Watlow Series F4P Temperature/Process Controller

Watlow Series F4P Temperature/Process Controller

Product basic information and positioning

1. Core positioning and system role

The Watlow Series F4P is a 1/4 DIN (96 × 96mm) industrial grade temperature/process controller with core functions of high-precision parameter measurement and closed-loop control. It can operate independently or be integrated into automation systems, and is suitable for heating, cooling, pressure regulation, and other scenarios. Its core value lies in balancing basic control (such as switch control, PID regulation) with advanced extended functions (cascade control, proportional control), supporting single loop independent control or multi module collaboration, and widely used in semiconductor manufacturing, chemical industry, food processing, HVAC and other fields.

2. Basic specifications and environmental adaptability

(1) Physical and Power Supply Specifications

Project parameter description

Installation method: Panel installation (in accordance with DIN standards) requires reserved panel openings of 92-93mm, vertical installation, to avoid horizontal/inclined installation affecting heat dissipation; Supports NEMA 4X/IP65 protection (requires correct tightening of gaskets, screw torque to ensure clearance ≤ 0.508mm)

The external dimensions are 96mm (width) x 96mm (height) x 97mm (depth), with a weight of approximately 450g. Maintenance space needs to be reserved for top/bottom ≥ 17.6mm and front ≥ 16mm

Power supply requirements: 100-240V AC (50/60Hz) or 24-28V AC/DC Class 2/SELV certified power supply, maximum power consumption of 39VA, supporting Semi F47-0200 voltage drop standard (keep running during voltage drop)

Wire specifications support 12-22 AWG single/multi strand copper wire stripping length of 7-10mm, terminal torque of 0.5-0.6 Nm, to avoid damage to terminals due to over tightening

(2) Environmental and Certification Standards

Environmental parameters: operating temperature 0-65 ° C (non condensing), storage temperature -40-70 ° C, relative humidity 0-90% RH (non condensing), vibration level IEC 60068-2-6 (10-500Hz, 2G), impact level IEC 60068-2-27 (15G, 11ms).

Certification qualifications: UL 916, EN 61010-1, CE (EMC/Low Voltage Directive), Class 1 Div. 2 (optional), Groups A-D， Temperature code T4), RoHS, WEEE, some models have passed FM certification.

Warranty policy: 3-year warranty, covering manufacturing defects, excluding faults caused by transportation damage, human misuse, or unauthorized modification; Returns need to apply for an RMA number from Watlow in advance, providing the product model, serial number, and fault description.

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Core functions and technical features

1. Input/output capability (core control interface)

(1) Input type and specifications

The F4P controller input is divided into general analog input and digital input. The advanced model (F4P _ - _ AB - _ _) supports 2-3 analog inputs and is suitable for multi parameter acquisition scenarios:

Input type quantity, key parameter configuration points, applicable scenarios

Universal Analog Input (Basic Version) 1-channel - Thermocouple: Supports 11 types of J/K/T/N/C/E/PTII/D/B/R/S, with cold end compensation accuracy of ± 0.1 ° C

-RTD: 2-3 wire 100 Ω platinum resistor, supports JIS/DIN curve, wire resistance compensation (≤ 10 Ω)

-Process signals: 0-10V DC (input impedance 20k Ω), 1-5V DC, 0-20mA DC (input impedance 100 Ω), 4-20mA DC, 0-50mV DC (input impedance 20M Ω)

-Sampling rate: 20Hz (input 1), 10Hz (input 2-3) requires configuring "Sensor" (sensor type), "Tipo" (linearization curve), "Decimal" (decimal places), "Escala baja/ata" (range), temperature, pressure, flow rate and other continuous parameter collection in "P á gina Configuraci ó n>Entrada anal ó gica x", such as industrial furnace temperature and pipeline pressure monitoring

General Analog Input (Advanced Edition) 2-3 channels, the same as the Basic Edition, supports input isolation (to avoid grounding loops), can be configured as remote set points, cascade control internal loop input needs to distinguish "Control" parameters (such as "Normal", "Cascada", "Relaci ó n"), input 2-3 only supports partial sensor types (such as RTD, process signals) multi parameter collaborative control, such as cascade control external loop (process temperature) and internal loop (heat source temperature) acquisition

4-channel digital input - supports dry contact/DC voltage input: dry contact closing resistance<50 Ω (valid), open circuit resistance>100k Ω (invalid); DC voltage low state<2V, high state>3V

-Response frequency: 10Hz, supports "Estado Bajo/Alto" (effective level), "Flanco Ascendante/Ascendante" (trigger edge) configuration in "P á gina Configuraci ó n>Entrada digital x", sets "Funci ó n" (functions such as triggering alarms, switching setpoints), "Condici ó n" (effective conditions), "Activate Mensaje" (associated static messages), external status feedback (such as equipment door switches, limit signals), control triggering (such as manual start stop signals)

(2) Output type and specifications

The output is divided into control output (driving actuator), alarm output (fault linkage), and retransmission output (signal forwarding), supporting multi output collaborative work:

Output type quantity, key parameter configuration points, applicable scenarios

Control output (1A/1B) 2-channel - mechanical relay (Form C): 2A/250V AC or 30V DC, 100000 cycles life, no contact suppression

-Solid state relay (SSR): 0.5A/24-253V AC, zero crossing trigger, optical isolation, leakage current ≤ 10 μ A

-Open collector: 42V DC/0.5A, requires external power supply, supports switching DC loads

-Process output: 4-20mA DC (maximum 800 Ω load) or 0-10V DC (minimum 1k Ω load), accuracy ± 30 μ A/± 15mV, supports "D ú plex" (dual-mode, such as heating/cooling bidirectional control), in "P á gina Configuraci ó n>Salida control x", set "Funci ó n" (functions, such as "Calor" and "Fr í o"), "Tipo del tiempo del ciclo" (cycle type: fixed/variable), "Proceso" (process output range) to drive actuators such as heaters, refrigerators, valves, frequency converters, etc., such as PID regulating heating power and valve opening control

Alarm output 2-channel mechanical relay (Form C): 2A/250V AC or 30V DC, supports "Autoborrado"/"Enganche" modes, can be associated with process/deviation/rate alarms. Set "Tipo de alarma" (alarm type), "Lados de alarma" (high and low end triggering), "L ó gica de alarma" (normally open/normally closed) fault linkage (such as overheating to cut off power, triggering buzzer), status prompt (such as running/standby indication) in "P á gina Configuraci ó n>Salida de alarma x"

Resend output (optional) 1-2 channels of same process output, can resend input signals or control output signals, supports "Compensataci ó n de escala" (range offset) in "P á gina Configuraci ó n>Salida de retracns x" setting "Fuente de retracmisi ó n" (signal source, such as input 1, control output 1A), "Rango anal ó gico" (output range) signal forwarding to recorders, PLCs or other controllers, such as retransmitting temperature signals to SCADA systems

2. Control and computation functions (core algorithms)

(1) Basic control mode

F4P supports switch control and PID control, adapting to different precision requirements scenarios. Parameters can be configured through "P á gina Operaiones":

Applicable scenarios for key parameters of control mode core logic

On Off control is based on the set point and hysteresis to start and stop the output: if the temperature is higher than the set point+hysteresis → turn off the heating; Below the set point - hysteresis ->turn on heating - Hist é resis (hysteresis): 1-9999 units, avoid frequent switching

-Need to set 'Banda proportional' to 0 (disable PID) for low precision control, such as insulation boxes and small heating equipment

Proportional control (P) output power is proportional to deviation: deviation=set point - process value, output power=(deviation/proportional band) × 100%, with static deviation ("Ca í da") - Banda proportional (proportional band): 0-30000 units, the smaller the proportional band, the higher the gain

-Suitable for medium precision control in scenarios without static deviation requirements, such as fan speed regulation and simple heating control

Proportional integral control (PI) adds an integral effect on the basis of proportional control to eliminate static bias: integral output=(deviation x time)/integral time - integral: 0.00-99.99 minutes (SI units), the shorter the time, the stronger the integral effect

-It is necessary to avoid high-precision control of system oscillation caused by excessive integration, such as the temperature of chemical reaction vessels and food baking furnaces

Proportional integral differential control (PID) increases differential action and suppresses overshoot: differential output=differential time × deviation change rate, adjust output in advance to deal with rapid deviation - Derivativa (differential time): 0.00-9.99 minutes (SI units), the longer the time, the stronger the differential action

-Need to cooperate with "Banda muerta" (dead zone) to avoid high-frequency fluctuations, high-precision, and large hysteresis systems, such as plastic extruder temperature and semiconductor wafer heat treatment

(2) Advanced control functions

Advanced models support extended functions such as cascade control, proportional control, valve positioning control, etc., suitable for complex industrial scenarios:

Functional Type Core Logic Configuration Steps Applicable Scenarios

Cascada dual loop linkage: The output of the external loop (such as process temperature) serves as the set point for the internal loop (such as heat source temperature), and the internal loop controls the heat source to reduce hysteresis and overshoot of the external loop. 1. Configure the external loop: "P á gina Configuraci ó n>Entrada anal ó gica 3" is set to "Cascada", and "Margen bajo/alto" (internal loop range) is set

2. Set the internal loop PID: "P á gina Operaiones>Autoafinar PID" Select "Lazo interno cassad"

3. Set the PID of the external circuit: select "Lazo externo cassad", and the set point of the internal circuit dynamically changes with the deviation of the external circuit, such as industrial furnaces (external circuit: furnace temperature; internal circuit: heating tube temperature), refrigeration systems (external circuit: cabin temperature; internal circuit: evaporator temperature), etc

Proportional control (Relaci ó n) process value and reference value are linked proportionally: output set point=reference value x proportional coefficient, supports 4 sets of digital trigger proportional switching. 1. Configure reference input: "P á gina Configuraci ó n>Entrada anal ó gica 3" set to "Relaci ó n"

2. Set the proportional coefficient: "P á gina Operaiones>PE de control" configure "P.E. Digital de relaxi ó n"

3. Associated trigger signals: digital input triggers ratio switching (such as different product formulas corresponding to different ratios), mixing process (such as mixing two materials in proportion), synchronous control (such as multi axis speed ratio adjustment)

The valve positioning control (Posici ó n de v á lvula) feeds back the valve position through the potentiometer, controls the valve switch with dual outputs, supports dead zone and lag adjustment, and avoids frequent actions. 1. Configuration input 3: "P á gina Configuraci ó n>Entrada anal ó gica 3" is set to "Posici ó n de v á lvula", and calibrates the potentiometer range (100-1200 Ω)

2. Set dead zone: "Bandamuerta (res.cur)" (0.3-100%) to avoid triggering actions with small deviations

3. Configuration output: 1A control valve closed, 1B control valve open, based on PID deviation adjustment action time fluid flow control (such as three-way valve), gas mixing ratio adjustment

Ramp control (Rampa) set point changes at a fixed rate: linearly rising from the current value to the target value to avoid process fluctuations caused by rapid changes. 1. Configuration mode: "P á gina Operaiones>Rampa x a Punto establecido" set to "Proceso" or "Punto establecido"

2. Set parameters: "Velocidad de rampa" (1-999 units/minute/hour), "Escala de rampa" (units)

3. Trigger start: Trigger ramp heating/cooling process (such as semiconductor annealing, glass forming) from "P á gina Principal" or digital input to avoid thermal shock

(3) PID automatic tuning and multiple sets of PID

Autoafinaci ó n: Through 4 oscillation tests across the set point, the optimal PID parameters are automatically calculated, supporting local (internal loop) or global tuning. During the tuning process, the controller switches to switch control and automatically restores PID control after completion. You need to select "Conjuno PID" (storage group) and "Tipo Autoafinac. PID" (heating/heating+cooling only) in "P á gina Operaiones>Autoafinar PID", and pay attention to choosing a safe setting point (to avoid overheating and damaging the product).

Multiple sets of PID storage: Supports 5 sets of PID parameters (Conjunto 1-5), which can be triggered to switch based on set points or process values (such as Conjunto 1 for low temperature section and Conjunto 2 for high temperature section). The switching point can be configured with "Hist é resis" (-1 unit) to avoid frequent switching, and the switching condition can be set in "P á gina Operaiones>Cambio de PID".

3. Alarm and safety functions (fault protection)

(1) Alarm type and configuration

Support process alarm, deviation alarm, and rate alarm, with 2 independent alarm outputs that can be associated with different fault scenarios:

Key parameter configuration points for triggering logic of alarm types

Process alarm (Proceso): Process value exceeds fixed threshold: above "P.E. alto de alarma" or below "P.E. bajo de alarma" triggers - P.E. alto/bajo de alarma: threshold must be within sensor range and above/below set point

-Hist é resis de alarma: 1-9999 units, to avoid frequent alarm triggering. Set the threshold in "P á gina Operaiones>Punto establecido de alarma" and set "Lados de alarma" (high/low only/dual end) in "P á gina Configuraci ó n>Salida de alarma x"

Deviation alarm (Desviaci ó n): The deviation between the process value and the set point exceeds the threshold: Deviation=Process value - Set point. If it is higher than "Desv. alta" or lower than "Desv. baja", it triggers - Desv. alta/baja: 1-9999 units (can be negative), and the deviation threshold dynamically changes with the set point

-The threshold for scenarios with frequent changes in the set point should be set in "P á gina Operaiones", and the alarm range should be adjusted synchronously with the set point (such as when the set point is raised from 100 ℃ to 200 ℃, the deviation threshold should be maintained at ± 5 ℃)

Rate alarm (Tasa) process value change rate exceeds threshold: change per unit time>"Velocidad m á x. de alarma" trigger - Velocidad m á x. de alarma: 1-30000 units/second, matching the maximum allowable change rate of the process

-Suitable for preventing sudden changes in parameters (such as temperature drops caused by heating tube breakage), set "Tipo de alarma=Vel. m á x." in "P á gina Configuraci ó n>Salida de alarma x" and set the threshold in "P á gina Operaiones"

(2) Alarm response and security mechanism

Alarm output logic: supports "Autoborrado" (automatic reset after fault relief) or "Enganche" (manual reset), "Silenciamiento" (mute during startup phase to avoid false alarms during initial heating), "Mensajes de alarma" (P á gina Principal displays fault information).

Fault protection:

Sensor open circuit detection: After triggering, the controller switches to manual mode (output 0%) and displays "oPLP `" (open circuit fault). The wiring needs to be repaired and restarted to restore.

Power failure response: Supports "Modo de falla" (failure mode), such as "Fijo" (maintain output before failure) and "Apagado" (turn off output), with parameters stored in non-volatile memory (not lost when power is turned off).

Independent limit control: It is recommended to connect an external limit controller (such as Watlow 97 series) as redundant protection to prevent overheating/overpressure caused by main controller failure.

4. Communication and Expansion Functions (System Integration)

(1) Communication Protocol and Configuration

Support EIA-232 and EIA-485 buses, adapt to Modbus RTU protocol, and achieve communication with PLC, HMI, SCADA systems:

Key parameter configuration points for communication types, applicable scenarios

EIA-232- Transmission distance: maximum 15 meters

-Baud rate: 9600/19200/38400bps

-Data format: 8-bit data bit, 1-bit stop bit, no checksum (8N1)

-Interface: DB9 terminal, TX/RX/GND. Set "Baudios" (baud rate) and "Direcci ó n" (addresses 1-247) in "P á gina Configuraci ó n>Comunications", support "Modbus RTU" protocol, can transmit input values, setpoints, and output status for short distance point-to-point communication (such as controller and local PC)

EIA-485- Transmission distance: up to 1200 meters (shielded twisted pair)

-Baud rate: Same as EIA-232

-Topology: daisy chain, supporting 32 nodes (expandable through repeaters)

-Terminal resistance: A 120 Ω resistor should be connected to the front and rear nodes to reduce signal reflection. The wiring should distinguish T+/T -/GND (EIA-485 terminal: CA=T -, CB=T+, CC=GND), and star topology is prohibited. Communication lines and power lines should be wired separately (spacing ≥ 10cm) for long-distance multi node communication (such as multiple controllers networked to PLC)

(2) Extended functionality and integration

Remote Setpoints: Switch 3 sets of remote setpoints through analog input (such as 4-20mA) or digital input, suitable for multiple process scenarios (such as different temperature settings corresponding to different products).

Data Resend: Resend output can forward input signals (such as temperature) or control output signals (such as valve opening), support range offset ("Compensataci ó n de escala"), and adapt to the signal requirements of third-party devices.

Software integration: Supports configuring parameters, monitoring status, and backup/restore configurations through EZ-ZONE Configurator software. The software is compatible with Windows systems and requires connection through a USB-EIA-485 converter.

Operation and Configuration Guide

1. Menu navigation and operation logic

The F4P controller software is divided into 4 levels of pages, which are navigated through panel buttons and support wizard style configuration. The operation is intuitive:

(1) Page Structure

Page hierarchy core function access path common operations

P á gina Principal (homepage) displays real-time data (process values, setpoints, output status), fault alarms, quick access to other pages, default page for startup, switches display items by pressing "Up/Down" to view temperature/pressure values, confirms alarm information, and presses "Go to Operations/Configuraci ó n/F á brica" to enter the corresponding page

PID tuning, alarm threshold setting, manual PID parameter adjustment, slope control homepage → "Go to Operations" to start automatic tuning, modify alarm threshold, adjust proportional band/integral time, trigger slope control

P á gina Configuraci ó n (configuration page) Input/output configuration, system parameters (units, filtering), communication parameters, static message homepage → "Go to Configuraci ó n" Select sensor type, set output function, configure baud rate, edit static message (such as "PUERTA ABERTA")

P á gina F á brica (factory page) security permissions (password/lock), calibration (input/output), diagnosis, restore factory settings homepage → "Go to F á brica" (permission required) Set user/administrator password, calibrate input/output accuracy, view fault codes, restore factory parameters

(2) Panel button function

Example of Key Function Operation

Up/Down: Move the cursor, increase or decrease values, switch display items to adjust the set point: Select "P.E. 1" on the homepage, press Up to increase, Down to decrease

Left/Right: Switch menu, confirm selection, exit current page, confirm alarm reset: Select alarm message, press Right to confirm reset

Auto/Manual Switch Control Mode: Auto (Closed loop)/Manual (Open loop) Manual Adjust Output: Press the Auto/Manual key, confirm and use Up/Down to adjust the output power

Informaci ó n displays parameter definitions and operation prompts. View the definition of "Banda propositional": select the parameter and press the information key to display instructions

2. Core configuration process (taking single loop temperature control as an example)

(1) Basic Configuration (Required Steps)

System parameter configuration (P á gina Configuraci ó n>Sistema)

Unit setting: "Unidades PID" is set to "SI" (℃/minute) or "Inglesas" (℉/time/minute), and "° F o ° C" is set to the required unit for the process (such as ℃).

Power failure: Set "Modo de falla" to "Apagado" (turn off output in case of failure), and set "Deterci ó n de lazo abierto" to "Encendido" (enable open circuit detection).

Filter setting: Set "Tiempo de filtrado" to 1-5 seconds (to reduce signal noise and avoid frequent adjustments).

Input configuration (P á gina Configuraci ó n>Entrada anal ó gica 1)

Sensor type: "Sensor" is set to the actual usage type (such as "J" type thermocouple), and "Tipo" is set to the corresponding curve (such as "J").

Range setting: "Escala baja/alta" is set to the sensor range (such as 0-750 ℃ for J-type thermocouples), and "L í mite bajo/alto P.E." is set to the process allowable set point range (such as 50-500 ℃).

Compensation setting: Set "Tipo de compensaci ó n" to "Linear sencillo" (single point compensation). If there is a deviation in the sensor, enter the compensation value (such as+1 ℃) in "Valor de compensaci ó n de la calibraci ó n".

Output configuration (P á gina Configuraci ó n>Salida control 1A/1B)

1A output (heating): Set "Funci ó n" to "Calor" (heating), "Tipo del tiempo del ciclo" to "Disparo variable" (variable period), and "Valor del tiempo de ciclo" to 1-10 seconds (adjusted according to load to avoid contactor wear).

1B output (optional, cooling): If cooling is required, set "Funci ó n" to "Fr í o" (cooling), with the same parameters as 1A; if not required, set "Apagado".

Process output (optional): If temperature signal needs to be resent, set "Proceso" to "4-20mA" and "Escala baja/alta" to 0-500 ℃ corresponding to 4-20mA.

Alarm configuration (P á gina Configuraci ó n>Salida de alarma 1/2)

Alarm 1 (Overtemperature): Set "Tipo de alarma" to "Proceso", "Lados de alarma" to "Alto", "Enganche" to "Autoborrado" (automatically reset after fault relief), and "Hist é resis alarma" to 5 ℃.

Alarm 2 (low temperature): "Tipo de alarma" is set to "Proceso", "Lados de alarma" is set to "Bajo", and all others are the same as alarm 1.

(2) PID tuning and optimization (ensuring control accuracy)

Automatic tuning (P á gina Operaiones>Autoafinar PID)

Select tuning object: "Conjuno PID can. 1" is set to 1 (storage group 1), "Tipo auto afinac. PID" is set to "Calentar y exhaust" (if cooling is available) or "Ur nicamente calentar".

Start tuning: Confirm the safety of the set point (such as 90% of the process temperature), press Right to start, and the controller will automatically store PID parameters after completing 4 oscillations.

Verification result: After the setting is completed, observe whether the process value is stable within ± 1 ℃ of the set point. If the overshoot is large, the differentiation time can be manually reduced; If the fluctuation is large, increase the proportion band.

Manual optimization (when the automatic tuning effect is poor)

Proportional band: If the process value fluctuates greatly, increase the "Banda proportional" (such as changing from 10 ℃ to 15 ℃); If the response is slow, reduce the proportional band.

Integral time: If there is a static deviation (such as a set point of 100 ℃ and a stable temperature of 98 ℃), reduce the "Integral" (such as changing from 5 minutes to 3 minutes); If there is oscillation, increase the integration time.

Differential time: If the overshoot is large (such as set point 100 ℃, peak 105 ℃), increase "Deriviva" (such as changing from 0.5 minutes to 1 minute); If the response is slow, reduce the differential time.

(3) Advanced configuration (choose as needed)

Cascade control: It is necessary to first configure the input of the internal circuit (heat source temperature) (such as connecting input 3 to the heat source sensor), set "Cascada" in "P á gina Configuraci ó n>Entrada anal ó gica 3", tune the PID of the internal circuit, and then tune the external circuit.

Remote Setpoint: Set input 2 to "Remoto" and switch between local/remote setpoints in "P á gina Operaiones>Punto establecido remoto/local". The remote signal should match the input range (e.g. 4-20mA corresponds to 50-500 ℃).

Security permissions: Set permissions in "P á gina F á brica>Fijar bloq", such as "Contrast ñ a" for "P á gina Configuraci ó n", and set a 4-digit password to prevent unauthorized modifications.

3. Calibration and maintenance (ensuring accuracy)

(1) Input calibration (P á gina F á brica>Calibraci ó n>Caliblar entrada x)

Suitable for scenarios with large sensor reading deviations, requiring standard signal sources (such as precision signal generators, standard resistance boxes):

Key parameters for input type calibration steps

Thermocouple 1. Connect the standard thermocouple compensator (0 ℃ reference), input 0mV (corresponding to 0 ℃), select "0.00mV" in "Caliblar entrada 1", and press Right to store

2. Enter 50mV (corresponding to J-type thermocouple at approximately 500 ℃), select "50.00mV", and press Right to store

3. Connect the actual thermocouple and verify that the deviation between the reading and the standard value is ≤ ± 0.1%. Ensure that the compensator accuracy is ± 0.01mV. Preheat the controller for 20 minutes before calibration

RTD 1. Short circuit input terminal (0 Ω), select "Tierra", press Right to store

2. Connect to 15.00 Ω (corresponding to approximately -200 ℃ for Pt100), select "15.00 Ω", and press Right to store

3. Connect to 380.00 Ω (corresponding to approximately 800 ℃ for Pt100), select "380.00 Ω", and according to the Right storage standard, the accuracy of the resistance box should be ± 0.01 Ω, and the wire resistance should be ≤ 0.1 Ω

Process signal (4-20mA) 1. Input 4.000mA, select "4.000mA", press Right to store

2. Enter 20.000mA, select "20.000mA", press Right to store the signal source accuracy of ± 0.01mA, input impedance matching (100 Ω)

(2) Output calibration (P á gina F á brica>Calibraci ó n>Caliblar salida x)

Suitable for scenarios where there is a large deviation in output/retransmission accuracy, requiring a high-precision multimeter (3.5 bits or more):

Key parameters for output type calibration steps

Process output (4-20mA) 1. Connect a multimeter (in series), select "4.000mA" in "Caliblar salida 1A", adjust the multimeter to display 4.000mA with Up/Down, and press Right to store

2. Select "20.000mA", adjust it to 20.000mA, press Right to store the load resistance of 800 Ω (maximum), and ensure that the output is stable for 1 second before calibration

Process output (0-10V) 1. Connect a multimeter (in parallel), select "1.000V", adjust to 1.000V, and store

2. Select "10.000V" and adjust it to 10.000V. Store the load resistance of 1k Ω (minimum) to avoid no-load calibration

(3) Daily maintenance

Regular inspection (monthly):

Appearance: The panel is undamaged, the indicator lights are normal (Power green light is always on, Comm green light is flashing), and the wiring terminals are not loose or oxidized.

Function: Verify alarm triggering (such as simulating overheating, alarm output action), manual/automatic switching (output response normal after switching).

Annual maintenance:

Calibration: Re calibrate the input and output accuracy, restore the factory calibration value ("Restablecer cal. ent x"), and then re calibrate.

Cleaning: Wipe the panel with a dry cloth to remove terminal dust. Do not use corrosive cleaning agents such as alcohol and acetone.

Fault record: Record the fault code (such as "oPLP '" A-dLO "), occurrence time, and solution for subsequent troubleshooting.

Installation and Wiring Guide

1. Installation process (panel installation)

(1) Installation preparation

Tools: Phillips # 2 screwdriver, panel drilling tool (such as drill), torque wrench (0.5-0.6 Nm).

Environment: The installation location should be away from heat sources (such as heating pipes and frequency converters), avoid direct sunlight, have good ventilation, and meet the protection level requirements (NEMA 4X should be installed in a closed cabinet).

Size verification: The panel thickness is ≤ 9.5mm, and the opening size is 92-93mm (width x height) to ensure that the controller can be smoothly embedded.

(2) Installation steps

Panel perforation: Drill holes according to the size of 92-93mm, clean the burrs on the edges of the perforation, and avoid scratching the controller housing.

Embedded controller: Insert the controller from the front of the panel, ensuring that the sealing gasket (back) is attached to the panel without any offset.

Fixed bracket: Install the fixed bracket from the back of the panel, align the controller screw holes, and use a Phillips screwdriver to tighten 4 screws (torque 0.5 Nm). For NEMA 4X protection, ensure that the sealing gasket is compressed evenly with a gap of ≤ 0.508mm.

Check installation: Gently shake the controller without looseness; There are no protrusions/indentations on the front of the panel, and the display is normal.

(3) Rail installation (optional, multi module collaboration)

If multi module rail installation is required (such as installing a controller on rail 1 and an expansion module on rail 2), it needs to be connected through an Inter module Bus, with a maximum distance of 200 feet. The communication line uses shielded twisted pair, single ended grounding, and independent power supply (to avoid voltage drop).

2. Wiring specifications (key terminals and safety requirements)

(1) Core terminal definition (back terminal block)

Terminal group terminal number functional wiring requirements

Power terminal 1 (L), 2 (N) 100-240V AC input connected to L/N, requires 2A slow melting fuse (250V) to be connected in series, and the live wire needs to be connected to a switch/circuit breaker (for easy power-off maintenance)

Power terminals 3 (+) and 4 (-) 24-28V AC/DC input are only applicable to F4PL model, distinguish positive and negative poles, and prohibit reverse connection

Analog inputs 1 59 (+), 60 (S2), 61 (S1), 62 (S3/-) Thermocouples/RTDs/process signals - Thermocouples: 59 (+), 62 (-)

-RTD (3-wire): 60 (S2), 61 (S1), 62 (S3)

-Process signal (4-20mA): 60 (+), 62 (-)

Digital inputs 27 (GND), 28 (DI1), 29 (DI2), 30 (DI3), 31 (DI4). Digital input signal 27 is connected to the common terminal, DI1-DI4 are connected to the signal, and the dry contact requires external power supply (such as 24V DC). The voltage input needs to match the level

Control output 1A, 42 (NO), 43 (COM), 44 (NC) relay/SSR output - Relay: 42 (NO), 43 (COM) connected to load, 44 (NC) backup

-SSR: 42 connected to control signal+, 43 connected to control signal -, requires external power supply to drive SSR

Control outputs 1B, 39 (NO), 40 (COM), 41 (NC), and 1A. If they are process outputs, signals 39 (+) and 40 (-) should be connected, and 41 should be used as a backup

Communication terminals 12 (T -), 13 (T+), 16 (GND) EIA-485 Communication 12=T -, 13=T+, 16=GND, daisy chain connection, connected with 120 Ω resistors at the beginning and end, shielding layer connected with 16

(2) Safety wiring requirements

Electrical isolation:

The input, output, and communication circuits should be isolated from each other to avoid common grounding (grounding resistance ≤ 4 Ω). Analog signal cables and power cables (such as 380V AC) should be wired separately (with a spacing of ≥ 10cm), and shielded twisted pair cables should be used. The shielding layer should be grounded at one end (on the control room side).

Dangerous area (Class 1 Div. 2): Use explosion-proof junction boxes and armored cables, prohibit live plugging and unplugging wiring, terminal tightening torque ≥ 0.56 Nm, and wire insulation level ≥ 600V.

Inductive load protection:

When driving inductive loads such as relays and solenoid valves, it is necessary to parallel an RC suppressor (Watlow 0804-0147-0000) or a freewheeling diode (diode direction opposite to the load current direction) to prevent voltage spikes from damaging the module.

Anti interference measures:

Thermocouple cables use dedicated compensating wires (such as JX-HS-FF for J-type) to avoid parallel wiring with power lines. RTD cables use a 3-wire system (compensating wire resistance), and the shielding layer of the process signal cable is grounded.

The communication line adopts CAT5 or above shielded twisted pair to avoid interference sources such as frequency converters and motors. When the length exceeds 100 meters, a repeater needs to be added.

3. Typical application wiring examples

(1) Single loop temperature control (heating+alarm)

Input: J-type thermocouple connected to 59 (+), 62 (-).

Output 1A: Relay outputs 42 (NO) and 43 (COM) are connected to a heater and connected in series with a temperature limit controller (redundant protection).

Alarm output 1:48 (NO), 49 (COM) connected to buzzer, alarm output 2:45 (NO), 46 (COM) connected to indicator light.

Communication: Connect 12 (T -), 13 (T+), and 16 (GND) to the EIA-485 port of the PLC, with a baud rate of 9600bps and address 1.

(2) Cascade control system (external loop+internal loop)

External circuit input (process temperature): Input 1 is connected to a K-type thermocouple (600 ℃ range).

Internal circuit input (heat source temperature): Input 3 Pt100 RTD (3-wire system, 200 ℃ range).

Internal circuit output (heat source control): Output 1A connected to SSR to drive the heating tube.

External circuit output (no direct output, the set point of the internal circuit is determined by the external circuit): No additional wiring is required, cascade logic can be configured through software.

Troubleshooting and Maintenance

1. Common faults and solutions

Possible causes of malfunction, troubleshooting steps, and solutions

No display/power light not on 1. Abnormal power supply (insufficient voltage, reversed wiring)

2. Fuse blown (2A/250V)

3. The power module is damaged. 1. Measure the voltage of the power supply terminal with a multimeter and confirm that it is 100-240V AC or 24-28V DC

2. Check the fuse between the power terminals (internal to the controller, non user replaceable)

3. Replace the backup controller for testing. 1. Repair the power supply and correct the positive and negative wiring

2. Contact Watlow to replace the fuse (to be returned to the factory)

3. Apply for RMA repair or replacement of controller

Abnormal sensor reading (high/low) 1. Sensor type configuration error

2. Loose/reversed wiring

3. Shielding interference (poor grounding)

4. Calibration deviation 1. Check the "Sensor" and "Tipo" parameters against the actual sensor model

2. Re tighten the sensor wiring, and distinguish the positive and negative poles of the thermocouple

3. Check the grounding of the shielding layer and keep it away from the power line

4. Perform input calibration or restore factory calibration values. 1. Reconfigure sensor parameters

2. Repair the wiring to ensure good contact

3. Improve shielding grounding and separate wiring

4. Complete calibration and verify reading accuracy

Output unresponsive 1. Output type configuration error (such as "Apagado")

2. Load overload/short circuit

3. Relay/SSR damaged

4. Manual mode not switched. 1. Check the "Funci ó n" parameter of "P á gina Configuraci ó n>Salida control x"

2. Measure the load resistance and confirm that there is no short circuit and the current is ≤ the rated output value

3. Use a multimeter to measure the output terminal. If the relay is not engaged, it will be damaged

4. Confirm that the controller is in automatic mode (Auto light off) 1. Reconfigure the output function

2. Repair the load short circuit and replace the overloaded equipment

3. Replace the relay/SSR module (original spare parts required)

4. Switch to automatic mode or manually adjust the output

Communication failure (PLC/HMI unable to connect) 1. Baud rate/address mismatch

2. Reverse wiring (T+/T -)

3. Terminal resistor not connected/damaged

4. Excessive bus load (over 32 nodes) 1. Check the "Baudios" and "Direcci ó n" of "P á gina Configuraci ó n>Comunicaciones" against the PLC parameters

2. Swap T+/T - wiring test

3. Add a 120 Ω resistor to the front and rear nodes and measure the resistance value

4. Check the number of nodes, if exceeded, add a repeater. 1. Unify communication parameters and restart the controller

2. Correct the polarity of the wiring

3. Replace the terminal resistor

4. Add EIA-485 repeaters (such as B&B 485RPT)

Alarm not triggered 1. Threshold setting error (above/below range)

2. Alarm function not enabled ("Tipo de alarma=Apagado")

3. Excessive hysteresis (such as 50 ℃)

4. The mute has not been lifted. 1. Check the alarm threshold of "P á gina Operaiones" to ensure it is within the sensor range

2. Confirm that the "Tipo de alarma" in "P á gina Configuraci ó n>Salida de alarma x" is not "Apagado"

3. Reduce "Hist é resis alarma" (such as changing from 50 ℃ to 5 ℃)

4. Confirm that "Silenceam." is set to "Apagado", or wait for the startup phase to end. 1. Reset the reasonable threshold

2. Enable the alarm function and select the corresponding type

3. Adjust the lag to an appropriate value

4. Release the startup mute or wait for the mute time to end

2. Fault codes and their meanings

Possible causes and solutions for displaying fault code information

OPLP Lazo Abierto sensor open circuit, loose wiring, shielding interference check sensor wiring, repair open circuit, improve shielding grounding

A-dLO Error entry: The A-dLO input signal is below the lower range limit (such as thermocouple breakage). Check the sensor, confirm that the signal is normal, and recalibrate

A-dHI Error entry: The A-dHI input signal is higher than the upper range limit (such as sensor short circuit). Check the sensor, eliminate the short circuit, and recalibrate

SEnLo Error entry: SEnLo RTD resistance is below the lower range limit (such as wire short circuit). Check the RTD wiring, repair the short circuit, and recalibrate

SEnHi Error entry: The resistance of the SEnHi RTD is higher than the upper range limit (such as an open wire). Check the RTD wiring, repair the open circuit, and recalibrate

Atod ` Error entrada: Atod ` A/D conversion failure, internal circuit abnormality restarts controller, invalid, apply for RMA repair

Error: Suma comp. Parameter checksum error, memory damage restored to factory settings ("Valores previewos"), repair if invalid

Typical application scenarios

1. Industrial furnace temperature control (single loop PID)

Requirement: Control the temperature of the resistance heating furnace, with a set point of 150 ℃ and an accuracy of ± 1 ℃. Alarm for over temperature of 200 ℃ and low temperature of 50 ℃.

Configuration:

Input: K-type thermocouple connected to input 1, with a range of 0-300 ℃ and a filtering time of 3 seconds.

Output 1A: SSR output, driving 1kW heater, cycle 5 seconds, PID parameters (proportional band 10 ℃, integration time 5 minutes, differentiation time 0.5 minutes).

Alarm 1: Over temperature of 200 ℃, triggering SSR shutdown; Alarm 2: Low temperature of 50 ℃, triggering buzzer.

Advantages: PID automatic tuning, fast adaptation to loads, alarm redundancy protection for equipment safety, and remote monitoring of communication functions.

2. Cascade control (industrial refrigeration system)

Requirement: Control the temperature of the refrigerated compartment (external circuit, 0 ℃) by adjusting the compressor (internal circuit, -10 ℃) to avoid temperature fluctuations in the compartment.

Configuration:

External circuit (cabin temperature): Input 1 connected to Pt100 RTD (-30-50 ℃), set point 0 ℃, PID parameters (proportional band 5 ℃, integration time 10 minutes).

Internal circuit (compressor): Input 3 Pt100 RTD (-50-0 ℃), set point determined by external circuit output (range -15-0 ℃), PID parameters (proportional band 2 ℃, integration time 3 minutes).

Output 1A: Control compressor (cooling), output 1B: Control heater (insulation).

Advantages: The internal circuit quickly responds to the external circuit requirements, reduces cabin temperature overshoot (such as rapid cooling after opening the door), and improves control accuracy.

3. Valve positioning control (fluid flow)

Requirement: Control pipeline flow, adjust valve opening, potentiometer feedback valve position (0-100% corresponds to 100-1200 Ω), flow target 50%.

Configuration:

Input 1: Flow sensor (4-20mA, 0-100% flow).

Input 3: Potentiometer (100-1200 Ω, feedback valve position), set to "Posici ó n de v á lvula", dead zone 1%.

Output 1A: Control valve to close (relay), output 1B: Control valve to open (relay), PID parameters (proportional with 5%, integration time of 2 minutes).

Advantages: Closed loop control based on position feedback avoids flow deviation caused by valve jamming, and dead zone setting reduces frequent actions.