoginput tomatch sensor.
• Check sensor isolation. Inputs 2 and
3 are not isolated from each other.
• Sensor open.
• Sensor wired backwards.Display
decreases as process increases.
• Input typeset towrongsensor.
• Ground loop
Upper [A-dhi]
Lower !I n pu t x At oD+
(x is 1 t o 3)
• Repair or replace sensor.
• Reversesensor wiringconnections.
Red lead is usually negative for tc.
• Set analoginput tomatch sensor.
• Check sensor isolation. Inputs 2 and
3 are not isolated from each other.
• Sensor shorted (RTD).
• Sensor wired backwards.Display
decreases as process increases.
• Input typeset towrongsensor.
• Ground loop
Upper [A-dLO]
Lower !I n pu t x At oD
(x is 1 to 3)
Input Errors
(Upper Displa y sh ows error code
for in pu t 1 on ly. Lower Displa y
shows additional errors. Input
2 and 3 error messages appear
in Lower Display. Alarm
Output Indicator is lit.)
• TunePIDset.
• Check power limit settings.
• Replace fuseor reset circuit breaker.
• Reposition sensor toaccuratelymea-
sure process.
• Check slidewire settings.
• PID values set incorrectly.
• Power limit set incorrectly.
• Open fuseor circuit breaker on energy
source.
• Incorrect sensor location in the pro-
cess.
• Slidewire (ifused)settings incorrect.
•Process will not reach set
point.
• Check operation mode.Automaticis
closed loop, ma n u a l is open loop.
• Check power limit settings.
• Check sensor,repair or replace.
• Check outputs,repair or replace.
• Check output settings.
• Check system wiring.
• Controller in manualoperation mode
(per cen t power ).
• Power limit set incorrectly.
• Thermocouple shorted.
• Shorted power switchingdevice.
• Output set incorrectly(heat vs.cool).
• System wired incorrectly.
•Process runs away (too high or
too low).
• Check power limit settings.
• TunePIDset.
• Usecorrect PIDset.
• Power limit set incorrectly.
• PID values set incorrectly.
• Incorrect PIDset active.
Controllability
•Process will not
stabilize.
• Check alarm logicsettingand output
wiring.
• Alarm logicsettingincorrect or output
wired incorrectly.
• Alarm output action is
reversed.
Corrective ActionProbable Cause(s)Indication

2.6 ■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
• Add power linefilter for input power.
• Return controller to factory for repair.
• Noiseon power line.
• Component failure.
• Checksum error in
Cycle device power.
• Press any key.Allparameters will de-
fault .
• Module changed.• Module change.Defaults will
occur. Accept wit h a n y key.
• Replace incorrect modulewith re-
transmit module.
• Wrongmodulein retransmit 2 slot.• Retransmit 2ModuleError!
Only process modules
supported.
• Replace incorrect modulewith re-
transmit module.
• Wrongmodulein retransmit 2 slot.• Retransmit 1ModuleError!
Only process modules
supported.
• Check for correct installation ofmod-
ule.
• Modulenot seatedcorrectlyin slot.• Verifythemodule.
• Check for correct installation ofmod-
ule.
• Module installed incorrectly or in
wrong slot.
• Modulenot allowed
• Replace output module.• Output module failure.• Output 1A
• Output 1B
• Output 2A
• Output 2A
• Move module tocorrect input slot.
• Move module tocorrect input slot.
• Input module 2or 3 is in input 1 slot.
• Input module 1is in input 2 or 3slot.
• VerifyInput 1
• VerifyInput 2 or 3
• Replace moduleor return controller
to factory for repair
• Amodule has lost its programming ID.• Incorrect ID!
• Contact factoryfor further informa-
tion and diagnosis.
• Component failure.• Unknown Error!
Record this number. Contact
the factory.
• Add filter toAC power line and verify
unit is power by AC voltage.
• Controller can’t detect zerocrosspoint.
Noise is present on AC power line or
unit is not powered by AC voltage.
• ZeroCross Failure!
Switched to Fixed
Time control.
System Errors
(Upper Displa y shows er r or
numbers. Lower Display mes-
sages indicate cause and
action to take.)
• Check wiringand process valve for
compa t ibilit y.
• Process valve is wired incorrectly or in-
compa t ible.
Upper
Lower Slidewire time out
• Increaseslidewire time out value.
• Replace process valve.
• Increaseslidewire time out value.
• Check wiringand process valve for
compa t ibilit y.
• Slidewire time out valueset tooshort.
• Slidewire valve is stuck or not
responding.
• Process valve is wired incorrectly or in-
compa t ible.
Upper
Lower Slidewire time out
• Return tofactoryfor evaluation.• Component failure.
Upper
Lower !I n pu t x E r r or
(x is 1 t o 3)
Corrective ActionProbable Cause(s)Indication

Wat l ow Ser i es F4P Oper at i ng f r om t he Fr ont Panel ■2.7
• Repair heating/coolingcircuits.
•Check circuit breakers, switches,
heater elements, compressor.
• Heater/coolingnon-functional.
• Replace sensor.• Sensor shorted.
• Replace relay.• Output relayopen or shorted.
• Place sensor near source.• Sensor not properlylocated
• Check allwiringand components.
• Turn the controller off,then on again.
Open Loop Detect
(Upper Displa y shows er r or
code for in pu t 1 on ly. Lower
Display shows additional
errors.
Upper: [oPLP`]
Lower: Open Loop
• Return controller to factory for repair.• Controller has failed.• Flash memoryFailed.
Return controller to the
Factory.
• Return controller to factory for repair.• Controller has failed.• RAMTest Failed!
Return controller to the
Factory.
• Turn the controller off, then on again.
If problem persists, power line filter is
required.
• Power line noisehas corrupted memory.• Checksum Error!
Parameter memory.
• Checksum Error!
Unit Config memory
• Checksum Error!
Profile memory.
• Normal operation following flash up-
date of firmware.
• Controller firmware has been updated.• Firmwarechange.
Parameters are initializing.
• Return controller to factory for repair.• Power was interrupted during a flash
update or there is a component failure.
• Flash MemoryFailed!
Return controller to the
Factory.
• Return controller to factory for repair.• Component failure.• RAMTest Failed!
Return controller to the
Factory.
• Should not appear in thefield.Call
the factory if you get this message.
• Controller powered up for the first time.• First power-up.
Parameters are initializing.
• This is normalupon modulechange.• Input or output module was changed.• Modulechange.
All pa r a m et er s ar e in it ializin g.
Corrective ActionProbable Cause(s)Indication

2.8 ■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
Notes:

Wat l ow Ser i es F4P Oper at i o n s Pag e ■3.1
Chapt er Thr ee: Operati ons Page
Alarm Set Points . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1
Autotune PID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2
Edit PID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2
Multiple PID Sets . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
Cascade Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
This chapter explains how to establish alarm set points,
autotune and manually tune and establish cascade con-
trol through the Operations Page of the software.
To configu r e t h e a la r m out puts, go t o t h e Set u p P a ge of
the software (see related information in the Parameters
Chapter).
For the alarm clearing procedure, go to the Troubleshoot-
ing Alarms and Errors table in the Navigation and
Operating from the Front Panel Chapter.
For background information about alarms; proportional,
integral and derivative control; and cascade, see the Fea-
tures Chapter.
Al ar m Se t Poi nts
The Series F4P includes two alarm outputs, which can be
programmed as process, deviation or rate alarms.
Process alarms notify the operator when process values
exceed or fall below Alarm Low and Alarm High Set
Points. Deviation alarms notify the operator when the
process has deviated from the set point beyond the devia-
tion limits. Rate alarms are triggered by a change in
temperature or process value that is faster than the se-
lected rate.
For more information, see the Features Chapter. To set
up the alarms, see the Setup Chapter.
Ala r m set poin t s ar e t h e poin t s a t wh ich a la r m s switch
on or off, depen din g on t h e a la rm set t ing. Alarm set
points can be viewed or changed in the Alarm Set Point
Menus (Operations Page).
The Alarm High Set P oint defines the high value that,
if exceeded, will trigger an alarm. This value must be
higher than the alarm low set point and lower than the
high limit of the sensor range.
The Alarm Low Set Point defines the low value that, if
exceeded, will trigger an alarm. This value must be lower
than the alarm high set point and higher than the low
limit of the sensor range.
The Alarm Low Deviation defines the deviation value
on th e low side of set poin t a t wh ich t h e a la rm will be
triggered.
The Alarm High Deviation defines the deviation value
on th e h igh side of set point at which t h e a la r m will be
triggered.
✔Note:You m a y want to set u p th e a la r m s wit h n a m es
that will identify the alarm conditions. See the Setup
Page.
To Cl ea r an Al a rm or Error
In an alarm condition, the alarm status light will be lit.
An ala r m m essa ge will appear on the Main P a ge if con-
figu r ed to do so. To silen ce a n a larm, t h e Silen cin g opt ion
in the Alarm Output menu (Setup Page) must be en-
abled. To silence the alarm, move the cursor to the alarm
message and press the Right key. A message will confirm
the silencing of the alarm, 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.
3

3.2 ■Oper at i o n s Pag e Wat l ow Ser i es F4P
Aut ot une PI D
In autotuning, the controller automatically selects the
PID parameters for optimal control, based on the ther-
mal response of the system. In the Series F4P, five sets of
PID values are available. Default PID values exist for all
PID sets, although these values typically do not provide
opt im a l con trol. PID va lu es can be a u t o-t u n ed or a dju st -
ed manually. When autotuning is complete, the PID val-
ues will be stored in the Edit PID Menu.
Set point changes for remote, ratio and differential con-
trol are ignored until autotuning is complete.
Autotuni ng Pr ocedur e
Aut ot u n ing is in it ia t ed fr om th e Oper a t ion Men u .
1. Before initiating auto-tune, go to the System Menu
(Set u p P a ge), an d est a blish t h e Au t ot u n e Set Poin t
to a percentage of set point. This percentage is based
on you r knowledge of t h e system a n d how m u ch
over sh oot or u n der shoot ther e is likely t o be in on -off
cont r ol.
Select to display Tune Status in the Custom Main
Page Menu.
2. Go to the Main Page and adjust set point.
3. Go to the Autotune PID Menu (Operations Page) and
choose t h e P ID set in wh ich t o st or e t h e va lues. You
must exit back to Main Page with the left arrow. A
message will be displayed on the Main Page during
the autotuning process.
4. When autotuning is complete, the controller will
store the values for optimum control in the specified
PID set.
For additional information about autotuning and propor-
tional, integral and derivative control, see the Features
Chapter.
✔Note: While the controller is autotuning, only the Op-
eration Page of the software can be entered.
ç
CAUTI ON: Choose an aut otune set poi nt va l ue that wi l l
protect your product from possi bl e damage from overshoot
or undershoot duri ng the autotuning oscil lati ons. If the
product is sensi tive, sel ect the autotune set point very
careful ly to prevent product damage.
Edi t PI D
The Edit PID Menu is useful when Auto-tune PID does
not provide adequate control. Each of the PID parame-
ters can be adjusted manually:
Proportional Band:Define a band for PID control, en-
tered in degrees or units. Lower values increase gain,
which reduces droop but can cause oscillation. Increase
the proportional band to eliminate oscillation.
Integral (Reset): Define the integral time in minutes
per repeat; define reset in repeats per minute. Set re-
peats per minute if units are U.S.; minutes per repeat if
units are SI.
Derivative (Rate): Define the derivative (rate) time in
minutes. Large values prevent overshoot but can cause
sluggishness. Decrease if necessary.
Dead Band: Define the dead band in degrees or units.
Heating dead band shifts the set point down. Cooling
dead band shifts the set point up. For more information,
see the Features Chapter.
For background information, see Chapter 7, Features.
Manual Tuning Procedure
1. Apply power to the Series F4P and establish a set
point on the Main Page.
2. Establish Cycle Time in the Control Output Menu
(Set u p P a ge), as r equir ed. Typica l cycle tim es a r e 1.0
second for an SSR and 5.0 seconds for a mechanical
relay. Faster cycle times sometimes achieve the best
system control. However, if a mechanical contactor or
solenoid is switching power to the load, a longer cy-
cle t im e m a y be desir a ble t o min im ize wear on th e
mechanical components. Experiment until the cycle
time is consistent with the desired quality of control.
3. Go to the Edit PID Menu (Operations Page), and
choose t h e ch a n n el an d PID set . Est a blish va lu es for
the PID parameters: Proportional Band, 5; Integral
(Reset ), 0; Der iva tive (Ra t e), 0; an d Au t ot u n e, Tun e
Off. Tuning begins when you choose a PID set.
4. When the system stabilizes, watch the value of Input
1 on the Main Page. If this value fluctuates, increase
the proportional band setting until it stabilizes. Ad-
just the proportional ba nd in 3° to 5° in cremen ts, al-
lowing time for the system to stabilize between ad-
justments.
5. When Input 1 has stabilized, watch the percent pow-
er on the Main Page. It should be stable, ±2%. At
this point, the process temperature should also be
stable, but it will exhibit droop (stabilized below set
point). The droop can be eliminated with integral (re-
set).

Wat l ow Ser i es F4P Oper at i o n s Pag e ■3.3
6. Start with an integral setting of 99.9 minutes and al-
low 10 minutes for the process temperature to get to
set point. If it has not, decrease the setting by half
and wait another 10 minutes. Then halve the setting
again and wait another 10 minutes until the process
value equals the set point. If the process becomes un-
stable, the integral value is too small. Increase it un-
til the process stabilizes.
7. Increase Derivative/Rate to 0.10 minute. Then in-
crea se t h e set poin t by 11° to 17°C. Wa t ch th e sys-
tem's approach to the set point. If the process value
over sh oot s the set poin t , in cr ea se Der iva t ive/Ra t e t o
0.50 minute.
Increase the set point by 11° to 17°C and watch the
approach to the new set point. If you increase
Derivative/Rate too much, the approach to the set
point will be very sluggish. Repeat as necessary until
the system rises to the new set point without over-
shoot or sluggishness.
For additional information about the burst fire feature,
manual tuning and PID control, see the Features Chapter.
Multiple PID Sets
Environmental chambers, ovens and furnaces typically
have different thermal requirements at high and low
temperatures or pressures. To accommodate this, the Se-
ries F4P can store five different PID sets.
Multiple Tuning Procedure
To autotune multiple PID sets, follow the Autotuning
procedure above for each PID set. When autotuning is
fin ish ed for on e set , pr oceed with an ot h er.
Cascade
Cascade control is available on enhanced (F4P _ - _ _ AB
- _ _ _ _) Ser ies F4P con t r oller s. For ba ckgr ou n d in for ma-
tion about cascade control, see the Features Chapter.
Select cascade control through the Analog Input 3 Menu
(Set u p P a ge), an d choose Process Ca sca de or Devia t ion
Cascade. To set the range for the inner loop set point,
Process Cascade uses Low and High Range settings that
are independent of set point; Deviation Cascade uses De-
viation Low and High settings that are deviations from
the primary set point.
When tuning a cascade system, the inner loop must be
tuned first. The inner loop comprises outputs 1A and 1B
and the Analog Input 1 sensor, which usually measures
the energy source temperature. The output device con-
trols a power switching device, which in turn switches
the heating and cooling. The set point for the inner loop
is generated by the outer loop. For Process Cascade, this
will have a range between the Cascade Low Range and
Cascade High Range.
Casca de Se tup Proce dure
1. First, configure Analog Input 3, Cascade Low Range
and Cascade High Range.
Go to the Analog Input 3 Menu (Setup Page). Choose
Process or Deviation Cascade. Deviation Cascade refer-
ences Channel 1 set point allowing a range above and
below the current control set point. For Process Cascade
cont r ol of a h ea t /cool or cool on ly syst em , set th e Ca sca de
Low Range to a value slightly lower than the lowest
temperature desired in the chamber. For heat-only sys-
tems, set the Cascade Low Range to a value slightly low-
er than the ambient temperature; otherwise the heat
out pu t will never t u r n fu lly off.
For heat/cool or heat only systems , set the Cascade
High Range to a value slightly higher than the highest
temperature desired in the chamber. For cool-only
systems, set the Cascade High Range to a value slightly
higher than the ambient temperature; otherwise the
coolin g will n ever fu lly turn off.
2. Next, configure the controller to tune and display data
for th e ou t er loop. To view In n er Loop Set P oint in t h e
upper display, go to the Setup Page, Custom Main Page
Menu, select the Inner Set point as one of the parame-
ters, P1 to P16, to be displayed in the Main Page.
To also view Analog Input 3 in the upper display, go to
the Setup Page, Process Display Menu, and choose Al-
ternating. Under Set Display Time, choose a duration
for th e displa y of t h e In put 1 and In pu t 3 va r ia bles.
Casca de Aut otuni ng Pr oce dure
1. Go to Setup Page, Custom Main Page Menu. Choose
Tune Status 1 and Tune Status 2 to appear as 2 of the
16 parameters that can be displayed on the Main Page.
The Main Page will now display the status of the auto-
tuning process.
2. Autotune the inner loop. Go to the Autotune PID Menu
(Oper a t ion s P a ge), an d select Ca sca de In n er-loop.
Choose Cascade Inner Loop PID Set 1 to 5, where PID
values will be stored after autotuning. Autotuning be-
gins when you choose the PID set. While autotuning,
the F4 controller will control the energy source in an
on-off m ode t o a t em per a t ure equal to t h e Ca sca de H igh
Range setting x Channel 1 Autotune Set Point. For best
results, use proportional control only on the inner loop.

3.4 ■Oper at i o n s Pag e Wat l ow Ser i es F4P
3. Next, autotune the outer loop. Go to the Autotune PID
Menu (Operations Page). Choose Cascade Outer Loop,
then choose Outer Loop PID set 1 to 5, where PID val-
ues will be stored after autotuning. Autotuning begins
when you choose the PID set. While autotuning, the
out er loop will be con t r olled in a n on -off m ode a t a set
point equal to static set point x Ch 1 Autotune Set
Point. In most cases, the autotuning feature will tune
for a ccept a ble con t r ol. If n ot , ma n u a lly tu n e t h e ou t er
loop (step 4 below). Before manually tuning, record the
values generated by the autotuning feature.
4. To manually tune the outer loop, go to the Edit PID
Menu (Operations Page). Choose Cascade Outer Loop,
then choose Outer Loop PID set 1 to 5. Begin manual
tuning by setting the Proportional Band to 5, Integral
(Reset ) t o 0, a n d Ra t e t o 0. Est a blish th e desired set
point and let the system stabilize. When the system
stabilizes, watch the Inner Loop Set Point on the Main
Page. If this value fluctuates, increase the proportional
band until it stabilizes. Adjust the proportional band
in 3° to 5° increments, allowing time for the system to
stabilize between adjustments.
5. When Input 1 has stabilized, watch the percent power
on th e Ma in P a ge. It shou ld be st a ble, ±2%. At t h is
point, the process temperature should also be stable,
but it will exhibit droop (stabilized below set point).
The droop can be eliminated with Integral (reset).
6. Start with an integral setting of 99.9 minutes, and al-
low 10 minutes for the process temperature to come up
to set point. If it has not, decrease the setting by half
and wait another 10 minutes. Then halve the setting
again and wait another 10 minutes until the process
value equals the set point. If the process becomes
unstable, the integral value is too small. Increase it
until the process stabilizes.

Wat l ow Ser i es F4P Setup Page ■4.1
Chapt er Four : Setup Page
Parameter Setup Order . . . . . . . . . . . . . . . . . . . . . .4.1
Customizing the Main Page . . . . . . . . . . . . . . . . . .4.2
Static Messages . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2
4
This chapter explains how to configure the controller
software through the Setup Page menus. Setup Page pa-
rameters affect the way the controller responds to your
application, which parameters and functions are visible
in other pages, and the way information is displayed on
the Main Page. Set up the controller properly to provide
a sound foundation for settings in other pages.
For ranges, defaults and other information about specific
parameters, see the Parameters Chapter. Record your
settings in the Parameter Setup Record, also in that
cha pt er.
For background information about inputs, outputs,
alarms and other features, see the Features Chapter.
Parameter Setup Order
Initial configuration of the Series F4P is best done in the
followin g or der :
1. Go to the System Menu (Setup Page) to configure:
•PID units — SI (Integral, Derivative) or U.S. (Re-
set, Rate);
•Celsius or Fahrenheit scales;
•display of units in the controller’s upper display;
•Aut ot u n e set poin t ;
•open -loop det ect ion wa r n in gs; a n d
•cont r oller r espon se t o a power ou t a ge.
2. Go to other menus on the Setup Page to configure:
•Ana log In pu t x (1 to 3);
•Digital Input x (1 to 4);
•Control Output x (1A, 1B);
•Ala r m Ou t pu t x (1 or 2);
•Retransmit Output x (1 or 2);
•Communications; and
•Custom Main Page and Custom Messages.
3. Go to the Operations Page to tune the PID sets.
4. Go to the Operations Page to set the alarm set
points.
After t h is init ia l configu r a t ion , th e m ost fr equ en t
cha n ges will be t o the Oper a t ion s Page (a la r m set poin t s
and PID sets).
If the Series F4P is already installed in an environmen-
tal chamber, oven, furnace or other equipment, most pa-
rameters will already be configured and access to the
Setup Page may be limited (see Chapter 5, Factory
Page).
Changing Setup Page parameters may change other pa-
rameters. In some cases, a change in one parameter will
affect the defaults of others. To see how all the pages,
menus and parameters are grouped, see the software
map on the inside back cover of this manual.
✔Note: For more information about how parameter set-
tings affect the controller’s operation, see the Features
Chapter.
çWARNING: Only auth or ized a n d qu a lified person n el
should change the factory-default settings, which may
cause ch a n ges in oth er set t in gs. Fa ilu r e to com ply with
this recommendation may result in damage to equipment
and property and injury to personnel.

4.2 ■Setup Page Wat l ow Ser i es F4P
Cust omi zi ng the Mai n Page
Up to 16 lines can be added to the Main Page to display
status and information from the controller.
Go to the Custom Main Page Menu on the Setup Page.
The first screen will prompt you to choose one of the 16
lines to customize. "P1 Parameter" is the first line; "P16
Parameter" is the 16th. After choosing this line by press-
ing ., select a parameter to monitor.
Your choices a r e listed u n der Cu st om Ma in Page in t h e
Setup Page Parameter Table in this chapter.
Figure 4. 2 — Example of Parameters on the Custom Mai n
Page.
Input1 26°C
PID Set 1
Power1A 0%
Power1B 55%
DigitalIn _234
Choose P:1 Display_ _
>None
Input 1 Value ■
Input 1 Value bar ▼
Choose:_ _ _____
>P1 Parameter
P2 Parameter ■
P3 Parameter ▼
Stati c Messages
Digital inputs can be configured to display a message
that the user enters. The message is displayed on the
Main Page when the digital input is active.
This feature could, for instance, display “DOOR OPEN” if
an oven door is not closed all the way.