Watlow EZ-ZONE RMC Operating Manual

Winona, Minnesota USA

ISO 9001

N

EZ-ZONE® RMC (Control) Module

User’s Guide

Control Module

TOTAL

CUSTOMER

SATISFACTIO

3 Year Warranty

Registered Company

1241 Bundy Boulevard., Winona, Minnesota USA 55987

Phone: [phone], Fax: [phone] http://www.watlow.com

0600-0070-0000 Rev. E Made in the U.S.A.

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 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/ISA 12.12.01-2007. File E184390
QUZW, QUZW7. See: www.ul.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 Factory Mutual as a Temperature
Limit Device per FM Class 3545 standard. See: www.fmglobal.com

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® RMC (Control) 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 [phone] between 7 a.m. and 5 p.m., Central Standard Time
(CST). Ask for for an Applications Engineer. Please have the following information available
when calling:

• Complete model number

• All configuration information

• User’s Guide

• Factory Page

Return Material Authorization (RMA)

1. Call Watlow Customer Service, [phone], 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 RMA number from the Customer Service Department is required when
returning any product for credit, repair or evaluation. Make sure the RMA 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.

This EZ-ZONE RMC User’s Guide is copyrighted by Watlow Electric, Inc., © March 2016 with all
rights reserved.

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

TC

Table of Contents

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

Chapter 1: Overview ................................5

Available EZ-ZONE RM System Literature and Resources ...........5

Introduction ..............................................6

A Conceptual View of the RMC Module .........................8

Functions .............................................10

Inputs ................................................10

Outputs ...............................................11

What is a Profile ........................................11

Input Events and Output Events ............................12

Actions ...............................................12

Chapter 2: Install and Wire ...........................17

Dimensions .............................................17

RMC Installation and Removal on a DIN Rail ...................21

Wiring .................................................24

Conventions Used in the Menu Pages .........................50

Chapter 3: Operations Pages .........................53

Analog Input Menu .......................................56

Process Value Menu ......................................57

Digital Input/Output Menu ..................................59

Action Menu .............................................60

Limit Menu ..............................................60

Monitor Menu ...........................................61

Control Loop Menu .......................................63

Alarm Menu .............................................67

Current Menu ............................................69

Linearization Menu ........................................71

Compare Menu ..........................................72

Timer Menu .............................................73

Counter Menu ...........................................74

Logic Menu .............................................75

Math Menu ..............................................77

Special Output Function Menu ...............................78

Profile Status Menu .......................................81

Chapter 4: Setup Pages .............................87

Analog Input Menu .......................................91

Process Value Menu ......................................97

Digital Input/Output Menu .................................102

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

TC

Table of Contents (cont.)

Action Menu ............................................106

Limit Menu .............................................108

Control Loop Menu ......................................110

Output Menu ...........................................121

Alarm Menu ............................................127

Current Menu ...........................................132

Linearization Menu .......................................134

Compare Menu .........................................139

Timer Menu ............................................141

Counter Menu ..........................................145

Logic Menu ............................................149

Math Menu .............................................162

Special Output Function Menu ..............................168

Variable Menu ..........................................174

Global Menu ............................................175

Profile Menu ...........................................177

Communications Menu ...................................186

Chapter 5: Profiling Page ...........................189

How to Setup and Start a Profile ............................189

Chapter 6: Factory Pages ...........................216

Custom Setup Menu .....................................217

Security Setting Menu ....................................218

Diagnostics Menu .......................................222

Calibration Menu ........................................223

Chapter 7: Features ...............................225

Saving and Restoring Settings Using an RUI ..................228

Tuning the PID Parameters ................................228

Autotune .............................................228

Manual Tuning ........................................229

Autotuning with TRU-TUNE+

Inputs .................................................231

Calibration Offset ......................................231

Calibration ............................................231

Filter Time Constant ....................................233

Sensor Selection .......................................233

Sensor Backup ........................................233

Set Point Low Limit and High Limit ........................234

Scale High and Scale Low ...............................234

® ..................................230

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

TC

Table of Contents (cont.)

Range High and Range Low ..............................234

Receiving a Remote Set Point ............................234

Ten Point Linearization ..................................235

Outputs ...............................................235

NO-ARC Relay .........................................235

Duplex ...............................................236

Retransmitting a Process Value or Set Point .................236

Cool Output Curve .....................................237

Control Methods ........................................237

Output Configuration ...................................237

Auto (closed loop) and Manual (open loop) Control. . . . . . . . . . . . 237

On-Off Control ........................................239

Proportional (P) Control .................................239

Proportional plus Integral (PI) Control ......................240

Proportional, Integral and Derivative (PID) Control ............240

Variable Time Base .....................................241

Single Set Point Ramping ................................242

Cascade Control .......................................243

Compressor Control ....................................244

Differential Control .....................................244

Ratio Control ..........................................245

Motorized Valve Control .................................245

Alarms ................................................246

Process and Deviation Alarms ............................246

Alarm Set Points .......................................246

Hysteresis ............................................246

Latching .............................................246

Silencing .............................................247

Blocking .............................................248

Resetting a Tripped Limit ..................................248

Current Sensing .........................................249

Open Heater Circuit Detection .............................249

Shorted Heater Circuit Detection ...........................249

Open Loop Detection ...................................249

Using Password Security .................................250

Modbus - Using Programmable Memory Blocks ................251

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

TC

Table of Contents (cont.)

Software Configuration ...................................252

EZ-ZONE Configurator Software ...........................252

Using EZ-ZONE Configurator Software .....................255

Function Block Descriptions ...............................257

Action Function ........................................257

Alarm Function ........................................258

Analog Input Function ...................................260

Compare Function ......................................262

Control Loop Function ..................................264

Counter Function ......................................266

Custom Function .......................................267

Diagnostic Function ....................................267

Digital Input/Output Function .............................268

Global Function ........................................269

Limit Function .........................................270

Linearization Function ...................................271

Logic Function ........................................273

Math Function .........................................277

Modbus® Function .....................................282

Output Function .......................................283

Profile Function ........................................284

Process Value Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Security Function ......................................296

Special Output Function .................................297

Timer Function ........................................300

Variable Function ......................................306

Chapter 9: Appendix ..............................307

Troubleshooting Alarms, Errors and Control Issues .............307

Modbus - Programmable Memory Blocks .....................314

Control Module Specifications ..............................317

RM Ordering Information ..................................324

How to Reach Us ........................................326

Watlow EZ-ZONE® RMC Module • 4 • Table of Contents

1

Chapter 1: Overview

Available EZ-ZONE RM System Literature and Resources

Document Title and Part Number Description

EZ-ZONE Rail Mount Access (RMA)
User's Guide, part number: 0600­0072-0000

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

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: 0600­0071-0000

EZ-ZONE Rail Mount Limit (RML) Us­er's Guide, part number: 0600-0075­0000

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

Describes how to connect the RM system into an
industrial network, how to use data logging, mod­ule backup and the real-time clock.

When additional I/O is needed the Expansion mod­ule fills the gap. This document describes common
usage and the various types of I/O available.

This module extends the density of the standard
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 common usage and
the various types of I/O available.

This module will protect against unwanted ther­mal runaway and over temperature conditions.
The User Guide describes configuration, program­ming and communications capabilities.

The RUI provides a visual LED display to the RM
configuration and setup menus. This document
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
number: 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://www.watlow.com/literature/index.cfm. Once there, simply type in the desired part
number (or name) into the search box and download free copies.

Watlow EZ-ZONE® RMC Module • 5 • 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[e-mail]

Introduction

The EZ-ZONE® Rail Mount Control module (RMC) takes the pain out of solving your thermal
loop requirements whether it be for a single loop, multi-loop, stand-alone or distributed con­trol applications.

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

Standard Features and Benefits

Integrated PID and over/under safety limit controller in one package

• Provides two mounting options (DIN rail, chassis mount)

• Reduces wiring time and termination complexity compared to connecting discrete products

• Reduces panel space and installation cost

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

Integrated power controller output

• Includes the patented NO-ARC, which drives up to 15 amp resistive loads directly

• Reduces component count and cost of ownership

• Saves panel space and simplifies wiring

Current monitoring (traditional or algorithm)

• Detects heater current flow and provides alarm indication of a failed output device or
heater load

• For use in single phase loads

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

Additional Control Integration Options

• Provides a sequencer function

• Includes programmable timer functions

• Includes programmable counter functions

• Allows for simple math and logic programming options

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

Advanced PID Control Algorithm

• Offers TRU-TUNE®+ adaptive control to provide tighter control for demanding applications

• Provides auto-tune for fast, efficient startup

Integrated Thermal Loop Diagnostics

• Users can easily tell that the entire thermal system is functioning properly

• Provides complete system diagnostics that are far superior to simple discrete level diag­nostics

• Allows for flexible synergistic use of hardware, such as using one loop's sensor as a backup
to another loop in the event of sensor failure.

• Helps prevent load loss or allow for maintenance to be scheduled when more convenient.

• Provides notification of system problems to help reduce maintenance and service costs

Off-the-Shelf Designed System Solution

• Improves system reliability with a factory integrated solution that minimizes inter-module
connections and potential problems at screw termination points.

• Reduces installation cost

• Eliminates compatibility headaches often encountered with using many different compo­nents and brands

Controller Handles High Ambient Temperatures

• Operates in an unprecedented temperature range of -18 to 65°C (0 to 149°F) for cabinets
and panel enclosures with elevated temperature levels

Memory for Saving and Restoring User-Defined Parameter Default Settings

• Allows customers to save and restore their own defined defaults for machine parameter
settings

• Reduces service calls and downtime due to inadvertent end user parameter adjustments

RMC Modules Allow for Greater Design Flexibility

• Allows PID loops to be added in increments of one.

• Saves money because you do not pay for any more than you need and don’t settle for any
less functionality than you need

Synergistic Module Control (SMC)

• Allows outputs selected for control (heat/cool), alarms or events to be located in any phys­ical module, regardless of which module is connected to the input sensor

Split-Rail Control (SRC)

• Allows modules to be mounted together or mounted remotely from one another (maximum
distance 200 feet or 61 meters)

• Shares control operation via Synergistic Module Control (SMC) capability

• Allows individual modules to be mounted closer to the physical input and output devices
to which they are wired

• Improves system reliability and lowers wiring costs

Factory Mutual (FM) Approved Safety Limit

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

• Supports SEMI S2 specification

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

Agency Approvals: UL® listed, CE, RoHS, W.E.E.E. FM, SEMI F47-0200, Class 1 Div. 2 Rating
on Selected Models

• Assures prompt product acceptance

• Reduces panel builder's documentation and agency costs

Removable Connectors

• Assures reliable wiring and reduces service calls

• Simplifies installation

Prole Capability

• Allows ramp/soak programming

• Provides 25 profiles and 400 total steps

Remote Set Point Operation

• Supports efficient set point manipulation from a remote device such as a master control or
PLC

• Allows one or more loops to be programmed to control based on another loop's set point
eliminating the cost of purchasing additional retransmit and remote set point hardware

Retransmit

• Supports industry needs for process recording

Three-Year Warranty

• Demonstrates Watlow’s reliability and product support

A Conceptual View of the RMC Module

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

The RMC can be connected at the system level to as many as 17 modules, one of which can
be an Access module and the others (16 maximum) can be any combination of available mod­ules. The user will define each address via the button on the face of each module. Each in­stalled RMC module must have a unique Standard Bus address ranging from 1-9, A-F, where the
factory defaults for each is Standard Bus address 1.

Getting Started Quickly

The RMC (Controller) can be ordered with up to four PID loops with default loop configura­tions (all loops) out of the box as follows:

• Analog Input functions set to thermocouple, type J

• Control loops 1-4 use Analog Inputs 1-4

• Heat algorithm set for PID, Cool algorithm set to off

• Outputs set to off

• Control mode set to Auto

• Set point set to 75 °F

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

To enable a loop for heat simply follow the steps below:

1. Navigate to the Setup Page

2. Once on the Setup Page navigate to the Output Menu and then the output of choice

3. Change the default setting of Off to Heat Power

4. Select the desired loop instance

EZ-ZONE RMC Default Configuration

Input

Function

Input Sensor

Analog Input 1

Thermocouple Type J

PID

Controller

Heat

Slot A

Loop 1

Output 1

Off

Output

Function

Heat

Note:

Zones can communicate with one another over the backplane (local and split rail). Once
the system is configured and running, changing zone addresses without careful delibera­tion may cause disruption in operation.

Some of the user selectable ordering options are listed below:

1. Class 2 or SELV (Safety Extra Low Voltage) equivalent Power Supplies:

• 90-264 Vac to 24Vdc @ 31 watts

• 90-264 Vac to 24Vdc @ 60 watts

• 90-264 Vac to 24Vdc @ 91 watts

2. RMC Module can provide:

• 1 to 4 control loops, limits or CT inputs

• 1 to 9 inputs (various types)

• 1 to 12 outputs (various types)

• Modbus RTU communications

As can be seen above the RMC module is fully scalable with regards to power requirements,
number of loops, inputs, and outputs.

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

Outputs

Inputs

Functions

PID

Heat

Power

Silence
Alarms

Process

Alarm

High

Sequencing

Outputs

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

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, sensor backup
could be utilized to avoid an unwanted shutdown.

To set up a function, one of the first things that must be considered is the function source
and instance. For example, if the control is equipped with Digital Inputs (source) and it was
decided to use DI 9 (instance) it can then be associated with an Action to reset an individual
alarm or all alarms.

To configure a Digital Input as described above:

1. Navigate to the Setup Page and then to the Digital I/O menu.

2. Select the desired instance and set the direction to input voltage or input dry contact.

3. Navigate to the Setup Page and then the Action menu.

4. Set the Action Function to Alarm

5. Select which alarm instance will be reset (0 equals all)

6. Select the Source Function to Digital I/O

7. Select the Source Instance (step 2 above)

8. Select the Source Zone (0 equals the module being configured).

9. Select the Transmitter Active Level to execute the desired function.

This configuration is now complete. When the selected digital input is active, the alarm or all
alarms that are latched without a currently existing alarm condition will be reset. If a specific
alarm instance (1 - 8) is selected (step 5) 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 Latching prompt is set to non-latching (Setup Page, Alarm 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.

Inputs

The inputs provide the information that any given programmed function can act upon. In a
simple form, this information may come from an operator pushing a button, or as part of a
more complex function it may represent a remote set point being received from another zone.

Each analog input can be configured for thermistors, thermocouples, or RTDs to read the pro­cess variable. It can also read mV/volts, current or resistance, enabling usage of various devic­es to read humidity, air pressure, operator inputs and other 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. A RM system can be equipped
with multiple digital I/O. Each I/O point must be configured to function as either an input or
output with the direction parameter in the digital I/O Menu (Setup Page).

Another concept that needs to be understood is the difference between an input tied to a re­al-world device such as a thermocouple and one that is tied to an internal function.

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

Analog

Input

Function

Control

Function

Output

Function

In the example above the analog input function on the left is tied directly to the control func­tion where its internal output is routed to a real-world output.

With a slight modification of the graphic above the example below now ties the real-world in­puts directly to the control and alarm functions. For the sake of this example the following is
true:

- Two unique high process alarms are congured for analog inputs 1 and 2

- The logic block is congured as an OR function

- The output function is tied to the internal output of the logical OR function

When either process alarm is true (analog input value is greater than the alarm high set point,
the real-world output will be driven on.

Analog
Input
Function

1

2

Control
Function

Alarm

Function

Alarm

Function

Logic

Function

Output
Function

Output
Function

Outputs

Outputs can perform various functions or actions in response to information provided by a
function such as: heat power from the output of the control, using a digital output to serve as
a profile event, drive a light on or off, unlocking a door or turning on a buzzer.

Assign an output to a function in the Output Menu or Digital I/O Menu. Then select which in­stance of that function will drive the selected output. For example, you might assign an out­put to respond to an internal output of a compare function or to retransmit the value of ana­log input 2 (instance 2).

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.

What is a Profile

A profile is a set of instructions consisting of a sequence of steps. When a profile runs, the
controller automatically executes its steps in sequence. The step type determines what ac­tion the controller performs. Steps can change temperatures and other process values gradu­ally over time, maintain the temperatures and process values for specific periods, or repeat a
sequence of steps numerous times. At each step the profile can activate or deactivate outputs
that control other equipment. Also a step can have the controller wait for specific conditions
before proceeding such as, waiting for a switch closure and/or a specific process value to be
detected by a sensor.

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

Input Events and Output Events

Input and output events are internal states that are used exclusively by profiles. The source of
an event input can come from a real-world digital input or an output from another function.
Likewise, event outputs may control a physical output such as an output function block or be
used as an input to another function.

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, starting and stopping a profile, silencing
alarms, turn control loops off and placing alarms in non-alarm state.

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.

RMC Module Connected to a Remote User Interface (RUI) and a PC

In this configuration the RUI and PC are connected to the RMC module via Watlow's Standard
Bus where both will be able to talk directly to the RMC module. The PC running EZ-ZONE
Configurator software and the RUI can be used to configure and then monitor the RMC mod­ule.

RM

Control

Slot C

Powe r

Supply

PC

EZ-ZONE

Configurator

485 to USB

Converter

RUI

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

In this configuration the PLC can be connected to the RMC module via the Access module us­ing one or more available protocols:

1. EtherNet/IP and or Modbus TCP

2. DeviceNet

3. Modbus RTU

RM

Control

RM

Access

Slot CSlot C

Slot E

Power

Supply

PLC

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

RMC Module Connected to an Operator Interface Terminal (OIT) through an RUI/Gateway

In this configuration the OIT can be running any of a number of protocols communicating to
the RM system through Watlow's RUI/Gateway. Available protocols for the RUI/Gateway follow:

1. EtherNet/IP and or Modbus TCP

2. DeviceNet

3. Modbus RTU

RM

Control

Slot C

RUI

Gateway

OIT

Powe r
Supply

RM System 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 200 feet. In this configuration the OIT can communicate with all
modules (maximum 16 modules any combination with one Access module).

Slot E

RM

Control

Slot C

RM

Expansion

Slot C

RM

Access

Slot C

Power

Supply

RM

Control

Slot C

RM

Expansion

Slot C

RM

Expansion

Slot C

OIT

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

RM Control Module Connected to an OIT Running Modbus RTU

In this configuration the control module connected to the OIT is equipped with the Modbus
RTU protocol (RMCxxxxxxxxx1xx). It is important to
note that Modbus communications takes place be­tween the OIT and the control it is connected to. All
modules must be set for the same protocol with the
Modbus wiring connected to one module.

RM

Control

RM

Control

Slot C

Slot C

Power

Supply

OIT

Module Orientation

The picture below represents one of six possible RM modules. All six 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 (white circle) un­der the Zone address (5) that when pushed and held has the following functions:

1. For any module, push and hold for approximately 2 seconds. The address will intensify indi-

cating that it can now be changed. Release and repeatedly press to change to the desired
unique address.

2. For the control module, if equipped with the Modbus protocol (RMCxxxxxxxxx1xx) pushing

and holding this button for approximately 6 seconds will cause the display to reflect 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 Access module is shipped at address J or 17.

Module Status

(Slot A, B, D, or E)

E

D

B

A

Protocol
Standard Bus - red
Modbus - green

Module Outputs

1 through 16, all may or

may not be used depending

on module type

Note:

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

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

Input

Some input/output combinations not possible, see ordering matrix

Zone and Status

LED

Zone Selection

Output Status

LEDs

2

3

4

5

6

1

10

11

12

13

14

9

7

81516

Button

D

E

B

A

S

M

Function

Input Sensor

EZ-ZONE RM-Control Module - System Diagram

with 6-Digital Input/Output card in slot E

Analog Input 1, 2, 3, 4

None, CT, Thermocouple, RTD (100, 1k),
Thermistor (5k, 10K, 20k, 40k), Process
(mV, V, mA) or 1k Potentionmeter

Current

Transformer

Sense (CT),

Limit or

PID Controller

(When ordered, all
loops have Ramp/
Soak, max 25 files
& 400 steps.)

Slot A, B, or D

(optional)

Output 1, 3, 5

None, Switched dc/Open Collector,
5A Mechanical Relay Form C, Process,
or 0.5A Solid-State Relay Form A

Class 1 Div II not available
with mechanical relay
outputs.

Output 2, 4, 6

None, 15A NO-ARC Form A,
Switched dc, 5A Mechanical Relay
Form A, or 0.5A Solid-State Relay
Form A

Output

Function

Options

See:

Setup Page,

Output Menu

See:

Setup Page,

Output Menu

If Limit, this output
must be Limit.

RUI,

PC, PLC or HMI

Other RM Modules

Power Supply

Digital Input (or output) 7 - 12

Switch contact or volts dc

EIA - 485 Communications

Standard Bus

(optional Modbus RTU)

Inter-module Bus

20.4 to 30.8 Vac or Vdc

6 - Digital

Inputs or Outputs

Slot E

Modbus RTU

Address 1 - 16

Standard Bus

Zone 1 - 16

Supervisory &

Power Board

Slot C

Digital Output (or input) 7 - 12

Switch contact or volts dc

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® RMC Module • 15 • Chapter 1 Overview

Some input/output combinations not possible, see ordering matrix

Zone and Status

LED

Zone Selection

Output Status

LEDs

2

3

4

5

6

1

10

11

12

13

14

9

7

81516

Button

D

E

B

A

S

M

Input

Function

Input Sensor

RUI,

PC, PLC or HMI

Other RM Modules

Power Supply

EZ-ZONE RM-Control Module - System Diagram

without 6-Digital Input/Output card in slot E

Analog Input 1, 2, 3, 4

None, CT, Thermocouple, RTD (100, 1k),
Thermistor (5k, 10K, 20k, 40k), Process
(mV, V, mA) or 1k Potentionmeter

EIA - 485 Communications

Standard Bus

(optional Modbus RTU)

Inter-module Bus

20.4 to 30.8 Vac or Vdc

Current

Transformer

Sense (CT),

Limit or

PID Controller

(When ordered, all
loops have Ramp/
Soak, max 25 files
& 400 steps.)

Slot A, B, D or E

(optional)

Modbus RTU

Address 1 - 16

Standard Bus

Zone 1 - 16

Supervisory &

Power Board

Slot C

Output 1, 3, 5, 7

None, Switched dc/Open Collector,
5A Mechanical Relay Form C, Process,
or 0.5A Solid-State Relay Form A

Class 1 Div II not available
with mechanical relay
outputs.

Output 2, 4, 6, 8

None, 15A NO-ARC Form A,
Switched dc, 5A Mechanical Relay
Form A, or 0.5A Solid-State Relay
Form A

Output

Function

Options

See:

Setup Page,

Output Menu

See:

Setup Page,

Output Menu

If Limit, this output
must be Limit.

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® RMC Module • 16 • Chapter 1 Overview

2

Chapter 2: Install and Wire

Dimensions

As can be seen below the dimensions of the RMC 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 and bottom of
each module.

Module Removal Clearance Standard Connectors

147.07 mm
( 5.8 in )

75.08 mm

116.08 mm
( 4.57 in )

44.45 mm
( 1.75 in )

101.60 mm
( 4.00 in )

( 3.0 in )

51.56 mm

Latch in open position

( 2.03 in )

Module Removal Clearance Straight Connectors

155 mm

( 6.10 )

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 )

0

15

165 mm
( 6.50 in )

Module Removal Displacement

15

°

173.90 mm
( 6.85 in )

Module Removal Displacement

Watlow EZ-ZONE® RMC Module • 17 • 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

17.53 mm
( 0.69 in )

60.45 mm
( 2.38 in )

35.81 mm
( 1.41 in )

( 2.31 in )

32.77 mm
( 1.29 in )

35.05 mm
( 1.38 in )

51.56 mm
( 2.03 in )

16.76 mm
( 0.67 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

-

DC LO
DC OK

2.087 in

-

DSP30

1.697 in

43.1 mm

49.00 mm

1.929 in

0.384 in

LN

56

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

DSP 60

56

71.00 mm

91.00 mm

14.20 mm

9.75 mm

55.6 mm

0.559 in

LN

56

89.9 mm

91.00 mm

14.20 mm

9.75 mm

56.8 mm

0.559 in

1234

++

3.583 in

-

-

DC LO
DC OK

2.795 in

vout ADJ.

DSP60

LN

DSP 100

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

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® RMC Module • 19 • 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® RMC Module • 20 • Chapter 2 Install and Wire

RMC Installation and Removal on a DIN Rail

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® RMC Module • 21 • 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® RMC Module • 22 • 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® RMC Module • 23 • Chapter 2 Install and Wire

Wiring

Controller Module (RMCxxxxxxxxxxxx)

Slot A Slot B Slot D Slot E Terminal Function Configuration

Inputs Universal, RTD, Potentiometer and Thermistor Inputs 1 - 4

1 2 3 4

T1

S1

R1

T1

S1

T2

S2

R2

T2

S2

T3

S3

R3

T3

S3

T4

S4

R4

T4

S4

B7
D7
D8

D9
D10
D11
D12

Z7

T_ (RTD) or current

+S_ (RTD), thermocouple -,
current -, potentiometer,
thermistor or volts -

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

Current Transformer Inputs 1 - 4

mA ac

mA ac

Digital Inputs 7 - 12

Common
dc +input
dc +input
dc +input
dc +input
dc +input
dc +input
Internal Supply

Universal/Thermistor Input
Part # Digits 4, 6, 8, 10
Input 1: RMC[1,2,3,4,5,6]
xxxxxxxxxxx
Input 2: RMCxx[1,2,5,6]xxxxxxxxx
Input 3: RMCxxxx[1,2,5,6]xxxxxxx
Input 4: RMCxxxxxx[1,2,5,6]xxxxx

Current Transformer

Part # Digits 4, 6, 8, 10

Input 1: RMC[7]xxxxxxxxxxx
Input 2: RMCxx[7]xxxxxxxxx
Input 3: RMCxxxx[7]xxxxxxx
Input 4: RMCxxxxxx[7]xxxxx

Digital Inputs/Outputs

Part # Digit 11
Slot A: Option not valid
Slot B: Option not valid
Slot D: Option not valid
Slot E: RMCxxxxxxx[C]xxxx

Outputs Switched dc / Open Collector Outputs 1, 3, 5 and 7

1 2 3 4 5 6 7 8

X1

W1

Y1

X3

W3

Y3

X5

W5

Y5

X7

W7

Y7

common

dc- (open collector)

dc+

Switched DC/Open Collector

Part # Digits 5, 7, 9, 11

Output 1: RMCx[U,D,E,F,G]
xxxxxxxxxx
Output 3: RMCxxx[U,D,E,F,G]
xxxxxxxx
Output 5: RMCxxxxx[U,D,E,F,G]
xxxxxx
Output 7: RMCxxxxxxx[U,D,E,F,G]
xxxx

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

Controller Module (RMCxxxxxxxxxxxx)

Slot A Slot B Slot D Slot E Terminal Function Configuration

Outputs (cont.) Switched dc Outputs 2, 4, 6 and 8

W2

Y2

F1

G1

H1

L1

K1

J1

L2

K2

L2

K2

F3

G3

H3

L3

K3

J3

W4

Y4

L4

K4

L4

K4

F5

G5

H5

L5

K5

J5

W6

Y6

L6

K6

L6

K6

W8Y8dc-

dc+

F7

G7

H7

L7

K7

J7

voltage or current -

voltage +

current +

normally open

common

normally closed

L8K8normally open

common

L8K8normally open

common

Switched DC

Part # Digits 5, 7, 9, 11

Output 2: RMCx[E,K,P]xxxxxxxxxx
Output 4: RMCxxx[E,K,P]xxxxxxxx
Output 6: RMCxxxxx[E,K,P]xxxxxx
Output 8: RMCxxxxxxx(E,K,P]xxxx

Universal Process Outputs 1, 3, 5 and 7

Universal Process

Part # Digits 5, 7, 9, 11

Output 1: RMCx[N,P,R,S]xxxxxxxxxx
Output 3: RMCxxx[N,P,R,S]xxxxxxxx
Output 5: RMCxxxxx[N,P,R,S]xxxxxx
Output 7: RMCxxxxxxx[N,P,R,S]xxxx

Form C - Mechanical Relay Outputs 1, 3, 5 and 7

Mechanical Relay 5 A, Form C
Part # Digits 5, 7, 9, 11
Output 1: RMCx[H,J,K,L,M]
xxxxxxxxxx
Output 3: RMCxxx[H,J,K,L,M]
xxxxxxxx
Output 5: RMCxxxxx[H,J,K,L,M]
xxxxxx
Output 7: RMCxxxxxxx[H,J,K,L,M]
xxxx

NO-ARC Form A - Mechanical Relay Outputs 2, 4, 6 and 8

NO-ARC 15 A, Form A
Part # Digits 5, 7, 9, 11
Output 2: RMCx[D,J,Y]xxxxxxxxxx
Output 4: RMCxxx[D,J,Y]xxxxxxxx
Output 6: RMCxxxxx[D,J,Y]xxxxxx
Output 8: RMCxxxxxxx[D,J,Y]xxxx

Form A - Mechanical Relay Outputs 2, 4, 6 and 8

Mechanical Relay 5 A, Form A
Part # Digits 5, 7, 9, 11
Output 2: RMCx[B,F,L,R]xxxxxxxxxx
Output 4: RMCxxx[B,F,L,R]xxxxxxxx
Output 6: RMCxxxxx[B,F,L,R]xxxxxx
Output 8: RMCxxxxxxx[B,F,L,R]xxxx

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

Controller Module (RMCxxxxxxxxxxxx)

Slot A Slot B Slot D Slot E Terminal Function Configuration

Outputs (cont.) Solid State Relay Outputs 1 - 8

L1K1L2K2L3K3L4K4L5K5L6K6L7K7L8K8normally open

common

B7
D7
D8
D9
D10
D11
D12
Z7

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

Digital Outputs 7 - 12

Solid-State Relay 0.5 A, Form A

Part # Digits 5, 7, 9, 11
Output 1: RMCx[G,M,S,T,Y,Z]
xxxxxxxxxx
Output 2: RMCx[G,M,S,T,Y,Z]
xxxxxxxxxx
Output 3: RMCxxx[G,M,S,T,Y,Z]
xxxxxxxx
Output 4: RMCxxx[G,M,S,T,Y,Z]
xxxxxxxx
Output 5: RMCxxxxx[G,M,S,T,Y,Z]
xxxxxx
Output 6: RMCxxxxx[G,M,S,T,Y,Z]
xxxxxx
Output 7: RMCxxxxxxx[G,M,S,T,Y,Z]
xxxx
Output 8: RMCxxxxxxx[G,M,S,T,Y,Z]
xxxx

Digital Inputs/Outputs

Part # Digit 11
Slot A: Option not valid
Slot B: Option not valid
Slot D: Option not valid
Slot E: RMCxxxxxxx[C]xxxx

Power and Communications

Slot C Terminal Function 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 13
RMCxxxxxxxxxAxx

Standard Bus or Modbus
Part # Digit 13
RMCxxxxxxxxx1xx

Inter-module Bus

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