EtherCAT EZ-ZONE RMZ4 User Manual

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EZ-ZONE

User’s Guide

RMZ4 EtherCAT

Adapter

0600-0103-0000 Revision A.7

Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507, http://www.watlow.com

1241 Bundy Boulevard, Winona, Minnesota USA 55987

WATLOW

EZ-ZONE

RMZ4 - 1 - ETHERCAT

ADAPTER

1 TABLE OF CONTENTS

1 Table of Contents .................................................................................................................................. 2

2 Table of Figures ..................................................................................................................................... 4

3 Overview ............................................................................................................................................... 5

4 Mounting and Dimensions .................................................................................................................... 6

5 Connections and Wiring ........................................................................................................................ 7

5.1 RMZ4 with up to 48 Control Loops ........................................................................................... 7

5.2 RMZ4 with Optical Sensor Card................................................................................................. 8

5.3 RMZ4 with Serial Communications Card and Bluetooth ........................................................... 9

5.4 RM System Connections .......................................................................................................... 11

5.5 Slot C Power Connection ......................................................................................................... 12

5.6 Earth Ground ........................................................................................................................... 13

5.7 EZ-ZONE ST and EZ-ZONE PM Wiring ...................................................................................... 14

5.8 EtherCAT® Wiring .................................................................................................................... 15

5.9 USB Wiring ............................................................................................................................... 15

5.10 Modbus® Wiring ...................................................................................................................... 15

6 Theory of Operation ............................................................................................................................ 17

7 Setting up the System ......................................................................................................................... 20

7.1 Steps to Implement ................................................................................................................. 20

7.2 EtherCAT® Master and ESI file ................................................................................................ 20

7.3 Master instructions ................................................................................................................. 20

7.4 Explicit Device Identification ................................................................................................... 20

7.5 Mapping Loop to CoE Object Indexes ..................................................................................... 21

7.6 Configuring the RMZ4 ............................................................................................................. 22

7.7 Identifying the RMZ4 Itself ...................................................................................................... 22

7.8 Setting Addresses on Connected Devices ............................................................................... 22

7.9 Identifying Connected Devices ................................................................................................ 22

7.10 Adding Slots ............................................................................................................................. 25

7.11 Mapping I/O to Loops (Slots) .................................................................................................. 26

8 Using Controller Features ................................................................................................................... 27

8.1 Sensor and Control Loop ......................................................................................................... 27

8.2 Optical Sensing ........................................................................................................................ 32

8.3 Open Loop Detect ................................................................................................................... 33

8.4 Digital Heat Control Outputs ................................................................................................... 34

8.5 Over-Temperature Limits ........................................................................................................ 35

8.6 Current Sensing ....................................................................................................................... 37

8.7 Cooling Digital Outputs ........................................................................................................... 38

8.8 Analog Heat Outputs ............................................................................................................... 39

8.9 Analog retransmit Outputs ..................................................................................................... 41

8.10 Alarm Outputs ......................................................................................................................... 42

8.11 Analog Cooling Outputs .......................................................................................................... 44

8.12 Direct Digital Input .................................................................................................................. 45

8.13 Direct Digital Output ............................................................................................................... 46

8.14 Direct Analog Input ................................................................................................................. 47

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8.15 Direct Analog Output ................................................................. Error! Bookmark not defined.

8.16 Alarm Groups .......................................................................................................................... 49

9 Setting Parameters and Running ........................................................................................................ 54

9.1 Using PDOs .............................................................................................................................. 54

9.2 Running ................................................................................................................................... 54

9.3 Tuning ...................................................................................................................................... 54

10 EtherCAT® Protocol ............................................................................................................................. 55

10.1 Device Objects ......................................................................................................................... 55

10.2 Commands .............................................................................................................................. 56

10.3 Default RxPDO ......................................................................................................................... 58

10.4 Default TxPDO ......................................................................................................................... 58

10.5 User RxPDO ............................................................................................................................. 58

10.6 User TxPDO.............................................................................................................................. 58

11 Control Operation ............................................................................................................................... 66

11.1 Network State and Control States ........................................................................................... 66

11.2 Data Retention ........................................................................................................................ 66

11.3 Control Loops .......................................................................................................................... 66

11.4 Alarms ..................................................................................................................................... 66

12 Additional Connectivity ....................................................................................................................... 67

12.1 Bluetooth® ............................................................................................................................... 67

12.2 Modbus® Slave ........................................................................................................................ 67

12.3 Modbus® Master ..................................................................................................................... 67

13 Flash Loading ....................................................................................................................................... 67

13.1 Over EtherCAT® ....................................................................................................................... 67

13.2 Over USB ................................................................................................................................. 67

14 Supporting Documents and Files ........................................................................................................ 68

15 Troubleshooting Guide ........................................................................................................................ 69

16 RMZ4 Specifications ............................................................................................................................ 70

17 Optical Adder Card Specifications ....................................................................................................... 71

18 Serial Communications Adder Card Specifications ............................................................................. 72

19 Part Numbering ................................................................................................................................... 73

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2 TABLE OF FIGURES

Symbol

Explanation

Symbol

Explanation

ESD Sensitive product, use proper grounding and handling techniques when installing or servicing product.

Unit protected by double/reinforced insulation for shock hazard prevention. Functional earth ground connection may be present.

Do not throw in trash, use proper recycling techniques or consult manufacturer for proper disposal.

Enclosure made of Polycarbonate material. Use proper recycling techniques or consult manufacturer for proper disposal.

Unit can be powered with either alternating current (ac) or direct current (dc).

Unit is a Listed device per Underwriters Laboratories®. It has been evaluated to United States and Canadian requirements for Process Control Equipment. UL/EN 61010-1 and CSA C22.2 No.

61010. File E195611 QUYX, QUYX7. See www.ul.com

Unit is a Listed device per Underwriters Laboratories®. It has been evaluated to United States and Canadian requirements for Hazardous Locations Class 1 Division II, Groups A, B, C and D. ANSI/ASI 12.12.01-2012. File E184390 QUZW, QUXW7. See www.ul.com

Unit is compliant with applicable European Union Directives. See Declaration of Conformity for further details on Directives and Standards used for compliance.

Figure 1 - Dimensions .............................................................................................................................................. 6

Figure 2 – Connections points for RMZ4-__AA-AAAA............................................................................................. 7

Figure 3 – Connections points for RMZ4-xx04-AAAA with Optical Temperature Sensing ...................................... 8

Figure 4 – Connection points for RMZ4-xxAA-11AA with serial comms card and Bluetooth ................................. 9

Figure 5 - Ground Wire Location ........................................................................................................................... 13

Figure 6 - Ground Wire Insertion .......................................................................................................................... 13

Figure 7 – Modbus® Master and Slave RJ-12 Connector Pinout ........................................................................... 16

Figure 8 – Connections and Topology ................................................................................................................... 18

Figure 9 – RM Control Loop Topology ................................................................................................................... 19

Figure 10 – Complete Network Interaction Diagram ............................................................................................ 19

Figure 11 – Modular Loop Layout ......................................................................................................................... 21

Figure 12 - Alarm Group Example ......................................................................................................................... 53

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3 OVERVIEW

The Watlow EtherCAT® Adapter allows integration of the EZ-ZONE RM systems into larger EtherCAT® controlled processes. EtherCAT® is an industrial control network that uses standard 100 Base-T Ethernet wiring to provide very fast access to controllers and their data points. The Watlow EtherCAT® Adapter conforms to the EtherCAT® Temperature Controller Specific Device Profile ETG 5003-2060. It has been conformance tested by an ETG test facility.

EtherCAT® provides access to system parameters using a CAN open interface scheme. The ETG 5003-2060 specification describes the data point organization. The data is accessed via SDO (Service Data Objects) during startup and configuration and via PDO (Process Data Objects) exchange during operation. SDO access is transactional in nature, the master asking for or setting a value in the slave device. The device supports reading and writing an entire index in one transaction. The feature is called SDO complete. PDO data is a continuous stream of data from the master and back from the devices at high speed.

USB and Bluetooth® interfaces are provided for configuration and system monitoring from a PC or tablet devices. Bluetooth® is an option so it can be excluded for production equipment where wireless security is important.

The Watlow EtherCAT® Adapter can also host a legacy communications adder card. This card provides additional connection points for Modbus®, DeviceNet™ and Watlow Standard Bus. These cards are intended to extend the network beyond RM modules to include displays like Watlow Silver Series and EZ-ZONE EZK and legacy controllers such as the EHG® SL-10. The Watlow EZ-ZONE ST and EZ-ZONE PM may be integrated from the “C” connector without requiring a Legacy Communications card.

The Watlow RMZ4 EtherCAT® Adapter operates within a larger RM system. The RMZ4 part number defines the number of loops supported. The largest system supported is 48 loops. The RMZ4 module does not support adhoc RM modules and function block programming. Function blocks in the RMS and RME I/O modules may be programmed using EZ-ZONE Configurator software via the USB port.

The RMZ4 supports 4 optical temperature sensors for high RF or voltage environments like plasma, power distribution transformers, or medical imaging.

Features

 ETG Conformance Tested by ETG

 ETG.5003.2060 compliant EtherCAT®  Up to 48 control loops with EZ-ZONE RM, ST, or PM controllers  One process and one deviation alarm per loop  USB device serial port emulation supporting EZ-ZONE Configurator and Composer  Bluetooth® serial port emulation serving system information via XML (Optional)  Modbus® Slave RS-485 port to host an HMI touch screen (Optional)  Modbus® Master RS-485 port to monitor up to 16 EHG line heaters (Future Option)  Extra Standard Bus RS-485 port for EZK remote display or PC tools connection (optional)  Optional 4 RF-immune fiber optic sensor.

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4 MOUNTING AND DIMENSIONS

FIGURE 1 - DIMENSIONS

Recommended chassis mounting hardware:

1. #8 screw ¾” Long

2. Torque to 10-15 in-lb

3. No washers

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5 CONNECTIONS AND WIRING

RM Module Bus Backplane

Explicit Device ID Switches

EtherCAT® IN

EtherCAT® OUT

USB Configuration Port for PC

EtherCAT® status LEDs

Slot C - Power and Standard Bus

5.1 RMZ4 WITH UP TO 48 CONTROL LOOPS

FIGURE 2 – CONNECTIONS POINTS FOR RMZ4-__AA-AAAA

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5.2 RMZ4 WITH OPTICAL SENSOR CARD

RM Module Bus Backplane

Explicit Device ID Switches

EtherCAT® IN

EtherCAT® OUT

USB Configuration Port for PC

EtherCAT® status LEDs

Slot C - Power and Standard Bus

FIGURE 3 – CONNECTIONS POINTS FOR RMZ4-XX04-AAAA WITH OPTICAL TEMPERATURE SENSING

The RMZ has an option for using fluorescent decay via fiber optic cable for sensing temperature in high RF environments. The number of channels of optical sensing is defined in the model number xxxx-xx04-xxxx. The fluorescent probes are available from Watlow. The range is generally -100 to +200C without special probe construction. Each probe is connected via a bayonet style ST connectors. To use this input in a control loop define the bus as Optical (option 4) and select instance 1, 2, 3, or 4.

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5.3 RMZ4 WITH SERIAL COMMUNICATIONS CARD AND BLUETOOTH

RM Module Bus Backplane

Explicit Device ID Switches

EtherCAT® IN

EtherCAT® OUT

USB Configuration Port for PC

EtherCAT® status LEDs

Slot C - Power and Standard Bus

Connection to Modbus slave devices

Connection to HMI Modbus Master

Extra Standard Bus Connection

Bluetooth Connection to Tablet/Phone/ PC

FIGURE 4 – CONNECTION POINTS FOR RMZ4-XXAA-11AA WITH SERIAL COMMS CARD AND BLUETOOTH

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5.5 RMZ4 WITH DEVICE NET AND HMI MODBUS

DeviceNet M12

Explicit Device ID Switches

EtherCAT® IN

EtherCAT® OUT

USB Configuration Port for PC

EtherCAT® status LEDs

Slot C - Power and Standard Bus

Connection to HMI Modbus Master

DeviceNet Address Switches

Bluetooth Connection to Tablet/Phone/ PC

DeviceNet Speed Switch

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5.6 RM SYSTEM CONNECTIONS

The RM system controlled by an RMZ4 module can be installed as stand-alone modules or can be interconnected on the DIN rail as shown below. When modules are connected together as shown, power and communications are shared between modules over the modular backplane interconnection. Therefore, bringing the necessary power and communications wiring to any one connector in slot C is sufficient. The modular backplane interconnect comes standard with every module ordered and is generic in nature, meaning any of the RM modules can use it.

The modules can also be mounted in different locations and the backplane connected via wires in a Split Rail configuration as shown in the figure. Notice in the split rail system diagram that a single power supply is used across both DIN rails. One notable consideration when designing the hardware layout would be the available power supplied and the loading effect of all of the modules used.

Watlow provides three options for power supplies listed below:

1. 90-264VAC to 24VDC @ 31 watts (Part #: 0847- 0299-0000)

2. 90-264VAC to 24VDC @ 60 watts (Part #: 0847- 0300-0000)

3. 90-264VAC to 24VDC @ 91 watts (Part #: 0847- 0301-0000)

With regards to the modular loading affect, maximum power for each is listed below:

1. RMCxxxxxxxxxxxx @ 7 watts / 14VA

2. RMEx-xxxx-xxxx @ 7 watts / 14VA

3. RMAx-xxxx-xxxx @ 4 watts / 9VA

4. RMLx-xxxx-xxxx @ 7 watts / 14VA

5. RMHx-xxxx-xxxx @ 7 watts / 14VA

6. RMSx-xxxx-xxxx @ 7 watts / 14VA

So in the worst case EtherCAT® integrated system, 48 loops, the maximum current draw on the supply would be 39 watts.

- 1 RMZ4 consumes 4 watts

- 3 RMS modules consumes 21 watts

- 2 RME modules consumes 14 watts

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5.7 SLOT C POWER CONNECTION

Power and Communications

Slot C

Terminal Function

Configuration

98 99

Power Input: AC or DC+

Power Input: AC or DC-

Only needed on one module, shared on backplane

Standard Bus EIA-485 Common

Standard Bus EIA-485 T-/R- (A)

Standard Bus EIA-485 T+/T+ (B)

EIA-485 connection for EZ-ZONE Configurator

CZ CX CY

Inter-module Bus Inter-module Bus Inter-module Bus

Wire for Split-Rail Configurations

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5.8 EARTH GROUND

The RJ-45 connector bodies are grounded to earth using the wire traps found on the bottom of the case. To ground the connector, insert a ground wire into either of the traps as viewed from the case bottom. The ETG.5003 Semi Standard recommends grounding the jacket. Each jacket is connected to the terminal trap via a 50ohm resistor. This earth ground is not connected to the power.

FIGURE 5 - GROUND WIRE LOCATION

FIGURE 6 - GROUND WIRE INSERTION

Use 18 – 26 AWG Solid or Stranded, Trim Length 3.5 ± 0.5mm (0.138 ± .02”). Twist wire to remove.

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5.9 EZ-ZONE ST AND EZ-ZONE PM WIRING

Connect EZ-ZONE STs or PMs via the CF (Com), CD(A-), and CE(B+) terminals on the Slot “C” connector. This is the RS-485 Standard Bus connection. The RMZ4 will recognize these devices automatically. View and confirm discovered devices using the 0xF500 objects.

5.10 DEVICE WIRING

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5.11 ETHERCAT® WIRING ON RJ-45

EtherCAT® uses standard CAT5 or CAT6 Ethernet cable. The network is wired device to device in series. Connect a cable from the EtherCAT® master or an upstream device to the IN RJ-45 port. If there are additional EtherCAT® devices on the network connect the OUT jack to those. If there are none, leave the jack empty.

EtherCAT®

Master

5.12 DEVICENET WIRING ON M12

5.13 USB WIRING

Connect a USB mini cable from a PC to configure RM features that are outside the EtherCAT® specification. These could be function blocks such as Logic or Compare blocks. Use the EZ-ZONE Configurator software to connect via the USB port. All the RM devices in the system should appear when the network is scanned. Use the Watlow_USB.inf driver located on watlow.com to create a USB serial port on your PC.

5.14 MODBUS® RTU RS-485 WIRING RJ-12 MASTER OR SLAVE

If the RMZ4 has the optional Legacy Communications card, it can be connected to simple Modbus® temperature controllers and act as a master using the Modbus M port. It can also be connected to graphical HMIs such as Watlow Silver Series to display system information using the Modbus S port. These are both RS485 connections on RJ-12 phone jacks.

The Modbus register table is defined in a supporting spreadsheet RmzParameterMap.xlsx available on watlow.com.

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FIGURE 7 – MODBUS® MASTER AND SLAVE RJ-12 CONNECTOR PINOUT

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6 THEORY OF OPERATION

EtherCAT® is a protocol that runs on standard Ethernet hardware – CAT5 cable, RJ45 jacks and standard physical layer transceivers. The Ethernet Media Access Controller (MAC) is a slight variation of a standard MAC implemented with an ASIC. It allows data to be read and modified on-the-fly as the bits pass through the MAC. This implies EtherCAT® is a ring topology with each device being part of a single chain. Data frames are not received and responses formulated. It is more like a train of bytes that does not slow down at the station, data jumps on and off as the ‘train’ passes though. This allows cycle times around the network in the microsecond range, even with thousands of data points. This is the PDO (Process Data Object – real-time data) mechanism.

Responsiveness is very important in a large system to keep scan times short. This means products should not introduce latencies in the system’s data cycle. Therefore the data of interest to the larger system must be maintained close to the EtherCAT® access port. It is not acceptable to have long latencies while data is retrieved via the backplane. To assure the required speed, the EZ-ZONE architecture has been modified slightly to maintain critical data objects in the EtherCAT® module itself rather than each RM module.

EtherCAT® models data as CoE objects. CoE is CANOpen over EtherCAT®. This is the object model developed for the CAN Open protocol and reused as the EtherCAT data model. It uses objects defined by indexes (0x0000 to 0xFFFF) each containing up to 255 sub-indexes or data elements of simple or complex data type.

EtherCAT® transports data using PDO and SDO methods. PDO is Process Data Object. It is the regular data shared to and from the master to all the slave devices. The network PDO scan times are very fast, 0.5 to 4ms typically. The data in the PDO is a selected set of Object:SubIndex parameters. Typical PDO parameters are process temperature, set point, output power, and errors. PDO data is only exchanged when the system is in the operational mode (OP mode). As a default, the RMZ4 controller only controls temperature in the operational mode. The Safe State parameter configures this behavior.

SDO is Service Data Object. This is an asynchronous, on-demand mailbox service that provides access to all the CoE objects in the device. The SDO method is used to configure the device or tweak settings. Setting PID, Proportional Integral Derivative control loop parameters or starting an auto-tune would be typical uses for an exchange. SDO exchanges can occur during normal operation but are secondary to PDO traffic. SDO exchanges can occur in all modes except boot mode.

The EtherCAT® module holds all the data that is part of the Semi TWG (Technical Working Group) Standard for all the loops being controlled locally in the EtherCAT® module. The control loops are hosted by the EtherCAT® module. The EtherCAT® module works in conjunction with RM modules to act as sensor inputs and heater outputs only. The PV (Process Value Temperature) is produced by an RM and consumed by the EtherCAT® module via data sharing. The loop power is produced by the EtherCAT® module and consumed by an RM output via data sharing. The values accessed by the EtherCAT® module are the values held internally. This includes PV, SP (Set Point), PID values, control mode, percent power, etc.

In legacy product configurations (ST,PM,SL-10) the pertinent data is held locally within the EtherCAT® adapter for instant access but the control loops still execute in the individual devices due to the lower bandwidth buses. There means parameter changes made over EtherCAT® can take up to 200ms to be written to the remote legacy device since they need to be sent by proxy on the legacy communications bus. Input values are continuously scanned by the RMZ4 and the latest value is available for PDO access.

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Some configuration data such as sensor type, cycle time, input and output scaling are considered configuration data by EtherCAT®. It is not part of the EtherCAT®’s fast I/O cycle. These values are written out to each of the RM modules on power-up or value change to ensure the I/O configuration matches the SDO values. Local copies in the EtherCAT® module are maintained for immediate access even though a proxy write is required on change. The configuration values changed will take effect within 200ms.

The RMZ4 models individual control loops as modules or slots as described by the EtherCAT® Modular Device Profile. Each control loop is mapped to a module or slot. This is a logical association. The EtherCAT® loop module does not map one to one with physical RM modules. The configuration section describes how to map the I/O in each RM physical module with the appropriate control loop. Any of the RM family with IO may be used in conjunction with the RMZ. This includes RMC, RMH, RMS, RML, and RME.

Details and specifications for EtherCAT® are available at: http://www.ethercat.org/

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FIGURE 8 – CONNECTIONS AND TOPOLOGY

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FIGURE 9 – RM CONTROL LOOP TOPOLOGY

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FIGURE 10 – COMPLETE NETWORK INTERACTION DIAGRAM

ADAPTER

7 SETTING UP THE SYSTEM

7.1 STEPS TO IMPLEMENT WITH ETHERCAT

1. Mount controllers

2. Wire power, sensors and outputs to heaters

3. Wire CAT5/6 cable to EtherCAT® jacks

4. Set explicit Device ID if needed

5. Verify RM module addresses are set correctly

6. Install Master Software

7. Import the ESI for the RMZ, Watlow_RMZ.xml into the master software.

8. Connect to RMZ4 from Master

9. Configure module/slots for loops needed

10. Setup I/O mapping in 0x4nn0 objects

11. Configure device with 0x4nn1 and 0x8nn0 objects

12. Configure any user specific PDO data beyond the default set

13. Change mode to operational.

14. Program Set Point and Control State in output PDO

15. Monitor system with input PDO

7.2 ETHERCAT® MASTER AND ESI FILE

EtherCAT® systems have a master that configures the network and the devices then manages data interactions with the devices during operation. Beckhoff®’s TwinCAT® or EtherCAT® Configurator are common master software programs that run on a standard 32 bit Windows® PC. The Master needs an ESI file to describe the device and its capabilities. This file is in XML format and provided by Watlow for the RMZ. The ESI file contains the object dictionary for the RMZ. There is one ESI file regardless of the version of RMZ that contains the parameter details for all product versions. The master will select the correct version from the ESI based on the version information reported from the RMZ. If a new version produce is added to the system make sure to have the master reload the correct definition from the latest ESI file.

7.3 MASTER INSTRUCTIONS

 Under I/O Device right click and Scan for Device  Scan for Boxes answer Yes  Start Free Run - Yes  You should see Box 1 (Watlow RM)  We need to add a Module for each control loop by right clicking Append Module  Add the correct number of control loops  Reload Configuration to the RMs under Action

7.4 EXPLICIT DEVICE IDENTIFICATION

Use the two rotary address switches to set the devices Explicit Device ID. The 0x10 switch sets the upper nibble and 0x01 sets the lower nibble of the unique ID value. This is available over EtherCAT® in register 0x134. This allows absolute, unique identification of each device in the system.

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7.5 MAPPING LOOP TO COE OBJECT INDEXES

Loop

Watlow

Outputs

Watlow Outputs

I/O

Mapping

Configuration Inputs Outputs Setup TxPDO RxPDO

User

TxPDO

User

RxPDO

1 0x2000 0x3000 0x4000 0x4001 0x6000 0x7000 0x8000 0x1600 0x1A00 0x1601 0x1A01 2 0x2010 0x3010 0x4010 0x4011 0x6010 0x7010 0x8010 0x1602 0x1A02 0x1603 0x1A03 3 0x2020 0x3020 0x4020 0x4021 0x6020 0x7020 0x8020 0x1604 0x1A04 0x1605 0x1A05 4 0x2030 0x3030 0x4030 0x4031 0x6030 0x7030 0x8030 0x1606 0x1A06 0x1607 0x1A07 5 0x2040 0x3040 0x4040 0x4041 0x6040 0x7040 0x8040 0x1608 0x1A08 0x1609 0x1A09 6 0x2050 0x3050 0x4050 0x4051 0x6050 0x7050 0x8050 0x160A 0x1A0A 0x160B 0x1A0B 7 0x2060 0x3060 0x4060 0x4061 0x6060 0x7060 0x8060 0x160C 0x1A0C 0x160D 0x1A0D 8 0x2070 0x3070 0x4070 0x4071 0x6070 0x7070 0x8070 0x160E 0x1A0E 0x160F 0x1A0F

9 0x2080 0x3080 0x4080 0x4081 0x6080 0x7080 0x8080 0x1610 0x1A10 0x1611 0x1A11 10 0x2090 0x3090 0x4090 0x4091 0x6090 0x7090 0x8090 0x1612 0x1A12 0x1613 0x1A13 11 0x20A0 0x30A0 0x40A0 0x40A1 0x60A0 0x70A0 0x80A0 0x1614 0x1A14 0x1615 0x1A15 12 0x20B0 0x30B0 0x40B0 0x40B1 0x60B0 0x70B0 0x80B0 0x1616 0x1A16 0x1617 0x1A17 13 0x20C0 0x30C0 0x40C0 0x40C1 0x60C0 0x70C0 0x80C0 0x1618 0x1A18 0x1619 0x1A19 14 0x20D0 0x30D0 0x40D0 0x40D1 0x60D0 0x70D0 0x80D0 0x161A 0x1A1A 0x161B 0x1A1B 15 0x20E0 0x30E0 0x40E0 0x40E1 0x60E0 0x70E0 0x80E0 0x161C 0x1A1C 0x161D 0x1A1D 16 0x20F0 0x30F0 0x40F0 0x40F1 0x60F0 0x70F0 0x80F0 0x161E 0x1A1E 0x161F 0x1A1F 17 0x2100 0x3100 0x4100 0x4101 0x6100 0x7100 0x8100 0x1620 0x1A20 0x1621 0x1A21 18 0x2110 0x3110 0x4110 0x4111 0x6110 0x7110 0x8110 0x1622 0x1A22 0x1623 0x1A23 19 0x2120 0x3120 0x4120 0x4121 0x6120 0x7120 0x8120 0x1624 0x1A24 0x1625 0x1A25 20 0x2130 0x3130 0x4130 0x4131 0x6130 0x7130 0x8130 0x1626 0x1A26 0x1627 0x1A27 21 0x2140 0x3140 0x4140 0x4141 0x6140 0x7140 0x8140 0x1628 0x1A28 0x1629 0x1A29 22 0x2150 0x3150 0x4150 0x4151 0x6150 0x7150 0x8150 0x162A 0x1A2A 0x162B 0x1A2B 23 0x2160 0x3160 0x4160 0x4161 0x6160 0x7160 0x8160 0x162C 0x1A2C 0x162D 0x1A2D 24 0x2170 0x3170 0x4170 0x4171 0x6170 0x7170 0x8170 0x162E 0x1A2E 0x162F 0x1A2F 25 0x2180 0x3180 0x4180 0x4181 0x6180 0x7180 0x8180 0x1630 0x1A30 0x1631 0x1A31 26 0x2190 0x3190 0x4190 0x4191 0x6190 0x7190 0x8190 0x1632 0x1A32 0x1633 0x1A33 27 0x21A0 0x31A0 0x41A0 0x41A1 0x61A0 0x71A0 0x81A0 0x1634 0x1A34 0x1635 0x1A35 28 0x21B0 0x31B0 0x41B0 0x41B1 0x61B0 0x71B0 0x81B0 0x1636 0x1A36 0x1637 0x1A37 29 0x21C0 0x31C0 0x41C0 0x41C1 0x61C0 0x71C0 0x81C0 0x1638 0x1A38 0x1639 0x1A39 30 0x21D0 0x31D0 0x41D0 0x41D1 0x61D0 0x71D0 0x81D0 0x163A 0x1A3A 0x163B 0x1A3B 31 0x21E0 0x31E0 0x41E0 0x41E1 0x61E0 0x71E0 0x81E0 0x163C 0x1A3C 0x163D 0x1A3D 32 0x21F0 0x31F0 0x41F0 0x41F1 0x61F0 0x71F0 0x81F0 0x163E 0x1A3E 0x163F 0x1A3F 33 0x2200 0x3200 0x4200 0x4201 0x6200 0x7200 0x8200 0x1640 0x1A40 0x1641 0x1A41 34 0x2210 0x3210 0x4210 0x4211 0x6210 0x7210 0x8210 0x1642 0x1A42 0x1643 0x1A43 35 0x2220 0x3220 0x4220 0x4221 0x6220 0x7220 0x8220 0x1644 0x1A44 0x1645 0x1A45 36 0x2230 0x3230 0x4230 0x4231 0x6230 0x7230 0x8230 0x1646 0x1A46 0x1647 0x1A47 37 0x2240 0x3240 0x4240 0x4241 0x6240 0x7240 0x8240 0x1648 0x1A48 0x1649 0x1A49 38 0x2250 0x3250 0x4250 0x4251 0x6250 0x7250 0x8250 0x164A 0x1A4A 0x164B 0x1A4B 39 0x2260 0x3260 0x4260 0x4261 0x6260 0x7260 0x8260 0x164C 0x1A4C 0x164D 0x1A4D 40 0x2270 0x3270 0x4270 0x4271 0x6270 0x7270 0x8270 0x164E 0x1A4E 0x164F 0x1A4F 41 0x2280 0x3280 0x4280 0x4281 0x6280 0x7280 0x8280 0x1650 0x1A50 0x1651 0x1A51 42 0x2290 0x3290 0x4290 0x4291 0x6290 0x7290 0x8290 0x1652 0x1A52 0x1653 0x1A53 43 0x22A0 0x32A0 0x42A0 0x42A1 0x62A0 0x72A0 0x82A0 0x1654 0x1A54 0x1655 0x1A55 44 0x22B0 0x32B0 0x42B0 0x42B1 0x62B0 0x72B0 0x82B0 0x1656 0x1A56 0x1657 0x1A57 45 0x22C0 0x32C0 0x42C0 0x42C1 0x62C0 0x72C0 0x82C0 0x1658 0x1A58 0x1659 0x1A59 46 0x22D0 0x32D0 0x42D0 0x42D1 0x62D0 0x72D0 0x82D0 0x165A 0x1A5A 0x165B 0x1A5B 47 0x22E0 0x32E0 0x42E0 0x42E1 0x62E0 0x72E0 0x82E0 0x165C 0x1A5C 0x165D 0x1A5D 48 0x22F0 0x32F0 0x42F0 0x42F1 0x62F0 0x72F0 0x82F0 0x165E 0x1A5E 0x165F 0x1A5F

The RMZ4 supports up to 48 loops. The EtherCAT® module slots map to the control loops as defined in this table.

FIGURE 11 – MODULAR LOOP LAYOUT

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7.6 CONFIGURING THE RMZ4

The I/O in the EtherCAT® system uses RZ-ZONE RMS, RMH, and RMC modules for sensor inputs and RME, RMS, or RMC modules for heater outputs. The RMZ4 module performs the actual control algorithms. The controls loops are mapped to the I/O modules in the same manner regardless of the loop count. Limits implemented in the RML are still maintained in the RML module but configured via the EtherCAT® interface. The number of loops in the system is defined by the part number. Each control loop in the object ranges (0x4000, 0x6000, 0x7000 and 0x8000) is offset by 0x10 as show in the table is section 6.5. The RMZ4 is a Modular EtherCAT® device. When using TwinCAT® Master software to add each control loop to your master configuration, add additional control loop slots under “Box 1 (Watlow RM): Append Module.” The loops are connected to I/O using the 0x4000 range of objects. The RMZ4 can also be used with EZ-ZONE ST as an interface to these standalone controllers. The data is presented to the network with the same model.

7.7 IDENTIFYING THE RMZ4 ITSELF

The identity of the RMZ4 module is accessed through objects 0x1000.

7.8 SETTING ADDRESSES ON CONNECTED DEVICES

Each EZ-ZONE RMS, RME, RML, RMF, RMC, or RMH device needs a unique address to identify it on the bus. This is the orange digit in the upper right hand side of the device. To change, hold the orange button until the digit glows brightly then press to increment by 1; the value will wrap around to 1. Make sure each device has a unique value.

The DIP switches on the front of the EZ-ZONE ST devices set the device’s zone. If the system contains both RM and ST devices, they all need to have unique addresses because they share the standard bus address space.

This is the Zone Number used to map I/O in the 0x4000 objects.

7.9 IDENTIFYING CONNECTED DEVICES

The RM modules connected to the RMZ4 via the backplane or split-rail are visible in objects 0xF500 to 0xF504. The ST or PM modules connected to the RMZ4 via the Standard Bus connection are visible in objects 0xF510 to 0xF514. The products ID, part number, revision, and serial number may be observed.

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7.10 ADDING SLOTS

A slot is a logical organization of modular control loops. Each slot or loop represents a sensor, PID loop, set point and power level. Add the number of loops needed in your system. Once added, loops are mapped to the inputs, output, limits, current sensor, and over-temp limits available in the RM modules or EZ-ZONE ST or PM. Typically a system will use and RMS for input and an RME for outputs and current transformers. This system can be augmented with an RML limits module for over-temp protection. If the system has few loops an RMC is an option for integrating sensor, outputs, limits and CT is one hardware module. The 0x4000 objects are used to define the I/O location for each loop. The maximum number of slots/control loops the user can add is defined in the module number. RMZ4-nnAA-AAAA where nn is the maximum number of loops that can be added.

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7.11 MAPPING I/O TO LOOPS (SLOTS)

Bus #

Bus

Loop Location

Sensor

Outputs

Current

Limits

None

Not Active

Yes

RM Backplane / Split-Rail

Internal RMZ

Yes

Yes 2 EZ-ZONE ST or PM

External Device

Yes

Yes 3 EHG SL-10 Modbus

External Device

Yes

No 4 Fiber Optic Sensor

Internal RMZ

Yes

Remote Loop PV

(written via EtherCAT)

Internal RMZ

Yes

The 0x4000 objects define the connection between the RMZ4 control loops and the system I/O. Each loop has a configuration object offset by 0x10 like all modular objects. Each of the control loops needs to be associated with I/O in the attached EZ-ZONE RM or ST modules.

Important: The default mapping is loop sensor inputs 1 to 16 map to zone 1 instances 1 to 16. Digital

outputs map to zone 2, DIO instance 1 to 16. This may not match your system. Make sure to verify all mapping points and set unmapped elements to bus 0 (unused) to ensure proper operation. Send the Save Non-Volatile Command to ensure the mapping is maintained.

Bus Designators:

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8 USING CONTROLLER FEATURES

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Loop Location

0x4nn0

0x67

0x11

Indicates if the loop is hosted locally (0) or remotely (1). If the sensor is mapped to the RM bus or optical inputs or Remote PV then loops are locally executed in the RMZ4 modules. If the sensors are in the ST, PM, SL-10, or CLS then the loops are remote since those devices are fully integrated controllers.

Sensor Bus

0x4nn0

0x67

0x12

Defines the bus the loop uses for the control sensor. 0 = Unused 1 = RM 2 = Legacy ST/PM 3 = Modbus 4 = Internal Optical Sensor Card 5 = Remote PV from 0x3000:0x13

Sensor Zone

0x4nn0

0x67

0x13

Defines which zone or address that is hosting this sensor input. For EZ-ZONE products it is the zone number displayed on the front. For EHG SL-10 it is the Modbus address. Optical sensors 1-4 are local in the RMZ4 so this value does not have meaning. Independent RMF optical modules are considered sensor type 1 – on the backplane.

Sensor Instance

0x4nn0

0x67

0x14

Defines which sensor instance on a particular zone for devices that have multiple inputs. For instance, an RMS module can have 16 TC inputs. To map to sensor 5 on RMS zone 3:

Select Bus 2, Zone 3, Instance 5.

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Sensor Type

0x8nn0

0x6D

0x11

Sets the input type to 0 = TC 1 = RTD100

8.1 SENSOR AND CONTROL LOOP

Mapping

Configuring Sensor

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2 = RTD1000 3 =4-20mA 4 = 0-20mA 5 = 0-10V

Thermocouple Type

0x8nn0

0x6D

0x12

Sets the thermocouple type 0: K 1: J 2: T 3: E 4: N 5: R 6: S 7: B 8: C 9: D 10: F

RTD Lead Wires

0x4nn1

0x68

0x11

Sets the number of lead wires for RTD type inputs to 2 or 3 wires.

Input Calibration Offset/Bias

0x8nn0

0x6D

0x23

Allows the system to offset the input reading to compensate for system errors.

Process Scaling High

0x8nn0

0x6D

0x18

The process value corresponding to the high electric value for process input 10V or 20mA.

Process Scaling Low

0x8nn0

0x6D

0x19

The process value corresponding to the low electric value for process input 0V, 4mA, or 0mA.

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Heat Proportional Band

0x8nn0

0x6D

0x26

Sets the heat gain as a proportional band. Increase reduces gain and increases stability. Decreasing increases responsiveness.

Integral Time

0x8nn0

0x6D

0x27

Sets the rate the power increases or decreases. This will pull the temperature to set point. A low value integrates power quickly but can cause instability.

Derivative Time

0x8nn0

0x6D

0x28

Sets the derivative time constant. Reacts in opposition to changes in the process. Unless the system has significant lag, this value should be kept low or even zero.

Cool Algorithm

0x4nn1

0x68

0x12

Cooling action is Off, PID, or On/Off

Cool Proportional

0x8nn0

0x6D

0x29

The gain of the cooling part of the control loop. This is in effect if the cool mode is PID.

Cool Hysteresis

0x4nn1

0x68

0x13

If the cool mode is ON/OFF this is the switching hysteresis.

Dead Band

0x4nn1

0x68

0x2A

This is the space between the heating and the cooling regions to keep the system from oscillating continuously between heat and cool. It can also be set to a negative value so the

Configuring Control Loop

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heat and cooling actions will happen simultaneously in the band. This allows heat to modulate a less agile cooling system.

Ramp to Set Point Enable

0x4nn1

0x68

0x20

Enables set point ramping. If enabled, changes in set point will cause the actual set point to ramp from the current PV to the target SP at the programmed rate. 0 = Off 1 = Start Up 2 = Set Point Change 3 = Both

Ramp to Set Point Rate

0x4nn1

0x68

0x21

Defines the rate of set point ramping in degrees per minute.

Safe State Action

0x8nn0

0x6D

0x16

How the control operates in the Safe State. Loop Off (default), Manual, Standby Auto, or Nominally. 0 = Actual Control State (0x6nnn SI 0x01) = OFF 1 = Actual Control State (0x6nnn SI 0x01) = ON, Actual Control Mode (0x6nnn SI 0x02) = AUTO, Controlling Set Point (0x6nnn SI 0x16) = Target Set Point (0x7nnn SI 0x11) 2 = Actual Control State (0x6nnn SI 0x01) = ON, Actual Control Mode (0x6nnn SI 0x02) = AUTO, Controlling Set Point (0x6nnn SI 0x16)= Standby Set Point (0x8nnn SI 0x20) 3 = Actual Control State (0x6nnn SI 0x01) = ON, Actual Control Mode (0x6nnn SI 0x02) = MANUAL, Manipulated Value (0x6nnn 0x12) = Forced MV (0x7nnn SI 0x12) 4 = Operate as configured

Standby Set Point

0x8nn0

0x6D

0x20

Sets an alternate Set Point which way be used in the safe state to keep the system operational at a nominal set point.

Set Point High Limit

0x8nn0

0x6D

0x21

Defines the upper settable Target Set Point value. Use to ensure the set point is in an acceptable range.

Set Point Low Limit

0x8nn0

0x6D

0x22

Defines the lowest settable Target Set Point value. Use to ensure the set point is in an acceptable range.

MV High Limit

0x8nn0

0x6D

0x24

Defines the upper settable Forced MV value. Use to ensure the set manual power is in an acceptable range.

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MV Low Limit

0x8nn0

0x6D

0x25

Defines the lowest settable Forced MV value. Use to ensure the manual power is in an acceptable range.

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Process Sensor Value (PV)

0x6nn0

0x6B

0x11

The temperature process value reading of the sensor

Sensor Error

0x6nn0

0x6B

0x03

Indicates if the temperature reading is valid or has an error.

Target Set Point (SP)

0x7nn0

0x6C

0x11

Set the desired system temperature with this value.

Actual Controlling Set Point

0x6nn0

0x6B

0x16

The set point currently used for control. This may not be the target set point if the system is in the safe state or is ramping. This will show the current ramping set point when that feature is enabled.

Set Point is Ramping

0x2nn0

0x65

0x03

Indicates if the set point is ramping. This will not occur unless set point ramping is enabled.

Manipulated Value

0x6nn0

0x6B

0x12

The output of the control loop which manipulates the heater.

Heat Manipulated Value

0x6nn0

0x6B

0x13

The positive portion of the Manipulated Value which routes to heat outputs.

Cool Manipulated Value

0x6nn0

0x6B

0x14

The negative portion of the Manipulated Value which routes to cool outputs.

Forced Manipulated Value

0x7nn0

0x6C

0x12

This manual power directly drives the loop’s

output at this level when the loop’s Control Mode is Manual. This is part of the default output PDO.

Desired Control State

0x7nn0

0x6C

0x01

Turns the control system on and off. Part of the default output PDO.

Actual Control State

0x6nn0

0x6B

0x01

Indicates if the control loop is on or off. In the safe state this will follow the state defined in the safe state parameter, typically off.

Desired Control Mode

0x7nn0

0x6C

0x02

Sets the control loop mode to Auto (Closed Loop) or Manual (Open Loop). Set Point drives the loop in Auto mode and Forced MV drives the loop power in Manual Mode. This is part of the defaults output PDO.

Using

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Actual Control Mode

0x6nn0

0x6B

0x02

Indicates the actual controlling mode Auto or Manual. If there is a sensor error the loop cannot be in the Auto mode.

Tune Occurring

0x6nn0

0x6B

0x04

Indicates if an auto-tune is in progress. Tuning is started using command 0xFB30.

Remote PV

0x3nn0

0x66

0x13

An external value may be used as the Process Variable. If the Sensor Map is set to 5. This value will be the process value and should be provided by the master in an Output PDO.

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8.2 OPTICAL SENSING

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Optical Sensor Type

0x4nn1

0x68

0x14

Sets a sensor curve to match the connected probe type. The device supports 3 probe curves. After changing the curve type, send a

SaveNonVolatileParameters command and cycle power to the unit. The probe curve is only loaded on power-up.

0 = Type 0 is the Watlow standard probe 1 = Type 1 is a legacy probe 2 = Type 2 is customizable

Optical Sensor Warning

0x4nn1

0x68

0x2E

Sets a warning point for the probe LED current. The default is 15mA. When the LED current exceeds this level the status indicator on the front on the module will flash green and red alternately. This can occur if the optical pathway is becoming opaque or the extension cable is not properly seated.

Optical Sensor Error

0x2nn0

0x65

0x02

Indicates an error with the sensor probe.

Optical Sensor LED Current

0x2nn0

0x65

0x11

Indicates the optical sensor LED current used to actuate the luminescent probe. Increasing current can indicate increasing attenuation in the extension cable.

RMZ4 modules (RMZ4-xx04-xxxx) with integrated optical sensing support these parameters. These integrated

sensors are activated by setting the Sensor Bus to 4 and selecting instance 1, 2, 3, or 4. These parameters are also available from RMF modules connected and mapped as a normal RM module input in that case.

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8.3 OPEN LOOP DETECT

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Open Loop Detect Enable

0x4nn1

0x68

0x2F

1 = Enables the Open Loop Detect Feature 0 = Disables the feature

Open Loop Detect Time

0x4nn1

0x68

0x30

Sets the amount of time given for the process value to change by at least the Deviation amount.

Open Loop Deviation

0x4nn1

0x68

0x31

Sets the amount the process value must change within the Detection Time or an open loop error will be set.

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Open Loop Error Status

0x2nn0

0x65

0x04

0 = Control Loop is operating properly 1 = Control Loop is not closed, output power set to 0%.

Clear Open Loop Detect Error

0x3nn0

0x66

0x01

Clear the open loop error. The loop will function again. If the condition has not be correct the error will occur again after the power reaches 100% for the detection time.

RMZ4 has the capability to detect if the control loop is out of control. The loop is detected as being “open” if the manipulated value of output power is not having an effect on the measure process value. Open loops can be caused by various issues. Open fuses, heaters or interlock contactors will prevent power from reaching the load. Sensors that are not in proper contact with the load will not detect changes in temperature correctly. This will cause thermal runaway. Since loads change at different rates and respond to power differently the feature is configured with an amount of change expected in a period of time. Typically the process value will not increase at all in response to 100% output power. Set the value conservatively to prevent false trips. For example, If the process would normally change 20 degrees per minute at 100% power, the feature could be set to 5 degrees in 60 seconds. This would trip if the measured process value does not change at less than ¼ its normal rate.

Configuring

Using

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8.4 DIGITAL HEAT CONTROL OUTPUTS

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Digital Heat Bus

0x4nn0

0x67

0x15

Defines the zone that hosts the Heat Outputs. Only loops that are locally hosted can support output mapping. EZ-ZONE ST and PM, EHG SL-10 devices do not have a mechanism to map their outputs to foreign control loops. However, this will indicate where the output setup parameters like cycle time should be sent for any controller type. 0 = Unused 1 = RM 2 = Legacy ST/PM 3 = Modbus SL-10

Digital Heat Zone

0x4nn0

0x67

0x16

Defines which RM zone is providing the digital heat control output. Only loops that are locally hosted can support output mapping. EZ-ZONE ST and PM, EHG SL10 devices do not have a mechanism to map their outputs to foreign control loops. They will use their own outputs automatically.

Digital Heat Instance

0x4nn0

0x67

0x17

Defines which digital output instance on a particular zone implement the control output.

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Output 1 Cycle Time

0x8nn0

0x6D

0x1A

Set the cycle time for the digital heat output. The output will pulse at this rate with the duty cycle defined by the heat manipulated value (MV) power level.

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Heat Manipulated Value

0x6nn0

0x6B

0x13

The heat control output value can be observed in this sub index 0.0 to 100.0%

Manipulated Value

0x6nn0

0x6B

0x12

The total control output value can be observed in this sub index whether heating or cooling -100.0 to 100.0%

These parameters associate an RM’s digital output back with the control loops in the RMZ. The RMZ4 is zone 16 so the mapping for with output will be Function=Heat, Zone=16, Instance= the RMZ4 loop number.

Mapping

Configuring

Using

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8.5 OVER-TEMPERATURE LIMITS

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Limit Bus

0x4nn0

0x67

0x1B

Sets the bus where the over-temp sensing function is located. Over-temp control has dedicated trip circuitry. This extra sensor is read at 0:2000:14 for verification. The limit is parameterized in the RMZ4 with trip points that are routed to the appropriate RML, RMC, ST or PM module. The limit function and output are independently controlled by the limit module but parameterized through the RMZ. 0: Unused 1 = RM 2 = Legacy ST/PM 3 = Modbus SL-10

Limit Zone

0x4nn0

0x67

0x1C

Defines which zone is hosting the limit sub module.

Limit Instance

0x4nn0

0x67

0x1D

Defines which limit sub-module corresponds to this control loop.

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Limit Sensor Type

0x4nn1

0x68

0x1E

Sets the limit input type to 0 = TC 1 = RTD100 2 = RTD1000 3 = 4-20mA 4 = 0-20mA 5 = 0-10V

Limit Thermocouple Type

0x4nn1

0x68

0x1F

Set the limit thermocouple type to 0: K 1: J 2: T 3: E 4: N 5: R 6: S 7: B 8: C 9: D 10: F

Limit Function

0x4nn1

0x68

0x15

Set the limit type to 0 = Disabled

Over-temperature cut off is accomplished using an independent limit. The EZ-ZONE family has physically integrated yet independent limit circuits to provide thermal protection. Systems can be protected from thermal runaway by interlocking through the relay output of the limit circuit. The limit has its own input sensor to configure as well as trip points to configure. The limit relay will open if a limit condition occurs. The limit must be cleared by the system master after the limit condition has cleared, it will not self clear.

Mapping

Configuring

WATLOW

EZ-ZONE

RMZ4 - 35 - ETHERCAT

ADAPTER

1 = High Only 2 = Low Only 3 = Both High and Low Trip Enabled

Limit Hysteresis

0x4nn1

0x68

0x16

Set the hysteresis for the limit, which is how far back into the safe band the temperature must return before the limit can be cleared.

Limit Over-Temp Trip Point

0x8nn0

0x6D

0x34

Sets the high trip point where the over temperature relay will open.

Limit Under-Temp Trip Point

0x8nn0

0x6D

0x35

Sets the low trip point where the under temperature relay will open.

Limit Set Point Upper Bound

0x4nn1

0x68

0x17

Define the maximum settable trip point value.

Limit Set Point Lower Bound

0x4nn1

0x68

0x18

Define the minimum settable trip point value.

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Limit Temperature Reading

0x2nn0

0x65

0x14

Indicates the current temperature of the limit sensor.

Limit Sensor Error

0x2nn0

0x65

0x01

Indicates if the limit sensor is valid or in error. If the sensor is in error, the temperature reading will return 9999.9C and be invalid. The limit circuit will also open the relay on any sensor error.

Limit Condition

0x6nn0

0x68

0x18

Indicates if a limit condition is occurring.

Limit Clear

0x3nn0

0x66

0x11

Write a 1 to this index to clear a tripped limit. The limit can be cleared if:

1. The sensor reading is valid.

2. The temperature is within the trip

points.

Using

WATLOW

EZ-ZONE

RMZ4 - 36 - ETHERCAT

ADAPTER

8.6 CURRENT SENSING

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Current Sense Bus

0x4nn0

0x67

0x1E

Defines the bus connected to the current sensing module. This is typically an RME, RMC, or ST. The current sensing circuit needs to be associated with output controlling the heater to compare measured output against the desired output to generate errors when the current is not in alignment with the output signal. 0 = Unused 1 = RM 2 = Legacy ST/PM 3 = Modbus SL-10

Current Sense Zone

0x4nn0

0x67

0x1F

Defines which zone is hosting the current sense functionality.

Current Sense Instance

0x4nn0

0x67

0x20

Defines which current sense instance belongs to this loop in a module that hosts multiple current sensors.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Heater Failure Function

0x4nn1

0x68

0x19

Current Trip Level High

0x4nn1

0x68

0x1A

A heater fault is generated if the RMS current exceeds this point.

Current Trip Level Low

0x4nn1

0x68

0x1B

A heater fault is generated if the RMS current falls below this point. This is used to detect the loss of a heater or fuse.

Current Transformer Scaling High

0x4nn1

0x68

0x1C

Matches the current reading to the Current Transformer (CT) used and the number of wire windings.

Current Transformer Offset

0x4nn1

0x68

0x1D

Allows user calibration of the current reading.

Heat outputs may be associated with a current sensor. The RM uses current transformers and the ST uses a built in current sensor. This will report the RMS current flowing through the heater. High and low trip points may be configured.

Mapping

Configuring

Using

WATLOW

EZ-ZONE

RMZ4 - 37 - ETHERCAT

ADAPTER

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

RMS Current Value

0x6nn0

0x6B

0x15

Provides a reading of the heater current.

Heater Fault

0x2nn0

0x65

0x12

Indicates the trip points have been exceeded.

8.7 COOLING DIGITAL OUTPUTS

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Digital Cooling Bus

0x4nn0

0x67

0x28

Specifies the bus connected to the device hosting the digital cool output. Only loops that are locally hosted can support output mapping. EZ-ZONE ST and PM, EHG SL-10 devices do not have a mechanism to map their outputs to foreign control loops. Cool outputs parameters like cycle time need this location even if they are hosted remotely. 0 = Unused 1 = RM 2 = Legacy ST/PM 3 = Modbus SL-10

Digital Cooling Zone

0x4nn0

0x67

0x29

Defines which RM zone is providing the digital cool control output. Only loops that are locally hosted can support output mapping. EZ-ZONE ST and PM, EHG SL-10 devices do not have a mechanism to map their outputs to foreign control loops. They will use their own outputs automatically. Still associate this with ST and PM devices to ensure proper parameter routing.

Digital Cooling Instance

0x4nn0

0x67

0x2A

Defines which digital output instance on a particular zone implement the cool control output. The cooling algorithm may be set to PID or ON/OFF with hysteresis.

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Output 2 Cycle Time

0x8nn0

0x6D

0x1B

Set the cycle time for the digital cool output. The output will pulse at this rate with the duty cycle

Cool outputs are driven off the same control loop as the heat output and map negative power to this cool outputs when it is mapped. These are slow switching PWM for PID or simple ON/OFF.

Mapping

Configuring

WATLOW

EZ-ZONE

RMZ4 - 38 - ETHERCAT

ADAPTER

defined by the cool manipulated value (MV) power level.

Using

Parameter

ECAT

Index

DNET

Class

Sub /Attr

Description

Cool Manipulated Value

0x6nn0

0x6B

0x14

The cool control output value can be observed in this sub index 0.0 to 100.0%

Manipulated Value

0x6nn0

0x6B

0x12

The total control output value can be observed in this sub index whether heating or cooling -100.0 to

100.0%

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Analog Heat Bus

0x4nn0

0x67

0x18

Specifies the bus connected to the device hosting the analog heat output. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane.

Analog Heat Zone

0x4nn0

0x67

0x19

Defines which RM zone is providing the analog heat output.

Analog Heat Instance

0x4nn0

0x67

0x1A

Defines which analog output in the mapped module provides the heat output.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Analog Heat Output Type

0x4nn1

0x68

0x21

0 = Milliamps 1 = Volts

Analog Heat Output Electrical High

0x4nn1

0x68

0x23

This is the analog output value associated with 100% heat power such as 10V or 20mA

Analog Heat Output Electrical Low

0x4nn1

0x68

0x24

This is the analog output value associated with 0% heat power such as 0V or 4mA.

8.8 ANALOG HEAT OUTPUTS

Analog outputs can drive analog actuator like valves, power controller or phase angle SSR. The heat output level is determined by the control loop and PID. This configuration routes the power to an analog output and allows appropriate scaling.

Mapping

Configuring

Using

WATLOW

EZ-ZONE

RMZ4 - 39 - ETHERCAT

ADAPTER

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Heat Manipulated Value

0x6nn0

0x6B

0x13

The heat control output value can be observed in this sub index 0.0 to 100.0%

Manipulated Value

0x6nn0

0x6B

0x12

The total control output value can be observed in this sub index whether heating or cooling -100.0 to 100.0%

0 20 40 60 80 100 120

Resultant Electrical Ouptut

Power

Analog Power Scaling

WATLOW

EZ-ZONE

RMZ4 - 40 - ETHERCAT

ADAPTER

8.9 ANALOG RETRANSMIT OUTPUTS

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Analog Heat Retransmit Bus

0x4nn0

0x67

0x18

Specifies the communication bus connects to the output module for the analog retransmit output. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane.

Analog Heat Retransmit Zone

0x4nn0

0x67

0x19

Defines which device zone/address on the bus is providing the analog retransmit output.

Analog Heat Retransmit Instance

0x4nn0

0x67

0x1A

Defines which output in this device provides the analog retransmit output.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Analog Retransmit Output Type

0x4nn1

0x68

0x28

0=Milliamps 1=Volts

Analog Retransmit Output Scale High

0x4nn1

0x68

0x29

This is the process value that maps to the high electrical retransmit output. (0x4nn1:28) such as 500 Degrees C.

Analog Retransmit Output Scale Low

0x4nn1

0x68

0x2A

This is the process value that maps to the high electrical retransmit output. (0x4nn1:29) such as 100 Degrees C.

100 200 300 400 500

Resultant Electrical Ouptut

Process Temperature

Retransmit Scaling

Analog outputs can retransmit the loop’s process value for use by external devices. The analog output is scaled from the temperature reading using a transfer function defined using 4 parameters, 2 process values and the matching 2 electrical values. This defines a line that maps any temperature to an appropriate analog value.

Mapping

Configuring

WATLOW

EZ-ZONE

RMZ4 - 41 - ETHERCAT

ADAPTER

Analog Retransmit Output Electrical High

0x4nn1

0x68

0x2B

This is the electrical analog output value associated with the Scale High value (0x4nn1:26) such as 10V or 20mA.

Analog Retransmit Output Electrical Low

0x4nn1

0x68

0x2C

This is the electrical analog output value associated with the Scale High value (0x4nn1:27) such as 0V or 4mA.

8.10 ALARM OUTPUTS

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Process Alarm 1 Bus

0x4nn0

0x67

0x2B

Specifies the communication bus connects to the outputs for the process alarm 1. 0 = Unused 1 = RM 2 = Legacy ST/PM 3 = Modbus SL-10

Process Alarm 1 Zone

0x4nn0

0x67

0x2C

Defines which device zone/address on the bus provides the process alarm 1.

Process Alarm 1 Instance

0x4nn0

0x67

0x2D

Defines which output in this device provides the process alarm 1 output.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Deviation Alarm 2 Bus

0x4nn0

0x67

0x2E

Specifies the communication bus connects to the outputs for the deviation alarm 2 0 = Unused 1 = RM 2 = Legacy ST/PM

Deviation Alarm 2 Zone

0x4nn0

0x67

0x2F

Defines which device zone/address on the bus provides the output for deviation alarm

Deviation Alarm 2 Instance

0x4nn0

0x67

0x30

Defines which output in this device provides the output for deviation alarm 2.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Alarm 1 Enable

0x8nn0

0x6D

0x14

0 = Disable the process alarm 1 = Enabled the process alarm

Mapping Process Alarm 1

Mapping Deviation Alarm 2

Configuring

WATLOW

EZ-ZONE

RMZ4 - 42 - ETHERCAT

ADAPTER

Alarm 1 High Set Point

0x8nn0

0x6D

0x2C

The point where a high alarm 1 becomes active. This is an absolute temperature.

Alarm 1 Low Set Point

0x8nn0

0x6D

0x2D

The point where a low alarm 1 becomes active. This is an absolute temperature.

Alarm 1 Set Point Upper Bound

0x8nn0

0x6D

0x2E

Alarm 1 High Set Point cannot be set above this value. This is typically set as the maximum allowable for the tool.

Alarm 1 Set Point Lower Bound

0x8nn0

0x6D

0x2F

Alarm 1 Low Set Point cannot be set below this value. This is typically set as the minimum allowable for the tool.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Alarm 2 Enable

0x8nn0

0x6D

0x15

0 = Disable the deviation alarm 1 = Enabled the deviation alarm

Alarm 2 High Set Point

0x8nn0

0x6D

0x30

The point where a high alarm 2 becomes active. This is a temperature relative to this loops set point, typically a positive number like 20C.

Alarm 2 Low Set Point

0x8nn0

0x6D

0x31

The point where a low alarm 2 becomes active. This is a temperature relative to this loops set point, typically a negative number like -20C.

Alarm 2 Set Point Upper Bound

0x8nn0

0x6D

0x32

Alarm 2 High Set Point cannot be set above this value. This is typically set as the maximum allowable for the tool.

Alarm 2 Set Point Lower Bound

0x8nn0

0x6D

0x33

Alarm 2 Low Set Point cannot be set below this value. This is typically set as the minimum allowable for the tool.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Alarm Condition

0x6nn0

0x6B

0x17

For each loop with will indicate if either of the 2 alarms is active. 0x0001 = Process alarm condition present 0x0002 = Deviation alarm condition present 0x0003 = Both alarm conditions present

Using

WATLOW

EZ-ZONE

RMZ4 - 43 - ETHERCAT

ADAPTER

8.11 ANALOG COOLING OUTPUTS

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Analog Cool Output Bus

0x4nn0

0x67

0x32

Specifies the communication bus connects to the analog outputs for the cooling action. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane.

Analog Cool Output Zone

0x4nn0

0x67

0x33

Defines which device zone/address on the bus provides the analog cooling output.

Analog Cool Output Instance

0x4nn0

0x67

0x34

Defines which output in this device provides the analog cooling output.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Analog Cool Output Type

0x4nn1

0x68

0x25

0 = Milliamps 1 = Volts

Analog Cool Output Electrical High

0x4nn1

0x68

0x26

This is the analog output value associated with 100% cool power such as 10V or 20mA

Analog Cool Output Electrical Low

0x4nn1

0x68

0x27

This is the analog output value associated with 0% cool power such as 0V or 4mA.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Cool Manipulated Value

0x6nn0

0x6B

0x14

The cool control output value can be observed in this sub index 0.0 to 100.0%

Manipulated Value

0x6nn0

0x6B

0x12

The total control output value can be observed in this sub index whether heating or cooling -100.0 to 100.0%

Cool outputs can drive analog actuator like valves, chillers or variable speed fans. The cool output level is determined by the control loop and PID. This configuration routes the cool power to an analog output and allows appropriate scaling.

Mapping

Configuring

Using

WATLOW

EZ-ZONE

RMZ4 - 44 - ETHERCAT

ADAPTER

8.12 DIRECT DIGITAL INPUT

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Direct Digital Input Bus

0x4nn0

0x67

0x35

Specifies the communication bus that connects to the module containing direct digital input. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane.

Direct Digital Input Zone

0x4nn0

0x67

0x36

Defines which device zone/address on the bus provides the direct digital input.

Direct Digital Input Instance

0x4nn0

0x67

0x37

Defines which output in this device provides the direct digital input.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Direct Digital Input Value

0x6nn0

0x6B

0x19

The digital input is available in this Sub-Index as 0 or 1. This value is can be mapped to the User PDO.

Direct digital inputs are made available for reading from the EtherCAT network. Map this point to the appropriate Digital input. The value is may be mapped to a User PDO.

Mapping

Using

WATLOW

EZ-ZONE

RMZ4 - 45 - ETHERCAT

ADAPTER

8.13 DIRECT DIGITAL OUTPUT

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Direct Digital Output Bus

0x4nn0

0x67

0x38

Specifies the communication bus that connects to module containing the direct digital output. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane.

Direct Digital Output Zone

0x4nn0

0x67

0x39

Defines which device zone/address on the bus provides the direct digital output.

Direct Digital Output Instance

0x4nn0

0x67

0x3A

Defines which output in this device provides the direct digital output.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Direct Digital Output Value

0x7nn0

0x6C

0x14

The directly mapped Digital output is set via this Sub-Index as 0 or 1. This value is can be mapped to the User PDO.

Direct digital outputs are controlled directly from the EtherCAT network. They are not controlled by algorithms in the RM system. This allows any digital output point in the RM system to be controlled remotely. The value can be mapped to User PDO.

Mapping

Using

WATLOW

EZ-ZONE

RMZ4 - 46 - ETHERCAT

ADAPTER

8.14 DIRECT ANALOG INPUT

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Direct Analog Input Bus

0x4nn0

0x67

0x3B

Specifies the communication bus that connects to the analog input module. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane.

Direct Analog Input Zone

0x4nn0

0x67

0x3C

Defines which device zone/address on the bus provides the analog input.

Direct Analog Input Instance

0x4nn0

0x67

0x3D

Defines which input in this device provides the analog input.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Direct Analog Input Sensor Type

0x4nn1

0x68

0x32

This is the sensor type for the direct digital input. 0 = TC 1 = RTD100 2 = RTD1000 3 = 4-20mA 4 = 0-20mA 5 = 0-10V

Direct Analog Input TC Type

0x4nn1

0x68

0x33

This is the sensor type for the direct digital input. 0: K 1: J 2: T 3: E 4: N 5: R 6: S 7: B 8: C 9: D 10: F

Process Scale High for Direct Analog Input

0x4nn1

0x68

0x34

This is the input value associated with the high electrical signal such as 0V or 4mA.

Process Scale Low for Direct Analog Input

0x4nn1

0x68

0x35

This is the input value associated with the low electrical signal such as 0V or 4mA.

Direct analog inputs are any sensor or process input in the RM system. These can be monitored directly from the EtherCAT network. The point may be mapped to User PDO. Make sure this input is not used by a control loop or limit. The configurations would interfere with each other.

Mapping

Configuring

Using

WATLOW

EZ-ZONE

RMZ4 - 47 - ETHERCAT

ADAPTER

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Direct Analog Input Value

0x2nn0

0x65

0x16

This is the most recent, live value of this input. This value can be mapped to the User PDO.

8.15 DIRECT ANALOG OUTPUT

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Direct Analog Output Bus

0x4nn0

0x67

0x3E

Specifies the communication bus connects to the analog outputs for the cooling action. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane.

Direct Analog Output Zone

0x4nn0

0x67

0x3F

Defines which device zone/address on the bus provides the analog cooling output.

Direct Analog Output Instance

0x4nn0

0x67

0x40

Defines which output in this device provides the analog cooling output.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Analog Cool Output Electrical High

0x4nn1

0x68

0x26

This is the analog output value associated with 100% cool power such as 10V or 20mA

Analog Cool Output Electrical Low

0x4nn1

0x68

0x27

This is the analog output value associated with 0% cool power such as 0V or 4mA.

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Direct Analog Output Value

0x3nn0

0x66

0x14

The output can be set here via SDO. This value can be mapped to the User PDO.

Direct digital outputs are controlled directly from the EtherCAT network. They are not controlled by algorithms in the RM system. This allows any analog output in the RM system to be controlled remotely. The value can be mapped to User PDO. This output share scaling with the cool analog output.

Mapping

Configuring

Using

WATLOW

EZ-ZONE

RMZ4 - 48 - ETHERCAT

ADAPTER

8.16 ALARM GROUPS

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Alarm Group 1 Logic

0x5F00

0x69

0x11

Specifies the logic state taken when any of the picked alarms is active. 0 = If any alarm is condition matches the pick for the group, the group will be FALSE. 1 = If any alarm is condition matches the pick for the group, the group will be TRUE.

Alarm Group 1 Output Bus

0x5F00

0x69

0x12

Defines which bus hosts the digital alarm group 1 output. This is only applicable to EZZONE RM device. 0 = Unused 1 = RM back plane.

Alarm Group 1 Output Zone

0x5F00

0x69

0x13

Defines which zone on the bus hosts the digital alarm group 1 output

Alarm Group 1 Output Instance

0x5F00

0x69

0x14

Defines which output in the zone implements the digital alarm group 1 output.

Alarm Group 2 Logic

0x5F00

0x69

0x15

Specifies the logic setting for alarm group 2.

Alarm Group 2 Output Bus

0x5F00

0x69

0x16

Defines which bus hosts the alarm group 2 output. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane

Alarm Group 2 Output Zone

0x5F00

0x69

0x17

Defines which zone on the bus hosts the alarm group 2 output

Alarm Group 2 Output Instance

0x5F00

0x69

0x18

Defines which output in the zone implements the digital alarm group 2 output.

Alarm Group 3 Logic

0x5F00

0x69

0x19

Specifies the logic setting for alarm group 3.

Alarm Group 3 Output Bus

0x5F00

0x69

0x1A

Defines which bus hosts the alarm group 3 output. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane

Each loop has a process and deviation alarm. These can be individually mapped to output. However many application want to trigger an output is any of a group of alarms is active. The RMZ4 provides 8 alarm groups to facilitate alarm aggregation. Each group may be mapped to a digital output. The group provides a means to pick which active alarms are part of the group from any control loop. The groups are configured in the 0x5F00 object. The control loops are assigned a group in the 8 Pick Lists 0x5F01 to 0x5F08. The groups are not slot/module based since they are not associated one to one with the control loops. Groups can be used to energize a contactor when all control loops associated with that power distribution bus are operating properly.

Mapping and Configuration

WATLOW

EZ-ZONE

RMZ4 - 49 - ETHERCAT

ADAPTER

Alarm Group 3 Output Zone

0x5F00

0x69

0x1B

Defines which zone on the bus hosts the alarm group 3 output

Alarm Group 3 Output Instance

0x5F00

0x69

0x1C

Defines which output in the zone implements the digital alarm group 2 output.

Alarm Group 4 Logic

0x5F00

0x69

0x1D

Specifies the logic setting for alarm group 4. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane

Alarm Group 4 Output Bus

0x5F00

0x69

0x1E

Defines which bus hosts the alarm group 4 output.

Alarm Group 4 Output Zone

0x5F00

0x69

0x1F

Defines which zone on the bus hosts the alarm group 4 output

Alarm Group 4 Output Instance

0x5F00

0x69

0x20

Defines which output in the zone implements the digital alarm group 4 output.

Alarm Group 5 Logic

0x5F00

0x69

0x21

Specifies the logic setting for alarm group 5.

Alarm Group 5 Output Bus

0x5F00

0x69

0x22

Defines which bus hosts the alarm group 5 output. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane

Alarm Group 5 Output Zone

0x5F00

0x69

0x23

Defines which zone on the bus hosts the alarm group 5 output

Alarm Group 5 Output Instance

0x5F00

0x69

0x24

Defines which output in the zone implements the digital alarm group 5 output.

Alarm Group 6 Logic

0x5F00

0x25

Specifies the logic setting for alarm group 6.

Alarm Group 6 Output Bus

0x5F00

0x26

Defines which bus hosts the alarm group 6 output. This is only applicable to EZ-ZONE RM device. 0 = Unused 1 = RM back plane

Alarm Group 6 Output Zone

0x5F00

0x69

0x27

Defines which zone on the bus hosts the alarm group 6 output

Alarm Group 6 Output Instance

0x5F00

0x69

0x28

Defines which output in the zone implements the digital alarm group 6 output.

Alarm Group 7 Logic

0x5F00

0x69

0x29

Specifies the logic setting for alarm group 7.

Alarm Group 7 Output Bus

0x5F00

0x69

0x2A

Defines which bus hosts the alarm group 7 output.

Alarm Group 7 Output Zone

0x5F00

0x69

0x2B

Defines which zone on the bus hosts the alarm group 7 output

Alarm Group 7 Output Instance

0x5F00

0x69

0x2C

Defines which output in the zone implements the digital alarm group 7 output.

Alarm Group 8 Logic

0x5F00

0x69

0x2D

Specifies the logic setting for alarm group 8.

Alarm Group 8 Output Bus

0x5F00

0x69

0x2E

Defines which bus hosts the alarm group 8 output.

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Alarm Group 8 Output Zone

0x5F00

0x69

0x2F

Defines which zone on the bus hosts the alarm group 8 output.

Alarm Group 8 Output Instance

0x5F00

0x69

0x30

Defines which output in the zone implements the digital alarm group 8 output.

Alarm Picking

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Alarm Group 1 Pick List

0x5F01

0x6A

0x01

Determines how alarms from loop 1 map into the group.

0 = Not part of the group 1 = Process alarms activate the group 2 = Non occurring process alarms activate the group 3 = Deviation alarms activate the group 4 = Non occurring deviation alarms activate the group 5 = A process AND a deviation alarm with activate the group 6 = A process OR a deviation alarm will activate the group.

0x5F01

0x6A

0x02

Determines how alarms from loop 2 map into group 1.

….

For each loop…

0x5F01

0x6A

0x30

Determines how alarms from loop 48 map into group 1.

Alarm Group 2 Pick List

0x5F02

0x6A

0x01 … 0x30

Determines how alarms from loop nn map into group 2.

Alarm Group 3 Pick List

0x5F03

0x6A

0x01 … 0x30

Determines how alarms from loop nn map into group 3.

Alarm Group 4 Pick List

0x5F04

0x6A

0x01 … 0x30

Determines how alarms from loop nn map into group 4.

Alarm Group 5 Pick List

0x5F05

0x6A

0x01 … 0x30

Determines how alarms from loop nn map into group 5.

Alarm Group 6 Pick List

0x5F06

0x6A

0x01 … 0x30

Determines how alarms from loop nn map into group 6.

Alarm Group 7 Pick List

0x5F07

0x6A

0x01 … 0x30

Determines how alarms from loop nn map into group 7.

Alarm Group 8 Pick List

0x5F08

0x6A

0x01 … 0x30

Determines how alarms from loop nn map into group 8.

Each sub index corresponds to a control loop module’s involvement. For each group select with alarm actions of a loop get incorporated in that alarm group.

Using

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These are the output values form each group. This value maps to the digital output. The logic setting in the

Parameter

ECAT

Index

DNET

Class

Sub

/Attr

Description

Alarm Group 1 Value

0x5F00

0x69

0x01

The output value for alarm group 1, True or False.

Alarm Group 2 Value

0x5F00

0x69

0x02

The output value for alarm group 2, True or False.

Alarm Group 3 Value

0x5F00

0x69

0x02

The output value for alarm group 3, True or False.

Alarm Group 4 Value

0x5F00

0x69

0x02

The output value for alarm group 4, True or False.

Alarm Group 5 Value

0x5F00

0x69

0x02

The output value for alarm group 5, True or False.

Alarm Group 6 Value

0x5F00

0x69

0x02

The output value for alarm group 6, True or False.

Alarm Group 7 Value

0x5F00

0x69

0x02

The output value for alarm group 7, True or False.

Alarm Group 8 Value

0x5F00

0x69

0x02

The output value for alarm group 8, True or False.

group will invert this value.

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FIGURE 12 - ALARM GROUP EXAMPLE

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9 SETTING PARAMETERS AND RUNNING

With the I/O mapped to the correct RM or ST the system is ready to be setup and run. Consider if it makes sense to execute a SaveNonVolatile command to store all the I/O mapping for immediate recall on power-up. While a typical EtherCAT® system will write all required parameter to the RMZ4 while before the operational mode is started, there is advantage to store the most desired configuration then ensure it is correct by

checking or simply writing again. This eliminates configuration latency on power up.

9.1 USING PDOS

Each loop has a default set of PDO input and outputs for normal sensor monitoring and set point and mode delivery. Each loop also has a set of user definable PDOs. The user can load these with parameters of interest on a loop by loop basis. The only limitation is that the items loaded into each loop must be parameters

belonging to that loop.

9.2 RUNNING

To operate the control loops, the loop must have the Control State set to On. The Safe Mode defines if the control loops can continue to operate if the EtherCAT® state transitions to the Safe State to prevent undesired cool-downs if desired. The Target Set Point, Control Mode, and Control State are by default provided by the Output PDOs once the system entered the operational mode. The must be set using the PDOs then the device is in operational mode.

9.3 TUNING

Tuning is a process that sets the PID values for a control loop automatically using a standard Zielger-Nichols algorithm. The system is put into oscillation below the Set point. The controller observes the responses to determine the systems gain and time constant. From that information appropriate PID values are calculate and put into effect. The process will return the controller to normal closed loop mode once the tune in complete.

The control loops may be tuned individually, in groups, or all at the same time via the InitiateTune command. The PID value can be set directly as well. The tune command takes a list of loops to tune. This is a string of bytes. This list of byte 0102030A10 will initiate a tune of loops 1, 2, 3, 10, and 16. To see if a loop is tuning, look at the TuneActive bit in the 0x6nn0:04. Sending 0 as the list will initiate a tune on all configured loops.

Tuning can be cancel on any loop using the CancelTune command. This uses the same command strings as the InitiateTune command, individual loops with a list or all with 0.

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10 ETHERCAT® PROTOCOL

Index Description Details

Modular

0x1000 Identity Object Device Name, Vendor ID, serial number… No 0x2000 Watlow Specific Input Data Limit sensor Yes 0x3000 Watlow Specific Output Data SP, Desired States… Yes 0x4000 Watlow Specific I/O Mapping TC Types, Ranges, Alarm Points… Yes 0x4001 Watlow Specific Configuration Cooling, Limits and CT parameters Yes 0x5F00 Alarm Grouping Aggregates Alarms No 0x6000 Input Data PV, Errors, Actual States, Current… Yes 0x7000 Output Data SP, Desired States… Yes 0x8000 Configuration Parameters TC Types, Ranges, Alarm Points… Yes 0xF000 Device Specifics Number of Modules, Module Index Offset… No 0xF300 Exceptions Exceptions and fault indication No 0xF500 Watlow Attached Devices RM and ST details No 0xF600 Input Status Status of PDO updates No 0xF900 Information Which features are present, generation of specs No 0xFA00 Diagnostic Messages Event log and EtherCAT® issue log No 0xFB00 Commands Start Autotune, Store parameters, Reset device No

The EtherCAT® implementation supports CoE (CANOpen over EtherCAT®) and FoE (File over EtherCAT®). CoE defines the mapping of device parameters to Indexes and Sub Indexes. FoE is used to write new application code into the product for revision upgrades.

10.1 DEVICE OBJECTS

Each system object type is mapped to an Index. In the Watlow EtherCAT® Adapter, objects are structured as arrays of objects representing each control loop separated by 0x10. The Sub Indexes within each index are the individual parameters that comprise the objects. EtherCAT® indexes are mapped to class instances using the Modular Device topology. Input data for loop 1 is located at index 0x6000. Input data for loop 2 in located at index 0x6010, etc. Items in the 0x200, 0x3000, 0x6000 and 0x7000 parameters can be mapped to the PDO sets.

Loops are mapped to repeating indexes with an offset of 0x0010 between Modular Object indexes.

A standard listing of objects is available in the Semi SDP ETG.5003.2060 from the EtherCAT website.

http://www.ethercat.org

The complete list of SDP and Watlow Specific objects is available from the Watlow website as an Excel

spreadsheet.

http://www.watlow.com

Search “Watlow EtherCAT SDP”

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10.2 COMMANDS

These are on-demand actions initiated from the master.

0xFB30 Start auto tuning a loop

The command is a list of loops as string. Example: “1,3,8” will start tuning loops 1, 3, and 8

Zero will tune all zones Example: “0” will start tuning on all loops

Additional method for version 2.0 or later:

The command is an array of bytes for the loops to tune. Example: 0x010308 will start tuning loops 1, 3, and 8

Zero will tune all zones Example: 0x00 will start tuning on all loops

0xFB31 Cancel a tune

The command is a list of loops as string. Example: “2,5,10” will stop tuning loops 2,5, and 10

Zero will stop tune on all zones Example: “0” will stop tuning on all loops

Additional method for version 2.0 or later:

The command is an array of bytes for the loops to stop. Example: 0x02050A will stop tuning loops 2, 5, and 10

Zero will stop tune on all zones Example: 0x00 will stop tuning on all loops

0xFBF0 Reset Device - both device restart and restore factory configuration

The command is a text string.

“teser” will reboot the device. “teserf” will reset the device to factory parameters.

0xFBF1 Reset Exceptions

The command is a byte. Writing 0x01 will cause any expectations to be cleared.

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0xFBF2 Store parameters to Non-volatile memory

The command is a code to cause the configuration parameters to get stored to NV memory. Otherwise the parameters will be lost on power cycle.

0x65766173 causes the parameters to be stored A status of 0 means no action. A status of 100 means in-progress. A status of 200 means complete.

0xFBF3 Calculate Parameter Checksum(s)

The command is a byte. Writing 0x01 will cause the checksum recalculation of all 0x4000 and 0x8000 parameters. A status of 0 means no action. A status of 100 means in-progress. A status of 200 means complete.

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10.3 DEFAULT RXPDO

PDO Sub Index

Name

PDO Entry Index

PDO Entry Sub Index

PDO Entry Name

0x01

Sub Index 001

0x7nn0

0x11

Target Set Point Loop nn

0x02

Sub Index 002

0x7nn0

0x13

Clear Alarms Loop nn

0x03

Sub Index 003

0x7nn0

0x12

Forced MV Loop nn

0x04

Sub Index 004

0x7nn0

0x02

Control Mode Loop nn

0x05

Sub Index 005

0x7nn0

0x01

Control State Loop nn

PDO Sub Index

Name

PDO Entry Index

PDO Entry Sub Index

PDO Entry Name

0x01

Sub Index 001

0x6nn0

0x11

Process Value Loop nn

0x02

Sub Index 002

0x6nn0

0x17

Alarm Condition Loop nn

0x03

Sub Index 003

0x6nn0

0x12

Manipulated Value (Control Output) Loop nn

0x04

Sub Index 004

0x6nn0

0x16

Controlling Set Point Loop nn

0x05

Sub Index 005

0x6nn0

0x01

Actual Control State Loop nn

0x06

Sub Index 006

0x6nn0

0x03

Sensor Error Loop nn

0x07

Sub Index 007

0x6nn0

0x02

Actual Control Loop Mode Loop nn

This is the data received by the controller every scan cycle (usually 1-10ms as controlled by the master). It is configured at index 0x1600 predefined standard data points and 0x1601 for user defined data points for loop1, 0x1602/0x1603 for loop2, etc. The parameters in the user defined (odd numbered) PDO can be changed by changing the Entry Index and Entry Sub Index contained in the PDO sub index but this is global, not on a permodule basis. The even PDOs are a standard set defined by the Standard Device Profile (SDP) and are fixed.

10.4 DEFAULT TXPDO

This is the data transmitted by the controller every scan cycle (usually 1-10ms as controlled by the master). Is it configured at index 0x1A00 for loop1, 0x1A02 for loop2, etc.

10.5 USER RXPDO

Users can define their own PDO data in the 0x1601, 0x1603, 0x1605… Any RX map-able PDO can be placed in this area. Each module/slot can have its own User RxPDO set. The only constraint is that the parameters must be part of this Loop/Module.

10.6 USER TXPDO

Users can define their own PDO data in the 0x1A01, 0x1A03, 0x1A05… Any TX map-able PDO can be placed in this area. Each module/slot can have its own User TxPDO set. The only constraint is that the parameters must be part of this Loop/Module.

11 DEVICENET® PROTOCOL

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11.1 DEVICENET CLASS MAPPING

Object

EtherCAT

Index

DeviceNet

Class

Device

0x1000

0x64 Watlow Inputs

0x2nn0

0x65

T2O Element

Watlow Output

0x3nn0

0x66

O2T Element

Watlow Mapping

0x4nn0

0x67 Watlow Setup

0x4nn1

0x68 Alarm Group

0x5F00

0x69 Alarm Picks

0x5F00

0x6A

Inputs

0x6nn0

0x6B

T2O Element

Outputs

0x7nn0

0x6C

O2T Element

Setup

0x8nn0

0x6D Optic Sensor

0x0

0x6E

Optic Calibration

0x0

0x6F

PDO Outputs/O2T Implicit User Setup

0x1A00

0x70

O2T Setup

PDO Inputs/T2O Implicit Setup

0x1C00

0x71

T2O Setup

O2T Data via Explicit

0x72

O2T Data

T2O Data via Explicit

0x73

T2O Data

User Implicit Output O>T (same as RxPDO)

Class 0x70 / Loop N=1-48 / Attribute 1-10

LSB

MSB

User 0x70/N/1

Class ID

Attribute ID

User 0x70/N/2

Class ID

Attribute ID

User 0x70/N/3

Class ID

Attribute ID

User 0x70/N/4

Class ID

Attribute ID

User 0x70/N/5

Class ID

Attribute ID

DeviceNet uses the same CAN OPEN data model as EtherCAT. The DeviceNet classes map to the objects per this table.

The DeviceNet Attributes are the same as the EtherCAT SubIndex. The DeviceNet instance in the Module Slot offset from EtherCAT. For example 0x6nn0 is instance nn over DeviceNet. The implicit data model follows the PDO model from EtherCAT too. The explicit DeviceNet reads and writes will match the EtherCAT SDO CoE with the class translation from the table above. See the EtherCAT ETG.5003.2060 Object Dictionary for the complete set of attributes (Sub-Indexes) per class.

11.2 O>T DEVICENET IMPLICIT SETUP CLASS 0X70

The implicit O>T data has fixed elements and user elements configured in class 0x70. The fixed elements are the same as the EtherCAT RxPDO. These are system command outputs received by the target from the originator. In the O>T image, the user data will follow the fixed elements.

 Setting the Class ID to 0 (i.e. set the entry to 0x0000) will remove the entry from the assembly.  There are 10 available user entries 0x01 to 0x0A  The instance corresponds to the control loop (EtherCAT slot)  Bit data types will pad themselves back to a byte boundary if followed by non-bit data. The best

practice is to put all the bit at the end of the section so they can pad out once before the next loop.

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User 0x70/N/6

Class ID

Attribute ID

User 0x70/N/7

Class ID

Attribute ID

User 0x70/N/8

Class ID

Attribute ID

User 0x70/N/9

Class ID

Attribute ID

User 0x70/N/A

Class ID

Attribute ID

O>T Value Read-Back / Settable

Class 0x72 / Loop N=1-48 / Attribute 1-10

Size

Value of User 0x70/N/1

Per Parameter

Value of User 0x70/N/2

Per Parameter

Value of User 0x70/N/3

Per Parameter

Value of User 0x70/N/4

Per Parameter

Value of User 0x70/N/5

Per Parameter

Value of User 0x70/N/6

Per Parameter

Value of User 0x70/N/7

Per Parameter

Value of User 0x70/N/8

Per Parameter

Value of User 0x70/N/9

Per Parameter

Value of User 0x70/N/A

Per Parameter

User Implicit Output O->T (same as RxPDO)

LSB

MSB

Bit Size

Target Set Point

0x6C

0x11

Clear Alarms

0x6C

0x13

Forced MV Value

0x6C

0x12

Loop Control Mode

0x6C

0x02

Loop Control State

0x6C

0x01 1 Alignment Padding

11.3 O>T DEVICENET IMPLICIT READ-BACK CLASS 0X72

The values for these entries in class 0x70 can be read in the 0x72 objects.

11.4 FIXED O>T DEVICENET ENTRIES

The fixed elements (same as RxPDO 0x1600) will appear in the implicit data ahead of the user set, per loop. These are predefined and cannot be changed. It is 12 bytes 96 bit in size.

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11.5 COMPLETE O>T IMPLICIT DATA IMAGE

Implicit T>O

Value Bit Size

Loop 1

Value of Set Point 1

Clear Alarm Word 1

Value of Forced MV Value 1

Loop Control Mode 1

Loop Control State 1

Alignment Padding

Value of User 0x70/1/1

Per Parameter (if configured)

Value of User 0x70/1/2

Per Parameter (if configured)

…

Value of User 0x70/1/A

Per Parameter (if configured)

Possible Alignment Padding

8-N bits

Loop 2

Value of Set Point 2

Clear Alarm Word 2

Value of Forced MV Value 2

Loop Control Mode 2

Loop Control State 2

Alignment Padding

Value of User 0x70/2/1

Per Parameter (if configured)

Value of User 0x70/2/2

Per Parameter (if configured)

…

Value of User 0x70/2/A

Per Parameter (if configured)

Possible Alignment Padding

8-N bits

Loop 3

Value of Set Point 3

Clear Alarm Word 3

Value of Forced MV Value 3

Loop Control Mode 3

Loop Control State 3

Alignment Padding

Value of User 0x70/3/1

Per Parameter (if configured)

Value of User 0x70/3/2

Per Parameter (if configured)

…

Value of User 0x70/3/A

Per Parameter (if configured)

Possible Alignment Padding

8-N bits

….

Loop N

Value of Set Point N

Clear Alarm Word N

Value of Forced MV Value N

Loop Control Mode N

Loop Control State N

Alignment Padding

Value of User 0x70/N/1

Per Parameter (if configured)

The configuration can be validated in the 0x04 objects. This will be the binary equivalent of the implicit O>T in class 0x04 at 0x04/0x64/3. This is the same data that will appear in the implicit messages. If you use bit data types they will automatically be padded to the next byte boundary.

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Value of User 0x70/N/2

Per Parameter (if configured)

…

Value of User 0x70/N/A

Per Parameter (if configured)

Possible Alignment Padding

8-N bits

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11.6 T>O DEVICENET IMPLICIT SETUP CLASS 0X71

User Implicit Output T>O (same as TxPDO)

Class 0x71 / Loop N=1-48 / Attribute 1-10

LSB

MSB

User 0x71/N/1

Class ID

Attribute ID

User 0x71/N/2

Class ID

Attribute ID

User 0x71/N/3

Class ID

Attribute ID

User 0x71/N/4

Class ID

Attribute ID

User 0x71/N/5

Class ID

Attribute ID

User 0x71/N/6

Class ID

Attribute ID

User 0x71/N/7

Class ID

Attribute ID

User 0x71/N/8

Class ID

Attribute ID

User 0x71/N/9

Class ID

Attribute ID

User 0x71/N/A

Class ID

Attribute ID

T>O Value Read-Back

Class 0x73 / Loop N=1-48 / Attribute 1-10

Size

Value of User 0x71/N/1

Per Parameter

Value of User 0x71/N/2

Per Parameter

Value of User 0x71/N/3

Per Parameter

Value of User 0x71/N/4

Per Parameter

Value of User 0x71/N/5

Per Parameter

Value of User 0x71/N/6

Per Parameter

Value of User 0x71/N/7

Per Parameter

Value of User 0x71/N/8

Per Parameter

Value of User 0x71/N/9

Per Parameter

Value of User 0x71/N/A

Per Parameter

User Implicit Output T>O (same as TxPDO)

LSB

MSB

Bit Size

The implicit T>O data has fixed elements and user elements configured in class 0x71. The fixed elements are the same as the EtherCAT TxPDO. These are system sensor inputs that are transmitted from the target to the originator. In the T>O image, the user data will follow the fixed elements.

practice is to put all the bit at the end of the section so they can pad out once before the next loop.

11.7 T>O DEVICENET IMPLICIT READ-BACK CLASS 0X73

The values for these entries in class 0x71 can be read in the 0x73 objects.

11.8 FIXED T>O DEVICENET ENTRIES

The fixed elements (same as TxPDO 0x1A00) will appear in the implicit data ahead of the user set, per loop. It is 16 bytes 128 bits

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Process Value

0x6B

0x11

Alarm Condition

0x6B

0x17

Manipulated Value

0x6B

0x12

Controlling Set Point

0x6B

0x16

Actual Loop Control State

0x6B

0x01 1 Sensor Error

0x6B

0x03 1 Actual Loop Control Mode

0x6B

0x02 1 Alignment Padding

Implicit T>O

Value Bit Size

Loop 1

Process Value 1

Alarm Condition 1

Manipulated Value 1

Controlling Set Point 1

Actual Loop Control State 1

Sensor Error 1

Actual Loop Control Mode 1

Alignment Padding

Value of User 0x71/1/1

Per Parameter (if configured)

Value of User 0x71/1/2

Per Parameter (if configured)

…

Value of User 0x71/1/A

Per Parameter (if configured)

Possible Alignment Padding

8-N bits

Loop 2

Process Value 2

Alarm Condition 2

Manipulated Value 2

Controlling Set Point 2

Actual Loop Control State 2

Sensor Error 2

Actual Loop Control Mode 2

Alignment Padding

Value of User 0x71/2/1

Per Parameter (if configured)

Value of User 0x71/2/2

Per Parameter (if configured)

…

Value of User 0x71/2/A

Per Parameter (if configured)

Possible Alignment Padding

8-N bits

Process Value 3

Alarm Condition 3

Manipulated Value 3

Controlling Set Point 3

Actual Loop Control State 3

11.9 COMPLETE T>O IMPLICIT DATA IMAGE

The configuration can be validated in the 0x04 objects. This will be the binary equivalent of the implicit T>O in class 0x04 at 0x04/0x96/3. This is the same data that will appear in the implicit messages. If you use bit data types they will automatically be padded to the next byte boundary.

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Loop 3

Sensor Error 3

Actual Loop Control Mode 3

Alignment Padding

Value of User 0x71/3/1

Per Parameter (if configured)

Value of User 0x71/3/2

Per Parameter (if configured)

…

Value of User 0x71/3/A

Per Parameter (if configured)

Possible Alignment Padding

8-N bits

…

Loop N

Process Value N

Alarm Condition N

Manipulated Value N

Controlling Set Point N

Actual Loop Control State N

Sensor Error N

Actual Loop Control Mode N

Alignment Padding

Value of User 0x71/N/1

Per Parameter (if configured)

Value of User 0x71/N/2

Per Parameter (if configured)

…

Value of User 0x71/N/A

Per Parameter (if configured)

Possible Alignment Padding

8-N bits

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12 CONTROL OPERATION

12.1 NETWORK STATE AND CONTROL STATES

EtherCAT® networks have a defined state Boot, Init, Pre-OP, Safe-Op and Operational. The control loops will function as defined by the Safe State Parameter 0x8nnn SI 0x16 at startup until the network state changes to Operational. At that point the Control State will change from OFF to RUN (if the Desired Control State is set to RUN).

If the control loops running in the EtherCAT® module lose connection with the RMS module, the loop will enter a fault state and the control mode for that loop will go to the Safe Mode configured in parameter 0x8nnn SI 0x16.

If the outputs in the RME modules lose connection with the control loop in the EtherCAT® adapter module, the modules will turn off until the link is re-established.

The exception reporting will indicate the loss of communication with modules in the system.

12.2 DATA RETENTION

EtherCAT® master applications typically configure the application on power-up to ensure correct settings before the system is made operational. Configuration will not be stored to non-volatile memory automatically. The master must issue an explicit store of parameters to non-volatile memory command. It does not occur implicitly behind the scenes.

To cause the configuration parameters to be stored to non-volatile memory, the master needs to write to Command 0xFBF2 with 0x65766173 to cause the parameters to be stored. The advantage of storing in nonvolatile is the system I/O will be configured properly at power-up before the master ensures it is correct.

12.3 CONTROL LOOPS

The EtherCAT® adapter supports up to 48 control loops that execute in the adapter itself. The process variable for each loop is consumed from the RMS, RMH, or RMC modules. The outputs generated by the control loops are published and the RME, RMC modules are configured to consume these as their power level. The control loops will function as soon as the Control State is set to RUN. Once the system is operational, you can use the Autotune command to determine PID values that are optimal for the system.

12.4 ALARMS

The EtherCAT® adapter module has two alarms per control loop. Alarm1 is a process alarm and Alarm2 is a deviation alarm. The PV source for each loop is mapped to the PV and SP for the associated alarms. The user may enable or disable each alarm but the alarm type and sources cannot be changed. The alarm status is available in the 0x6000 objects and in the exception object 0xF381.

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13 ADDITIONAL CONNECTIVITY

13.1 BLUETOOTH®

The EtherCAT® adapter can host an optional Bluetooth® module that contains the antenna, radio and firmware. This interface can assist with monitoring you system during development and test. This port streams XML containing readings and parameters. Android applications will be forthcoming.

The Bluetooth® module can be powered down from the processor for secure environments ensuring it will not pair.

The EtherCAT® devices will be identified on the Bluetooth® network as “EtherCATXXXXXXXX” where XXXXXXXX is the devices serial number. The device will appear in Windows® as a COM port.

This device complies with Part 18 of the FCC Rules (Section 18.212) and contains a Transmitter Module.

FCC ID: X3ZBTMOD5 IC: 8828A-MOD4 Bluetooth SIG Qualified Design, QD ID: B019224

13.2 MODBUS® SLAVE

The 2000, 3000, 4001, 6000, 7000, 8000 indexes map into the 6000 and 7000 banks of Modbus® registers with each control loop instance having an offset of 50. The primary purpose is to support HMI user interfaces that are Modbus masters.

13.3 MODBUS® MASTER

Not implemented in release 1. This will collect data from modus slave devices and present it in the EtherCAT® data model, allowing control of legacy Modbus controllers.

14 FLASH LOADING

14.1 OVER ETHERCAT®

The device firmware may be updated over EtherCAT using the FoE (File over EtherCAT) service. This is the process:

1. The master placed the RMZ4 in BOOT mode to accept the file.

2. The master download the file (*.bin) via FOE

3. The master changes the mode to INIT.

4. The slave will then program itself with the downloaded file. This will take several seconds and include a

reboot.

5. The slave will enter the INIT state with the new firmware in place.

14.2 OVER USB

Flash updates via USB require a flash update application on a PC that contains the embedded binary image.

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15 SUPPORTING DOCUMENTS AND FILES

These files are available from the www.watlow.com website.

WatlowRMZ.xml is the ESI file for the adapter.

RMZ4_xx_xx.bin is the flash image to send to the device over EtherCAT®.

ObjectDictionary_ETG5003_2060_Watlow_A.xlsx Specifies all EtherCAT® objects for the adapter.

RMZ_ModbusMap.xlsx Defines the object dictionary mapped to Modbus Registers. This is accessible over the

RJ-12 Modbus Slave Jack. This is a convenient point for connecting a Watlow Silver Series HMI. This interface is set to 38400 baud, 8 data bits, 1stop bit, No Parity at Address 1.

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16 TROUBLESHOOTING GUIDE

Issue

Likely Cause/Remedy

No LEDs lit on product

 24V not present on CT connector pins 98/98

Device is not identified over EtherCAT

 Check Link LED on Ethernet RJ45 jack  Incorrect/no ESI file loaded in Master. Make sure to use the

latest ESI, all past versions are supported in the latest ESI. When bumping up a product revision, make sure the master reloads the correct image from the ESI.

Can’t enter Operational State

 User PDO not byte aligned for data elements following bit

data type. All types other than bits must be byte aligned in the PDO image.

Optical inputs don’t read back

 Map the loop to bus 4 (optical) in the 0x4nn0 objects  Verify Optical LED current level. High values indicate poor

connection to the probe.

Optical inputs appear to read incorrectly

 Verify Probe Type (0x4nn1:0x14) setting matches the

connected probe

Control Sensor input don’t read back

 Sensors must be mapped to correct RM input module in

0x4nn0 objects

Limit Sensor input don’t read back

 Limits must be mapped to correct RM input module in 0x4nn0

objects

Limits won’t clear (relay pull in)

 The input must be between the Over-Temp and Under Temp

points.

 The limit function must be Both Sides, High or Low  The limit condition (0x6nnn:0x18) must be 0 (clear)  Clear the limit by writing to (0x3nnn:0x11)

Heater Current sense does not report values

 Verify the current sense is mapped in 0x4nn0  The Current sense must be on the same loop as the control

output and in the same RM module

 The output must be conducting to get valid readings

Mapping does not appear to get data from inputs or to outputs.

 Each RM module must have a unique zone number  Verify the RMs are discovered by the RMZ in the 0xF5nn

objects. Confirm zone numbers here.

Control loops don’t product power

 Control State must be set to 1 in Output PDO  RMZ must be in OPER mode

Can’t auto tune a loop

 The input sensor for the loop must be reading correctly (no

input error)

 RMZ must be in OPER mode  The loop must be in the On State and Auto Mode.  Start with the appropriate command 0xFB30

Controller setting are not maintained through a power cycle

 Issue a Non-Volatile Save command when the parameters are

at the desired value to save them

RMZ does not show on my PC when connected via USB port

 Use the WatlowUSB.inf driver file for this virtual COM port

Can’t flash load RMZ

 Mode must be BOOT to start a flash load  After loading, mode must be set to INIT to commit the new

firmware.

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17 RMZ4 SPECIFICATIONS

Feature

Specification

Supply Voltage

 20.4 to 30V AC/DC 50/60 Hz  Compliant with SEMI F47-200, Figure R1-1 voltage sag  External supply should comply with Class 2 or SELV  Wire on slot “C” connector

Power

 4 Watts Max, 14 VA

Environmental

 -18 to 65°C operating  -40 to 85°C storage  0 to 90% RH, non-condensing

Agency Approvals

 UL /EN 61010 Recognized; c-UL C22.2 #61010; File #

E185611 QUYX, QUYX7

 ANSI/ISA 12.12.01-2012 hazardous locations Class 1 Div.

 EN60529 IP20  RoHS by design  W.E.E.E.  FM Class 3545 on connected RML, RMC, ST module  CE

Weight

 200 grams (7 oz) without adder cards

Wiring

 Slot “C” connector  Touch-safe removable 12 to 30 AWG  Torque 0.8 N-m (7.0 lb-in) right angle

Mounting

 DIN-rail spec. EN50022 35x7.5mm

Control Loops

 48 max, set by model number

Process Alarms

 1 per control loop

Deviation Alarm

 1 per control loop

Connected EZ-ZONE RM controllers

 15 max

Compatible EZ-ZONE RM types

 RMC – Sensor inputs, outputs, limits, CT  RME – Outputs, CT  RMS – Sensor inputs, outputs  RMH – Sensor inputs  RML - Limits

Connected EZ-ZONE ST or PM controllers

 8 max

Heat Control Mode

 PID

Cool Control Modes

 PID / On-Off

Control Update Tate

 10 Hz

Ramp to Set Point

 Programmable in degrees per minute

Current Sense

 One configurable heater current sensor per control loop

(resident in RME and RMC modules)

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Over-Temp Limit

 Configures one over-temperature limit sensor per

control loop hosted by remote FM approved RMC or RML limit module

EtherCAT® Device Profile

 ETG.5003.2060 Temperature Controller

Unique EtherCAT® Identifier

 Two switches – 0x10, 0x01 for ID from 0 to 255

EtherCAT® LEDs

 RUN and ERROR

EtherCAT® Connections

 IN and OUT RJ-45

EtherCAT® PDO configurations

 2 sets per loop:

o One fixed default PDO set o One user programmable PDO set by loop

USB

 Mini USB device providing a CDC serial port

Serial Connections

 Standard bus RS-485 on slot “C” connector

Bluetooth

 Serial Port Profile (SPP) streaming XML

Optical Temperature Sensor Inputs

 4 max, set by model number

18 OPTICAL ADDER CARD SPECIFICATIONS

Feature

Specification

Optical Temperature Sensor Inputs

 4 max, set by model number  ST bayonet style connectors IEC 61754-2

Environmental

 -18 to 65°C operating  -40 to 85°C storage  0 to 90% RH, non-condensing

Supported Calibrated Probe Types

 Type A – Watlow Standard  Type B  Type C – User Specific

Probe Range

 -150 to +450 C Type A probe (Blue)

Accuracy (Unit to unit)

 ± 0.05 C

Precision (Sigma)

 ± 0.1 C

Resolution

 0.0007 °C

Short Term Stability (Noise)

 ± 0.15 C

Long Term Stability (Drift)

 ± 0.5 C per year

Dynamic Sampling Rate

 10 to 400 Hz

Weight

 362 grams (12.8 oz) RMZ4 with 4 optical cards

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19 SERIAL COMMUNICATIONS ADDER CARD SPECIFICATIONS

Feature

Specification

Modbus Master Port

 Modbus RTU 8,N,1  EIA-485 half duplex  Baud Rates 9600,19200,35400,57600  Polls addresses 1 to 247

Modbus Slave Port

 Modbus RTU 8,N,1  EIA-485 half duplex  Baud Rates 9600,19200,35400,57600

Extra Standard Bus Port

 RS-485 half duplex  Accepts connections from EZ-ZONE Configurator

or Composer

Bluetooth Interface

 Bluetooth v3.0  Bluetooth Design ID: B019224  SPP Serial Streaming  SCPI messaging system – see RMZ4 Bluetooth Spec.

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20 PART NUMBERING

Custom/Proprietary

xx=Number of Control Loops

xx=Number of Integrated Optical Sensors

A=No Bluetooth B=Bluetooth®

A=No Legacy Communications 1=Standard Bus 2=Modbus RTU 3=Standard Bus, Modbus RTU 5=Device NET

This is the part number for the RMZ4 EtherCAT® Adapter.

RMZ4 - xx xx - A A AA

Watlow®, EZ-ZONE® and EHG® are registered trademarks of Watlow Electric Manufacturing Company.

Windows® is a registered trademark of Microsoft Corporation.

EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.

Beckhoff® and TwinCAT® are registered trademarks of Beckhoff Automation GmbH, Germany.

Modbus® is a registered trademark of Schneider Automation Incorporated.

The Bluetooth® word mark and logo are registered trademarks owned by Bluetooth® SIG, Inc.

UL® is a registered trademark of Underwriter’s Laboratories, Inc.

DeviceNet™ is a trademark of Open DeviceNet Vendors Association.

This device complies with Part 18 of the FCC Rules (Section 18.212).

Contains Transmitter Module

FCC ID: X3ZBTMOD5

IC: 8828A-MOD4

Bluetooth SIG Qualified Design, QD ID: B019224

Designed and Manufactured in the USA.

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EtherCAT EZ-ZONE RMZ4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual