Product basic information and positioning

1. Core positioning

As the I/O expansion core of the RM system, it does not have independent PID control function and focuses on supplementing digital/analog I/O interfaces, providing logical operations, timing and counting, special equipment control (compressor/valve/sequencer) and other functions. It can be networked with RM series modules such as RMC (controller) and RMA (communication gateway), and supports up to 17 modules (1 RMA+16 other RM modules) to work together.

2. Basic specifications

Appearance and Installation: DIN rail installation (EN50022 standard), size 155mm × 116.08mm, weight 453.59g, requires vertical installation, reserves 76.2mm maintenance space, supports rail/panel installation methods.

Power supply requirements: 20.4-30.8V AC/DC, Class 2 or SELV certified power supply, power consumption 7W/14VA, supporting Semi F47-0200 voltage drop standard.

Environmental adaptability: Operating temperature -18~65 ° C, storage temperature -40~85 ° C, 0-90% RH (non condensing), protection level IP20, required to be installed in NEMA Type 1 or above protective enclosures.

Certification standards: UL/EN 61010, Class 1 Div. 2 (optional) RoHS、WEEE、CE， Some models have passed FM Class 3545 certification.

Warranty and Support: 3-year warranty (non misuse scenario), technical support can be obtained through phone, email or local representative, and RMA number needs to be applied for in advance for returns.

Core functions and technical features

1. I/O expansion function

(1) Input type and specifications

Digital input: up to 24 channels, supporting dry contact/DC voltage input (low state<2V, high state>3V), dry contact closing resistance<50 Ω, open circuit resistance>100K Ω.

Current Transformer (CT) Input: Up to 16 channels, input range 0-50mA AC, compatible with 16-0246 CT models, accuracy ± 1mA, response time ≤ 1 second.

(2) Output type and specifications

Applicable scenarios for key parameters of output types

Digital output (open collector) maximum 32V DC, single channel 1.5A, total sink current 8A, small relay drive, sensor power supply

Mechanical relay 5A/240V AC, Form A contact, 100000 cycle life, high-power equipment switch control

Solid state relay (SSR) 2A/20-264V AC (4 channels) or 10A/240V AC (2 channels) high-frequency switch load (heater, motor)

Process/retransmission output 0-10V DC (minimum 4k Ω load) or 0-20mA DC (maximum 400 Ω load) signal retransmission, valve positioner control

2. Control and calculation functions

(1) Basic control module

Logical operation: 16 logical instances, supporting 8 logical relationships such as AND/OR/NOT/XOR, and can access up to 8 input sources.

Timing function: 8 timer instances, supporting pulse/delay/single trigger/hold timing, with a time range of 0-9999 seconds.

Counting function: 8 counter instances, supporting increasing and decreasing counting, load value setting, target value triggering output, counting range 0-9999.

Mathematical operations: 8 mathematical examples, supporting 16 operations such as addition, subtraction, multiplication, division, mean, maximum/minimum, square root, etc., and supporting multiple input source combinations.

Linearization: 8 linearization instances, 10 point linearization calibration, suitable for non-standard sensor signal correction.

(2) Special equipment control

Compressor control: Supports linkage of 1-2 control circuits, with adjustable start stop thresholds and minimum start stop times to avoid frequent start stop wear.

Electric valve control: supports valve fully open/fully closed control, configurable travel time and dead zone, suitable for two-wire valve drive.

Sequencer control: distributes a single power signal into 4 outputs, supports linear/cyclic output sequence, and balances load wear.

3. Communication and Networking

(1) Support agreement

Standard configuration: Watlow Standard Bus (EIA-485), used for inter module communication, supports 17 nodes.

Optional: Modbus RTU (EIA-485/232), requires model configuration, supports 247 nodes, baud rate 9600/19200/38400bps.

Extension Protocol: Supports industrial buses such as EtherNet/IP, DeviceNet, PROFIBUS DP, etc. through RMA module.

(2) Networking standards

Topology: EIA-485 adopts a daisy chain topology, with 120 Ω terminal resistors connected at the beginning and end.

Distance limit: EIA-485 maximum 1200 meters (shielded twisted pair), EIA-232 maximum 15 meters.

Anti interference: Communication lines and power lines should be wired separately (with a spacing of ≥ 10cm), using shielded twisted pair cables, and the shielding layer should be grounded at one end.

4. Alarm and safety functions

Alarm function: 8 alarm instances, supporting process alarm/deviation alarm, configurable high and low alarm points, hysteresis, and locking/non locking modes.

Safety features: Class 1 Div. 2 models support use in hazardous areas (temperature code T4), require the use of certified components, and prohibit live plugging and unplugging of wiring.

Permission management: Supports user/administrator two-level passwords, with optional rolling passwords (automatically changed after power failure) to prevent unauthorized operations.

Installation and Wiring Guide

1. Installation process

Rail installation: The hook is fixed to the 35mm rail and the rotating buckle is locked; When splicing multiple modules horizontally, ensure that the backplane bus is fully in contact.

Rail installation: Connect two rails through Inter module Bus, with a maximum distance of 200 feet, and require independent power supply to avoid voltage drop. The communication line uses shielded twisted pair.

2. Wiring specifications

(1) Core terminal definition

Power terminal (Slot C, 98/99): 98+, 99-, AC/DC polarity should be distinguished and reverse connection is prohibited.

Communication terminal (Slot C): CF (common terminal) CD（T-/R-）、CE（T+/R+）， Used for Standard Bus/Modbus RTU communication.

I/O terminals (Slot A/B/D/E): Configure corresponding digital I/O, relay output, and process output terminals according to the model, and refer to the terminal table corresponding to the model for detailed definition.

(2) Wiring requirements

Wire specifications: Supports 12-30 AWG single/multi strand copper wire, with a stripping length of 7.6mm and a terminal torque of 0.56 Nm (right angle terminal)/0.5 Nm (front terminal).

Electrical isolation: Digital I/O and process outputs need to be electrically isolated from power lines to prevent grounding loops (grounding resistance ≤ 4 Ω).

Inductive load: When driving inductive loads such as relay coils and solenoid valves, RC suppressors or freewheeling diodes need to be connected in series.

3. Typical networking examples

Single rail I/O expansion: 1 RMA (communication gateway)+1 RMC (controller)+2 RME (expansion), RME provides digital I/O access to sensors/actuators, and communicates with RMC through Standard Bus.

Track based distributed control: Two rails are deployed with RME modules respectively, connected through Inter module Bus, sharing control logic and reducing on-site wiring length.

Operation and Configuration Guide

1. Menu and Operation

Configure through RUI (Remote User Interface) or EZ-ZONE Configurator software, with three levels of menus:

Operations page: View I/O status, alarm status, timing/counting results, etc.

Setup page: Configure core parameters such as I/O direction, logical relationships, timing parameters, alarm thresholds, etc.

Factory page: Configure security permissions, calibration parameters, device information, etc., requiring administrator privileges.

2. Software Configuration (EZ-ZONE Configurator)

Connection method: Connect the module’s Standard Bus terminal through a USB-EIA-485 converter, and the software will automatically scan the RM module in the network.

Core configuration: It can configure I/O functions, logical operation relationships, communication parameters, alarm rules, etc., and supports configuration file backup and batch import.

Maintenance and troubleshooting

1. Daily maintenance

Regular inspection: Check the terminal fastening, wiring integrity, and module indicator light status (Power/Comm light is normally green) every month.

Cleaning and maintenance: Wipe the shell with a dry cloth to avoid corrosive cleaning agents; SD card (if available) regularly backs up data to prevent full storage.

Spare parts management: Class 1 Div. 2 models require the use of original factory certified spare parts, and it is prohibited to replace components arbitrarily.

2. Common faults and solutions

Possible causes and solutions for the fault phenomenon

Communication failure address/baud rate mismatch, wiring error, terminal resistance not connected. Check communication parameters, check EIA-485 polarity, and connect 120 Ω resistors to the front and rear modules

Output unresponsive I/O direction configuration error, load overload, relay/SSR damage, reconfigure I/O direction, check load current, replace damaged components

Alarm does not trigger alarm threshold setting error, alarm source selection error, alarm blocking enable correction alarm threshold, select correct alarm source, disable unnecessary alarm blocking

Abnormal counting/timing trigger signal not connected, incorrect trigger level setting, check trigger signal wiring, adjust trigger level (high/low state)

Typical application scenarios

Industrial equipment I/O expansion: Supplement digital I/O to RMC controllers, connect temperature sensors, limit switches, solenoid valves and other devices, and achieve multi device linkage control.

Distributed control networking: In the track configuration, RME is deployed on site, connected to nearby device I/O, and communicates with the control room controller through the bus to reduce wiring costs.

Special equipment control: achieve stable operation of the refrigeration system through compressor control function, or adjust fluid flow through electric valve control, suitable for HVAC, chemical and other scenarios.

Logic and timing control: Equipment interlocking (such as pump and valve linkage) is achieved through logical operations, and delayed start stop is achieved through timing function, which is suitable for production line process control.

Product basic information and positioning

1. Core positioning

As the core extension module of the RM system, it does not have independent PID control function and mainly provides auxiliary functions such as communication gateway, data log, configuration backup, real-time clock, etc. It can be networked with RM series modules such as RMC (controller), RME (extension), RML (limit), etc. It supports up to 17 modules (1 RMA+16 other RM modules) to work together.

2. Basic specifications

Appearance and installation: DIN rail installation (EN50022 standard), size 155mm × 116.08mm, weight 453.59g, requires vertical installation, with reserved 76.2mm maintenance space.

Power requirements: 20.4-30.8V AC/DC, Class 2 or SELV power supply, power consumption 4W/9VA, supporting Semi F47-0200 voltage drop standard.

Environmental adaptability: working temperature -18~65 ° C, storage temperature -40~85 ° C, 0-90% RH (non condensing), protection level IP20.

Certification standards: UL/EN 61010, Class 1 Div. 2 (optional), RoHS, WEEE, FM Class 3545 (limited version).

Warranty and Support: 3-year warranty (non misuse scenario), technical support can be obtained through phone, email or local representative, and RMA number needs to be applied for in advance for returns.

Core functions and technical features

1. Communication function

(1) Support agreement

Mainstream protocol: Modbus ®  RTU/TCP、EtherNet/IP ™、 DeviceNet ™、 PROFIBUS DP， Some models include USB (Mini Type B) communication.

Basic communication: EIA-485/232 interface, Standard Bus (default), supports up to 247 Modbus nodes, maximum communication distance of 1200 meters.

(2) Communication parameters

Modbus: Address 1-247, baud rate 9600/19200/38400bps, supports Non/Even/Odd parity, configurable high and low byte order.

Ethernet: Supports DHCP/fixed IP, EtherNet/IP and Modbus TCP dual protocol enabled, with a maximum of 100 implicit communication members.

DeviceNet: Node address 0-63, baud rate 125/250/500kbps, supports Quick Connect for fast communication.

PROFIBUS DP: Address 0-126, supports DP-V0 (cyclic communication)/DP-V1 (non cyclic communication), maximum distance of 1200 meters.

2. Core extension functions

(1) Data Logging

Storage medium: Micro SD card (standard 2GB, supports larger capacity), CSV file format (can be opened directly with Excel).

Recording capability: up to 200 log points, with a recording period of 1-3600 seconds, supporting two full storage strategies: “stop” or “overwrite”.

Trigger method: Recording can be started/stopped through signals such as digital input, alarm, timer, etc. The log contains a timestamp (dependent on real-time clock).

(2) Configure backup and recovery

Backup capacity: The basic version supports backup of 4 modules, while the enhanced version (SD card storage) supports full configuration backup of 16 modules.

Recovery mode: Manual recovery (Now), automatic recovery after module replacement (Change), supports cross module cloning configuration, reduces downtime.

Backup content: Module parameters (excluding User Set 1/2), excluding communication protocol assembly configuration.

(3) Real time clock (RTC)

Function: Provides date and time stamps (log/program linkage), supports program continuation after power interruption (Power Off Time parameter configuration).

Accuracy: ± 30ppm (25 ° C), battery backup (BR1225 lithium battery), typical battery life of 3 years after power failure.

(4) Security and Permissions

Password protection: Supports user/administrator two-level passwords, and can enable rolling passwords (automatically changed after power failure) to prevent unauthorized operations.

Hazardous area adaptation: Some models support Class 1 Div. 2 (Groups A-D), temperature code T4, and require the use of certified components.

Installation and Wiring Guide

1. Installation process

Rail installation: The hook is fixed to the 35mm rail and the rotating buckle is locked; Optional panel installation (customers need to provide their own fasteners).

Module networking: Multiple modules are horizontally spliced, sharing power and communication through the backplane bus, and supporting remote networking (up to 200 feet) using the “_stplit rail”.

2. Wiring specifications

Terminal specifications: Supports 12-30 AWG wires, with a torque of 0.56 Nm (right angle terminal)/0.5 Nm (front terminal), and a stripping length of 7.6mm.

Core wiring:

Power supply: Slot C terminals 98 (+), 99 (-), need to distinguish AC/DC polarity.

Communication: Slot E (protocol terminal), Slot C (standard bus terminal CF/CD/CE), EIA-485 needs to distinguish T+/R+/T -/R -.

Bus wiring: Adopting a daisy chain topology, the first and last modules need to be connected to 120 Ω terminal resistors to avoid parallel wiring with power lines.

3. Typical networking methods

Single rail networking: RMA is directly connected to other RM modules through a backplane bus, sharing power and communication.

Track based networking: Connect two rails through Inter module Bus, provide single power supply across rails, and support remote module deployment.

Operation and Configuration Guide

1. Menu and Operation

Operation level: divided into three menus: Operations, Setup, and Factory, which can be configured through RUI (Remote User Interface) or software.

Core operation:

Address setting: Long press the panel button for 2 seconds to modify the Zone address (1-17), ensuring that the module address is unique.

Configuration method: Supports RUI local operation, EZ-ZONE Configurator/Composer software configuration (free download), Bluetooth (some models) remote configuration.

2. Key configuration items

(1) Communication configuration

Modbus: Set address, baud rate, parity, TCP mode requires configuring IP address (DHCP/fixed).

EtherNet/IP: Enable implicit/explicit communication and configure the number of assembly members (0-40).

DeviceNet: Set node address, baud rate, and enable Quick Connect.

(2) Data recording configuration

Log parameters: Set the recording period, full storage strategy, select up to 200 log points, support data sources such as analog inputs, alarms, process values, etc.

Format settings: Time format (HH: MM/HH: MM: SS), date format (MM/DD/YYYY/DD/MM/YYYY), configurable log precision (integer/decimal).

(3) Backup and Recovery Configuration

Backup operation: Setup → Backup → Save, select the backup range (single/multiple modules), and store the enhanced version to the SD card.

Recovery operation: Setup → Backup → Restore, supports manual triggering or module replacement for automatic recovery.

Maintenance and troubleshooting

1. Daily maintenance

Regular inspection: fastening of wiring terminals, SD card status, power stability, annual verification of communication links and log storage.

Cleaning and maintenance: Wipe the shell with a dry cloth to avoid corrosive cleaning agents, and regularly backup data for the SD card.

Battery replacement: After the real-time clock battery is depleted, the BR1225 model needs to be replaced by disconnecting the power supply.

2. Common faults and solutions

Possible causes and solutions for the fault phenomenon

Communication failure address/baud rate mismatch, wiring error, terminal resistance not connected. Check communication parameters, check EIA-485 polarity, and connect 120 Ω resistors at the beginning and end of the bus

Data recording failure: SD card not inserted/damaged, log points not configured. Replace SD card, reconfigure log point data source and cycle

Backup failed due to insufficient memory/SD card space, incompatible module model, cleaning storage media, confirming that the module belongs to the RM series and the address is unique

Power failure: voltage exceeds the range, power ripple is too large. Replace the compliant Class 2/SELV power supply and check the power supply circuit

Typical application scenarios

Multi protocol gateway: enables cross protocol communication between PLC and RM modules (such as EtherNet/IP to Modbus RTU).

Data collection and traceability: Record process parameters such as temperature and pressure, generate CSV logs for quality traceability.

System configuration backup: Batch backup of multiple module configurations for quick replacement of faulty modules and system recovery.

Distributed control networking: Through the track based networking function, remote module deployment and centralized monitoring can be achieved.

Product core positioning and basic information

1. Core positioning

A multifunctional integrated controller that supports PID control, limit protection, ramp/soak programming, multi protocol communication, and other functions. It can adapt to various process parameter controls such as temperature, pressure, and flow, and is widely used in industrial heating, cooling, and mixed processes.

2. Basic specifications

Dimensions: 1/16 DIN standard panel installation

Power supply range: high voltage (85-264VAC), low voltage (12-40VDC/20-28VAC), some models include 2 digital I/O channels

Display and operation: LCD display screen+smooth touch keyboard, supports programmable function keys, IP67 protection level (front panel)

Certification standard: UL ®、 CSA, CE, RoHS, FM, etc., some models support use in Class 1, Div. 2 hazardous areas

3. Warranty and Support

Warranty period: 3 years (for first-time buyers, not for misuse scenarios)

Technical support: can be provided through local representatives or email（ wintechsupport@watlow.com ）Or call (+1 (507) 494-5656) for assistance

Return policy: RMA number must be applied for in advance, and repair or replacement will be processed according to the warranty terms

Core functions and technical features

1. Input/output configuration

(1) Input type

Universal inputs: thermocouple (11 types including J/K/T/E), RTD (2/3 wire system, 100 Ω/1k Ω), thermistor (5k-40k Ω)

Process input: 0-20mA, 0-10VDC, 0-50mV, 1k Ω potentiometer, supports 10 point linearization calibration

Special inputs: current transformer (0-50mA), remote set point input, sensor backup (dual input redundancy)

(2) Output type

Switch output: DC switch/open collector, 5A mechanical relay (Form A/C), 15A NO-ARC relay (extended life), 0.5A solid-state relay (SSR)

Process output: 0-10VDC/0-20mA universal process output, supporting parameter retransmission function

Output functions: heating/cooling control, alarm triggering, event output, timer linkage, etc

2. Control function

Control algorithm: Supports On Off, P, PI, PD, PID control, built-in TRU-TUNE+adaptive tuning algorithm and Auto Tune automatic calibration

Special controls: ratio control, difference control, square root conversion, wet bulb/dry bulb humidity calculation, compressor control, electric valve control

Limit protection: Integrated high and low temperature limit controller, supports manual/automatic reset, ensuring equipment and personnel safety

Slope/constant temperature programming: 4 program files, a total of 40 steps, supporting step types such as time/rate mode, waiting for events (digital input/process value), jump loop, etc

3. Communication and Data Interaction

Supporting protocol: Modbus ®  RTU/TCP、EtherNet/IP ™、 DeviceNet ™、 PROFIBUS DP, J1939 CAN bus, some models include Bluetooth (EZ-LINK) ™  Remote configuration of app

Communication features: EIA-485/232 interface, supports up to 247 Modbus nodes, maximum communication distance of 1200 meters

Data retransmission: Process values/setpoints can be retransmitted to recorders or other controllers through analog outputs

4. Safety and protective features

Electrical safety: Double insulation design, touch safe terminals, anti ESD static interference

Fault detection: sensor open/short circuit detection, heater fault (current detection), open-loop detection (no process response alarm)

Alarm function: 4-channel independent alarm (high/low/deviation alarm), supporting latch/non latch, delayed triggering, and alarm shielding

Installation and Configuration Guide

1. Installation process

Panel opening: 44.96-45.47mm (width) × 53.3mm (height), distance between adjacent devices ≥ 21.6mm

Fixing method: Fix from the back of the panel through installation rings and brackets, with a torque of 3-4 in lbs

Wiring specifications: Supports 12-30 AWG wires, terminal torque 5.0 in lb, must comply with electrical standards such as NEC, and use certified switches in hazardous areas

2. Core configuration steps

Quick Start: The default configuration is J-type thermocouple input, heated PID control, with a set point of 75 ° F, which can be directly modified through the panel

Parameter configuration: Supports local panel configuration EZ-LINK ™  App Bluetooth configuration, COMPOSER/CONFIGURATOR software configuration

Key configuration items: input sensor type, control algorithm, output function allocation, communication protocol parameters, alarm threshold, program steps, etc

3. Programming (Ramp/Soak)

Global settings: First configure the slope type (time/rate), program type (set point/process value trigger), and soaking deviation zone

Step editing: Supports step types such as time/soaking/waiting for events/jumping, and can set target values, duration, and event output status

Startup mode: manual panel start, function key trigger, digital input trigger, remote communication start

Key points for operation and use

1. Basic operations

Main screen: displays process values, set points, and area numbers, supports direct sliding to modify set points

Operating modes: automatic (closed-loop control), manual (open-loop power output), shutdown (output off)

Event response: When an alarm/limit is triggered, the screen alternately displays normal data and event information, which can be cleared or muted through the panel

2. Advanced Operations

Optimization function: Auto Tune automatically calculates PID parameters, TRU-TUNE+adaptive optimization dynamic process control

Parameter backup: can save 2 sets of user configurations, supports restoring factory settings or user-defined settings

Security lock: Supports 5 levels of read and write permission grading, and can enable password protection (user password+administrator password) to prevent accidental operations

3. Maintenance points

Regular calibration: Input offset calibration, linearization curve calibration, it is recommended to use a precision signal source for verification

Cleaning and maintenance: The touch keyboard needs to be cleaned with a dry cloth to avoid corrosive cleaning agents

Fault record: Regularly check alarm history and fault logs for easy troubleshooting of duplicate issues

Typical application scenarios

Single loop temperature control: Temperature is collected through thermocouples/RTDs to drive heaters/refrigerators to maintain the set point, suitable for industrial ovens and reaction vessels

Sensor backup control: dual input redundancy, automatically switches to backup sensor in case of main sensor failure, ensuring continuous operation

Ratio control: maintaining a fixed ratio of two process parameters (such as fuel/air mixture ratio), suitable for combustion systems

Slope/constant temperature process: multi-step temperature curve control (such as heating insulation cooling), suitable for material heat treatment and food processing

Wet bulb/dry bulb humidity control: calculates relative humidity through dual temperature sensors, drives humidification/dehumidification equipment, suitable for environmental testing chambers

Troubleshooting and Common Problems

1. Core fault handling

Alarm cannot be cleared: Check if the latch function is enabled, manually clear it after the process value returns to the safe range

No output action: Confirm the control mode, output function allocation, wiring correctness, and troubleshoot load/fuse faults

Communication failure: Verify address, baud rate, parity parameters, check wiring polarity and terminal resistance (120 Ω)

Control accuracy deviation: Re execute Auto Tune, check the sensor installation position, and adjust the filtering time constant

2. Common error codes

Input Error: Sensor open/short circuit or type configuration error

Limit High/Low: The limit value is triggered and needs to be reset or the threshold adjusted

Loop Open Error: Open loop detection triggered, process value unresponsive (such as heater failure)

Heater Error: Abnormal current of heater (too high/too low), check the load or current transformer

Core Product System and Classification

（1） Spiral plug immersion heater (WATROD) ™  and FIREBAR ®  Screw Plug）

1. Product positioning and applicable scenarios

Specially designed for direct immersion heating of liquids, it can be used for heating various oils, heat transfer solutions, and other liquids. Typical applications include industrial rinse tanks, steam degreasing equipment, hydraulic oil heating, antifreeze (ethylene glycol) solution heating, and other scenarios. For example, in clean water heating scenarios, a 1-inch NPT screw plug paired with WATROD components can meet the heating needs of different water qualities such as deionized water and drinking water.

2. Structure and Component Characteristics

Heating element: It includes WATROD circular tubular element and FIREBAR flat tubular element, both of which adopt a hairpin bending design. According to the compatibility between the element sheath and the plug material, they are fixed on the spiral plug by welding or brazing. Among them, WATROD hair clips undergo recompacted treatment to maintain magnesium oxide (MgO) density, dielectric strength, heat transfer efficiency, and service life.

Terminal box: The standard configuration is a universal terminal box, and optional types such as moisture-proof, explosion-proof, and moisture-proof explosion-proof composite are provided to adapt to different environmental requirements. For example, in humid or explosive gas environments, corresponding protective terminal boxes can be selected, and the terminal boxes can be rotated for easy connection with existing conduits.

Auxiliary components: Some models are equipped with integral thermocouple sleeves, which facilitate the insertion and replacement of temperature sensors without the need to drain the heated fluid; Optional thermostats can achieve convenient process temperature regulation, such as SPST (single pole single throw) and DPST (double pole single throw) types, with a temperature control range covering 30-550 ° F.

3. Key performance parameters

Power and Voltage: The power density can reach up to 120 W/in ² (18.6 W/cm ²), with a power range from 250 watts to 38 kilowatts, voltage adaptation to 120-480VAC, and UL certification ®  CSA component certification supports up to 480VAC and 600VAC respectively.

Sheath material and temperature: Different sheath materials correspond to different maximum operating temperatures. Alloy 800/840 sheath has a maximum temperature of 1600 ° F (870 ° C), 304/316 stainless steel sheath has a maximum temperature of 1200 ° F (650 ° C), and steel sheath has a maximum temperature of 750 ° F (400 ° C), which can be selected according to the temperature requirements of the heating medium.

Size specifications: Spiral plug sizes include NPT specifications such as 3/4 inch, 1 inch, 1.25 inch, 2 inch, 2.5 inch, and some also support European G-type (brass material) and BSP type (stainless steel material) thread standards. Taking a 1-inch NPT plug as an example, it can be paired with 0.260-inch and 0.315-inch WATROD components; The 2.5-inch NPT plug can be compatible with 0.430-inch, 0.475-inch WATROD components and 1-inch FIREBAR components.

4. Customization and accessory options

Material customization: In addition to standard sheath and plug materials, special sheath materials such as Hastelloy C276 and titanium alloy, as well as plug materials such as 304H, 316H, and 321 stainless steel, can also be provided to meet the needs of highly corrosive or special working conditions.

Functional accessories: optional indicator lights (PL10 and PL11 models), PL10 is compatible with up to 250VAC and equipped with 6-inch (152mm) leads; PL11 is compatible with 480VAC and equipped with 4-inch (102mm) leads, which can visually display the power on/off status of the heater. In addition, an adapter for spiral plugs to flanges is also provided, which facilitates the replacement of spiral plug heaters with flange heaters. The adapter material is mostly steel, and different specifications correspond to different shipping weights. For example, the shipping weight of the 1.25 inch to 3-inch to 150 # adapter is 13 pounds (5.9kg).

（2） ANSI Flange Immersion Heater (WATROD and FIREBAR ANSI Flange)

1. Product features and applicable scenarios

Suitable for scenarios that require high-power heating and high installation stability, such as liquid heating in large storage tanks and industrial reactors. It can handle various media such as clean water, process water, heavy oil, asphalt, etc. Its flange structure ensures sealing performance under high pressure conditions, with pressure ratings ranging from 150 pounds, 300 pounds, 600 pounds, etc.

2. Core parameters and structure

Power and density: The power density can reach up to 100 W/in ² (15.5 W/cm ²), providing higher heating power to meet the rapid heating needs of large capacity media.

Flanges and components: Flange sizes range from 2 inches to 48 inches, suitable for different equipment interfaces; The heating element also includes WATROD and FIREBAR types, and the connection method between the element and the flange is determined based on material compatibility to ensure pressure sealing effect.

Protection and Control: The terminal box type is similar to the screw plug type, supporting universal, moisture-proof, explosion-proof, etc. It can also be matched with thermocouples and thermostats to achieve precise temperature control and monitoring.

3. Customization and adaptation

Support customization of flange size, pressure rating, and component arrangement according to customer needs. We can also provide flanges and components made of special materials to cope with harsh working conditions such as corrosion or high temperatures. For example, when dealing with highly corrosive solutions, flanges and components made of Hastelloy material can be used.

Typical application scenarios and adaptation solutions

（1） Water heating

1. Heating of clean water

Product selection: Common 1-inch, 1.25-inch, 2-inch, 2.5-inch NPT spiral plug heaters, paired with WATROD or FIREBAR components. Taking a 1-inch NPT screw plug as an example, if Alloy 800 sheath components are used, the power density can reach 60 W/in ² (9.3 W/cm ²), and the power can range from 0.5kW to 4kW at 240VAC. It is suitable for small water tanks, laboratory water heating and other scenarios.

Configuration options: Universal terminal box or moisture-proof terminal box can be selected, paired with SPST thermostat (temperature range 30-250 ° F or 175-550 ° F), such as models BCN4J1S2 (Type 2 temperature range) and BCN4J1S3 (Type 3 temperature range), both of which support next day shipping (RS identification).

2. Heating of deionized water/desalinated water

Material adaptation: Due to the possible corrosiveness of deionized water, components with 316 stainless steel plugs and 316 stainless steel sheaths are usually selected, such as 2.5-inch NPT spiral plug heater, model BLR77L3S4, sheath material of 316 stainless steel, power 3kW, voltage 240VAC, power density 9.3 W/cm ², which can effectively resist the corrosion of deionized water and ensure long-term stable operation.

Control and Protection: K-type thermocouples can be equipped for precise monitoring of process temperature. The terminal box is selected as moisture-proof and explosion-proof, suitable for environments that may be humid or have slightly corrosive gases.

3. Heating of process water

Product type: Depending on the flow rate and heating requirements of the process water, a 1.25-inch NPT FIREBAR element heater or a 2-inch NPT WATROD element heater can be selected. For example, a 1.25-inch NPT FIREBAR heater, model BDNF13A27S5A, with a power of 2.0kW, a voltage of 240VAC, and a power density of 7 W/cm ², is suitable for heating medium flow process water; 2-inch NPT WATROD heater, model BGS79J6S4, power 1.0kW, voltage 120/240VAC, compatible with different process equipment interfaces.

Installation requirements: It is necessary to ensure that the heater is installed on the path of the process water flow, and that the components are completely immersed in the water to avoid dry burning. At the same time, the installation angle of the components should be adjusted according to the direction of the water flow to improve heat transfer efficiency.

（2） Heating of oils and viscous media

1. Heating of light oil and heat transfer oil

Power density control: Due to the relatively low heat transfer efficiency of oils, heaters with medium power density, such as 23 W/in ² (3.6 W/cm ²), are usually selected. Taking the 1-inch NPT WATROD heater as an example, model BCS6J1S, with steel sheath material, power of 0.25kW, voltage of 120VAC, suitable for heating lightweight lubricating oil; 1.25-inch NPT WATROD heater, model BES6G6S, power 0.5kW, voltage 120/240VAC, can be used for heating heat transfer oil.

Structural design: Some models use flat FIREBAR components, which can increase the contact area with oil and improve heating uniformity, such as the 1.25-inch NPT FIREBAR heater, model BDNF 16G12S5A, power 1.7kW, voltage 240VAC, suitable for small oil tank heating.

2. Intermediate oil heating

Low power density adaptation: Medium quality oil has poor fluidity and requires the use of a lower power density heater, such as 15 W/in ² (2.3 W/cm ²), to avoid local overheating and carbonization of the oil. For example, a 1.25-inch NPT FIREBAR heater, model BDNF 13A29S5A, with a power of 0.67kW and a voltage of 240VAC, is suitable for heating medium lubricating oil; 2-inch NPT WATROD heater, model BHN79N12S4, power 1.0kW, voltage 240VAC, suitable for heating medium quality oil storage tanks.

Temperature control: Equipped with DPST thermostat with a temperature control range of 60-250 ° F to prevent excessive oil temperature. At the same time, a low level sensor can be selected to avoid dry burning and damage to the heater due to low oil level.

3. Heating of heavy oil, asphalt, and # 6 fuel oil

Extremely low power density: This type of medium has extremely high viscosity and poor heat transfer efficiency, requiring the use of heaters with extremely low power density, such as 8 W/in ² (1.3 W/cm ²). For example, a 1.25-inch NPT FIREBAR heater, model BDNF 16G22S5A, with a power of 0.43kW and a voltage of 240VAC, is suitable for the initial stage of asphalt heating; 2.5-inch NPT WATROD heater, model BLS717E12S4, with a power of 1.0kW and a voltage of 240VAC, can be used for heating and insulation of # 6 fuel.

Structure and Installation: Heaters are usually designed with long components to increase the contact length with the medium and improve heating efficiency. At the same time, the flowability of the medium should be considered during installation to avoid the heater being covered by sediment and affecting heat transfer. In addition, explosion-proof terminal boxes can be selected to adapt to the combustible gas environment that may be generated during the heating process of heavy oil.

（3） Heating in other special scenarios

1. Forced air heating

Product type: Multiple choice 1.25-inch NPT WATROD element heater, sheath material is 304 stainless steel, power 1.0-2.0kW, voltage 120/240VAC, such as model BEN13G6S, power 1.0kW, voltage 120/240VAC, can be used with a fan to achieve forced air circulation heating, suitable for winter insulation in small workshops and equipment rooms.

Protection requirements: The terminal box should be dust-proof to prevent dust from entering and affecting electrical performance. At the same time, the installation position of the heater should be away from flammable materials to prevent fire risks.

2. Heating of corrosive solutions

Special material selection: The sheath material is made of Hastelloy C276 or titanium alloy, and the plug material is 316 stainless steel to resist corrosion from solutions. For example, a 2.5-inch NPT WATROD heater with a sheath material of Hastelloy C276, a power of 3.0kW, a voltage of 240VAC, suitable for heating acidic solutions; 1.25-inch NPT WATROD heater with titanium alloy sheath material, power of 0.7kW, voltage of 120VAC, suitable for heating alkaline solutions.

Sealing and Protection: The connection between components and plugs adopts a special welding process to ensure sealing performance and prevent solution from infiltrating and corroding electrical components. The terminal box adopts a fully sealed moisture-proof and explosion-proof type to further improve the protection level.

Ordering Information and Delivery

（1） Model coding rules

The model code contains multiple parameter information. Taking the screw plug heater as an example, such as “BCN4J1S2”:

BC “: represents the basic series (screw plug type, WATROD component);

N “: indicates the material of the plug (brass);

4 “: corresponds to size” B “(4.5 inches, 114mm);

J “: Component diameter (0.315 inches, 8mm);

1: Voltage (120VAC);

S “: Terminal box type (universal type);

2 “: Thermostat type (Type 2, temperature range 30-250 ° F).

The core configuration of the heater can be quickly identified through model coding, facilitating accurate ordering.

（2） Delivery cycle

Standard products: Products with the “RS” logo support next day shipping, such as most 1-inch and 1.25-inch NPT spiral plug heaters, meeting emergency needs. For example, models BCN4J1S2, BDNF 13A27S5A, etc. have sufficient inventory and can be arranged for shipment the next day after placing an order.

Customized products: Customized products that require special materials, sizes, or functions, with a delivery cycle determined by specific needs, usually 2-4 weeks. For example, the selection of Hastelloy C276 sheathed heaters, customized size flange heaters, etc. require material procurement, processing and manufacturing, testing and other processes, with a relatively long delivery cycle.

（3） Accessories ordering

Sealing accessories: Multiple materials of gaskets are available, such as rubber gaskets (suitable for water-based media), asbestos free gaskets (suitable for general industrial scenarios), and wound gaskets (suitable for high-pressure conditions), which can be selected according to the usage scenario and pressure level of the heater.

Installation accessories: including lifting lugs (for easy installation and disassembly of large heaters), baffles (to prevent direct impact of media on components, protect components), extended lead thermocouples (for remote temperature monitoring), etc., can be ordered separately according to actual installation needs.

Key points for installation and maintenance

（1） Installation requirements

Immersion depth: The unheated section of the heater needs to be completely immersed in the heated medium, ensuring at least 1 inch (25mm) of unheated section is inside the medium to prevent overheating and damage to the unheated section. For example, in clean water heating, the unheated section of a 1-inch NPT heater needs to be completely submerged below the water surface to avoid exposure to air.

Installation position: The heater should be installed in the lower area of the container, but higher than the sediment layer at the bottom of the container, to prevent sediment from covering the components and affecting heat transfer. At the same time, it facilitates natural convection of the medium and improves heating uniformity. For containers with stirring devices, the heater should be installed within the range of the stirring blades to further enhance heat transfer.

Flow direction and angle: When installing the FIREBAR element heater, the installation angle of the element needs to be determined based on the flow direction of the medium, usually at a certain angle (such as 45 °) to reduce pressure loss and improve heat transfer efficiency. For example, in process water heating, FIREBAR components should be installed in the direction of water flow to avoid direct impact of water flow on the components causing wear.

Electrical connection: The electrical connection must comply with the national electrical specifications, and the specifications of the power cord should be selected according to the power and voltage of the heater to ensure sufficient current carrying capacity, while also taking waterproof and dustproof measures. The installation of terminal boxes should avoid direct exposure to rainwater or corrosive liquids. If installed outdoors or in humid environments, additional protective measures should be taken.

（2） Maintenance points

Regular cleaning: Disassemble the heater regularly (e.g. every 3 months), clean the surface of the components of dirt, sediment, and other impurities to prevent affecting heat transfer efficiency. When cleaning, a soft bristled brush or specialized cleaning agent can be used to avoid scratching the protective cover of the component with sharp tools, which can lead to increased corrosion.

Status check: Check whether the protective sheath of the component is corroded, deformed, leaking, etc. If the sheath is found to be damaged, the component should be replaced in a timely manner to prevent the medium from infiltrating the interior and damaging the electrical components. At the same time, check the sealing performance of the terminal box to ensure that no moisture or dust enters, whether the electrical connections are tight, and whether there are any looseness or oxidation phenomena.

Calibration of temperature monitoring equipment: Regularly (e.g. every 6 months) calibrate temperature monitoring and control equipment such as thermostats and thermocouples to ensure the accuracy of temperature measurement and control. If the accuracy deviation of the equipment exceeds the allowable range, it should be adjusted or replaced in a timely manner.

Maintenance records: Establish a maintenance record file to record the maintenance time, content, problems discovered, and solutions taken for each maintenance, in order to track the usage status of the heater, predict possible failures in advance, and develop a reasonable maintenance plan.

Safety precautions

Prevent dry burning: Before running the heater, it is necessary to ensure that the medium has reached the specified liquid level and that the components are completely immersed in the medium. It is strictly prohibited to start the heater without medium or with insufficient medium liquid level to avoid dry burning causing component damage or even fire. Low level sensor can be installed to achieve low level protection. When the liquid level is lower than the set value, the heater power supply will be automatically cut off.

Explosion proof safety: In environments with explosive gases or dust, explosion-proof terminal boxes must be selected, and the installation of heaters must comply with explosion-proof regulations to avoid electrical sparks causing explosions. Regularly inspect the explosion-proof sealing surface. If damage or aging is found on the sealing surface, the sealing components should be replaced in a timely manner to maintain the explosion-proof performance.

Temperature control: It is strictly prohibited to operate beyond the maximum working temperature of the heater. Based on the characteristics and process requirements of the heated medium, the temperature control of the thermostat should be set reasonably to avoid overheating, decomposition or deterioration of the medium. For heat sensitive media, an over temperature protection device should be equipped to further improve safety.

Electrical safety: The grounding of the heater must be reliable to prevent leakage accidents. When conducting maintenance or overhaul, it is necessary to first cut off the power supply and hang a “Do Not Close” sign to avoid accidental power on and personal injury.

Product Overview and Basic Information

1. Core parameters and authentication

Protection level: IP65 for front panel, IP10 for empty slot cover

Environmental requirements for working temperature: -18~50 ℃ (-0~122 ° F); Storage temperature: -40~85 ℃; Humidity 0~90% RH without condensation

High voltage power supply specifications (F4TXX [1-4]): 85~264Vac 50/60Hz; Low voltage type (F4TXX [5-8]): 20.4~30.8Vac/dc

Power consumption 23W (maximum), 54VA

certification standard  UL 61010（File E185611）、CSA 22.2#14（File 158031）、FM Class 3545、CE（EN 61326）、RoHS 2

2. User interface and operation

Display screen: 4.3-inch TFT PCAP color touch screen, supporting 4 physical buttons (home, menu, return, help)

Core Display: Loop Name, Control Mode (Auto/Manual), Process Value (PV), Set Point (SP), Output Power (PWR)

Menu functions: configuration files (40, 50 steps per file), data logs, system settings (network/security)

Installation and wiring specifications

1. Installation method and size

Key requirements for installation type

Panel installation hole size: 117.40mm (width) × 120.14mm (height); The fixing ring should be tightly attached to the panel to ensure an IP65 seal

Embedded installation requires PEM nut posts (such as S0-632-6 Z1 galvanized steel); The bracket is fixed with 6 # 6-32 screws, and the front panel needs to be covered

Install through the wall with a hole of 178 × 122mm; install the heat sink vertically, leaving a ventilation space of ≥ 102mm above and below

2. Terminal wiring requirements

Input terminal:

Wire diameter: 0.0507~3.30mm ² (30~12 AWG), double wire termination ≤ 1.31mm ² (16 AWG)

Torque: 0.57Nm (5.0 lb in), wire stripping length 5.5mm

Wire/load/ground terminal:

Wire diameter: 2.5~25mm ² (14~3 AWG)

Torque: 2.7Nm (24 lb in), wire stripping length 11mm; re tighten after 48 hours, every 3-6 months

Power wiring: Terminals 98 (+) and 99 (-) should follow NEC or local electrical regulations to avoid parallel wiring with power lines

3. Installation of Elastic Module (FM)

Slot dependency rules:

The communication module (FMCA series) can only be installed in slot 6;

The high-density dual SSR module (FMHA-KAAA) requires 2 adjacent slots and cannot be placed in slots 3/6;

The module needs to be inserted with the component side facing right, and the key design prevents reverse installation.

Module identification: Confirm the part number through the black label in the lower right corner of the connector (e.g. FMMA-UKAA-AAA is 1 universal input+1 SSR output).

Input/output wiring and module specifications

1. Input wiring (some key types)

Input type wiring requires accuracy and range

Connect the negative electrode (red wire) of the thermocouple to the S terminal; The compensating wire should be made of the same alloy as the thermocouple; Input impedance>20M Ω J-type: ± 1.75 ℃ (0~750 ℃); K-type: ± 2.45 ℃ (-200~1250 ℃)

RTD (Platinum) 2-wire/3-wire, 3-wire self compensating ≤ 10 Ω lead resistance; S1 (white line) connected to R1 100 Ω (0 ℃): ± 2.00 ℃ (-200~800 ℃); 1000Ω（0℃）：±2.00℃（-200~800℃）

Digital input voltage input: ≤ 36V (3mA), ≥ 3V (0.25mA) activated; Dry contact: ≤ 100 Ω activated, ≥ 500 Ω inactive update rate 10Hz; maximum short-circuit current 13mA

Current transformer input 0~50mAac; Requires Watlow 16-0246 module; The load line needs to pass through the CT in the same direction with a response time of ≤ 1 second; Accuracy ± 1mA

2. Output wiring (some key types)

Output type wiring requirements specification parameters

Mechanical relay 240Vac/30VDC, 5A resistance load; Minimum 20mA load at 24V; When connecting Quencac (0804-0147-0000) 120/240Vac across coils, a guiding power of 125VA is required; Rated load 100000 cycles

Solid state relay (SSR) 24~264Vac, 0.5A at 149 ° F (65 ℃), 1A at 50 ° F (10 ℃); only AC load optically isolated; The maximum off state leakage current is 105 μ A; 20VA guidance power at 120/240Vac

Switching DC 22~32VDC open circuit voltage; 2 output combination current ≤ 40mA; when driving external SSR, connect to DC+/DC – short circuit limit<50mA; DIN-A-MITE compatible

Universal process output 0~10Vdc (minimum load of 1k Ω) or 0~20mA (maximum load of 800 Ω); Voltage/current output accuracy of ± 15mV (voltage)/± 30 μ A (current) cannot be used simultaneously; Temperature stability 100ppm/℃

Calibration and PC connection

1. Calibration operation

Calibration prerequisite: Accurate signal source is required (such as thermocouple 0.000~50.00mV, RTD 50.0~350.0 Ω). It is recommended to first verify whether the error exceeds the specifications (such as thermocouple ± 1.75 ℃).

Operation method:

Composer software: Connect device → Device menu → Calibration → Select module/input → Enter 2 limit values as prompted;

Front panel: Menu → Service → Calibration → Select module/input → Perform on-site calibration.

Notes:

The calibration values will be reset to factory settings and cleared;

3-wire RTD calibration requires cross connection of R, T, and S inputs;

The security settings are divided into “full access/read only/no access”, and without access permission, the calibration screen cannot be accessed.

2. PC connection and Composer software

Ethernet settings:

Default parameters: IP 192.168.0.222, subnet 255.255.255.0, gateway 0.0.0.0;

DHCP connection: F4T is connected to the switch, and the DHCP server automatically assigns an IP address;

Fixed IP connection: PC is directly connected to F4T, and the first three segments of PC IP are consistent with F4T (such as 192.168.0. XXX).

Composer software:

Function: Configure elastic module (check if slot module matches), customize function block (alarm/timer/mathematical operation);

Troubleshooting and Maintenance

1. Common faults and solutions (partial)

Possible causes and solutions for the fault phenomenon

Alarm cannot be cleared/reset. 1. Alarm latch activation; 2. Alarm source setting error 1. Reset when the process is within range; 2. Select the correct input instance

No serial communication 1. Address/baud rate mismatch; 2. EIA-485 wiring error 1. Unified device protocol parameters; 2. T+/R+connected to B, T -/R – connected to A

Temperature runaway (overshoot/undershoot): 1. Thermoelectric dipole polarity reversal; 2. Heater short circuit: 1. Connect the red wire to the S terminal; 2. Replace the heater/repair the wiring

No display 1. Power off; 2. The fuse is open circuit; 3. Voltage error: 1. Check the circuit breaker/interlock; 2. Replace the fuse; 3. Confirm 24/240Vac

The process cannot reach the set point 1. The controller is not tuned; 2. Set the control mode to “off”. 1. Perform automatic tuning; 2. Set as “PID” or “on-off”

2. Battery replacement

Battery specifications: Model BR2032 (Watlow part number 0830-0858-0000), nominal voltage 3V, lifespan of 10 years at 77 ° F (25 ℃), and replacement time of 7.5 years in harsh environments.

Replacement steps:

Turn off all power sources of F4T;

Use a small screwdriver to push out the battery holder from the side hole and remove the old battery (note the polarity clearly);

Insert the positive pole of the new battery to the left and reset the battery holder;

It is recommended to recycle used batteries and not dispose of them casually.

Model ordering rules (example: F4T11A1A1AA)

Example of optional values for field meanings

The first and second product series F4=T series controller

3rd basic type T=touch screen

4th application type 1=Standard, X=Custom

The 5th future option A=none, J=data record

6th power supply and connector 1=100~240Vac right angle connector (with identification)

The 7th and 8th bits of the configuration file and function block AA=no configuration file+basic function block

Customization options for positions 9-15 (connector/firmware/document) 1A=including DVD document+gray personalized border

Key issues

Question 1: What are the types of elastic modules (FM) for F4T controllers? What are the different types of core functions and slot installation rules?

Answer:

Types and core functions of elastic modules:

Hybrid I/O module (FMMA series): includes 1 universal input (supporting thermocouple/RTD/0~10V/0~20mA)+1 output (such as SSR, mechanical relay, switched DC), used for conventional temperature acquisition and load control, such as FMMA-UKAA-AAA (1 universal input+1 SSR output);

Restriction module (FMLA series): used for safety interlock control, including 1 input (universal/thermistor)+1-2 outputs (such as C-shaped relay, supporting normally closed interlock), such as FMLA-LCJ-AAA (restriction control with universal input+switched DC output);

High density I/O module (FMHA series): integrates multiple inputs/outputs, such as FMHA-RAAA-AAA (4 universal inputs), FMHA-JAAA-AAA (4 mechanical relay outputs), suitable for multi-channel acquisition and control scenarios;

Communication module (FMCA series): Only supports Modbus RTU protocol (EIA-232/485), used for serial communication between the controller and PLC/PC, such as FMCA-2AA-AAA.

Slot installation rules:

Exclusive slot: The communication module (FMCA series) can only be installed in slot 6 and cannot be recognized in other slots;

Multi slot requirement: Some high-density modules (such as dual SSR output FMHA-KAAA) require 2 adjacent slots and cannot be placed in slot 3 (single slot design);

Keying error prevention: The module has a keying structure and cannot be inserted upside down. The component side should face right (when viewed from the back of the controller);

Label requirement: After installation, slot number labels should be affixed to the module and junction box to avoid controller failure caused by inserting the wrong slot during replacement.

Question 2: How to correctly wire the thermocouple input of F4T controller? What steps should be followed when calibrating thermocouple inputs?

Answer:

Requirements for correct wiring of thermocouples:

Polarity differentiation: The negative lead of a thermocouple is usually red and must be connected to the S terminal (signal negative) of the module, while the positive lead is connected to the R terminal (signal positive). Reversing the connections can result in incorrect temperature readings;

Compensation wire: It is necessary to use a compensation wire made of the same alloy as the thermocouple (such as K-type compensation wire for K-type) to reduce the influence of ambient temperature on readings;

Insulation requirements: The input impedance of the thermocouple should be greater than 20M Ω, and the maximum source resistance should be 2k Ω. When wiring, it is necessary to avoid parallel wiring with the power line to prevent electromagnetic interference;

Open circuit detection: The module has a built-in 3 μ A open circuit sensor for detection. If the wiring is open, it will trigger an “incorrect input” alarm.

Thermocouple input calibration steps (using Composer software as an example):

Preparation equipment: high-precision millivolt signal source (if able to output 0.000~50.000mV), copper wire (to minimize wiring error), voltage/ohmmeter (to verify the accuracy of the signal source);

Software connection: Start Composer → Connect F4T (enter IP 192.168.0.222) → Enter “Device menu → Calibration”;

Select channel: Select the module where the thermocouple is located and the input channel (such as input 1 of slot 1) in the “pluggable module”;

Enter calibration value:

Input the lower limit signal (such as 0.000mV, corresponding to 0 ℃) to the module, enter the actual signal value in the software, and click “Calibrate Lower Limit”;

Input the upper limit signal (such as 50.000mV, corresponding to approximately 1200 ℃, depending on the thermocouple type), input the actual value, and click “Calibrate Upper Limit”;

Verification and saving: After calibration, input the intermediate value (such as 25.000mV) to the module, confirm that the displayed value and actual value error are ≤ specifications (such as J-type ± 1.75 ℃), and save the calibration data;

Attention: If the factory settings are restored after calibration, the calibration values will be cleared; The calibration of a 3-wire RTD requires crossing the R, T, and S terminals, and the lead resistance should be ≤ 10 Ω.

Question 3: What are the possible reasons for the F4T controller experiencing a “temperature runaway (continuous increase after process value overshoot)” fault? What are the corresponding troubleshooting and resolution steps?

Answer:

Possible reasons:

Output function setting error (such as heating output set to cooling);

Reverse wiring of thermocouple/RTD (e.g. thermocouple red wire connected to positive electrode, RTD S1 not connected to R1);

Controller output wiring error (such as SSR output L1/L2 reversed);

Heater or wiring short circuit (causing continuous power supply to the load);

Power controller connection defects (such as DIN-A-MITE and F4T signal interruption, unable to turn off the load);

The control algorithm is set to “on-off” and the hysteresis is too large (causing the heating to not stop in time).

Troubleshooting and resolution steps:

Check the output function settings:

Front panel: Menu → Settings → Output → Select the corresponding output channel, confirm that the “Function Type” is “Heating” (not “Cooling”);

If there is an error, modify it to the correct type and restart the controller to take effect;

Verify sensor wiring:

Thermocouple: Disconnect the wiring, confirm that the red wire (negative electrode) is connected to the S terminal, the positive electrode is connected to the R terminal, and if the wiring is reversed, reconnect it;

RTD: 3 wire type needs to confirm S1 (white wire) connected to R1, T1 connected to S2, lead resistance ≤ 10 Ω (measured with an ohmmeter);

Check the output wiring and load:

After the power is cut off, use a multimeter to check the on/off switch of the heater wiring. If there is a short circuit, replace the heater;

Check SSR/relay output: output 100% power to the controller, measure the output terminal voltage (such as 240Vac), and the voltage should disappear after power failure. If there is continuous voltage, replace the SSR/relay;

Verify power controller connection:

If using a DIN-A-MITE power controller, check the signal lines between F4T and DIN-A-MITE (such as switched DC output) to ensure that there is no looseness/disconnection and that the signal can trigger DIN-A-MITE shutdown normally;

Adjust control algorithm:

If it is “on-off” control: menu → control → algorithm → change to “PID”, execute automatic tuning (TRU-TUNE) ®+）， Reduce overshoot;

If PID overshoot occurs: adjust the proportional band (increase) or integral time (extend) to reduce response speed;

Test validation:

Power on again, set the target temperature (such as 100 ℃), observe whether the process value stabilizes within the set point ± accuracy range (such as ± 1 ℃), and if it still loses control, troubleshoot the controller output hardware (such as replacing the output module).

Product basic information and manufacturer background

1. Product positioning and manual usage

This product is an industrial grade solid-state power controller, with the model identification as “DIN-A-MITE ®  Style C”， The manual clearly states that its core function is to guide users in completing product installation, wiring, parameter configuration, and safe operation and maintenance. It also includes specifications and recommended solutions for semiconductor fuses that users are concerned about, and emphasizes the need to follow national and local electrical safety regulations during installation.

2. Core configuration range of the product

Electrical basic parameters: Supports single-phase, three-phase 2-leg, and three-phase 3-leg (suitable for four wire star loads) configurations, with AC voltage coverage of 120-600V (ac) and current switching capability ranging from 30-80A depending on the model. Please refer to the output rated curve for specific specifications 🔶 1-9.

Control and protection options: Provide zero crossing variable time base or AC/DC input contactor versions, some zero crossing models have thyristor (SCR) short circuit protection and heater open circuit protection; Single phase models additionally support phase angle control and phase angle control with current limitation, and product configuration information can be directly identified through model coding.

Detailed technical specifications

1. General electrical parameters

(1) Current is related to power

Rated current: Please refer to the output rated curve on page 5. Different cooling methods (natural convection, fan cooling, through wall installation) and load types (resistive heater load) correspond to different rated values, and it is clear that the rated value is based on the resistive heater load 🔶 1-22.

Transient and limit current: The maximum peak surge current within 16.6 milliseconds is 1350A; the selection of fuses must meet the maximum value of 9100 A ² s for I ² t; The minimum latch current of SCR is 500mA, and the minimum holding current is 200mA to ensure stable triggering and operation of the device 🔶 1-24 🔶 1-25 🔶 1-26.

Auxiliary current and power consumption: The fan current varies depending on the power supply -0.14A at 24V (dc), 0.12A at 120V (ac), 0.06A at 240V (ac); the maximum off state leakage current is 1mA at 25 ° C (77 ° F); the power loss of each controlled branch is 1.2 watts/ampere (calculated based on switching ammeter) 🔶 1-28 🔶 1-29.

(2) Voltage range

Segmented by voltage level input range: 24-48V (ac) models with minimum 20V and maximum 53V; 120-240V (ac) models with minimum 48V and maximum 265V; 277-600V (ac) models with minimum 85V and maximum 660V, covering commonly used industrial voltage scenarios and adapting to different regional power grids 🔶 1-33 🔶 1-34.

(3) Environmental adaptability

The working humidity is 0-90% relative humidity (without condensation), and the storage temperature range is -40 to+85 ° C (-40 to 185 ° F); The insulation performance has only been tested below an altitude of 3000 meters, and additional evaluation is required for high-altitude scenarios 🔶 1-74 🔶 1-75； Simultaneously passing IEC 60068-2-32 (impact) and IEC 60068-2-6 (vibration) tests to ensure the anti-interference ability of industrial environments 🔶 1-59.

2. Operator interface and alarm function

(1) Interface configuration

Standard configuration includes command signal input and indicator lights, alarm output and indicator lights, and current limit indicator LEDs. Users can intuitively monitor the operating status of the equipment and quickly identify key working conditions such as signal input, alarm triggering, and current limit 🔶 1-18 🔶 1-19.

(2) Alarm function (limited to zero crossing models only)

SCR short circuit alarm: When the input command signal is turned off, but the current transformer detects a load current of 10A or above, an alarm is triggered (2 turns of winding are required for 5A current, 3 turns of winding are required for 2.5A current), and the alarm state is an abnormal combination of “signal off+load current present”.

Heater open circuit alarm: Only applicable to models with input control signal option “S”. It is triggered when the input command signal is turned on, but the load current detected by the current transformer is lower than the alarm set value, covering the fault scenario of “signal on+insufficient current”.

Alarm output characteristics: The alarm output is non latch type and is powered on when triggered; Adopting bidirectional thyristor (Triac) output, compatible with external power supply of 24-240V (ac), rated current varies at different temperatures -300mA at 25 ° C (77 ° F), 200mA at 50 ° C (122 ° F), 100mA at 80 ° C (176 ° F), typical holding current of 200 μ A, latch current of 5mA 🔶 1-42.

3. Certification and Security Compliance

International certification: meets ROHS environmental requirements; CE certification requires the use of appropriate filters to cover the 2004/108/EC Electromagnetic Compatibility Directive (EN 61326 Industrial Immunity Class A emission, not applicable to Class B environment) and the 2006/95/EC Low Voltage Directive (EN 50178 safety requirements), but phase angle and phase angle input control signal types with current limitation (P and L) do not have CE certification 🔶 1-45 🔶 1-46 🔶 1-47 🔶 1-48 🔶 1-49 🔶 1-50 🔶 1-51.

North American certification: UL ®  50 Type 4X shell certification, UL ANSI/ISA 12.12.01 temperature code T4A; The through wall heat sink component is suitable for Class I, Zone 2, Groups A, B, C, and D hazardous and non hazardous areas, but safety warnings such as “replacing any component may affect the applicability of hazardous areas” and “cannot be disconnected when the circuit is live unless the area confirms that there is no flammable concentration” are clearly stated 🔶 1-54 🔶 1-55 🔶 1-56； Simultaneously for UL ®  508 listed products, C-UL ®  Document number E73741.

Installation specifications and size requirements

1. Installation method and steps

(1) DIN rail installation (DIN EN 50022, 35 × 7.5mm rail)

Installation steps: ① Push the device in and press down to clamp the top rail hook into the rail; ② Rotate the bottom of the device towards the guide rail; ③ The guide rail buckle will “click” to fasten. If it is not fastened, check whether the guide rail is bent; ④ The heat sink must be installed vertically (core requirement to ensure heat dissipation efficiency) 🔶 1-223 🔶 1-224 🔶 1-225.

Disassembly steps: Press and release the buckle, while rotating the device upwards and away from the guide rail to remove it.

Spacing requirement: A 102mm (4.0 inches) gap should be reserved on the side for airflow and wire bending radius; The front is designed with anti touch features, requiring no additional clearance; Minimum snap distance 34.8mm (1.37 inches), maximum 35.3mm (1.39 inches) 🔶 1-236 🔶 1-245.

(2) Panel installation

Four M4 (# 8) fasteners are required for fixation. Please refer to the panel installation dimension diagram on page 7 of the manual for specific dimensions, with a focus on the grounding wire entry position (13mm/0.50 inches) and the parallel arrangement wire gap (83mm/3.25 inches).

(3) Wall through installation (UL) ®  50 Type 4X Shell Model

Additional materials: 1 silicone gasket, 8 M5 screws and locking washers, 1 DIN-A-MITE C wall penetrating device 🔶 1-253 🔶 1-254 🔶 1-255.

Installation steps: ① Drill holes and cut the panel according to the size diagram on the right; ② Remove the mounting screws from the heat sink; ③ Tear off the protective film of the silicone gasket, attach the gasket to the heat sink, and ensure that the gasket hole is aligned with the heat sink screw hole; ④ Vertically install heat sink, torque controlled at 2.26-2.82 Nm (20-25 inch pounds) 🔶 1-257 🔶 1-258 🔶 1-259.

Size and Gap: The panel opening should meet the contour requirements of 178mm (7.00 inches) × 122mm (4.81 inches), and a minimum gap of 102mm (4.0 inches) should be reserved above and below the heat sink for airflow. A minimum gap of 10mm (0.4 inches) should be reserved on both sides.

2. Requirements for wiring terminals

(1) Input terminal (control signal type)

Adopting a crimping design, compatible with 0.2-1.5mm ² (24-16 AWG) wires; Use a 3.5mm (1/8 inch) flathead screwdriver and tighten to a torque of 0.5 Nm (4.4 inch pounds); The stripping length of the wire is 5.5mm (0.22 inches); The insulation level of the wire must be ≥ 75 ° C and is only applicable to copper conductors 🔶 1-61 🔶 1-62 🔶 1-63 🔶 1-64.

(2) Main circuit terminals (phase line, load, grounding)

Also of crimping type, compatible with 2.5-25mm ² (14-3 AWG) wires; Can be tightened with a 6.4mm (1/4 inch) flathead screwdriver or a 1A type # 2 Pozidriv screwdriver to a torque of 2.7 Nm (24 inch pounds); Wire stripping length 11mm (7/16 inches); Core maintenance requirement: Re tighten after 48 hours (to reduce wire cold flow), and then re tighten every 3-6 months thereafter 🔶 1-66 🔶 1-67 🔶 1-68 🔶 1-69 🔶 1-70.

(3) Cooling fan terminal

Adopting a quick connect design (1/8 inch push in), compatible with 16-14 AWG wires; Recommend using Amp part number 640929-1 or equivalent product 🔶 1-85.

Control mode and signal configuration

1. Zero crossing control mode (including contactor and proportional control)

(1) Type of contactor (input control signal)

DC input (Type C): 4.5-32V (DC) input, with a maximum current of 6mA per channel at 4.5V. An additional 2mA total current is required for each additional LED; To extend the service life, the cycle time should be less than 3 seconds 🔶 1-94.

AC input (Type K): Suitable for 24V (ac) ± 10%, 120V (ac)+10%/-25%, 240V (ac)+10%/-25%, with a maximum current of 25mA per circuit; it is strictly prohibited to share with temperature controllers with RC buffer circuits. If used, the RC buffer circuit must be removed first; Cycle time should be less than 3 seconds to extend lifespan 🔶 1-95 🔶 1-98.

(2) Proportional control (Type F, 4-20mA DC)

Variable time base control for loop power supply, only applicable to F0 input option; A current source of 8.0V (dc) or higher is required, with no more than 2 series inputs; Linearity requirements: Full open point 19.5-19.9mA (dc), maximum peak voltage 6.2V; Input output power accuracy ± 5% (0% -100% range, 4.3-19.7mA or 12.3-19.7mA); Temperature stability<0.15%/° C 🔶 1-96 🔶 1-102 🔶 1-105 🔶 1-106.

2. Phase angle and single cycle variable time base control

(1) Phase angle control (single-phase specific)

Applicable models: Type P (pure phase angle), Type L (phase angle with current limitation), only supports single-phase configuration, and has no alarm option 🔶 1-111.

Input signal: Supports 0-20mA, 4-20mA, 12-20mA (DC) and 0-5V, 1-5V, 0-10V (DC); Input impedance: 4-20mA signal is 250 Ω, linear voltage signal is 5k Ω 🔶 1-112.

Output and accuracy: Output voltage covers 100-120V, 200-208V, 230-240V, 277V, 400V, 480V, 600V (ac), deviation -15%/+10%, frequency 50/60Hz (deviation ± 5%); At 25 ° C, the output conduction time is directly proportional to the command signal, with an accuracy of ± 5%; Temperature stability<0.25%/° C 🔶 1-115 🔶 1-117.

Soft start function: 5-second soft start when powered on, soft start when thermostat overtemperature occurs, soft start when half cycle dropout detection occurs, 1-second soft switching when set value changes, protecting load and devices 🔶 1-124 🔶 1-125 🔶 1-126.

(2) Single cycle variable time base (Type S)

Working logic: At 50% power, “1 cycle on, 1 cycle off”; At 25% power, “conduct for 1 cycle and close for 3 cycles”; Continuous conduction for no more than 1 cycle when power is less than 50%, and continuous shutdown for no more than 1 cycle when power is greater than 50% 🔶 1-110.

Accuracy and adaptability: The output power is proportional to the command signal at 25 ° C, with an accuracy of ± 5%; Temperature stability<0.25%/° C; supports linear voltage, 4-20mA or potentiometer input 🔶 1-120.

3. Resolution and Additional Options

Resolution: The accuracy of the output variation relative to the input range is greater than 0.1%.

Manual control kit: Optional 1k Ω single turn potentiometer (with 0-100% dial), part number 08-5362.

Ordering coding rules and current levels

1. Model code disassembly (complete code: DC+phase+cooling/current+voltage+control signal+alarm+language+customization)

Meaning and Options of Encoding Segments

DC prefix: Fixed identifier (DIN-A-MITE Style C)

Phase configuration 1=single-phase 1 controlled leg; 2=Three phase 2 controlled legs; 3=Three phase, three controlled legs (four wire star); 8=2 independent area; 9=3 independent areas

Cooling/current 0=natural convection (standard DIN rail/panel heat sink); 1=120V AC fan cooling; 2=240V AC fan cooling; 3=24V DC fan cooling; T=Natural convection (wall/cabinet type heat sink, UL 50)

Voltage level 02=24-48V AC (C/F/K control); 12=100-120V AC (L/P/S control); 20=200-208V AC (L/P/S control); 24=120-240V AC（C/F/K）/230-240V AC（L/P/S）； 27=277V AC（L/P/S）； 40=400V AC（L/P/S）； 48=480V AC（L/P/S）； 60=277-600V AC（C/F/K）/600V AC（L/P/S）

Control signal C0=4.5-32V DC contactor; K1=22-26V AC contactor; K2=100-120V AC contactor; K3=200-240V AC contactor; F0=4-20mA ratio (loop power supply); L (0-5)=phase angle with current limitation (single-phase); P (0-5)=phase angle (single-phase); S (0-5)=single cycle variable time base; Input types corresponding to 0-5 in parentheses: 0=4-20mA, 1=12-20mA (S only), 2=0-20mA, 3=0-5V DC, 4=1-5V DC, 5=0-10V DC

Alarm option 0=No alarm; S=SCR short circuit alarm (not applicable to 8/9 area or L/P control); H=heater open circuit+SCR short circuit alarm (only S control)

Manual language 0=English; 1=German; 2=Spanish; 3=French

Customized option 00=standard parts; 1X=1-second soft start (P/L control); XX=Custom Options/Identification

2. Current level table (by model prefix)

Model prefix Current level Remarks

DC10 55A natural convection (standard heat sink)

DC1T 62A natural convection (through wall/cabinet type heat sink)

DC11/DC12/DC13 75A fan cooling (120V AC/240V AC/24V DC)

DC20/DC80 40A three-phase 2-leg/2-zone, natural convection

DC2T/DC8T 46A three-phase 2-leg/2-zone, through wall heat sink

DC81/DC82/DC83/DC30/DC90 30A 2-zone fan cooling/three-phase 3-leg/3-zone natural convection

DC3T/DC9T 35A three-phase 3 leg/3 area, wall penetrating heat sink

DC31/DC32/DC33/DC91/DC92/DC93 55A three-phase 3 leg/3 zone, fan cooling

Selection of fuses and EMI filtering

1. Semiconductor fuse (suitable for applications with 600V AC and below)

Rated current of fuse Watlow fuse model Bussman fuse model Watlow bracket model Ferraz bracket model

30A 17-8030 FWP30A14F 17-5114 USM141i

40A 17-8040 FWP40A14F 17-5114 USM141i

50A 17-8050 FWP50A14F 17-5114 USM141i

63A 17-8063 FWP63A22F 17-5122 US221i

80A 17-8080 FWP80A22F 17-5122 US221i

100A 17-8100 FWP100A22F 17-5122 US221i

2. Combination fuse (suitable for applications with 600V AC and below)

Rated current of fuse Watlow, fuse model Bussman, Watlow bracket model Bussman, bracket model

30A 0808-0325-0030 DFJ30 0808-0326-1530 CH30J1i

40A 0808-0325-0040 DFJ40 0808-0325-3560 CH60J1i

50A 0808-0325-0050 DFJ50 0808-0325-3560 CH60J1i

63A 0808-0325-0060 DFJ60 0808-0325-3560 CH60J1i

80A 0808-0325-0080 DFJ80 0808-0325-7010 J60100-1CR

100A 0808-0325-0100 DFJ100 0808-0325-7010 J60100-1CR

3. EMI filtering requirements (electromagnetic interference suppression)

Mandatory scenario: When the load current is greater than 6A and the frequency is 150-250kHz, an external EMI filter must be used. Watlow verified that the “Tank Filter” can effectively suppress the EMI generated by the SCR power controller and meet the conducted emission limit.

Filter selection: For single-phase 230V (ac), choose Crydom 1F25 or Watlow 14-0019; Choose Crydom 3F20 or Watlow 14-0020 for three-phase 440V (ac); At the same time, a warning is issued that “slot filters may suppress useful communication in the 150-250kHz frequency band (such as baby monitors, medical alarm systems), and there is no safety risk that needs to be verified in advance” 🔶 1-437.

Product Family and Core Features

1. Product Line Overview

Core positioning of product series: Maximum operating temperature, maximum power density, key advantages

FIREROD ® Universal plug-in heater 1400 ° F (760 ° C) (Alloy 800 sheath) 400 W/in ² (62 W/cm ²) 60 years of industry validation, high thermal conductivity efficiency, supports multi scenario customization

High temperature FIREROD high-temperature working condition specific 1800 ° F (982 ° C) 100 W/in ² (15.5 W/cm ²) sealing design reduces oxidation, high emissivity sheath enhances heat transfer

Metric FIREROD global adaptation 1400 ° F (760 ° C) 330 W/in ² (50 W/cm ²) meets metric standards, has high dimensional accuracy, and is compatible with international equipment

MULTICELL ™ Multi zone precise temperature control 2050 ° F (1120 ° C) 30 W/in ² (4.6 W/cm ²) up to 6 independent temperature control zones, loose assembly design for easy disassembly and assembly

2. Core common advantages

Material and Structure: Made of nickel chromium resistance wire (uniform heating), magnesium oxide (MgO) insulation layer with specific grain purity (high dielectric strength, rapid heating), Alloy 800 or stainless steel sheath (anti-oxidation, corrosion-resistant).

Process design: Minimize the distance between the resistance wire and the sheath, reduce internal temperature, and support high power density operation; UL ®/ CSA certified leads, with insulation levels ranging from 250 ° C to 842 ° C.

Safety and reliability: non-volatile design, strong high-temperature stability; Some models support low leakage construction and are suitable for sensitive scenarios such as healthcare.

Detailed explanation of key technical specifications

1. Dimensions and tolerances

（1）FIREROD ®  standard size

Nominal diameter (in) Actual diameter (in/mm) Minimum sheath length (in/mm) Maximum sheath length (in/mm) Diameter tolerance

1/8 0.122（3.1） 7/8（22.2） 12（305） ±0.002 in（±0.05 mm）

1/4 0.246（6.3） 7/8（22.2） 36（915） ±0.002 in（±0.05 mm）

1/2 0.496（12.6） 7/8（22.2） 60（1520） ±0.002 in（±0.05 mm）

1 0.996（25.3） 1 1/4（32.0） 72（1830） ±0.003 in（±0.08 mm）

(2) Tolerance requirements

Length tolerance: The sheath with a length tolerance of ≤ 4.5 in (114 mm) is ± 3/32 in (± 2.4 mm); The sheath with a diameter greater than 4.5 inches is ± 2% (1/8 inch diameter is ± 3%).

Power tolerance: 1/8 inch diameter is+10%/-15%, other diameters are+5%/-10%.

Resistance tolerance: 1/8 inch diameter is+15%/-10%, other diameters are+10%/-5%; Resistance varies with temperature, with room temperature (before use) being 90% of the value calculated by Ohm’s Law, and after use being 95%.

2. Electrical performance

（1）FIREROD ®  Voltage and power range

Diameter (in) Maximum voltage (V) Maximum current (A) 120V Minimum power (W) 240V Maximum power (W)

1/8 240 3.1 – 720

1/4 240 4.4 100 1050

3/4 480 23.0 30 5520

1 480 23.0 – 5520

(2) Metric FIREROD Electrical Parameters (Example)

Diameter (mm) Maximum voltage (V) 230V Maximum power (W) 400V Maximum power (W) Maximum current (A)

6.5 250 1650 – 7.2

16 480 4830 8400 21

20 480 4830 8400 21

3. Power density and application adaptation

Power density directly affects heating efficiency and heater lifespan, and should be selected based on the heating medium and operating conditions

Metal heating: The maximum allowable power density varies with the aperture fit gap and temperature (for example, at 1400 ° F, a fit gap of 0.005 in corresponds to a power density of approximately 80 W/in ²).

Air/gas heating: At an ambient temperature of 70 ° F, the maximum allowable power density for a single heater is approximately 60 W/in ²; When multiple devices are parallel, they need to be multiplied by a correction factor of 0.95, and when equipped with a reflector, they need to be multiplied by 0.85.

Mobile air heating: The higher the wind speed, the greater the allowed power density (for example, at a wind speed of 100 FPM, the power density can reach 1000 W/in ²).

Installation and Wiring Guide

1. Installation preparation

Aperture matching: It is recommended that the aperture be 0.001-0.006 inches larger than the actual diameter of the heater (for metal heating). A gap that is too large can reduce thermal efficiency, while a gap that is too small may make disassembly difficult.

Installation location: The sensor should be installed in a temperature uniform area, away from the edge of the heat source; The sheath should be in full contact with the heating medium to avoid local overheating.

Environmental requirements: Avoid installing in close proximity to noise sources such as motors and relays; In humid environments, models with sealing (PTFE/silicone) should be selected.

2. Wiring specifications

(1) Lead type and specifications

Lead type, maximum temperature, applicable scenarios, wire diameter specifications (example)

GGS fiberglass 482 ° F (250 ° C) universal scenario 18 AWG (1/2 inch diameter heater)

MGT 842 ° F (450 ° C) high temperature scenario 18 AWG (3/4 inch diameter heater)

PTFE 392 ° F (200 ° C) corrosion-resistant scenario 20 AWG (3/8 in diameter heater)

Mineral Insulation (MI) 1500 ° F (815 ° C) Extreme High Temperature/Vibration Scenarios Conductor Diameter 0.044 in (3/8 in diameter heater)

(2) Wiring precautions

Lead length: Standard length of 12 inches (305 mm), customizable extension, extra long leads need to consider voltage drop (recommended wire diameter not less than 22 AWG).

Grounding requirements: Models with grounding leads must be reliably grounded to avoid the risk of electrical leakage; In high temperature scenarios, the lead wire should be kept away from the sheath (with a minimum length of 1 inch without thermal zone).

Multi zone control: MULTICELL ™  The heater needs to be wired separately for each temperature control zone to ensure independent adjustment.

3. Fixed method

Flange fixing: Stainless steel flange (FS/FM/FL type), suitable for panel installation, flange position can be customized (standard distance from lead end 1/4 in).

Threaded fixation: 304 stainless steel or brass threaded joints (NPT/DIN specifications), waterproof installation, suitable for pipeline or threaded hole scenarios.

Positioning ring: Stainless steel positioning ring, used for non precision fixed scenarios, installed at the end of the no heat zone.

Customized Options and Selection Guide

1. Core customization options

(1) End and sealing options

Option Type Function Applicable Temperature Minimum No Hot Zone Length

PTFE seal and lead anti moisture, oil, solvent 392 ° F (200 ° C) 1 in (25 mm)

Silicone sealing and lead anti moisture, mild corrosion 302 ° F (150 ° C) 1 in (25 mm)

Epoxy resin sealing high temperature sealing (up to 260 ° C) 260 ° F (500 ° C) 1 in (25 mm)

Mineral Insulated (MI) Seal for Extreme High Temperature, Vibration, Corrosion 1500 ° F (815 ° C) 6 in (152 mm)

(2) Lead protection options

Stainless steel hose: wear-resistant, suitable for harsh environments, standard length of 12 inches, lead wire 2 inches longer than hose.

Stainless steel woven mesh: high flexibility, wear-resistant, standard length of 12 inches, supports right angle wire output.

Galvanized conduit: Abrasion protection, with 90 ° bend, standard length 8 inches.

(3) Function extension options

Built in thermocouples: Style A (monitoring the internal temperature of the heater), Style B (approximate workpiece temperature), Style C (end temperature, suitable for plastic molding), supporting J/K type.

Distributed power: Set different power densities in segments along the length of the heater to compensate for edge heat loss (suitable for scenarios such as sealing strips).

Dual voltage design: supports switching between two voltages and is suitable for multi scenario power supply (only available for metric models with diameters of 12.5 mm and above).

Extension without hot zone: The lead end or terminal without hot zone can be extended (up to 2.5 inches) to avoid the influence of high temperature on the lead.

2. Selection steps

Determine operating parameters: maximum working temperature, heating medium (metal/air/liquid), aperture and installation method.

Calculate power demand: Determine the required power based on the heating area, heating rate, and heat loss (recommended power density not exceeding the maximum allowable value of the corresponding medium).

Select product series: FIREROD for general scenarios ®， Choose high-temperature FIREROD for high temperature scenarios, metric models for international equipment, and MULTICELL for multi zone temperature control ™。

Customized function options: Select the sealing type according to the environment, choose the lead protection and fixing method according to the installation space, and select the built-in thermocouple according to the temperature control accuracy.

Maintenance and troubleshooting

1. Daily maintenance

Regular inspection: Check the insulation layer of the lead wires and the sheath for oxidation and discoloration every month, and replace them promptly if any problems are found.

Cleaning and maintenance: Remove dust and oil stains from the surface of the sheath to avoid affecting heat transfer; WATLUBE can be used for disassembly ™  Lubricant, easy to disassemble and does not affect thermal conductivity.

Life management: Under high temperature conditions (such as above 1400 ° F), it is recommended to regularly check the resistance value and replace the heater when the resistance changes by more than 10%.

2. Common faults and solutions

Possible causes and solutions for the fault phenomenon

Slow heating, insufficient power density, loose aperture fit, excessive lead voltage drop, replacement with higher power model, adjustment of aperture gap, and thickening of lead wire diameter

Improper installation position due to local overheating, poor medium contact, adjust installation position, and ensure that the protective cover is fully attached to the heating surface

Damaged leads, high temperature baking, wear, corrosion, extended no heat zone, replacement of protected lead options (hose/braided mesh), selection of corrosion-resistant seals

Excessive leakage, insulation layer affected by moisture or damage, replacement of sealing model, drying environment, and inspection of reliable grounding

High power density due to heater burnout, reduced power density due to dry burning of medium, ensuring sufficient heating medium, and installing temperature protection devices

Typical application scenarios

Semiconductor manufacturing: wafer bonding, chamber heating (using high cleanliness, low leakage FIREROD) ®， With PTFE seal).

Plastic molding: mold heating, sealing strip heating (using models with distributed power and built-in thermocouples).

Medical equipment: patient insulation, instrument heating (using low leakage, small-sized FIREROD) ®）。

Freezing protection: Anti icing of equipment in low-temperature environments (using high-power density, waterproof sealing models).

High temperature process: Superplastic forming of titanium alloy, diffusion welding (using high-temperature FIREROD or MULTICELL) ™）。

Core features and specifications of the product

core functionality

Control mode: Supports PID or ON/OFF control, can be manually selected; Dual output design, output 1 can be set as heating or cooling, and output 2 can be set as heating, cooling, or off.

Input type: compatible with J, K, T, N, R, S, B, C, Pt2 thermocouples, RTD (2-wire or 3-wire) and 0-5VDC, 4-20mA process inputs.

Programming ability: Supports 24 step program curves, including four step types: set point (StPt), constant temperature (SoAh), jump cycle (JL), and end, and can achieve multi-stage temperature control.

Auxiliary functions: optional dual auxiliary output (alarm or time triggered event), set point/process value retransmission output, supports RS-422A/RS-423A/EIA-485 communication interface.

Data storage: Non volatile memory automatically saves all parameters, and data is not lost after power failure; Lithium battery backup operation parameters, with a service life of about 10 years.

Key specifications

Temperature range: thermocouple (-328 ° F~4200 ° F/-200 ° C~2315 ° C), RTD (-328 ° F~1112 ° F/-200 ° C~600 ° C), process input (-500~3500 units).

Accuracy: ± 0.1% ± 1 LSD of full scale (ambient temperature 77 ° F ± 5 ° F, rated voltage ± 10%).

Output specifications:

Solid state relay output: 0.5A@24-264VAC Optical isolation and zero crossing switching.

Mechanical relay output: 6A@120 /240VAC or 28VDC.

Process output: 0-5VDC/0-10VDC (minimum load 10K Ω), 4-20mA/0-20mA (maximum load 600 Ω).

Working environment: Temperature range of 32 ° F~149 ° F (0 ° C~65 ° C), humidity range of 0~90% (no condensation).

Installation and wiring process

Installation preparation

Panel Hole: Process panel holes according to size requirements (nominal 3.625 × 3.625 inches/92.08 × 92.08mm, thickness 0.06~0.25 inches/1.5~6.35mm).

Equipment fixation: Insert the controller housing into the opening, fix it from the back of the panel with the matching bracket, then insert the control chassis into the housing and lock it by rotating the front plate screw 90 ° clockwise (note that the screw should only be rotated 90 ° to avoid excessive force damage).

Wiring operation

Power wiring

Supports 120VAC or 240VAC power supply (50/60Hz universal, no adjustment required), requires connection to L1 and L2 power terminals and grounding terminals, and wiring must comply with the National Electrical Code (NEC) to avoid the risk of electric shock.

The power supply end needs to be connected in series with a fuse. When powered by 120VAC, the L1 end needs to be connected in series with a fuse. When powered by 240VAC, both the L1 and L2 ends need to be connected in series with a fuse.

Sensor wiring

Thermocouple: Use extension cords made of the same material as the thermocouple to avoid errors; If connecting non isolated external devices, an isolated thermocouple should be selected, with positive and negative terminals corresponding to terminals 7 (+) and 9 (-).

RTD: 2-wire RTD needs to short-circuit terminals 5 and 6, and 3-wire RTD needs to ensure that the resistance of the three extension wires is consistent (with the same wire diameter and material) to compensate for lead resistance errors (every 1 Ω lead resistance of 2-wire RTD will cause an error of about+2 ° C).

Process input: 0-5VDC input is connected to terminals 1 (+) and 3 (-), with an input impedance of 100K Ω; 4-20mA input requires short circuiting terminals 2 and 3, followed by connecting the positive and negative poles of the signal, with an input impedance of 249 Ω.

Output wiring

Output 1/2: Select the wiring method according to the model (solid-state relay, mechanical relay, DC switch, process output, etc.), refer to the wiring diagram of the corresponding model in the manual for details, and ensure that the load impedance matches (such as process output 4-20mA maximum load 600 Ω).

Auxiliary output: 6 auxiliary options are available (single relay, dual relay, relay+retransmission, etc.), wired according to the corresponding terminals (24-27) of the model, and the alarm/event output is a mechanical relay（ 6A@28VDC /120VAC）。

Wiring precautions

Separation of strong and weak electricity: The sensor signal line (low power) is wired separately from the power line and output line (high power), with a minimum spacing of 12 inches (305mm) to avoid cross interference; When crossing, use a 90 ° crossing.

Shielding and grounding: Shielded cables are used for low-level signal lines, and the shielding layer is only grounded at the controller end; The system is grounded at a single point to avoid grounding loops, and all grounding terminals are connected to a unified grounding body.

Parameter Configuration Guide

Enter the configuration menu

Press the UP and DOWN keys simultaneously for 3 seconds to enter the Setup menu (displaying LOC parameters); Continue holding down the UP and DOWN keys under the LOC parameter to enter the calibration menu.

During the configuration process, press the MODE key to switch parameters, use the UP/DOWN key to adjust values, and if there is no operation for 5 seconds, it will automatically save and return to the previous level, or press the MODE key to manually save and switch.

Key configuration parameters (Setup menu)

Parameter Category Core Parameter Function Description Default Values

Security and Permission LOC Operation Permission Lock (Level 0-3): Level 0 Full Permission, Level 3 Only View Setpoint/Process Values 0

Input configuration In Select input type (such as J, K, RTD, 4-20, etc.) J or r

Temperature unit (° F/° C), only displays F when input as thermocouple/RTD

The upper and lower limits of the range for the rL/rH set point/process input, as well as the default range for scaling and retransmitting the output range of the sensor

Output configuration Ot1/Ot2 output 1/2 action type (ht heating/CL cooling/no off) ht/CL

HYS1/HYS2 output 1/2 ON/OFF switching hysteresis (effective when Pb=0) 3 ° F

Alarm and event Ot3/Ot4 auxiliary output 3/4 function (AL alarm/Ent event/PrOC retransmission) AL/PrOC

AL1/AL2 alarm type (Pr process alarm/DE deviation alarm) Pr

Programming configuration PtYP program type (ti time basis/ratE ramp rate basis) ti

GSD constant temperature deviation window (program pauses when out of range) 0 (disabled)

Power outage recovery Pout program recovery method after power outage (Cont continue/HOLD hold/Abrt abort) Cont

Communication configuration: bAUD baud rate (300-9600), only models with communication function display 1200

Addr device address (0-31), only displaying 0 under FULL protocol

Operation menu parameters (Operation menu)

Setpoint (SP): Adjust the control target value within the range of rL~rH, and display OFF (disable all outputs) when it is lower than rL.

PID parameters (Pb1/Pr2, rE1/rE2, rA1/rA2): proportional band, reset/integral, rate/derivative, automatically generated after automatic tuning, or manually adjustable.

Automatic tuning (Aut): Only output 1 for heating display, select tuning rate (1 slow/2/3 fast), and the controller automatically optimizes PID parameters after startup.

Alarm setting (A1LO/A1HI, A2LO/A2HI): Process alarm setting upper and lower limits (Pr type) or deviation alarm offset (dE type).

Program Programming and Running

Fundamentals of Programming

Program structure: Up to 24 steps, each step can be selected from four types: StPt (Setpoint Slope), SoAh (Constant Temperature Holding), JL (Jump Loop), and End (Program End), supporting multiple program concatenation (a new program can start after one End step).

Programming entrance: Select Prog=YES from the Operation menu to enter the Program menu. Press the StEP parameter to select steps (1-24), and press StYP to select the step type.

Detailed explanation of four step programming methods

1. Set point step (StPt)

Core parameters:

SP: Target Set Point (rL~rH).

Time basis (PtYP=ti): HOUr/Min/SEC, total time is the sum of the three (0-23h59m59s).

Rate basis (PtYP=rAtE): rAtE, temperature change rate (0-360 ° F/min or 0-200 ° C/min).

Ent1/Ent2: On/Off status of event 1/2, displayed only when Ot3/Ot4 is set to Ent.

Example: Step 1 is set to StPt, SP=75 ° F, Min=0, SEC=1, Ent1=OFF, achieving the initial setting of reaching 75 ° F within 1 second.

2. Constant temperature step (SoAh)

Core parameters: HOUr/Min/SEC (constant temperature duration), Ent1/Ent2 (event switch), no SP parameter (inherited from the previous set point).

Example: Set Step 3 to SoAh, Min=0, SEC=25, Ent1=On, achieve 25 seconds of constant temperature and trigger Event 1.

3. Jump loop step (JL)

Core parameters:

JS: Jump to the target step (must be smaller than the current step, cannot jump to itself).

JC: Jump count (0=infinite loop, 1-100=finite loop).

Example: Set Step 6 to JL, JS=2, JC=1, implement a jump to Step 2 and repeat once (execute Steps 2-5 twice in total).

4. End step

Core parameters: End (HOLD remains in the last state/OFF closes all outputs/OFFA closes control outputs, retains alarms).

Example: Step 4 is set to End, End=OFF. After the program ends, all outputs are turned off, and ‘lower’ displays’ OFF ‘.

Program Execution and Control

Start program: In the non Setup menu interface, press the HOLD/RUN button, the RUN LED flashes, select the Start Step (StP), then press the HOLD/RUN button to confirm, the RUN LED stays on, and the program starts.

Pause and Resume: Press the HOLD/RUN button once to pause (RUN LED flashes); Press the HOLD/RUN key again to switch to the rESU parameter, and press the HOLD/RUN key to resume operation (only when the program has not been modified).

View operating status: Press the MODE key to switch parameters in the RUN menu, where you can view remaining time (HOUr/Min/SEC), current rate (rAtE), event status (Ent1/Ent2), etc.

Programming Example (Slope Constant Temperature Cycle)

Requirement: Initial temperature of 75 ° F → 25 seconds to rise to 100 ° F (event 1 activated) → 25 seconds constant temperature → 25 seconds to rise to 125 ° F (event 2 activated) → 25 seconds constant temperature → jump to step 1 and repeat twice → maintain the final state.

Step by step SP (° F) Time (minutes: seconds) Ent1 Ent2 JS JC End

1 StPt 75 0:01 OFF OFF – – –

2 StPt 100 0:25 ON OFF – – –

3 SoAh – 0:25 ON OFF – – –

4 StPt 125 0:25 OFF ON – – –

5 SoAh – 0:25 ON OFF – – –

6 JL – – – – 1 2 –

7 End – – – – – – HOLd

Tuning operation (automatic and manual)

Automatic tuning (recommended)

Applicable scenario: Quickly obtain optimized PID parameters after first use and system load changes.

Operation steps:

Enter the Operation menu and find the Aut parameter (displayed only when Ot1=ht).

Press the UP/DOWN keys to select the tuning rate (1 slow/2/3 fast, mostly 2 in most scenarios).

Press the MODE key to start tuning, and the lower display alternately flashes Aut and the current parameter. During tuning, the cooling output is turned off, and the heating output runs at 90% set point ON/OFF.

Complete tuning within 80 minutes, automatically save PID parameters, restore Aut to 0, and return to normal control mode; Modifying the set point during tuning will restart tuning. Press the UP/DOWN key to set Aut=0 to abort (restore the original parameters).

Manual tuning (precise optimization)

Operation steps:

Initialization parameters: Pb1=1, Ct1=5, rE1=rA1=0, CAL=0, Aut=0, set target temperature.

Proportional band (Pb1) adjustment: gradually increase Pb1 until the process temperature stabilizes (initial reset to 0, temperature may deviate from the set point).

Reset/Integral (rE1) Adjustment: Gradually increase rE1 until the temperature begins to oscillate, then slowly decrease until the temperature stabilizes near the set point.

Rate/Differential (rA1) Adjustment: Assuming rA1=1.00 minutes, raise the set point by 20-30 ° F. If the temperature is overshoot, increase rA1 (maximum 9.99) to avoid overshoot and slow response.

Cycle time (Ct1) adjustment: Optimized within the range of 1-60 seconds. It is recommended to choose a longer cycle time for mechanical contactors (to reduce wear) and a shorter time for electronic loads (to improve control accuracy).

Alarm and fault handling

Alarm function operation

Alarm type:

Process alarm (Pr): Based on the absolute temperature threshold (A1LO/A1HI), an alarm is triggered when the temperature exceeds the range.

Deviation alarm (dE): Based on the set point offset (such as+7 ° F/-5 ° F), the alarm threshold synchronously shifts when the set point changes.

Alarm status:

Non Locked (nLA): Automatically resets after the alarm condition disappears.

Lock (LAt): Manual reset is required (first eliminate the alarm condition, then press the HOLD/RUN button).

Alarm indication: The lower display alternately flashes “LO”/”HI” and the current parameter, the L3/L4 LED lights up, and the auxiliary output triggers (N.O. closed/N.C. open).

Common faults and solutions

Fault symptoms, error codes, possible causes, and solutions

The upper display shows “—-“, the lower display shows Er7 Er7 A/D overflow, the sensor is open/polarity reversed, check the sensor wiring (positive and negative poles, terminal contact), confirm that the In parameter is consistent with the sensor type

The upper display shows “—-“, the lower display shows Er1/Er2 Er1/Er2 sensor over/under range, A/D fault confirms that the sensor range matches rL/rH, checks if the sensor is damaged, and recalibrates the A/D

Pause during program operation – gSD deviation window enabled, adjust gSD value if temperature exceeds ± gSD range (increase window), check if heating/cooling system is normal, eliminate load interference

Communication failure – baud rate/protocol/address mismatch, wiring error. Confirm that bAUd (baud rate), Prot (protocol), Addr (address) in the Setup menu are consistent with the host, and check the communication line wiring (RS-485 requires corresponding A/B lines)

Large temperature measurement error – sensor wiring error, calibration offset, environmental interference. Reconnect and confirm sensor type, enter Cal menu to adjust CAL offset, check signal line shielding and grounding

Output unresponsive – Set the set point to OFF, configure the output type incorrectly, adjust the SP to the rL~rH range for load faults, confirm the Ot1/Ot2 parameters (ht/CL), check if the load impedance matches the output type, and test if the load is normal

Calibration operation (accuracy calibration)

Calibration prerequisite

Only enter under LOC parameters and require precise equipment (such as precision millivolt source, resistance box, voltage/current source, 4.5-inch multimeter).

Backup all parameters (Setup/Operation/Program) before calibration, turn off all outputs during calibration (except for process outputs), and automatically save calibration values when the RUN LED lights up.

Core Calibration Process (Taking Thermocouples as an Example)

Wiring: Connect the precision millivolt source to terminals 7 (+) and 9 (-), connect to AC power and ground.

Preheating: Power on for 15 minutes, enter the Cal menu (hold down the UP/DOWN key under LOC parameters), press the MODE key to select the tCL parameter.

Low range calibration: The millivolt source outputs 0.00mV, and after stabilizing for 10 seconds, press the MODE button.

High range calibration: J-type thermocouple outputs 50.00mV, R/S/B type outputs 16.035mV. After stabilizing for 10 seconds, press the MODE button.

Compensation calibration: Disconnect the millivolt source and connect the J-type reference compensator (32 ° F/0 ° C). After stabilizing for 10 seconds, press the HOLD/RUN button to exit the RUN mode and complete the calibration.

Other calibrations (RTD/process input/output)

RTD calibration: Use a 1K Ω precision resistance box to connect terminals 4-6, and input low/high resistance values according to the rLO/rHI parameters (refer to Table 7 in the manual).

4-20mA input calibration: Short circuit terminals 2-3, output 4.00mA (4A parameter) and 20.00mA (20A parameter) from the current source, and calibrate sequentially.

Process output calibration: Connect a multimeter and a matching resistor (such as 4-20mA connected to a 470 Ω resistor), adjust the output to the target value (such as 4.00mA/20.00mA) according to the O1LO/O1HI parameters.

Maintenance and Precautions

routine maintenance

Regular inspection: Check whether the sensor wiring is loose or corroded, whether the panel screws are tightened, and whether the heat dissipation is good.

Battery replacement: Lithium batteries (with backup operating parameters) have a lifespan of about 10 years. In case of abnormal Pout or Run parameters, they need to be returned to the factory for replacement.

Cleaning and maintenance: Wipe the panel with a dry soft cloth to prevent liquid from seeping into the interior of the equipment; Avoid using in damp, dusty, and corrosive environments.

Safety precautions

Disconnect the power supply before wiring, strictly follow NEC and local electrical regulations, and ensure reliable grounding (to avoid electric shock and interference).

The front plate screws should only be rotated 90 °, and excessive force should be avoided to avoid damaging the chassis locking structure.

Mercury relays are only suitable for resistive loads and are prohibited from being used for inductive loads (such as motors without buffering).

Calibration and maintenance must be carried out by professional personnel, and unauthorized disassembly of the equipment casing is prohibited (which may affect warranty).

The Watlow Series 988 controller is a 1/8 DIN microprocessor based temperature/process controller that integrates multiple functions, covering four models: 986, 987, 988, and 989. It has flexible configuration, compact size, and high durability, and can adapt to various temperature and process control scenarios. It supports multiple input/output options and complex control algorithms.

Core characteristics of controller

1. Hardware and functional highlights

Compact design: 1/8 DIN size, integrated with rich functions, balancing flexibility and durability

Control capability: Supports single unit cascade control, covering various process variables such as temperature, pressure, flow rate, etc

Featured features: including heater current monitoring, remote setpoint input, proportional control, and sliding line feedback valve control

Algorithm and Alarm: Equipped with extended self-tuning function, enhanced alarm function, and multiple unique control algorithms

2. Model coverage

When referring to “Series 988”, it includes both horizontal and low-voltage versions (986, 987, 988, 989)

There are differences in power specifications and installation methods among different models (such as 986/988 for vertical installation and 987/989 for horizontal installation)

Installation and hardware settings

1. DIP switch configuration

Number of switches: Depending on the model, the controller contains 1-6 DIP switches inside

Core functions: Configure input sensor types, provide power for external signal conditioners, lock some functions of the front panel

Operation steps: Press the release tabs on both sides/top of the panel to remove the controller chassis. After setting the switch as shown in the diagram, reset the chassis and ensure that all four tabs are securely fastened

2. Panel installation

Installation preparation: Contact the back of the panel and cut the panel cut according to the size requirements (recommended to use Greenlee 1/8 DIN hydraulic kit)

Installation steps: Slide the controller housing into the panel cut, ensure that the sealing gasket is flat, install the bracket and tighten the screws (to avoid deformation of the housing due to over tightening), and finally insert the chassis and clamp it tightly

Sealing requirements: Strictly follow the installation process to ensure NEMA 4X sealing level and prevent equipment damage

3. Wiring specifications

Safety prerequisite: Follow the National Electrical Code (NEC) safety standards to avoid the risk of electric shock

Core wiring: including power wiring (100-240V AC/DC or 24-28V AC/DC), sensor wiring (thermocouples, RTDs, etc.), input/output wiring (supporting up to 4 inputs and 4 outputs)

Isolation requirement: Optical isolation (500V AC isolation barrier) is used between analog input and controller output/digital input to avoid grounding loops

Operation interface and menu navigation

1. Front panel buttons and display

Core keys: Up arrow key (increase value), Down arrow key (decrease value), Mode key (confirm/switch menu), Display key (return to display loop), Auto/Manual key (mode switch/alarm reset)

Display function: upper displays actual process values, parameter values, or error codes; Lower displays set points, deviations, percentage outputs, etc; L1-L4 LED indicates whether the corresponding output is activated

Special operation: Press the up and down arrow keys simultaneously for 3 seconds to enter the settings menu, and press again for 3 seconds to enter the factory menu (which can be locked through DIP switch)

2. Core menu system

(1) Display Loop

Definition: The controller defaults to the “home” state and automatically returns after 1 minute of inactivity. Pressing the display button can return at any time

Display content: including input 1 reading, set point 1, input 2 reading (if equipped), deviation value, percentage output, temperature unit, etc

(2) Setup menus

Entry method: In the display loop state, press the up and down arrow keys simultaneously for 3 seconds

Includes menus: Input menu (InPt), Output menu (OtPt), Global menu (GLbL), Communication menu (COM, visible only for models equipped with communication function)

Operation rules: Output disabled during menu navigation. Use the up and down arrow keys to select the menu, and the mode key to step through the menu options

(3) Operation menus

Entry method: Press the mode key while displaying the loop state

Includes menus: System Menu (SYS), PID A Menu (PidA), PID B Menu (Pidb)

Core functions: Set second set point, idle set point, alarm trigger value, start self-tuning, etc

(4) Factory menus

Entry method: In the settings menu state, continue pressing the up and down arrow keys for 3 seconds

Includes menus: Panel Lock Menu (PLOC), Diagnostic Menu (diAg), Calibration Menu (CAL)

Restriction: When the hardware lock DIP switch is turned on, the menu cannot be accessed

Core functional configuration

1. Input/output configuration

Input settings: Select sensor type (thermocouple, RTD, 4-20mA, etc.), set decimal places, range upper and lower limits, calibration offset

Output settings: Configure output response mode (heating/cooling, alarm activation/deactivation), set lag value, alarm type (process alarm, deviation alarm, rate alarm)

2. Control mode and algorithm

Control type: supports normal control, cascade control, proportional control, differential control

Algorithm selection: Single group PID, proportional/differential control (with manual reset), dual group PID, duplex (heating/cooling) control can be selected

Self tuning function: supports automatic tuning of PID parameters, which needs to be started in the system menu. During the tuning process, the controller enters switch control mode

3. Alarm and error handling

Alarm function: Output 2-4 can be configured as an alarm, supporting lock type (manual reset required) and non lock type (automatic reset after fault relief)

Error code: including A/D conversion error, sensor over/under range error, ambient temperature error, etc. When an error occurs, the controller automatically switches to manual mode and maintains the preset output

Detailed explanation of software functions

1. General software functions

Core functions: including burst fire, communication function, dead zone control, digital events, heater current monitoring, input filtering, linearization, ramp to set point, remote set point, retransmission function, sliding line feedback, etc

Application scenario: Sudden ignition is suitable for zero crossing solid-state devices; Dead zone control prevents simultaneous activation of heating/cooling outputs; Sliding line feedback can control valve position

2. Enhanced software features (models equipped with enhanced software only)

Cascade control: precise control is achieved through two control loops (outer loop monitoring process values, inner loop monitoring heat source temperature) to reduce overshoot

Dual PID group: supports two independent PID parameters, which can be switched based on process values, setpoints, or event inputs

Proportional control: controlling the proportional value of one process variable to another, suitable for material mixing scenarios

Maintenance and Support

1. Calibration and Diagnosis

Calibration requirements: Factory calibrated. If regular calibration is required, please refer to the dedicated calibration manual

Diagnostic function: The software version, serial number, ambient temperature, A/D count, test display, and output functions can be viewed through the diagnostic menu

2. Warranty and Returns

Warranty period: 36 months warranty (from the date of first purchase and use), covering material and process defects

Return process: Contact customer service first to obtain a Return Merchandise Authorization (RMA) number. For returned products, prepaid shipping fees are required. For unused products, a 20% restocking fee may be charged

3. Technical support

Support time: 7am to 5pm Central Time in the United States

Support preparation: When contacting, please provide the controller model (12 digit number, located on the shell sticker and circuit board), user manual, configuration information, and diagnostic menu readings

Key Appendix Information

1. Specification parameters

Input type: Supports process signals such as J/K/T/N/R/S/B thermocouples, 100 Ω RTDs, 4-20mA, 0-10V, etc

Output options: Solid state relay (0.5A), electromechanical relay (5A), open collector, process output (4-20mA/0-10V), etc

Accuracy: ± 0.1% ± 1 LSD of full scale (ambient temperature 25 ℃± 3 ℃, rated voltage ± 10%)

2. Glossary of Terms

Core terms: including definitions of professional terms such as annunciator, burst fire, cascade control, PID (proportional integral derivative), dead band, etc

Product basic information

Core positioning: A DIN rail mounted temperature regulation controller that supports thermocouple or RTD sensor input, with both DIN rail quick installation and embedded installation methods. Designed for various safety application scenarios, it can achieve high/low limit temperature control and is suitable for industrial heating equipment, commercial cooking equipment and other scenarios that require temperature safety protection, such as ovens, reactors, heaters, etc.

Core Features and Advantages

Flexible and convenient installation: Supports DIN EN50022 standard 35mm × 7.5mm rail installation, which can be completed with simple manual tools. Embedded installation can also be selected to adapt to different installation environment requirements.

Diverse control modes: The factory can preset high/low limit control modes, support manual or automatic reset after power failure, and meet different safety control logics; Equipped with temperature over limit latch alarm function, requiring manual reset to enhance safety and reliability.

Intuitive and easy to understand operation: equipped with output status LED indicator lights, providing real-time feedback on working status; Support built-in/remote adjustable or fixed setpoints, calibrated dial to compensate for sensor nonlinearity errors; Simultaneously compatible with both Celsius (° C) and Fahrenheit (° F) temperature scales, suitable for different usage habits.

Comprehensive safety protection: equipped with thermocouple and RTD disconnection protection function, automatically cutting off output in case of sensor failure to avoid equipment damage; Obtained multiple certifications such as CE and FM Class 3545, compliant with EN61010 safety standards, EN61326 industrial electromagnetic compatibility standards (Class B emission), installation category II, pollution level 2, suitable for specific scenarios such as commercial cooking.

Strong adaptability: Supports multiple thermocouple (E, J, K, T type, etc.) and RTD (100 Ω, 1000 Ω) inputs, with optional power supply voltages of 24VAC, 120VAC, 230-240VAC to meet different on-site power supply and sensing needs.

Product Technical Specifications

（1） Control and operation specifications

Control mode: The factory can choose high limit or low limit control; The power-off reset mode can be selected manually or automatically; When the temperature exceeds the limit (too high/too low), a latch alarm is triggered and manual reset is required; Support built-in reset switch or external reset switch provided by the user.

Operation interface: LED indicator light displays output status (power on/off); Adjustable set point (built-in/remote) equipped with calibration dial to compensate for sensor nonlinearity; Fixed set point factory calibration according to user specified values; Dual temperature scale (° C/° F) switching.

（2） Enter specifications

Sensor type: Supports thermocouples (E, J, K, T, etc.) or platinum resistance RTDs, thermocouples have automatic cold junction compensation function, and can choose isolation or grounding type; RTD supports 2-wire or 3-wire system, calibrated at 100 Ω @ 0 ° C, and conforms to the 0.003850 Ω/Ω·° C curve.

Input protection: thermocouple and RTD disconnection protection function, automatically cuts off the output when the sensor is disconnected, preventing equipment from losing control.

Measurement range: Depending on the sensor type and model configuration, for example, E-type thermocouple 0-799 ° C (32-1470 ° F), J-type thermocouple 0-315 ° C (32-600 ° F), T-type thermocouple -200-350 ° C (-328-662 ° F); RTD measurement range -73-600 ° C (-100-1112 ° F), etc., fixed set points can be customized according to user needs (such as 200 ° C, 350 ° C, etc.).

（3） Output specifications

Output type: 8A electromagnetic relay, Form C (single pole double throw, SPDT), rated load: 8A@240VAC (obstructive) 8A@28VDC (Resistive), with a rated load of 275VA, can directly drive small heating equipment, contactor coils, and other loads.

Load protection: When switching inductive loads (such as relay coils, solenoid valves, etc.), an RC suppressor (Watlow recommended model Quencharc, part number 0804-0147-0000) needs to be installed to avoid electromagnetic interference damaging the controller.

（4） Accuracy and stability

Calibration accuracy: The adjustable set point (built-in/remote) is within ± 1% of the range at an ambient temperature of 25 ° C ± 3 ° C (77 ° F ± 5 ° F) and a rated line voltage of ± 1%, with a minimum range of 540 ° C (1000 ° F); The fixed set point has an error of ± 6 ° C/± 10 ° F under the same environmental and voltage conditions.

Setpoint accuracy: The precision of the adjustable set point dial is ± 3%.

Temperature stability: When the thermocouple is input, for every 1 ° C change in ambient temperature, the input reference drift typical value is 9 µ V/° C (5 µ V/° F); When inputting RTD, for every 1 ° C change in ambient temperature, the typical drift value is 0.2 ° C/° C (0.2 ° F/° F).

Voltage stability: For every 1% change in rated line voltage, the range drift is ± 0.01% (minimum range 540 ° C or 1000 ° F).

（5） Power and environmental specifications

Power parameters: Supports 24VAC (+10%/-15%), 120VAC (+10%/-15%), 230-240VAC (+10%/-15%), frequency 50/60Hz, maximum power consumption 10VA, power type needs to be specified by model (such as 1=120VAC, 2=230-240VAC, 3=24VAC).

Environmental conditions: working temperature 0-55 ° C (32-131 ° F), storage temperature -20-85 ° C (-4-185 ° F); Relative humidity 0-90% (non condensing), suitable for most industrial and commercial environments.

（6） Physical and installation specifications

Dimensions: Width 60mm (2.28 inches), height 115mm (4.45 inches), depth 100mm (3.89 inches), weight 0.3kg (0.7 pounds).

Terminal specifications: Captive screw cage clamping connection, supports maximum 4mm (0.155 inch) screwdriver head operation, compatible with 14-30 gauge wires.

Installation method: DIN rail installation (compatible with 35mm × 7.5mm rails) or embedded installation. Embedded installation requires drilling two 5mm (0.19 inch) holes on the panel and fixing them with # 8-32 screws.

Installation and Wiring Guide

（1） Installation process

1. Sub Panel Mounting

Attention: FM certification requires that limit switches be appropriately closed to reduce arbitrary adjustments to the set temperature.

Step 1: Use the controller as a template and mark two installation hole positions on the panel (refer to the hole size in Figure 2a of the document).

Step 2: Drill two 5mm (0.19 inch) diameter holes at the marked location.

Step 3: Use two # 8-32 screws to secure Series 146 to the panel.

2. DIN Rail Mounting

Step 1: Align the upper mounting clip of the controller with the upper edge of the DIN rail (refer to Figure 2b in the document).

Step 2: Press firmly on the upper edge of the front part of the controller, and the controller will be firmly fixed on the guide rail in a “snap” manner; If it cannot be fastened, check if the guide rail is bent. The clamping distance range of the guide rail is 34.8mm (1.37 inches) to 35.3mm (1.39 inches).

3. Disassemble from DIN rail

Step 1: Use your fingers to hold down the release lever at the bottom of the controller.

Step 2: Gently press the top of the controller (above terminals 1-9) and pull the release lever forward to remove the controller.

（2） Wiring specifications

1. General wiring rules

Use sensor types that match the device label model to ensure correct polarity of thermocouples or RTDs.

Thermocouples should be insulated from the installation surface during installation to avoid input errors caused by thermal conduction; Thermocouple leads should be made of twisted pair wires, wired separately, and kept away from other circuits.

In environments with severe electromagnetic interference (such as frequent switching of contactors, motors, and solenoid valves), shielded thermocouple leads should be used, and the shielding layer should only be grounded at the sensor end.

All wiring and fuse configurations must comply with the National Electrical Code (NEC NFPA70) and applicable local regulations; The independent load voltage needs to be fused on the L1 (live) side and connected to the common terminal (COM) of the relay.

It is recommended to install a power isolation switch near the controller to cut off the power supply in case of controller failure; The lead resistance of a 2-wire RTD can introduce errors (every 1 Ω lead resistance leads to additional errors). It is recommended to use a 3-wire RTD to compensate for lead resistance, and the three extension wires must have the same resistance (same wire gauge, copper stranded wire).

2. Power wiring

The power supply type is specified by the model: 120VAC corresponds to model 146_ -1_ -00000 230-240VAC corresponds to 146-2_ -0000, 24VAC corresponds to 146-3_ -0000.

Warning: To avoid the risk of electric shock, wiring must comply with national electrical safety standards. All wiring and fuses must comply with NEC and local regulations, otherwise it may cause equipment damage, property damage, or personal injury; The controller should be installed in an inconspicuous location to prevent unauthorized personnel from adjusting the set point. Only authorized personnel can operate the set point change, and unauthorized operation may cause safety risks; Applying incorrect voltage can cause irreversible damage to the controller.

3. Input wiring

Thermocouple wiring: Connect the positive and negative poles to the corresponding terminals as shown in Figure 3b of the document to ensure that the cold end compensation function is normal. Isolation and grounding thermocouples should be wired according to the model requirements.

RTD wiring: Refer to Figure 3c in the document for the wiring methods of 2-wire and 3-wire RTDs. The three leads of the 3-wire RTD need to have the same resistance. When wiring, pay attention to the correspondence between terminals S1 and S3 to ensure that the calibration curve matches (0.003850 Ω/Ω·° C).

4. Output wiring

The wiring of the electromagnetic relay (Form C type) should refer to Figure 3d in the document. The load should be connected in series between the normally open (NO) or normally closed (NC) terminal and the common terminal (COM). A fuse (recommended specification 1A) should be installed on the L1 side, and an RC suppressor should be connected in series for inductive loads.

5. Remote reset wiring

The remote reset switch is provided by the user, and the wiring method refers to Figure 3e in the document (terminals 13, 15, 16, 17, 14). Only the momentary switch meets FM certification requirements, and remote reset may affect the validity of FM certification.

6. System wiring example

Typical system wiring includes components such as power isolation switches, fuses, controllers, sensors, loads (heaters), contactors, solid-state relays, etc. Please refer to the two system wiring schemes in Figure 4 of the document to ensure that the power supply, input, output, and reset circuit wiring are complete and comply with safety regulations.

Model selection and order information

（1） Model Structure

The model format is 146E – (1/2/3) (100-999) – (1/2/3/4) (any three letters/numbers), and the meanings of each part are as follows:

146E: Product series and output type, E=8A electromagnetic relay (Form C type).

Line voltage code: 1=120VAC, 2=230-240VAC, 3=24VAC.

Input and Range Code: Represents sensor type and measurement range, for example:

E-type thermocouple: 619=0-799 ° C (32-1470 ° F).

J-type thermocouple: 601=0-315 ° C (32-600 ° F), 602=0-750 ° C (32-1382 ° F), 615=fixed 315 ° C (600 ° F), etc.

K-type thermocouple: 603=0-1250 ° C (32-2282 ° F), 611=0-600 ° C (32-1112 ° F), etc.

T-type thermocouple: 629=-200-350 ° C (-328-662 ° F), 632=fixed -75 ° C (-103 ° F), etc.

RTD: 101=-73-600 ° C (-100-1112 ° F, 100 Ω), 104=-73-600 ° C (-100-1112 ° F, 1000 Ω), 106=fixed 200 ° C (392 ° F), etc.

Limit mode code: 1=high limit+power-off manual reset, 2=low limit+power-off manual reset, 3=high limit+power-off automatic reset, 4=low limit+power-off automatic reset.

Remote option codes: 0=adjustable control+built-in setting potentiometer, N=adjustable control+no setting potentiometer (provided by the user), S=adjustable control+remote setting potentiometer+remote reset, P=adjustable control+remote setting potentiometer.

（2） Selection precautions

Confirm the on-site power supply voltage and select the corresponding line voltage code (1/2/3).

Select the sensor type (thermocouple/RTD) and corresponding range code based on the temperature measurement range and accuracy requirements, and specify the target temperature for the fixed set point.

Select the limit mode (high/low limit) and power-off reset mode (manual/automatic) according to safety control requirements.

Select remote options according to installation and operation requirements (built-in/remote setpoints, whether remote reset is required).

The warranty period for electromagnetic relays is usually 100000 closing operations, and the service life needs to be evaluated in conjunction with the load switching frequency.

Troubleshooting and Maintenance

（1） Common faults and solutions

Possible causes and solutions for the fault phenomenon

Load cannot start sensor open circuit maintenance or replacement of sensor

Check if the fuse, circuit breaker, load, and wiring of the load circuit are normal for an open circuit

Check the AC input connection according to the “Power Wiring” section (page 3) if it is not connected or connected incorrectly. If it is not connected, reconnect it

The load cannot be turned off. Connect the thermocouple correctly by reversing the thermocouple according to the “Input Wiring” section (page 4)

Controller failure cuts off the power supply of the controller and removes it from the system, only supplying power to the system; If the load is turned off, it indicates a controller malfunction and needs to be returned to the factory for repair; If the load is still running, it indicates that there are other faults in the system. Please contact the factory for consultation

（2） Maintenance

Regularly check whether the wiring terminals are loose, whether the sensors are damaged or aged, and ensure reliable connections.

Keep the controller clean, avoid dust and oil accumulation, and stay away from corrosive environments and severe vibrations.

Regularly verify the accuracy of set points and the reliability of output actions, and promptly troubleshoot sensor or wiring issues if any abnormalities are found.