Watlow EZ-ZONE RM User Manual

ISO 9001

EZ-ZONE® RM Limit Module

User’s Guide

RM Limit Module

TOTAL

CUSTOMER

SATISFACTION

3 Year Warranty

1241 Bundy Boulevard., Winona, Minnesota USA 55987

Phone: +1 (507) 454-5300, Fax: +1 (507) 452-4507

http://www.watlow.com

0600-0075-0000 Rev. D Made in the U.S.A.

Registered Company

Winona, Minnesota USA

March 2016

Safety Information

We use note, caution and warning symbols throughout this book to draw your attention to important operational and safety information.

• A “NOTE” marks a short message to alert you to an important detail.

• A “CAUTION” safety alert appears with information that is important for protecting your equipment and performance. Be especially careful to read and follow all cautions that apply to your application.

• A “WARNING” safety alert appears with information that is important for protecting you, others and equipment from damage. Pay very close attention to all warnings that apply to your application.

• The safety alert symbol, (an exclamation point in a triangle) precedes a general CAUTION or WARNING statement.

• The electrical hazard symbol, (a lightning bolt in a triangle) precedes an electric shock hazard CAUTION or WARNING safety statement. Further explanations follow:

Symbol Explanation

CAUTION – Warning or Hazard that needs further explanation than label on unit can provide. Consult User's Guide for further information.

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

Unit protected by double/reinforced insulation for shock hazard prevention.

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

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

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

Unit is a Listed device per Underwriters Laboratories®. It has been evaluated to United States and Canadian requirements for Process Control Equipment. UL 61010 and CSA C22.2 No. 61010. File E185611 QUYX, QUYX7. See: www.ul.com

Unit has been reviewed and approved by Factory Mutual as a Temperature Limit Device per FM Class 3545 standard. See:

www.fmglobal.com

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

Unit has been reviewed and approved by CSA International for use as Temperature Indicating-Regulating Equipment per CSA C22.2 No. 24. See: www.csa-international.org

Warranty

The EZ-ZONE® RM Limit module is manufactured by ISO 9001-registered processes and is backed by a three-year warranty to the first purchaser for use, providing that the units have not been misapplied. Since Watlow has no control over their use, and sometimes misuse, we cannot guarantee against failure. Watlows' obligations hereunder, at Watlows' option, are limited to replacement, repair or refund of purchase price, and parts which upon examination prove to be defective within the warranty period specified. This warranty does not apply to damage resulting from transportation, alteration, misuse or abuse. The purchaser must use Watlow parts to maintain all listed ratings.

Technical Assistance

If you encounter a problem with your Watlow controller, review your configuration information to verify that your selections are consistent with your application: inputs, outputs, alarms, limits, etc. If the problem persists, you can get technical assistance from your local Watlow representative (see back cover), by e-mailing your questions to wintechsupport@watlow.com or by dialing +1 (507) 494-5656 between 7 a.m. and 5 p.m., Central Standard Time (CST). Ask for for an Applications Engineer. Please have the following information available when calling:

• Complete model number

• All configuration information

• User’s Guide

• Factory Page

Return Material Authorization (RMA)

1. Call Watlow Customer Service, (507) 454-5300, for a Return Material Authorization (RMA) number before returning any item for repair. If you do not know why the product failed, contact an Application Engineer or Product Manager. All RMA’s require:

• Ship-to address

• Bill-to address

• Contact name

• Phone number

• Method of return shipment

• Your P.O. number

• Detailed description of the problem

• Any special instructions

• Name and phone number of person returning the product.

2. Prior approval and an Return Merchandise Authorization number from the Customer Service Department is required when returning any product for credit, repair or evaluation. Make sure the Return Merchandise Authorization number is on the outside of the carton and on all paperwork returned. Ship on a Freight Prepaid basis.

3. After we receive your return, we will examine it and try to verify the reason for returning it.

4. In cases of manufacturing defect, we will enter a repair order, replacement order or issue credit for material returned. In cases of customer misuse, we will provide repair costs and request a purchase order to proceed with the repair work.

5. To return products that are not defective, goods must be in new condition, in the original boxes and they must be returned within 120 days of receipt. A 20 percent restocking charge is applied for all returned stock controls and accessories.

6. If the unit cannot be repaired, you will receive a letter of explanation and be given the option to have the unit returned to you at your expense or to have us scrap the unit.

7. Watlow reserves the right to charge for no trouble found (NTF) returns.

EZ-ZONE RM is covered by U.S. Patent No. 6,005,577 and Patents Pending

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

Chapter 1: Overview ................................4

Available EZ-ZONE RM System Literature and Resources ...........4

A Conceptual View of the RML Module .........................7

Inputs .................................................7

Functions ..............................................7

Outputs ................................................8

Input Events and Output Events .............................8

Actions ................................................8

Module Limit ............................................8

Module Orientation .......................................11

Chapter 2: Install and Wire ...........................16

Dimensions .............................................16

Power Supplies ..........................................17

DIN Rail Installation and Removal ............................20

Wiring .................................................23

Conventions Used in the Menu Pages .........................40

Chapter 3: Operations Pages .........................43

Analog Input Menu .......................................45

Digital Input/Output Menu ..................................46

Action Menu .............................................46

Limit Menu ..............................................47

Alarm Menu .............................................48

Linearization Menu ........................................49

Compare Menu ..........................................50

Timer Menu .............................................51

Counter Menu ...........................................52

Logic Menu .............................................52

Math Menu ..............................................54

Chapter 4: Setup Pages .............................56

Analog Input Menu .......................................59

Digital Input/Output Menu ..................................63

Action Menu .............................................65

Limit Menu ..............................................66

Output Menu ............................................69

Alarm Menu .............................................71

Linearization Menu ........................................74

Compare Menu ..........................................78

Timer Menu .............................................81

Watlow EZ-ZONE® RML Module • 1 • Table of Contents

Table of Contents (cont.)

Counter Menu ...........................................83

Logic Menu .............................................86

Math Menu ..............................................94

Variable Menu ...........................................99

Global Menu ............................................100

Communications Menu ...................................102

Chapter 5: Factory Pages ...........................104

Limit Module Factory Page Parameters .......................104

Custom Setup Menu .....................................105

Security Setting Menu ....................................105

Diagnostics Menu .......................................108

Calibration Menu ........................................109

Chapter 6: Features ...............................110

Saving and Restoring User Settings .........................111

Module Limit ...........................................111

Inputs .................................................112

10 Point Linearization ...................................115

Alarms ................................................116

Process Alarms ........................................116

Alarm Set Points .......................................116

Alarm Hysteresis .......................................116

Alarm Latching ........................................116

Alarm Silencing ........................................117

Alarm Blocking ........................................117

Using Password Security ..................................118

Modbus - Using Programmable Memory Blocks ................119

Software Configuration ...................................120

Using EZ-ZONE Configurator Software ......................120

Function Block Descriptions ...............................125

Action Function ........................................125

Alarm Function ........................................126

Analog Input Function ...................................128

Compare Function ......................................130

Counter Function ......................................132

Custom Function .......................................133

Diagnostic Function ....................................133

Digital Input/Output Function .............................134

Global Function ........................................135

Linearization Function ...................................136

Watlow EZ-ZONE® RML Module • 2 • Table of Contents

Table of Contents (cont.)

Logic Function ........................................138

Math Function .........................................142

Modbus® Function .....................................147

Output Function .......................................148

Security Function ......................................149

Timer Function ........................................150

Variable Function ......................................156

Chapter 8: Appendix ..............................157

Modbus® - Programmable Memory Blocks ...................157

Troubleshooting Alarms, Errors and Module Issues .............161

RML Specifications ......................................165

RML Ordering Information .................................171

How to Reach Us ........................................173

Watlow EZ-ZONE® RML Module • 3 • Table of Contents

Chapter 1: Overview

Available EZ-ZONE RM System Literature and Resources

Document Title and Part Number Description

Describes how to connect the RM system EZ-ZONE Rail Mount Access (RMA) User's Guide, part number: 0600-0072-0000

EZ-ZONE Rail Mount Controller (RMC) User's Guide, part number: 0600-0070-0000

EZ-ZONE Rail Mount High Density (RMH) User's Guide, part number: 0600-0074-0000

EZ-ZONE Rail Mount Scanner (RMS) User's Guide, part number: 0600-0071-0000

EZ-ZONE Rail Mount Expansion (RME) User's Guide, part number: 0600-0073-0000

EZ-ZONE Remote User Interface (RUI) User's Guide, part number: 0600-0060-0000

into an industrial network, how to use data

logging, module backup and the real-time

clock.

The RMC module is an advanced integrated

controller capable of PID and limit control.

This document describes how to configure

and program all loops of control and com-

munications.

This module extends the density of the stan-

dard RM modules (number of control loops

and I/O points). The User Guide describes

common usage, communications and the

number I/O points available.

This module adds monitoring points to the

RM system. This document describes com-

mon usage and the various types of I/O

available.

When additional I/O is needed the Expan-

sion module fills the gap. This document de-

scribes common usage and the various types

of I/O available.

The RUI provides a visual LED display to the

RM configuration and setup menus. This doc-

ument illustrates and describes connections

and also describes the Home Page for each

RM module as viewed from the RUI. EZ-ZONE RM Specification Sheet, part num-

ber: WIN-EZRM-0414

Watlow Support Tools DVD, part number: 0601-0001-0000

The DVD described above ships with the product and as stated contains all of the literature above as well as much more. If the DVD is not available one can be acquired by contacting Watlow Customer Service at 1-507-454-5300.

As an alternative to the DVD, all of the user documentation described above can also be found on the Watlow website. Click on the following link to find your document of choice:

http://ww w.watlow.com/literature/manual s.cfm. Once there, simply type in the desired part

number (or name) into the search box and download free copies.

Watlow EZ-ZONE® RML Module • 4 • Chapter 1 Overview

Describes RM hardware options, features,

benefits and technical specifications.

Contains all related user documents, tutorial

videos, application notes, utility tools, etc...

Your Comments are Appreciated

In an effort to continually improve our technical literature and ensure that we are providing information that is useful to you, we would very much appreciate your comments and suggestions. Please send any comments you may have to the following e-mail address: TechlitCom-

ments@watlow.com

Introduction

The EZ-ZONE® Rail Mount Limit Module (RML) is used in thermal applications to limit inadvertent over-temperature conditions. The RML controller provides multi-loop (12 loops maximum) safety assurance against instances where over or under temperature runaway conditions could occur from a shorted input sensor or an output device that could fail in a closed position. The RML is recommended for any application where thermal runaway could result in large product scrap costs, affect operator safety, cause damage to equipment, or create a fire hazard.

It just got a whole lot easier to solve the thermal requirements of your system. The EZ-ZONE RML module is provided in a space-saving, rail-mount package and is highly scalable where you only pay for what you need. Ordering options allow for 1 to 12 loops and for those applications that require the ability to configure/monitor over a network the Modbus RTU communication protocol is an option. Other communications protocols are also available (e.g., EtherNet/IP, DeviceNet, Modbus TCP and Profibus DP) when used in conjunction with a Rail Mount Access (RMA) module or when using a Remote User Interface/ Gateway (RUI/GTW).

Standard Features and Benefits

Communication Capabilities

• Supports network connectivity to a PC or PLC

• Watlow Standard Bus or Modbus® RTU

• Provides plug and play capabilities with Remote User Interface (RUI’s) and RMA module

• Free standard bus communications port and free PC software (EZ-ZONE Configurator and

Composer)

FM Approved Over-under Limit with Auxiliary Outputs

• Increases user and equipment safety for over-under temperature conditions

Parameter Save & Restore Memory

• Reduces service calls and down time

Agency approvals: UL Listed, CSA, CE, RoHS, W.E.E.E. FM

• Assures prompt product acceptance

• Reduces end product documentation costs

• FM approval on Limit Models

• Semi F47-0 200

Three-year warranty

• Demonstrates Watlow’s reliability and product support

Touch-safe Package

• IP2X increased safety for installers and operators

Watlow EZ-ZONE® RML Module • 5 • Chapter 1 Overview

Removable cage clamp wiring connectors

• Reliable wiring, reduced service calls

• Simplified installation

Programmable Menu System

• Reduces set up time and increases operator efficiency

Full-featured Alarms

• Improves operator recognition of system faults

• Control of auxiliary devices

Watlow EZ-ZONE® RML Module • 6 • Chapter 1 Overview

A Conceptual View of the RML Module

The flexibility of the RML’s software and hardware allows for variation in configurations. Acquiring a better understanding of its functionality and capabilities while at the same time planning out how the controller can be used will deliver maximum effectiveness in your application.

It is useful to think of the controller in three parts: inputs, procedures and outputs. Information flows from an input to a procedure to an output when the controller is properly configured. An RML controller can carry out several procedures at the same time, e.g., monitoring for several different alarm situations, monitoring and acting upon digital inputs and driving output devices such as audible alarms, lights and contactors. Each process needs to be thought out carefully and the controller’s inputs, procedures and outputs set up properly.

Inputs

The inputs provide the information that any given programmed procedure can act upon. Simply stated, this information may come from an operator pushing a button or from a sensor monitoring the temperature of a part being heated or cooled.

Each analog input typically uses a thermocouple, RTD or thermistor to read the process temperature. It can also read volts, current or resistance, allowing it to use various devices to read humidity, air pressure, operator inputs and others values. The settings in the Analog Input Menu (Setup Page) for each analog input must be configured to match the device connected to that input.

Each digital input reads whether a device is active or inactive. An RML equipped with digital input/output hardware includes two sets of terminals where each of which can be used as either an input or an output. Each pair of terminals must be configured to function as either an input or output with the direction parameter in the Digital Input/Output Menu (Setup Page).

Functions

Functions use input signals to calculate a value. A function may be as simple as reading a digital input to set a state to true or false, or reading a temperature to set an alarm state to on or off. Alternatively, if a failure with the primary sensing device should occur the limit could trip a contactor removing power from the heating element to avoid damaging the load.

To set up a function, it’s important to tell it what source, or instance, to use. For example, if the control is equipped with digital inputs they can be configured to reset an individual alarm or all alarms. If configured as such, the next step would be to define which of the available digital inputs would be tied to the alarm reset function. The RML module can be equipped with up to 7 digital inputs, instance 1 - 6 and or 9. Once the specific input has been selected simply assign the alarm reset function to it (Setup Page, DIO Menu). The last step would be to define the alarm instance that should be reset. If zero is entered for the alarm instance when the digital input selected above is enabled, all latched alarms without a currently existing alarm condition will be reset. If a specific alarm instance (1 -16) is selected it will be that instance alone that will be reset.

Note:

Alarms will reset automatically when the condition that caused the alarm goes back to a non-alarm state if the alarm latching prompt is set to non-latching (Setup Page, ALM Menu).

Keep in mind that a function is a user-programmed internal process that does not execute any action outside of the controller. To have any effect outside of the controller, an output must be configured to respond to a function.

Watlow EZ-ZONE® RML Module • 7 • Chapter 1 Overview

Outputs

Outputs can perform various functions or actions in response to information provided by a function, such as removal of the control voltage to a contactor; turning a light on or off; unlocking a door; or turning on an audible alarm.

Assign an output to a function in the Output Menu or Digital Input/Output Menu. Then select which instance of that function will drive the selected output. For example, in using a Limit Control an output can be configured to respond to an alarm, i.g., (instance 15) or to a limit condition.

You can assign more than one output to respond to a single instance of a function. For example, alarm 2 could be used to trigger a light connected to output 1 and a siren connected to digital output 5.

Input Events and Output Events

Input events are internal states that are set by the digital inputs. Digital Input 1 provides the state of input event 1, and Digital Input 2 provides the state of input event 2. The setting of Digital Input Function (Setup Page, Digital Input/Output Menu) does not change the relationship between the input and the event. An input will still control the input event state, even if Digital Input Function is set to None.

Actions

Based on a given input (Digital I/O, Event output, Logic function, etc..) the Action function can cause other functions to occur. To name a few, set alarms to off, silencing alarms and reset a tripped limit condition.

Module Limit

This function allows the user to setup a single output to reflect an energized (safe) or deenergized (tripped) state for the module. If any configured limit is tripped (process value exceeds set point or limit input has malfunctioned), the output assigned to serve as this function will come on. By default (factory settings), output 8 is assigned this function where any output of choice can be configured as such.

A Conceptual View of RM Hardware Configurations

Due to the scalability and flexibility in the RM system a user has several options available in the way that the hardware can be connected. Listed below are a few examples.

Watlow EZ-ZONE® RML Module • 8 • Chapter 1 Overview

RML Connected to a Remote User Interface (RUI) and a Personal Computer (PC)

In this configuration the RUI and PC are connected to the RML module via Watlow's Standard Bus where both will be able to talk directly to the RML module.

Limit

Slot C

Power

Supply

485 to USB

Converter

RUI

PC Running

EZ-ZONE

Configurator

In the graphic above the PC running EZ-ZONE Configurator software and or the RUI can be used to configure and then monitor the RML and other modules connected to it.

RML Module Connected to a Programmable Logic Controller (PLC) on a DIN Rail

In this configuration the PLC can be connected to the RML module using the Modbus RTU protocol:

Limit

Slot C

Power

PLC

Supply

In this example, the RML module and the PLC must be equipped with the Modbus RTU protocol.

Note:

If it is intended to use an RUI or a PC using EZ-ZONE Configurator software it will be necessary to switch the protocol on the RML to Watlow's Standard Bus to successfully communicate; disconnect all Modbus devices from the network. Once done using the RUI or EZ-ZONE Configurator software, switch the protocol back to Modbus RTU and reconnect all Modbus devices to re-establish communications over Modbus.

Watlow EZ-ZONE® RML Module • 9 • Chapter 1 Overview

RML Module Connected to an Operator Interface Terminal (OIT) through an RMA

In this configuration the RML can be connected to the OIT through the RMA running any of a number of available protocols. The RMA and the OIT must be using the same protocol while the communications from RMA to the RML module is accomplished over the backplane using Watlow's Standard Bus protocol. Available protocols in the RMA follow:

1. EtherNet/IP and or Modbus TCP

2. DeviceNet

3. Modbus RTU

4. Profibus DP

Slot E

Limit

Access

Slot C

RUI

Slot C

OIT

Power

Supply

Notice that in the example above that there is an optional RUI connected to the RML along with the OIT. OIT's are not generally used to configure a control but are used more for runtime information. As an alternative for configuration the RUI could be used to configure and monitor in a remote location.

One advantage in using an RMA module when communicating on a network is that protocol switching is not needed on the RML module if using an RUI or EZ-ZONE Configurator or Composer software. The protocol of choice used with the RMA can run simultaneously with the Standard Bus protocol.

RML Connected to a Split Rail with OIT

In this configuration both the inter-module bus (backplane communications) and Standard Bus are connected between rails to allow for remote capabilities. It is recommended that the split rail connection not exceed 100 feet. In this configuration the OIT can communicate with all modules (maximum 16 modules any combination with one Access module).

RM PID

Controller

RM PID

Controller

Slot C

Limit

Slot C

Slot E

Access

Slot C

Power

Supply

Slot C

OIT

Watlow EZ-ZONE® RML Module • 10 • Chapter 1 Overview

Module Orientation

The picture that follows represents one of several different RM modules. All of them will have four slots on the face (slot A, B, D, and E) and one on the bottom (slot C) not shown. All of these slots are not always used on all modules. On the face of the module there is a button (yellow circle) under the Zone address (5). When pushed and held it has the following func- tions:

1. For any module, push and hold for ~ 2 seconds to change the Zone address

2. When a module is equipped with the Modbus protocol (RMxxxxxxxxxx1xx) pushing and

holding this button for ~ 6 seconds the LED display will return P for protocol. Releasing the button and then pushing it again (within 6 seconds) the display will toggle between N (Modbus) and s (Standard Bus). Valid addresses for Modbus and Standard bus range from 1

-16 (1 - q, A is 10, b is 11, C is 12, d is 13, E is 14, F is 15, and h is 16). The RMA (Access) module is shipped at address J or 17 and is the only module that can have its address set above 16.

Note:

For correct operation and accuracy, the module must be mounted in a vertical orientation as shown.

Module Status

(Slot A, B, D, or E)

Protocol Standard Bus - red Modbus - green

Module Outputs

1 through 16, all may or

may not be used depending

on module type

Getting Started Quickly

Consider taking the following steps to quickly commission your control:

• Wire and connect the power source to the control

• Wire and connect input and output devices to the control

• Power up the control and navigate to the Setup Page to configure inputs, outputs, alarms,

etc...

• Once the control is setup, navigate to the Operations Page to set limit and alarm set

points.

The default RML loop configuration out of the box is shown below:

• Analog Input functions are set to thermocouple, type J (to change go to the Setup Page)

• Limit sides set to both, high and low (to change go to the Setup Page)

• Output 8 set to module limit (to change go to the Setup Page)

• Limit low set point set to 0°F (to change go to the Operations Page)

• Limit high set point set to 0°F (to change go to the Operations Page)

• Limit is deenergized, also referred to as a tripped state

Watlow EZ-ZONE® RML Module • 11 • Chapter 1 Overview

Once the control has been wired and setup, power up the control and change the appropriate

EZ-ZONE RML Default Conﬁguration

limit set points (high and or low) to the desired value (on the RUI push the up ¿ and or down

¯ arrow key). Once the set point is set to the desired level, reset the limit by using one of

the four methods described below:

1. Use a digital input, function key or a variable to reset the limit

2. Using an RUI, push the green Advance Key ‰ and then the Infinity Key ˆ

3. If RML is equipped with Modbus RTU, send the enumerated value of zero (0) to register 1490, loop 1 (see the Operations Page, Limit Menu)

4. Cycle power on the control

Input

Function

Input Sensor

Analog Input 1

Thermocouple Type J

Limit

Controller

Output 8

Loop 1

Output

Function

Limit

Note:

Output 8 will default as a module limit. As a module limit, the LED will be illuminated when one or more limit loops is in a tripped (de-energized) state. When the module is in a safe state the output LED will be off.

The RML controller has a page and menu structure that is listed below along with a brief description of its purpose. The menu structure can be easily seen and navigated using EZ-ZONE

Configurator software or the Remote User Interface (RUI).

Note:

The menu navigation as described below applies when the RML is connected to the RUI which is optional equipment.

Watlow EZ-ZONE® RML Module • 12 • Chapter 1 Overview

Setup Page

Using the RUI, push and hold the up and down keys (¿ ¯) for 6 seconds to enter. (See the Setup Page for further information)

Operations Page

Using the RUI push and hold the up and down keys (¿ ¯) for 3 seconds to enter. (See the Operations Page for further information)

Factory Page

Using the RUI push and hold the Infinity and the green Advance keys (ˆ ‰) for 6 seconds to enter. (See the

Factory Page for further infor-

mation)

Home Page

When using the RUI the control is at the Home Page when initially powered up.

Note:

The Home Page is visible only when using the RUI.

A user would want to setup their control prior to operation. As an example, define the limit sides (high and or low), change the input type, or set the output function.

After setting up the control to reflect your equipment, the Operations Page would be used to monitor or change runtime settings. As an example, the user may want to change the limit high/low set point or perhaps change an alarm set point.

For the most part the Factory Page has no bearing on the control when running. A user may want to enable password protection, view the control part number or perhaps create a custom Home Page.

Pushing the green Advance Key ‰ and then the Infinity Key ˆ will reset a limit if tripped (if trip condition no longer exists); or, by pushing the green Advance Key ‰ the limit high and or low set points could be displayed and changed using the up and down keys (¿ ¯).

Watlow EZ-ZONE® RML Module • 13 • Chapter 1 Overview

Input

EZ-ZONE RML-Limit Module - System Diagram

Function

Input Sensor

12 Limit Loops-Slots A, B, D

4-Form A Mechanical Relay Outputs Slot E

Analog Input 1 through 12

None, Thermocouple, 2-Wire RTD (100, 1k), Thermistor (5k, 10K, 20k, 40k), Process (V, mV, mA)

Limit

Controller

Slot A, B, D

Output

Function

RUI, PC,

PLC or HMI

Other RM Modules

Power Supply

Mechanical Relay

Outputs

Slot E

4-Form A

EIA - 485 Communications

Standard Bus

(optional Modbus RTU)

Inter-module Bus

20.4 to 30.8 Vac oe Vdc

Some input/output combinations not possible, see ordering matrix

Modbus RTU

Address 1 - 16

Standard Bus

Zone 1 - 16

Supervisory &

Power Board

Slot C

Output 7, 8, 9 and 10

5A Mechanical Relay Form A

Note:

Output 8 will always be the limit output

regardless of Slot E options. It will be either the global limit or assigned to a speciﬁc loop.

Zone and Status

Output Status

LEDs

LED

Zone Selection

Button

See:

Setup Page,

Output Menu

Indicates Zone

Address

Push to select Zone

Address and Protocol

Card Status

Slots A, B, D, E

Indicates communications activity (Modbus or Standard Bus)

Indicates I/O

Status

Watlow EZ-ZONE® RML Module • 14 • Chapter 1 Overview

Input

EZ-ZONE RML-Limit Module - System Diagram

Function

Input Sensor

6-Digital Inputs or Output Card in Slot D

1-Digital Input/2 Mechanical Relay Outputs Slot E

Analog Input 1 through 12

None, Thermocouple, 2-Wire RTD (100, 1k), Thermistor (5k, 10K, 20k, 40k), Process (V, mV, mA)

Digital Input 1, 2, 3, 4, 5 or 6

Switch contact or volts dc

Digital Input 9

Switch contact or volts dc

Controller

Inputs / Outputs

any combination

1 - Digital Input 2 - Mechanical Relay Outputs

Limit

Slot A, B

6 - Digital

Slot D

Output 1, 2, 3, 4, 5 or 6

switched dc/open collector

Output 7

5A Mechanical Relay Form C

Output 8

5A Mechanical Relay Form A

Output

Function

See:

Setup Page,

Output Menu

See:

Setup Page,

Output Menu

RUI, PC,

PLC or HMI

Other RM Modules

Power Supply

Slot E

EIA - 485 Communications

Standard Bus

(optional Modbus RTU)

Modbus RTU

Address 1 - 16

Standard Bus

Zone 1 - 16

Inter-module Bus

Supervisory &

Power Board

20.4 to 30.8 Vac oe Vdc Slot C

Some input/output combinations not possible, see ordering matrix

Note:

Output 8 will always be the limit output

regardless of Slot E options. It will be either the global limit or assigned to a speciﬁc loop.

Zone and Status

LED

Output Status

LEDs

Zone Selection

Button

Indicates Zone

Address

Push to select Zone

Address and Protocol

Card Status

Slots A, B, D, E

Indicates communications activity (Modbus or Standard Bus)

Indicates I/O

Status

Watlow EZ-ZONE® RML Module • 15 • Chapter 1 Overview

Chapter 2: Install and Wire

Dimensions

As can be seen below the dimensions of the RML module will change slightly based on the type of connector used.

Note:

Modules should always be mounted vertically. For easy removal and placement of modules it is recommended that there be a 76.2 mm (3.00 in) clearance on the top, bottom and front of each module.

Module Removal Clearance Standard Connectors

147.07 mm ( 5.8 in )

75.08 mm ( 3.0 in )

116.08 mm ( 4.57 in )

44.45 mm ( 1.75 in )

101.60 mm ( 4.00 in )

51.56 mm

Latch in open position

( 2.03 in )

Module Removal Clearance Straight Connectors

155 mm

( 6.10 in )

44.45 mm ( 1.75 in )

116.08 mm ( 4.57 in )

101.60 mm ( 4.00 in )

51.56 mm ( 2.03 in )

75.08 mm ( 3.0 in )

15

165 mm ( 6.50 in )

Module Removal Displacement

173.90 mm ( 6.85 in )

Module Removal Displacement

Watlow EZ-ZONE® RML Module • 16 • Chapter 2 Install and Wire

Dimensions (cont.)

53.00 mm

91.00 mm

14.20 mm

9.75 mm

55.6 mm

0.559 in

Chassis Mount Front View (Module Removed) - Screw Connection Pattern

58.67 mm (2.31 in)

51.56 mm (2.03 in)

16.76 mm (.66 in)

17.53 mm (.69 in)

60.45 mm (2.38 in)

35.81 mm (1.41 in)

32.77 mm (1.29 in)

35.05 mm (1.38 in)

The view above is representative of the modular backplane without the module.

Recommended chassis mount hardware:

1. #8 screw, 3/4" long

2. Torque to 10 -15 in-lb

3. No washers of any kind

Power Supplies

DSP 30

2.189 in

32.10 mm

1.264 in

3.583 in

91.00 mm

1234

3.583 in

2.087 in

DC LO DC OK

DSP30

1.697 in

43.1 mm

49.00 mm

1.929 in

0.384 in

Watlow EZ-ZONE® RML Module • 17 • Chapter 2 Install and Wire

DSP 60

71.00 mm

91.00 mm

14.20 mm

9.75 mm

55.6 mm

0.559 in

14.20 mm

9.75 mm

56.8 mm

0.559 in

89.9 mm

91.00 mm

3.583 in

DC LO DC OK

2.795 in

vout ADJ.

DSP60

1.697 in

43.1 mm

0.384 in

49.00 mm

1.929 in

2.189 in

32.10 mm

1.264 in

3.583 in

91.00 mm

1234

3.583 in

DC LO DC OK

3.539 in

vout ADJ.

DSP100

DSP 100

1.697 in

43.1 mm

0.384 in

49.00 mm

1.929 in

2.236 in

32.10 mm

1.264 in

3.583 in

91.00 mm

Watlow EZ-ZONE® RML Module • 18 • Chapter 2 Install and Wire

Power Supply Specifications

DSP 30 DSP60 DSP100

AC Input Voltage Range VAC

Input Frequency Hz 47 - 63Hz DC Input Voltage range VDC 120 - 370VDC Inrush Current (115 / 230VAC) A 25 / 50A 30 / 60A 30 / 60A Output Voltage Accuracy % ±1% of Nominal Over voltage Protection V 120 - 145% LED Indicators - - - - Green LED = On, Red LED = DC Output Low

Operating Temperature - - - -

Storage Temperature - - - - -25 to +85°C Operating Humidity - - - - 20 - 95% RH (non condensing)

Vibration (Operating) - - - -

Safety Agency Approvals

90 - 264VAC, Class II double insulated (No ground connection required)

-25 to +71°C (Derate linearly 2.5%/°C from 55 to 71°C)

IEC 60068-2-6 (Mounting by rail: Random wave, 10-500 Hz, 2G, ea. along X, Y, Z axes 10 min/ cycle, 60 min)

UL1310 Class 2(1), UL508 Listed, UL60950-1, EN60950-1, CE

For a comprehensive listing of these specifications point your browser to : http://us.tdk-lamb-

da.com/lp/products/dsp-series.htm

Watlow EZ-ZONE® RML Module • 19 • Chapter 2 Install and Wire

DIN Rail Installation and Removal

Modular Backplane Connector

The picture on the right shows the Modular Backplane Connector, both front and rear view. The rear view is bringing in to focus a metal clip. If the DIN rail is grounded the Modular Backplane Connector and the module connected to it will be also (recommended).

Installing the Modular Backplane Connector

To install the backplane follow the steps below:

1. Hook backplane assembly to upper edge of DIN rail, (see rear view above, backplane hook detail that mates with upper rail edge is circled)

2. Next, rotate back plane assembly downward to engage the lower edge of the rail. (Note: Din Rail clipping distance ranges from 1.366 -1.389 inches. The back plane assembly will not latch onto the rail successfully if the rail is out of dimension).

3. For final positioning and locking, the red tab is to be pushed upward to further engage the bottom edge of the rail with an over center snap action latch. (The red locking tab protrudes from the bottom side of the back plane assembly).

Note:

For easy removal and placement of modules it is recommended that there be a 76.2 mm (3.00 in) clearance on the top, bottom and front of each module.

Watlow EZ-ZONE® RML Module • 20 • Chapter 2 Install and Wire

Installing Multiple Modular Backplane Connectors

Multiple modules are easily aligned and latched together. Each module includes matched mating geometry that facilitates accurate and consistent interconnections.

To install backplane connectors follow the steps below:

1. Attach individual modules to the rail separately.

2. Laterally slide the modules together until they touch.

3. When the multi-module system is attached and laterally positioned to the desired placement the locking tab should be engaged to secure the control system to the rail.

Module Installation

In the picture to the right notice that the arrow is pointing at the top lip of the module (on side).

To install modules on the backplane follow the steps below:

1. Slide the lip of the module over the top of the Modular Backplane Connector and then push down on the rear of the module. The module will then slide over the two posts just above the green connector (see pictures below).

Watlow EZ-ZONE® RML Module • 21 • Chapter 2 Install and Wire

Module Removal

To remove a module from the backplane follow the steps below:

1. Find the red tab protruding from the bottom of the module and pull back on it as shown to the right.

2. Pull back on the red tab, the two mounting posts will then release the module.

3. Lift the module up and slide it up; this will release the module lip from the backplane.

Backplane Removal from DIN Rail

To remove a modular backplane connector from the DIN rail follow the steps below:

1. Insert a screw driver into the red locking tab just behind the green connector.

2. Apply downward pressure on the tab by lifting the screwdriver upwards..

3. When released, the tab will move downward and the connector can then be lifted up off of the DIN rail.

Watlow EZ-ZONE® RML Module • 22 • Chapter 2 Install and Wire

Wiring

Limit Module (RMLx-xxxx-xxxx)

Slot A Slot B Slot D Slot E Terminal Function Configuration

Inputs Universal, RTD and Thermistor Inputs 1 -12

1 - 4 5 - 8 9 - 12 - - -

S1 R1 S2 R2 S3 R3 S4 R4

- - - - - - 1 - 6 - - -

- - -

- - - - - - - - - 9

- - -

- - - - - - - 1 - 4 7 - 10

- - -

S5 R5 S6 R6 S7 R7 S8 R8

S10

R10

S11

R11

S12

R12

- - -

S_ (RTD), thermocouple -, volts -, mA

-, potentiometer or thermistor

R_ (RTD), thermocouple +, volts +, mA +, potentiometer wiper or thermistor

Universal/Thermistor Input

Part # Digits 5, 6, 7

Input 1-4: RMLx-(5,6)xxx-xxxx Input 5-8: RMLx-x(5,6)xx-xxxx Input 9-12: RMLx-xx(5,6)x-xxxx

Digital Inputs 1 - 6

- - -

B1 D1 D2 D3 D4 D5 D6 Z1

- - -

Common DC +input DC +input DC +input DC +input DC +input DC +input Internal Supply

Digital Inputs (DI)

Part # Digit 7 Slot A: Option not valid Slot B: Option not valid Slot D: RMLx-xx(C)x-xxxx Slot E: Option not valid

Digital Input 9

- - -

- - B9D9Common

DC +input

Digital Input (DI)

Part # Digit 8 Slot A: Option not valid Slot B: Option not valid Slot D: Option not valid Slot E: RMLx-xxx(B)-xxxx

Outputs Form A - Mechanical Relay Outputs 1- 4 and 7 - 10

- - -

L7 K7 L8 K8 L9 K9

L10

K10

normally open common normally open common normally open common normally open common

Mechanical Relay 5 A, Form A

Part # Digits 7, 8

Slot D: : RMLx-xx(J)x-xxxx Slot E: : RMLx-xxx(J)-xxxx

Watlow EZ-ZONE® RML Module • 23 • Chapter 2 Install and Wire

Wiring (cont.)

Outputs

Form C - Mechanical Relay Output 7 and

Form A - Mechanical Relay Output 8

Slot A Slot B Slot D Slot E Terminal Function Configuration

- - - - - - - - - - 7 - 8

- - -

- - - - - - 1 - 6 - - -

- - -

B1 D1 D2 D3 D4 D5 D6 Z1

L7 K7 J7 L8 K8

- - -

normally open common normally closed normally open common

Digital Outputs 1 - 6

Common open collector/ switched dc open collector/ switched dc open collector/ switched dc open collector/ switched dc open collector/ switched dc open collector/ switched dc Internal Supply

Form C and Form A Relay Out-

puts Part # Digit 8 Slot A: Option not valid Slot B: Option not valid Slot D: Option not valid Slot E: RMLx-xxx(B)-xxxx

Digital Outputs (DO)

Part # Digit 7 Slot A: Option not valid Slot B: Option not valid Slot D: RMLx-xx(C)x-xxxx Slot E: Option not valid

Power and Communications

Slot C Configuration

98 99

CF CD CE

CC CA CB

CZ CX CY

Power input: ac or dc+ Power input: ac or dc-

Standard Bus EIA-485 common Standard Bus EIA-485 T-/RStandard Bus EIA-485 T+/R+

Standard Bus or Modbus RTU EIA-485 common Standard Bus or Modbus RTU EIA-485 T-/RStandard Bus or Modbus RTU EIA-485 T+/R+

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

All

Standard Bus

Part # Digit 10

RMLx-xxxx-x(A)xx

Standard Bus or Modbus

Part # Digit 10

RMLx-xxxx-x(1)xx

Inter-module Bus

Watlow EZ-ZONE® RML Module • 24 • Chapter 2 Install and Wire

RML Module - Front View -

Standard Connector

Slot D

Slot A

Slot E

Slot B

Slot C

power

Watlow EZ-ZONE® RML Module • 25 • Chapter 2 Install and Wire

RML System Isolation Blocks

Controller Power Supply

20.4 to 30.8VÎ (dc)

20.4 to 30.8VÅ (ac)

Safety Isolation

Mechanical Relay,

Outputs

Safety Isolation

Controller

Low Voltage Power Bus

Low-voltage Isolation: 42V peak

Safety Isolation: 1,528VÅ (ac)

No Isolation

Low-voltage

Isolation

Low-voltage

Isolation

Digital Inputs & Outputs

Analog Input 1 - 12

(Ungrounded sensors only)

Communications Ports

Watlow EZ-ZONE® RML Module • 26 • Chapter 2 Install and Wire

+ 147 hidden pages

Watlow EZ-ZONE RM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Chapter 1: Overview

Available EZ-ZONE RM System Literature and Resources

A Conceptual View of the RML Module

Inputs

Functions

Outputs

Input Events and Output Events

Actions

Module Limit

Module Orientation

Chapter 2: Install and Wire

Dimensions

Power Supplies

DIN Rail Installation and Removal

Wiring