Product Core Information

Product positioning: Industrial grade PID controller, suitable for basic temperature control and limit monitoring scenarios, supporting composite functions such as PID control, limit detection, and multi class alarms.

Model specifications: available in two panel sizes: 1/32 DIN (PM3) and 1/16 DIN (PM6), supporting AC/DC dual power supply mode and compatible with multiple input/output configurations.

Core advantages: simple and easy to operate menu, PID self-tuning function, multi bus communication support, FM certified over/under temperature protection, three-year warranty, and features such as touch safe packaging, waterproof and dustproof (NEMA 4X/IP66/IP67).

Product Features and Technical Parameters

（1） Input function

Analog input

Type and Range: Supports thermocouples (such as J, K, T, E, etc., with different measurement ranges for different types, such as J type -346 to 2192 ° F, i.e. -210 to 1200 ° C), RTDs (calibrated at 100 Ω, 1k Ω, 0 ° C, in accordance with DIN curves, 2-3 wire system, 20 Ω total lead resistance, typical excitation current 0.09mA, lead resistance per ohm may cause 0.03 ° C reading deviation), thermistors (5k Ω, 10k Ω, 20k Ω, 40k Ω), process signals (voltage 0-10VDC, input impedance 20k Ω; current 0-20mA, input impedance 100 Ω); Millivolt 0-50mVdc, input impedance 20k Ω), 1k Ω potentiometer, and all analog inputs can be scaled to meet different measurement requirements.

Configuration requirements: Sensor type (sEn), linearization (Lin, for thermocouples), number of leads (rt.L, for RTDs), unit, scaling high and low values (s.Lo, s.hi), range high and low values (r.Lo, r.hi) and other parameters need to be configured in the “Setup Page – Analog Input Menu” to ensure compatibility with the connected input device. For example, thermocouples should pay attention to polarity (negative pole is usually red, connected to S1 terminal), and the extension wire should be made of the same material as the thermocouple to reduce errors; The S1 lead (usually white) of a 3-wire RTD needs to be connected to R1 and/or R2 terminals, and the resistance of the three leads must be consistent to ensure accuracy.

Performance indicators: thermocouple input impedance>20M Ω, maximum source resistance 2k Ω, with 3 µ A open circuit sensor detection function; The input accuracy of RTD is affected by lead resistance and needs to be compensated through calibration; The scaling range of process input can be set according to actual needs, such as 4-20mA corresponding to 0-100% humidity, etc.

Digital input

Hardware configuration: The model with Digital Input/Output (DIO) hardware includes two sets of terminals (5 and 6), each set can be configured as an input or output, and needs to be set through the “Direction” parameter in the “Setup Page Digital Input/Output Menu” (input can choose voltage input or dry contact input).

Input characteristics: When voltage is input, the maximum input voltage is 36Vdc, the activation voltage is>3Vdc (0.25mA), and the non activation voltage is<2VDC; When using dry contact input, the activation resistance is less than 100 Ω, the non activation resistance is greater than 500 Ω, and the maximum short-circuit current is 13mA. The update rate is 10Hz, which can be used to detect equipment start stop status, external trigger signals, etc.

Special Input: The Reset button on the front of the controller can be configured as a digital input through the “Digital Input Function” parameter in the “Setup Page Reset Key Menu” to achieve function switching, such as limit reset, alarm mute, etc.

（2） Output function

Output type and characteristics

Mechanical relay: Form C type (output 1, 3), rated load 5A@240Vac Or 30Vdc (resistive), minimum load 20mA@24V ， 125VA pilot duty at 120/240Vac, 25VA pilot duty at 24Vac, with a lifespan of 100000 cycles (rated load), supporting AC/DC loads, no power output, requiring external power supply; Form A type (outputs 2 and 4) has parameters similar to Form C type, with only normally open contacts. Output 2 is default bound to the limit function and serves as the main output for limit protection.

Solid state relay (SSR): Form A type (output 3, 4), rated load 0.5A@20-264Vac (Resistive), 20VA pilot duty at 120/240VAC, optocoupler isolation, contactless suppression, maximum off state leakage current of 105 µ A, minimum holding current of 10mA, only supports AC load, no power output.

Switching DC/collector open circuit output: Supports outputs 1, 3, and 4, with a maximum open circuit voltage of 22-25Vdc, a maximum current of 30mA for a single output, and a maximum total current of 40mA for paired outputs (1&2, 3&4). Typical driver 4.5Vdc@30mA Short circuit current limit<50mA (NPN transistor current), can drive external solid-state relays, supports multiple sets of DIN-A-MITE relays in parallel/series (such as 1 pole up to 4 sets in parallel/series, 2 poles up to 2 sets in parallel/series, 3 poles up to 2 sets in series).

Universal process output: Only supports 3 outputs, can be configured as voltage (0-10VDC, minimum load 1k Ω) or current (0-20mA, maximum load 800 Ω) output, with scaling function (s.Lo, s.hi, r.Lo, r.hi), can be used to retransmit process values or set values, output accuracy ± 15mV (voltage), ± 30 µ A (current), temperature stability 100ppm/° C, need to configure parameters such as type (o.ty), function (fn), and retransmission source (r.Sr) in the “Setup Page Output Menu”.

Output configuration logic: All outputs need to be assigned functions (such as limit, alarm, retransmission, etc.) and function instances (such as alarm 1-4, limit 1, etc.) in the corresponding menu (Output Menu or Digital Input/Output Menu) of the “Setup Page”. For example, output 1 can be configured as “Alarm 1” and output 2 can be fixed as “Limit”; Support multiple outputs associated with the same functional instance, such as alarm 2, which can simultaneously trigger output 1 (indicator light) and output 5 (buzzer).

（3） Core control and protection functions

PID control: supports hot/cold control, switch control, P, PI, PD, PID control algorithms (not specific to limit controllers), with automatic tuning function, can be started through “Operations Page” or configuration software, sampling rate input 10Hz, output 10Hz, control accuracy is affected by input sensor accuracy, calibration status and load characteristics, calibration accuracy is ± 0.1% range ± 1 ° C (0.2% for S-type thermocouples, 0.2% for T-type thermocouples below -50 ° C) at rated ambient temperature (25 ° C ± 3 ° C) and rated line voltage, minimum range 1000 ° F (540 ° C), maximum temperature stability ± 0.1 ° F/° F (± 0.1 ° C/° C) Environmental temperature rise.

Limit protection: As the core function, it supports high/low limit or dual limit monitoring. The limit upper and lower limits (Lh. s, LL. s), hysteresis value (L.hy, 0.001-9999 ° F/° C, default 3 ° F or 2 ° C), and limit sides (L.sd, high, low, or dual sides) can be set in the “Setup Page Limit Menu”; When the process value exceeds the limit range, output 2 (Form A relay) loses power, cuts off the load power supply, and maintains a locked state, requiring manual reset (through the Reset button, digital input, or communication command); Support limit reset source configuration (sfn. a, such as digital input, function keys) to ensure that normal operation can only be restored after troubleshooting.

Alarm function: Supports 4 sets of alarms (1-4), which can be configured as process alarms (high/low alarms, deviation alarms, etc.). Set the alarm type (a.ty), source (sr.a, such as analog input 1-2), upper and lower limits (a.hi, a.Lo), hysteresis value (a.hy), logic (a.Lg, power on alarm or power off alarm), latch (a.La, whether to manually clear), blocking (a.bL, whether to block alarm when starting or setting value changes), mute (a.si, whether to support mute), delay time (a.dL, 0-9999 seconds) and other parameters in the “Setup Page Arm Menu”; When an alarm is triggered, it can be notified through output actions (such as indicator lights, buzzers) or communication signals. Locked alarms need to be cleared through the “Clear Alarm (a.CLr)” command, and silent alarms need to pause output through the “Silence Alarm (a.sir)” command.

（4） Communication function

Support protocols and ports

Modbus RTU: Supports EIA-485 (Port 1/2) and EIA-232 (Port 2), with Port 1 supporting Standard Bus by default and switchable to Modbus RTU; Modbus addresses 1-247 (Standard Bus addresses 1-16), baud rates of 9600, 19200, 38400bps, parity bits none/odd/even, data bits 8, stop bit 1; Supports 16 bit register read and write, floating-point parameters occupy 2 registers, default low byte first (can set “Modbus Word Order” to Lohi or hiLo in the “Setup Page Communications Menu”); Supports Map 1 (compatible with old models) and Map 2 (compatible with new features), and recommends using Map 2 for new applications.

EtherNet/IP ™ Compared to Modbus TCP: only supported on port 2, requires configuration of IP address (fixed or DHCP), subnet mask, gateway, supports 10/100Mbps Ethernet, and can run both protocols simultaneously; CIP implicit assembly (input/output member count 1-20), explicit communication supports Class/Instance/Attribute addressing, compliant with ODVA standards.

DeviceNet ™： Port 2 support, node addresses 0-63, baud rates 125, 250, 500kbps, supports Quick Connect, CIP implicit assembly input/output members up to 200, explicit communication for configuration and diagnosis.

Profibus DP: Port 2 support, addresses 0-126, maximum baud rate of 12Mbps, supports DP-V0 (cyclic data exchange) and DP-V1 (non cyclic data exchange, used for configuration and diagnosis); GSD file configuration is required, supporting up to 32 devices per network segment, with a maximum transmission distance of 1200 meters (EIA-485), and a terminal resistance configuration option (150 Ω).

Communication configuration and tools: All communication parameters need to be configured in the “Setup Page Communications Menu” (such as protocol, address, baud rate, IP parameters, etc.); Can be accessed through Watlow PM LEGACY ™  The Limit Configurator software (free download from the official website) enables communication between the PC and the controller, supporting online configuration, parameter backup/recovery, device scanning, and other functions; During the communication process, attention should be paid to cable selection (such as using twisted pair for EIA-485, avoiding parallel wiring with power lines), terminal resistance (only network end devices need to be connected to a 120 Ω resistor), and grounding isolation (to prevent grounding loops).

Installation and wiring

（1） Installation process

Panel perforation: The PM3 controller needs to be perforated according to the size on page 6 of the document, and the PM6 controller needs to be perforated according to the size on page 7 to ensure that the controller can be smoothly embedded into the panel.

Component disassembly: Remove the green terminal connector and installation ring assembly to avoid damaging the components during installation.

Controller embedding: Insert the controller into the opening from the front of the panel. Taking PM6 as an example, ensure that the installation direction is correct.

Installation ring fixation: Move the installation ring base plane forward, with the screw opening facing the side, and slide it over the back of the controller; Slide the installation bracket over the controller again, aligning the screws with the base, and gently push until the hook clicks into the slot of the housing; Finally, use a Phillips screwdriver to tighten the two # 6-19 x 1.5 inch screws with a torque of 3-4 inch pounds, ensuring that the device is flush with the panel.

Terminal reset: Reinstall the terminal connector to its original position to complete the installation.

Installation spacing requirements: 1/32 DIN (PM3) recommends a panel spacing of 44.96-45.47mm (1.77-1.79 inches), a minimum panel thickness of 21.6mm (0.85 inches), and a panel thickness range of 1.53-9.52mm (0.060-0.375 inches); 1/16 DIN (PM6) recommends a panel spacing of 44.96-45.47mm (1.77-1.79 inches), with other thickness requirements consistent with PM3 to ensure heat dissipation and operational space.

（2） Wiring specifications

Power wiring

Low power model (PM6 [L, M] [3,4} _J-A_G _): supports 12-40Vdc, 20-28Vac (50/60Hz), maximum power consumption of 10VA (PM6), power terminals are 98 (ac/dc+) and 99 (ac/dc -) of Slot C, pay attention to voltage polarity, and comply with NEC or local electrical standards to avoid overvoltage or reverse connection damage to equipment.

High power model (PM6 [L, M] [1,2} _J-A_G _): Supports 85-264Vac, 100-240Vac (Semi Sig F47 standard, 50/60Hz), maximum power consumption of 10VA (PM6), power terminals are also 98 and 99 of Slot C, and suitable fuses are required to prevent overload.

Input wiring

Analog input (Slot A): The terminals of universal sensor input 1 include T1, S1, R1 (thermocouple+ RTD S1、 Potentiometer sliding end, S3 (thermocouple – RTD S3、 Current – etc.), wiring needs to be done according to the sensor type, for example, thermocouples need to distinguish between positive and negative poles, and RTD 3-wire system needs to connect S1 to R1/R2; The process input (voltage/current/millivolts) should be wired according to the terminal identification (such as voltage+connected to S1, voltage – connected to S3) to ensure signal integrity.

Digital input (Slot C): The terminals of digital input 5/6 are D5, D6 (signal), and B5 (common terminal). The voltage input needs to be connected to a DC power supply (such as 24Vdc), and the dry contact input needs to be directly connected to an external contact. When wiring, attention should be paid to isolating from other circuits to prevent interference.

Output wiring

Mechanical relay/SSR (Slot A/B): The terminals of Form C relay are L_ (normally open), K0 (common), and J2 (normally closed), while the terminals of Form A relay are L_ (normally open) and K0 (common). The wiring should be based on the load type (AC/DC), and the load current should not exceed the rated value; SSR only supports AC loads, please pay attention to the phase and voltage range.

Switch DC/collector open circuit (Slot A/B): The terminals are W_ (dc+), X_ (dc -, collector open circuit), and Y1 (common), and an external power supply is required to drive the load (such as a solid-state relay) to ensure that the power supply voltage matches the load and avoid short circuits.

Universal process output (Slot B): The voltage output terminals are F3 (-) and G3 (+), and the current output terminals are F3 (-) and H3 (+). The wiring should be based on the configured output type, and the load impedance should meet the requirements (minimum voltage output of 1k Ω, maximum current output of 800 Ω).

Communication wiring

EIA-485 (Slot C/B): The terminals of Standard Bus/Modbus RTU are CC (common) CA（T-/R-）、CB（T+/R+）， Twisted pair cables (such as Cat 5) should be used, with a Daisy chain network topology, a maximum of 16 nodes (Standard Bus) or 247 nodes (Modbus), a maximum transmission distance of 1200 meters, and a 120 Ω terminal resistor connected to the end device.

EtherNet/IP ™/ Modbus TCP (Slot B): The RJ-45 interface is wired according to the T568B standard, with pins E1 (white orange, transmit+), E2 (orange, transmit -), E3 (white green, receive+), E6 (green, receive -). The other pins are not used and need to be connected to a 10/100Mbps Ethernet switch.

DeviceNet ™ (Slot B): The terminals are V+(power+), CH (CAN_S), SH (shielded), CL (CAN_L), V – (power -), and shielded twisted pair cables are required. The node address is 0-63, the baud rate is 125/250/500kbps, and the shielding layer needs to be single ended grounded.

Profibus DP (Slot B): The terminals are VP (+5Vdc), B (T+/R+), A (T -/R -), DG (digital ground), trB (terminal resistance B), trA (terminal resistance A), and require Profibus dedicated cables. The end device needs to be equipped with a terminal resistance (150 Ω), address 0-126, and a maximum transmission distance of 1200 meters.

Wiring precautions: All wiring must comply with NEC or local safety standards, and power-off operation is required; The wire specification is 0.0507-3.30mm ² (30-12 AWG) single stranded wire, or two 1.31mm ² (16 AWG) wires, with a terminal torque of 0.56 Nm (5.0 inch pounds); Unused terminals must not be wired to prevent short circuits; Analog inputs, digital I/O, switch DC outputs, and process outputs must be electrically isolated to prevent grounding loops; When switching inductive loads (such as relay coils and solenoid valves), it is necessary to install an RC suppressor (Watlow recommended model 0804-0147-0000) to avoid electromagnetic interference damaging the equipment.

Operation and Configuration Guide

（1） Page navigation and basic operations

page switching

Home Page: By default, it displays process values (PV) and limit states (safE/faiL), which can be returned from any page by long pressing the Reset button for 2 seconds.

Operations Page: Press and hold the Up+Down key for 3 seconds from the home page to enter, displaying parameters that can be monitored/modified such as analog input values, limit status, digital I/O status, alarm status, etc. Use the Up/Down key to switch menus, the Advance key to enter submenus, and the Reset key to return to the previous level or home page.

Setup Page: Press and hold the Up+Down key for 6 seconds from the homepage to enter (hold down continuously until “SEt” is displayed), used to configure input, output, alarm, communication, global parameters, etc. The operation logic is consistent with the operation page, and some parameters need to be restarted to take effect after modification.

Factory Page: Press and hold the Advance+Reset button for 6 seconds from the homepage to enter. It is used for customizing the homepage, calibration, security settings (password/lock), diagnosis, etc. Caution is required when operating, and some functions (such as calibration) require professional personnel to perform.

Button Function

Up/Down keys: Modify writable parameter values (such as limit settings) on the homepage, and switch parameters/options in the menu.

Advance button: Switch display parameters on the homepage (such as low limit → high limit), enter submenus in the menu or confirm the selection.

Reset button: Reset limit (after troubleshooting), clear alarm (latch alarm), return to the previous page, long press for 2 seconds to return to the home page.

Function key (Fn, only 1/16 DIN): a programmable key that can configure functions (such as limit reset, alarm mute, user settings recovery, etc.) in the “Setup Page Function Key Menu”, supporting level triggering or edge triggering.

（2） Key parameter configuration

Home page customization: Enter the “Factory Page Custod Menu (CuSt)” and select 20 parameters to add to the homepage (such as analog input values, limit settings, alarm status, etc.). Parameter instances (such as alarms 1-4) need to be selected separately; Set the number of display pairs (1-10) through “Setup Page Global Menu-d-prs (Display Pairs)”, and set the automatic switching time (0-60 seconds, 0 is not automatic switching) through “d.ti (Display Time)”. Custom homepage parameters will be updated synchronously after modification on the original page (operation page/settings page), and vice versa.

Simulated input configuration (Setup Page Analog Input Menu)

Sensor type (sEn): Select the type that matches the connected device (such as thermocouple J-type, RTD 100 Ω, 0-20mA, etc.), “off” indicates disabling the input.

Linearization (Lin): Only thermocouples need to be set, select the corresponding linearization curve for the thermocouple type (such as J, K, T, etc.).

Scaling and Range (s.Lo/s.hi, r.Lo/r.hi): Process inputs need to be set, for example, 4-20mA corresponds to 0-100 ℃, so s.Lo=4.00mA, s.hi=20.00mA, r.Lo=0.0 ℃, r.hi=100.0 ℃; The scaling value is the input signal range, and the range value is the display/control range. It supports reverse scaling (e.g. 50psi corresponds to 4mA, 10psi corresponds to 20mA).

Filtering (fiL): Set the filtering time constant (0.0-60.0 seconds, default 0.5 seconds) to smooth the input signal, reduce noise interference, and filter without affecting the limit sensor signal.

Calibration offset (i.Ca): Used to compensate for sensor errors or lead resistance, it can be modified in the “Operations Page Analog Input Menu” (-1999.000-9999.000 ° F/° C), with positive offset increasing the input value and negative offset decreasing the input value.

Set Page Limit Menu

Limit Sides (L.sd): Select “high”, “Lo І”, or “both” to determine the upper, lower, or both limits of the monitoring process value.

Limit setting value (Lh. s/LL. s): Set the high/low limit trigger value (-1999.000-9999.000 ° F/° C, default 0.0 ° F or -18.0 ° C), which needs to be set according to process requirements, for example, the high limit of the heating equipment is set to 200 ℃ and the low limit is set to 50 ℃.

Lag value (L.hy): Set the process value deviation required for limit reset (0.001-9999.000 ° F/° C, default 3.0 ° F or 2.0 ° C), for example, if the high limit is 200 ℃ and the lag is 2 ℃, the process value needs to drop below 198 ℃ to reset the limit.

Reset source (sfn. a/si. a): Select the trigger source for limit reset (such as numeric input 5, Function key) and corresponding instance to ensure that the reset operation is effective.

Alarm configuration (Setup Page Arm Menu)

Alarm type (a.ty): Select “off” or “Pr.AL”, process alarms support high/low alarms (set according to a.sd).

Alarm source (sr.a/is.a): Select the input source (such as analog input 1) and instance for alarm monitoring to ensure matching with the controlled object.

Alarm setting value (a.hi/a.Lo): Set the high/low alarm trigger value (-1999.000-9999.000 ° F/° C, default high alarm 300.0 ° F or 150.0 ° C, low alarm 32.0 ° F or 0.0 ° C), which needs to be set according to the process safety range.

Lock and mute (a.La/a.si): When “a.La” is set to “LAt (lock)”, it needs to be manually cleared after the alarm is triggered; When “a.si” is set to “on”, the alarm output can be muted through the Reset key or communication command.

Communication Configuration (Setup Page Communications Menu)

Protocol (pCoL): Select the protocol for port 1 (Standard Bus or Modbus RTU), and port 2 supports Modbus RTU, EtherNet/IP, DeviceNet, Profibus DP depending on the model.

Address and baud rate: Modbus addresses 1-247, Standard Bus addresses 1-16, DeviceNet addresses 0-63, Profibus addresses 0-126; The baud rate should be selected according to network requirements (such as Modbus RTU 9600bps, DeviceNet 250kbps), and all network devices should be consistent.

IP parameters (EtherNet/IP/Modbus TCP only): Set “iP. ∧Џ” to “dhCP (auto fetch)” or “F.Add (fixed IP)”. Fixed IP requires setting ip.f1-ip.f4 (IP address), ips1-ips4 (subnet mask), and ipg1-ipg4 (gateway). After modification, the controller needs to be restarted to take effect.

（3） Calibration operation

Calibration prerequisite: It is necessary to confirm that the input/output readings exceed the accuracy range (such as a large deviation between the simulated input display value and the standard signal source). Before calibration, a standard signal source with higher accuracy than the equipment (such as a high-precision thermocouple simulator, DC power supply), a high-precision measuring instrument (such as a 4.5 bit multimeter), and the controller must be at a stable ambient temperature (25 ° C ± 3 ° C).

Analog Input Calibration (Factory Page Calibration Menu)

Input offset (ELi. o): Connect a low range standard signal (such as a thermocouple 0.000mV, current 0.000mA), read the controller display value, and if there is a deviation from the standard value, adjust “ELi. o” to make the display value equal to the standard value (range -1999.000-9999.000).

Input slope (ELi. S): Connect a high range standard signal (such as thermocouple 50.000mV, current 20.000mA), read the controller display value, and if there is a deviation from the standard value, adjust “ELi. S” to make the display value equal to the standard value (range -1999.000-9999.000). Slope calibration affects the accuracy of the entire range.

Output Calibration (Factory Page Calibration Menu)

Output offset (ELo. o): Configure the output to a low range value (such as voltage 0.0V, current 4.0mA), measure the actual output value with a multimeter, adjust “ELo. o” to make the actual value equal to the set value (range -1999.000-9999.000).

Output slope (ELo. S): Configure the output to a high range value (such as voltage 10.0V, current 20.0mA), measure the actual output value with a multimeter, adjust “ELo. S” to make the actual value equal to the set value (range -1999.000-9999.000).

Calibration precautions: Calibration parameters need to be saved to EEPROM (via “Setup Page Global Menu Usr. s”) to avoid power loss; After calibration, it is necessary to verify the accuracy of multiple intermediate points to ensure that the entire range meets the requirements; Non professionals are not recommended to perform calibration operations, please contact Watlow technical support.

Equipment Overview and Application Scenarios

core positioning

NAE (Network Automation Engine) and NIE (Network Integration Engine) are monitoring devices that support web access and are based on Ethernet. Their core functions are to monitor and control on-site building automation equipment, HVAC equipment, and lighting systems. Unless otherwise specified in the document, the MS-NAE55xx-x and MS-NIE55xx-x series are collectively referred to as NAE55.

Emission compliance requirements

United States: Compliant with FCC Part 15 Class A digital device restrictions, only applicable to commercial environments. If interference occurs in residential environments, users need to resolve it themselves.

Canada: Meets the requirements of the Canadian Interference Equipment Regulations (R è glement sur le mat é riel brouilleur du Canada).

Preparation before installation

Package contains components

1 NAE55 host

1 data protection battery (individually packaged)

1 installation manual

Required materials and specialized tools

4 fasteners for compatible mounting surfaces (M4 screws for Europe, # 8 screws for North America)

2 sections of DIN rails 36 centimeters (14 inches) and above (only for DIN rail installation scenarios)

1 small flathead screwdriver (used to fix the communication cable of the terminal block)

Installation environment requirements

Stay away from corrosive gases and follow the environmental restrictions specified in the technical specifications.

Avoid installing on surfaces that are prone to vibration (such as pipelines) or near electromagnetic interference sources (to prevent interference with communication).

Reserve sufficient space for wiring and terminal connections (refer to size requirements in Figure 2).

The power supply should not be installed below NAE55.

When installing panels/enclosures, it is necessary to avoid sealing the enclosure and ensure that the enclosure walls or transformers do not obstruct the equipment ventilation openings.

Devices that cause the temperature of the NAE55 processor to exceed 77 ° C (171 ° F) must not be added inside the casing (embedded temperature sensor data must be viewed through diagnostic tags).

Installation process

Installation method selection

NAE55 supports three installation methods: wall mounting, DIN rail mounting, and shell mounting. The core operations are as follows:

1. Wall installation (vertical surface)

Mark the four installation hole positions on the wall according to the dimensions in Figure 3 (horizontal installation hole spacing of 317.5mm, vertical installation hole spacing of 63.5mm) or directly using the host as a template.

After drilling, if anchor bolts need to be fixed, they should be inserted into the holes. First, screw the screws into the top two holes, leaving enough space to accommodate the installation feet.

When installing horizontally, hang the top mounting foot of the host on the screw; When installing vertically, the host needs to be held in a fixed position.

Insert the screws into the two holes at the bottom, being careful not to tighten them too tightly (to avoid damaging the mounting feet or housing).

2. DIN rail installation

Install two sections of DIN rails horizontally, with a center to center distance of 125 millimeters (4.9 inches).

Pull the DIN buckle at the bottom of the host to the outer position.

Hang the DIN rail hook on the back of the host onto the rail.

Push the DIN buckle back to its original position and secure the host.

Disassembly steps: First, move the DIN buckle to the outside, and then remove the host from the guide rail.

3. Shell installation

Install the casing according to the manufacturer’s instructions.

Following the “Installation Environment Requirements” and the above installation specifications, fix NAE55 inside the casing.

Special installation requirements

The UL 864 certified models (MS-NAE5510-0U and MS-NIE5510-0U) must be installed inside a lockable housing.

Wiring operation

Precautions before wiring

Before wiring, a data protection battery must be installed (see “Settings and Adjustments” section), and a 24VAC power supply must not be connected.

Only copper conductors are used, and wiring must comply with local, national, and regional regulations.

Do not exceed the electrical rating of the equipment (NAE55 is a low-voltage equipment,<30VAC), and do not connect to high voltage (otherwise the equipment will be damaged and the warranty will be invalidated).

The terminal block key must not be removed, and the terminal plug and socket are designed to be foolproof and can only be correctly connected.

Prevent electrostatic discharge (avoid damaging equipment and void warranty).

The power cord and communication cable should be kept at least 50 millimeters (2 inches) away from the ventilation duct on the side of the equipment.

Reserve a certain degree of slack in the cables, and arrange the wiring neatly to ensure ventilation, LED visibility, and maintenance convenience.

Core wiring steps

Ethernet connection: Insert the Ethernet cable into an 8-pin RJ-45 Ethernet port (supporting 10/100 Mbps).

Building Automation System (BAS) Network Connection:

N2 or MS/TP network: Connect three bus lines to a 4-terminal plug labeled FC A or FC B (Figure 6).

LONWorks compatible network: Connect the bus line to a 3-terminal plug (Figure 7), and there is no polarity requirement for the network wiring.

Note: The N2 and BACnet MS/TP bus protocols are different and cannot be connected to the same FC bus port; If connecting to N2 or MS/TP bus, an End of Life (EOL) switch needs to be set up (see “Settings and Adjustments” section).

Modem connection: If needed, connect the phone line to the MODEM port (built-in modem model), or connect an external modem to the USB A port.

RS-232 serial port connection (if required): Use a 9-pin male to male null modem cable to directly connect to a computer, only for point-to-point protocol (PPP) network connection (Serial A port) or obtaining an IP address (Serial B port).

Power connection: Connect the power cord of the 24VAC transformer to the power terminal block (Figure 8) to ensure that the transformer phases of all network devices are consistent (reducing interference and grounding loop issues).

Different network topology wiring specifications

Core limitations and requirements for network types

The N2 network supports 100 devices on a single bus, with a maximum cable length of 1500 meters without repeaters; Recommended 1.5mm ² (18 AWG) 3-core wire,+/- bus must be twisted pair

BACnet MS/TP network supports 100 devices on a single FC bus, with a cable length of 1500 meters without repeaters; Recommended 0.6mm (22 AWG) 3-core shielded twisted pair cable

Ethernet network star topology (requiring network hub/switch), with a maximum of 100 devices connected to a single site

LONWorks network bus topology stub cable with a maximum length of 3 meters; FTT-10 nodes can have a maximum of 64 (without repeaters) or 128 (with repeaters); Install corresponding terminators according to topology type

Settings and Adjustments

Install data protection battery

Remove the battery and open the battery compartment cover on the device (Figure 1).

Connect the connector of the battery cable to the connector inside the battery compartment.

Place the battery in the compartment and secure it with a battery strap (pass through the hole and fasten to reduce movement).

Cover the cabin and immediately connect the 24VAC power supply (to avoid battery depletion and damage).

Attention: The battery can only provide data protection in the event of a power outage after at least 2 hours of initial charging. Full charging (24 hours) can support three consecutive power outages for protection; The battery model is MS-BAT1010-0, with a service life of 3-5 years (at 21 ° C).

Set End Connection (EOL) switch

The devices at both ends of the FC bus section need to be set as network termination devices, and each FC port of NAE55 corresponds to a set of EOL switches:

If NAE55 is an FC bus termination device, set both sets of EOL switches for the corresponding ports to the ON position (default factory ON).

If it is not a terminating device, turn the switch to positions 1 and 2.

Startup and shutdown operations

boot process

Confirm that all wiring is correct and the battery is installed.

Connect the 24VAC power supply, and the device will take up to 5 minutes to start.

Startup completion indicator: The green RUN LED is constantly on, and the red GEN FAULT LED is off.

LED test sequence at startup

After the power is turned on, the PEER COM, RUN, GENL FAULT LEDs (NAE55 also includes FC A, FC B) light up, indicating that the operating system is started.

The above LED is off and the RUN LED is flashing, indicating that the device software is loading.

The LED displays the running status of the device, and if the RUN LED is constantly on, it indicates that the device is ready.

Shutdown process

Disconnect the 24VAC power supply (unplug the power terminal block plug).

The device is powered by a data protection battery and continues to operate for 1-8 minutes (backup volatile data) until the POWER LED goes out.

If the power outage exceeds 48 hours, the data protection battery should be removed after the POWER LED is turned off (to avoid battery depletion and damage).

System restart switch

The System Re Boot switch (Figure 1) can only be pressed when the device is unresponsive and cannot be accessed through the user’s device. Restarting will lose the data saved last time (including alarm, trend, and audit tracking data), and other troubleshooting methods should be attempted first.

Troubleshooting

LED status indication (core reference)

Meaning and handling suggestions for abnormal LED names in normal states

POWER (green) constantly on and off indicates that the device is turned off; Always on indicates power supply from battery or 24VAC

ETHENET (green) flashing off indicates no Ethernet traffic, possibly due to network failure or poor connection

FC A/FC B (green) flashing constantly indicates that the port has defined a controller but there is no communication; Extinguish indicates no controller definition (NIE55 does not have this port)

BATT FAULT (red) is off and constantly on, indicating a battery fault (not connected, unable to charge). If it still lights up after 48 hours, check the connection or replace the battery

GENL FAULT (red) off and constantly on indicates general faults (such as high CPU/memory usage, high temperature, battery failure, etc.)

Common problem handling

Battery failure: Check the battery connection. If the connection is normal but still reports an error, replace the MS-BAT1010-0 model battery.

Communication failure: Confirm that the cable connection is correct, the topology meets specifications, the EOL switch setting is correct, and stay away from electromagnetic interference sources.

High temperature: Check the equipment combination inside the casing to ensure that there are no excessive heating devices and good ventilation.

Technical specifications and ordering information

Core technical parameters

Power requirements: Dedicated 24VAC power supply (North American Class 2, European SELV), 50/60Hz, input voltage 20-30VAC

Maximum power consumption of 50 VA

Working environment 0-50 ° C (32-122 ° F), 10-90% RH (dew point ≤ 30 ° C)

Storage environment -40-70 ° C (-40-158 ° F), ≤ 95% RH (dew point ≤ 30 ° C)

Processor MS-NAE5510-0U/NIE5510-0U uses 300MHz Geode GX1; Other models use 400MHz Geode GX533

512MB Flash non-volatile memory, 256MB DRAM

Dimensions (height x width x depth) 226 x 332 x 96.5mm (8.9 x 13.1 x 3.8 inches)

Protection level IP20 (IEC 60529)

Product and accessory ordering

Core product models (partial)

Product code description

MS-NAE5510-1 supports 2 N2 or BACnet MS/TP buses

MS-NAE5510-0U UL 864 8th edition certification, suitable for smoke control

MS-NAE5520-1 supports 1 LONWorks bus and 2 N2/MS/TP buses

MS-NAETUNL-8 N2 Tunnel Function Enabling Tool

Key components

Product code description

MS-BAT1010-0 Data Protection Battery (Replacement)

AS-XFR100-1 24VAC power transformer (with casing)

MS-SECVT-0 Serial to Ethernet Converter (N2 Tunnel Application)

Note: Add “G” after the product code for the US version, “E” for the European version, and “-701” for repair parts.

Maintenance and Compliance Information

Equipment replacement and registration

After replacing the NAE or adding new devices, it is necessary to update the site registration to ensure that the devices are recognized and communicate properly (refer to the NAE Debugging Guide LIT-1201519).

Compliance certification

United States: UL 916 certification, FCC Part 15 Class A, UL 864 smoke control certification (specific models).

Europe: CE mark, compliant with EMC Directive 89/336/EEC.

Australia/New Zealand: C-Tick logo.

International: BACnet BTL 135-2004 certification (B-BC level).

Product Core Overview

The Watlow Series 96 is a 1/16 DIN sized microprocessor based temperature controller with universal input, multi output configuration, and flexible control capabilities, designed specifically for scenarios such as plastic processing, packaging, semiconductors, food processing, and laboratory equipment. The product has high stability and multifunctional scalability as its core advantages, supporting single/dual PID control, curve programming (Ramp/Soak), remote set point retransmission and other functions. Combined with NEMA 4X front panel protection and 0.1% measurement accuracy, it can meet the precise temperature control requirements of harsh industrial environments.

Core features:

Input/output flexibility: 1 universal input (compatible with thermocouples, RTDs, process signals), 1 auxiliary input (event/remote set point), 4 configurable outputs (relay/SSR/switch DC/process retransmission), suitable for multiple types of sensors and actuators.

Control capability: Supports On Off, P, PI, PID control modes, built-in Auto tune and Burst Fire functions, curve programming supports 2 files, 8 steps per file, and can be linked and extended to 16 step continuous curves.

Convenient operation: The patented Custom Menu can add 16 commonly used parameters, dual 4-digit LED display, support ° C/° F/process unit switching, intuitive button operation, and can be quickly mastered by both new and expert users.

Communication and Expansion: Optional EIA/TIA-232/485 communication (Modbus RTU protocol), supports remote configuration and data retransmission, and some models have event input triggering functions (such as start/pause curves, reset alarms).

Product model and core configuration

（1） Model coding rules

The model consists of 12 characters, and the key dimensions are defined as follows. The complete model format is 96 [power] [input 2] [output 1] [output 2] [output 3] [output 4] [software/display]:

Encoding position meaning optional configuration

Power supply (3rd position) Power supply type A=100-240V AC/DC, B=24-28V AC/DC

Input 2 (4th digit) Auxiliary input function 0=None, 1=Event input+Remote set point (0-5V/4-20mA)

Output 1-4 (bits 5-8) Output type C=switch DC/open collector, D=electromechanical relay (2A), F=process output (0-10V/4-20mA), K=SSR (0.5A), A=none

Software/Display (bits 9-12) Function and Display 00=Standard Software, AA=Curve Programming Software; RR/RG/GR/GG=red/green dual display combination

（2） Core hardware specifications

Category detailed parameters

Input Characteristics – General Input: Thermocouples (J/K/T/N/E/R/S/B, etc.), RTDs (2/3-wire 100 Ω platinum resistors), process signals (0-10V/4-20mA, etc.).

-Input accuracy: ± 0.1% range ± 1 ° C (standard conditions), sampling rate 10Hz (single input)/5Hz (dual input).

-Auxiliary input: Event input supports dry contact or 3-36V DC voltage, remote set point supports 4-20mA/0-10V signal.

Output capability – Relay output: Form C contact, 2A@250V  AC/30V DC， The mechanical lifespan is 100000 cycles.

-SSR/DC switch: SSR output 0.5A@20-280V  AC， Switch DC maximum 200mA@42V  DC。

-Process output: 0-10V (minimum 1k Ω load) or 4-20mA (maximum 800 Ω load), accuracy ± 15mV/± 30 μ A.

Environment and Protection – Operating Temperature: 0-65 ° C (non condensing), Relative Humidity: 0-90% (non condensing).

-Protection level: front panel NEMA 4X, enclosure IP4X.

-Power consumption: Maximum 7VA, supports power-off data storage (non-volatile memory).

Installation and wiring specifications

（1） Installation requirements

Panel opening and fixing

Hole size: 52mm × 52mm (2.05in × 2.05in), panel thickness 1.5-9.7mm (0.06-0.38in).

Installation steps: Confirm that the front panel sealing ring is in place → Insert the controller from the front of the panel → Install the fixing ring and buckle → Tighten the screws (with a maximum gap of 0.025 inches) to ensure a leak proof seal.

Attention: Avoid excessive tightening of screws that may cause damage to the panel. When installing multiple units in parallel, a heat dissipation distance of ≥ 30mm should be reserved and kept away from corrosive gases and strong vibration environments.

Power supply and wiring safety

Power wiring: For high-power models (A), connect L1/L2 terminals (100-240V AC/DC), and for low-power models (B), connect+/- terminals (24-28V AC/DC), matching the power type indicated on the model label.

Wiring specification: Wire specification 12-22 AWG, terminal torque 5.0 in lb, analog input and power/digital signals need to be isolated and wired to avoid ground loop interference.

Safety compliance: Following NEC wiring standards, explosion-proof switches are required for hazardous environments, and sensor wiring must match the type (thermocouple extension wire material is consistent, 3-wire RTD lead resistance is balanced).

（2） Key wiring example

Sensor wiring

Thermocouple: The negative electrode (usually red) should be connected to the S1 terminal, and the extension wire should match the thermocouple material (such as K-type wire) to avoid errors caused by mixing.

When wiring RTD with a 3-wire system, the resistance of the three leads should be consistent (≤ 20 Ω), and S1 should be connected to a white lead to compensate for the effect of lead resistance through wiring.

Process signal: 4-20mA signal connected to+R1/- S1 terminal (input impedance of 100 Ω), 0-10V signal connected to+T1/- S1 terminal (input impedance of 20k Ω), requiring separate shielded wiring.

Output and communication wiring

Relay output (D-type): When connecting to an AC load, an RC suppressor (Watlow model 0804-0147-0000) should be connected in series to avoid arcing damage to the contacts due to power failure of inductive loads.

Communication wiring: EIA-485 uses twisted pair cables, with T+/R+connected to terminal B and T -/R – connected to terminal A. A 120 Ω terminal resistor needs to be added at the end of the bus, and it can support up to 32 devices in a network (with extension relays up to 247).

Event input: The dry contact is connected to the EVENT+/- terminal, with an active state resistance of<2k Ω and an inactive state resistance of>23k Ω. The voltage input supports 3-36V DC, with an active state resistance of>3V and an inactive state resistance of<2V.

Operating interface and core functions

（1） User interface

Keys and Display

Key functions: up/down arrow keys (parameter adjustment/menu scrolling), forward key (confirm/enter submenu), infinite key (return to home page/start/pause curve).

Display mode: The process value/error code is displayed on the upper screen, and the set value/parameter name is displayed on the lower screen. The indicator lights include output activation (1-4), manual mode (%), and profile mode.

Custom menu: Press and hold the forward key+infinite key for 6 seconds to enter the factory page, where you can add commonly used parameters (such as set points, PID parameters, alarm thresholds), up to 16 items, for quick access without the need for layer by layer navigation.

Menu Structure

Home Page: Display process values and set points, allowing for direct adjustment of commonly used parameters.

Operations page: including monitoring, users PID1/2、 Alarm menu, configurable control mode, automatic setting, alarm threshold.

Setup page: Configure input types, output functions, global parameters (units, fault modes, etc.).

Factory page: Customize menu, lock, diagnostic, calibration functions (permission required).

（2） Core function operation

PID control and automatic tuning

Automatic tuning: Enter “Operations – Auto tune” and select “tune”. The controller aims to achieve 90% of the current set point and calculates the optimal PID parameters by crossing the target value multiple times. During the tuning period, it outputs 100% power and ensures load safety.

Control mode switching: On Off control (proportional band set to 0), PI/PID control (adjusting proportional band/integral/derivative parameters), in dual PID mode, output 1 corresponds to heating, output 2 corresponds to cooling, and a dead zone can be set to avoid antagonism.

Burst Fire: Suitable for resistive loads, reduces electromagnetic interference (RFI) through zero crossing switching, requires the “Burst” function to be enabled in the PID menu, with a cycle time of 0.1-60 seconds.

Curve Programming (Ramp/Soak)

Curve configuration: Supports 2 files (File1/File2), with 8 steps per file. The step types include Set Point, Soak, Jump Loop, and End. Event output can be set (such as starting an external device).

Operation: Press the infinite key from the homepage to enter the pre run menu, select the file and start steps, and then press the infinite key to start; Press the infinite key to pause during operation, and the pause step can be restored through the “resU” parameter.

Waiting function: The insulation step supports “Wait for Event” (event input trigger) and “Wait for Deviation” (process value entering deviation zone trigger), and timing can only start after meeting the conditions.

Alarm and fault handling

Alarm configuration: 4-channel alarms can be set as process alarms (fixed threshold) or deviation alarms (relative to the set point), supporting high/low alarms, locking/non locking, and mute functions. Hysteresis can be set to 1-9999 units to avoid false triggering.

Fault diagnosis: Input error (sensor open circuit/over range), system error (RAM/ROM fault), open-loop detection (100% output without process value change), locate the problem through the error code on the display screen (such as Err1-Err16), refer to the appendix for troubleshooting.

Fault mode: When the sensor fails, it can be set to Bumpless, Manual mode, or Off output mode. Bumpless switching can maintain the output power before the fault and avoid process fluctuations.

Communication and Remote Configuration

（1） Communication parameter settings

Protocol and hardware: Supports Modbus RTU protocol, optional EIA-232 (model including “R”) or EIA-485 (model including “U”) communication module, wiring needs to distinguish T+/R+/T -/R-terminals.

Configuration steps: Enter “Setup – Output4- Baud Rate” to set the baud rate (1200/2400/4800/9600/19200), and set the device address (1-247) in “Address” to ensure consistency with the parameters of the upper computer (PLC/PC).

Data retransmission: Output 4 can be configured as a retransmission function (model includes “M”), supporting retransmission process values, setpoints, or output power. The signal range is calibrated through “Scale Low/High” and “Range Low/High” (such as 4-20mA corresponding to 0-100 ° C).

（2） Remote operation example

The upper computer reads the process value (register 100), set point (register 300), and alarm status (register 106) through Modbus.

Remote start curve: By writing the Modbus command register (40001=1 to start File140002=1 to start Step1).

Remote parameter modification: Write the set point to register 300 and write the PID parameter to the corresponding register (such as proportional band 500), ensuring communication write permission (non-volatile memory disable requires closing register 24).

Maintenance and troubleshooting

（1） Daily maintenance

Regular inspection: Clean the sealing ring and heat dissipation area of the front panel on a monthly basis, tighten the terminals quarterly (to avoid cold flow loosening), and calibrate the input/output annually (through the “Factory Calibration” menu, a standard signal source is required).

Parameter backup: Save commonly used parameter configurations or record key parameters (input type, PID parameters, alarm thresholds) through the “Factory Custom Menu” to avoid reconfiguration after faults.

Calibration process: Input calibration requires providing high and low point standard signals (such as thermocouple 0mV/50mV), calculating the correction value through “Electrical Input Slope/Offset”, and outputting calibration in the same way (such as 4-20mA signal calibration).

（2） Common fault handling

Possible causes and solutions for the fault phenomenon

No display/output power supply not connected, fuse burned out, safety interlock activated. Check the power supply voltage and fuse (Slot C terminal 98/99), confirm the interlock switch status, and re tighten the power supply wiring

The process value deviation is large. The sensor wiring is incorrect, the calibration offset is not set, and the input type does not match. Check the sensor wiring (thermocouple positive and negative poles/RTD leads), adjust the “Calibration Offset”, and confirm that the “Input Type” is consistent with the sensor

Communication failure: baud rate/address mismatch, reversed wiring, no terminal resistor added. Unify device communication parameters, check the correspondence between T+/R+and A/B terminals, and add a 120 Ω resistor at the end of the bus

The alarm cannot be cleared. The alarm condition has not been lifted and the alarm lockout confirmation process value has returned to the safe range (including the hysteresis area). Press the infinite key to clear the lockout alarm and check the “Latching” parameter setting

The curve cannot be started and has not entered the pre run mode. The step type configuration is incorrect. Press the infinite key to enter the pre run menu, select the file and step, and confirm that there is no “Jump” loop error in the curve step (such as jumping to the current step)

Product Core Overview

Watlow PM PLUS ™  It is an enhanced PID/integrated limit controller that optimizes user experience and functional scalability while being compatible with the previous generation EZ-ZONE PM controller. The product is positioned as an industrial grade temperature and process control, supporting single/dual PID control loops and integrating functions such as limit control, timing, and curve programming. It is widely used in semiconductor manufacturing, chemical reactions, equipment heating, and other scenarios. Its core advantages include Bluetooth wireless configuration, intuitive touch operation, support for multiple communication protocols, and comprehensive security authentication, which can adapt to the precise control needs in complex industrial environments.

Core features:

Compatibility and Upgradeability: Fully compatible with the wiring and parameter settings of EZ-ZONE PM, can be replaced without hardware modification, and upgraded with smooth touch keyboard, multilingual display (English/German/Spanish) and other operations.

Control capability: Supports PID (including P/PI/PD mode), switch control, curve programming (4 curves, a total of 40 steps), equipped with TRU-TUNE+adaptive algorithm and automatic tuning function to improve dynamic control accuracy.

Communication and wireless functions: Supports Bluetooth (via EZ-LINK mobile application), Modbus RTU/TCP, EtherNet/IP, DeviceNet and other protocols, allowing remote configuration of parameters and monitoring, reducing on-site wiring dependence.

Safety and Certification: Certified by UL, CSA, CE, RoHS, FM, etc., some models support Class 1, Zone 2 hazardous environments, integrate limit control and multiple alarms to ensure equipment and personnel safety.

Product model and core configuration

（1） Model classification and structure

The product is divided into three series based on installation size and function. The core model parameters are defined by a 14 digit configuration code, and the key dimensions are as follows:

Classification, specific specifications, applicable scenarios

Installation size: 1/16 DIN (PM6), 1/8 DIN vertical (PM8), 1/8 DIN horizontal (PM9). Different panel space requirements, 1/16 DIN is suitable for compact scenarios, and 1/8 DIN is suitable for multi parameter display requirements

Core function – PID basic type (C/R/T/J/N): including universal input, curve programming (some models), and timing function

-Integrated limit type (L/M): Additional support for sensor backup, over limit protection, output 4 fixed limit control – Basic type: Single heating/cooling control

-Integrated type: Scenarios that require dual safety protection (such as high-temperature furnaces and hazardous material heating)

The power supply and I/O power supply can be selected from 100-240V AC or 20-28V AC/12-40V DC. The digital I/O supports 2-point or 6-point expansion to adapt to the global power grid. Multiple I/O point models can be connected to external trigger signals (such as emergency stop and start switches)

Output types support switch DC, mechanical relay (5A), SSR (0.5A), NO-ARC relay (15A), universal process output (0-10V/4-20mA) – NO-ARC relay: high-power resistive load (such as large heaters)

-Universal process output: signal retransmission to recorder or PLC

（2） Core hardware specifications

Category detailed parameters

Input Characteristics – Universal Input: Thermocouple (J/K/T/E, etc.), RTD (100 Ω/1k Ω), Process Signal (0-20mA/0-10V)

-Input accuracy: ± 0.1% range (typical value), temperature stability ± 100ppm/° C

-Sensor backup: supports dual sensor switching, automatically switches to backup sensor in case of failure

Output Capacity – Maximum Output: 15A NO-ARC Relay (AC Load Only)

-Process output: 0-10V (minimum 1k Ω load) or 4-20mA (maximum 800 Ω load), accuracy ± 20 μ A/± 10mV

Environmental adaptability – Operating temperature: 0-65 ° C (non condensing)

-Protection level: Front panel IP67/IP4X (indoor)

-Anti interference: Compliant with IEC 61000-4 series standards, anti-static and radio frequency interference resistant

Installation and wiring specifications

（1） Installation requirements

Panel opening and fixing

Size standards: 1/16 DIN (PM6) opening 45 × 45mm, 1/8 DIN (PM8/9) opening 45 × 92mm (vertical)/92 × 45mm (horizontal).

Installation steps: Remove the terminal and fixing ring → Insert the controller from the front of the panel → Align the fixing ring and tighten the screws (torque 3-4 in lbs) → Reinstall the terminal.

Environmental restrictions: Avoid corrosive gases and high vibration environments, install vertically to ensure heat dissipation, and reserve a spacing of ≥ 30mm for parallel installation of multiple units.

Power supply and wiring safety

Power adaptation: High power models (1/2) are connected to 100-240V AC, while low-power models (3/4) are connected to 20-28V AC/12-40V DC, and must match the power type indicated on the equipment label.

Wiring specifications: Wire specifications are 12-30 AWG, terminal torque is 5.0 in lb, unused terminals need to be empty, analog input and power/digital signals need to be isolated and wired to avoid grounding loops.

Attention to hazardous environments: Class 1, Zone 2 models (with “12” at the end of the configuration code) require the use of explosion-proof switches. It is prohibited to plug or unplug wiring when powered on, and replacement parts must comply with hazardous environment certification.

（2） Key wiring example

Sensor wiring

Thermocouple: Connect the negative electrode (usually red) to the S1/S2 terminal, and the extension wire should be consistent with the thermocouple material (such as K-type extension wire for K-type).

RTD: 2/3 wire system, 3-wire system needs to ensure that the resistance of the three leads is consistent (≤ 20 Ω), S1 is connected to a white lead to compensate for the lead resistance.

Process signal: 4-20mA signal connected to+R1/- S1 terminal, 0-10V signal connected to+T1/- S1 terminal, requiring separate shielded wiring.

Output and communication wiring

NO-ARC relay: only connected to AC loads (85-264V AC), load current ≤ 15A, prohibited from series use, cycle time ≥ 5 seconds.

Communication wiring: RS-485 uses twisted pair cables (T+/R+connected to B, T -/R – connected to A), and a 120 Ω terminal resistor needs to be added at the end of the bus. The distance between the communication line and the power line should be ≥ 305mm.

Digital I/O: 2-point I/O model (configuration code 2/4) supports dry contact or 3-36V DC input, 6-point I/O model (configuration code C/D/M/N) expandable switch output, with a maximum load of 1.5A per channel.

Operating interface and core functions

（1） User interface

Touch buttons and display

Key functions: Home button (return to home page), left and right buttons (menu navigation), increase and decrease buttons (parameter adjustment), custom function buttons (F1/F2, can set start/stop curves, reset alarms, etc.).

Display mode: default display of process values (such as temperature), set values, and regions, supporting 4 themes (such as white background, high contrast blue background), customizable display parameters (such as output power, remaining time).

Message prompt: Automatically switch display in case of alarm/error, such as “Limit High” or “Input Error”. The lock alarm can be cleared by pressing the home button.

Menu Structure

Operations List: Real time monitoring and adjustment of operating parameters (such as set values, manual power).

Setup: Configure basic parameters such as input type, control algorithm, alarm threshold, etc.

Profile: Edit curve steps (heating/holding/waiting for events).

Factory List: Calibration, password locking, factory reset (permission required).

（2） Core function operation

PID control and tuning

Auto tuning: Enter “Operations – Autotune” and select “Yes”. The controller aims to achieve 90% of the set value and automatically calculates parameters such as proportional band and integration time. During the tuning period, it outputs 100% power and ensures load safety.

TRU-TUNE+adaptive: enabled in the “Setup Control Loop”, automatically optimizes PID parameters by monitoring process value fluctuations, suitable for scenarios with dynamic load changes (such as batch production).

Manual tuning: If the automatic tuning effect is not good, you can manually adjust the Heat Prop. Band and Time Integral. It is recommended to set the integration time to 0 first and gradually reduce it after stabilization to eliminate static errors.

Curve Programming (Ramp/Soak)

Curve configuration: Enter the “Profile List”, each curve supports 10 steps, including Time/Ramp Rate, Soak, Wait for Event/Process, Jump, etc.

Example: Set the target temperature for “Step 1 (heating up)” to 150 ° C for 30 minutes; Step 2 (insulation) lasts for 60 minutes; Set ‘Step 3’ to ‘Hold’ to maintain the final temperature.

Startup method: It can be remotely started through function keys, numerical input, or communication. It can pause/resume during operation. If the restart time is ≤ the set “Power Off Time” after power failure, the curve can be continued.

Alarm and limit control

Alarm configuration: Supports 4 alarm channels, including process alarm (fixed threshold), deviation alarm (relative set value), and can be set to lock/non lock, shield (not triggered temporarily when starting/set value changes).

Limit control: The integrated limit model (L/M) supports high/low limit, and automatically cuts off the output when it exceeds the limit. It needs to be manually reset (through buttons, digital inputs, or communication), and outputs 4 fixed limit dedicated.

Current monitoring: Equipped with a current transformer (CT) input, it can detect open/short circuits in the heater, trigger the “Heater Error” alarm, and protect the load and controller.

Communication and Remote Configuration

（1） Communication Protocol and Settings

Protocol configuration key points applicable scenarios

Bluetooth (EZ-LINK application) devices can be paired through Bluetooth after being powered on, supporting parameter reading and writing, alarm viewing, curve downloading, and quick on-site configuration without the need for physical wiring, reducing wiring costs

Modbus RTU baud rate 1200-19200bps, addresses 1-247, supports function codes 03 (read register), 06 (write single register), and 16 (write multiple registers) to connect PLC or HMI and achieve multi device networking

EtherNet/IP supports DHCP or fixed IP, with a maximum of 40 members in the I/O assembly, capable of real-time transmission of process values and control commands in industrial Ethernet environments, requiring high-speed data exchange

DeviceNet node address 0-63, baud rate 125/250/500kbps, supports implicit/explicit communication, compatible with Rockwell and other brands of PLCs, suitable for device layer networking

（2） Remote configuration process (using Bluetooth as an example)

Download the EZ-LINK app (supports iOS/Android), turn on the controller Bluetooth (“Setup – Global – Bluetooth” set to “On”).

Search for and pair devices within the application, enter “Parameter Configuration”, and modify input types (such as thermocouple J-type), PID parameters, and alarm thresholds.

Save parameters to the device or local (supports 2 sets of user configurations), monitor process values and output power in real-time during operation, and receive alarm push notifications.

Maintenance and troubleshooting

（1） Daily maintenance

Regular inspection: monthly cleaning of panels and heat sinks, quarterly tightening of terminals (to avoid cold flow loosening), annual calibration of input/output (via the “Factory Calibration” menu, requiring a standard signal source).

Parameter backup: Save the configuration to User Set 1/2 through “Setup – Global – Save Settings As” to avoid resetting after a malfunction.

Firmware Upgrade: Supports firmware upgrade through communication port. The latest firmware and upgrade tool must be downloaded from the Watlow official website. Power off is prohibited during the upgrade process.

（2） Common fault handling

Possible causes and solutions for the fault phenomenon

No display/output power supply not connected, fuse burned out, loose terminals. Check the power supply voltage and fuse (Slot C terminal 98/99), re tighten the terminals, and replace the fuse (matching model required)

The temperature cannot reach the set value due to heating output fault, improper PID parameters, sensor error check output wiring and load, re perform automatic tuning, calibrate sensor offset (“Setup – Analog Input – Calibration Offset”)

Alarm cannot be cleared. Alarm not cleared, alarm locked, parameter error confirmation process value returned to safe range. Clear it through “Operations – Alarm – Clear Alarm” and check the alarm type configuration

Communication failure: Address/baud rate mismatch, wiring error, interference with unified device communication parameters. Check RS-485 polarity (A/B lines), route away from power lines, and add terminal resistors

Product Core Overview

The Watlow ceramic fiber heater is a radiation type heater designed specifically for high-temperature scenarios. The core consists of an alumina silica ceramic fiber insulation layer and built-in heating elements, which have the characteristics of low quality, high insulation, and strong thermal shock resistance. Its maximum working temperature can reach 2200 ° F (1204 ° C), with a power density range of 5-30 W/in ² (0.8-4.6 W/cm ²). It only works through radiation heat transfer and can directly adapt to common power supply voltages without the need for transformers. It is widely used in industrial scenarios such as high-temperature furnaces, metal melting, semiconductor processing, and glass ceramic processing.

Core advantages:

High temperature adaptation: far exceeding the temperature limit of traditional heaters, suitable for extreme working conditions of 815-1204 ° C.

Efficient and energy-saving: Low quality insulation materials (10-15 lb/ft ³ density) heat up rapidly, and energy is concentrated on the load rather than self loss.

Flexible structure: Supports various forms such as flat, semi cylindrical, and fully cylindrical, and can customize multi-faceted integrated structures to adapt to complex installation environments.

Durable and reliable: inorganic adhesive and ceramic coating design, resistant to thermal cycling and chemical corrosion (except hydrofluoric acid, phosphoric acid, and strong alkali).

Core product configuration and features

（1） Types and differences of heating elements

The heater provides 5 core component configurations, suitable for different power densities and application scenarios:

Component type, structural characteristics, key advantages, power density improvement, applicable scenarios

Embedded Sined components are embedded inside ceramic fibers, divided into flat/V-shaped insulation with large thickness and strong thermal stability. The V-shaped insulation is 27% higher than the flat insulation in medium high temperature and medium power density scenarios, suitable for large-sized flat/semi cylindrical devices

Exposed Sined components are exposed on the surface of ceramic fibers, and the temperature difference between the flat/V-shaped components and the cavity is small, resulting in a long lifespan. The V-shaped components have a 20% increase in surface area and large inner diameter compared to flat components, and require rapid heating scenarios

Embedded Coil: a coil element embedded in complex curved surfaces, suitable for fitting small customized chambers, operating under high voltage, low current, low power density, and low duty cycle conditions, suitable for small tube furnaces

（2） Product Form and Specifications

Basic form

Flat panel: Supports four types: Type 5 (full heating), Type 6 (side insulation), Type 7 (end insulation), and Type 8 (full edge insulation), with sizes ranging from 4 × 6 in to 36 × 36 in.

Semi cylindrical: Type 1 (full vestibule), Type 2 (left vestibule), Type 3 (right vestibule), Type 4 (no vestibule), with an inner diameter of 1/2 inch to 8 inches and a length of 6-42 inches.

Full cylindrical shape: with an inner diameter of 1/2 inch to 8 inches and a length of 6-12 inches, suitable for small tube heating scenarios.

Customized molding: It can mold box shaped structures with up to five integrated sides, supporting complex curve and polygon designs.

Key specification parameters

Voltage: Standard 60/120/240 VAC (± 5%), customizable up to 600 VAC or three-phase wiring scheme.

Power: 60-11500 W per unit, supporting multiple units for combined expansion. High power density models (suffix “T”) have a power density of 14.6-17.2 W/in ².

Dimensional tolerance: Heating area ± 1/16 in (± 1.6 mm), outer diameter ± 1/8 in (± 3.2 mm), wall thickness standard 2 ± 1/4 in (51 ± 6 mm).

（3） Core functions and protection

high-temperature stability

Within 24 hours of first use (1600-2200 ° F), there may be a shrinkage of ≤ 4%, which can be compensated for by factory pre firing treatment or on-site filling of ceramic fiber cotton gaps.

Ceramic fiber material does not contain organic binders, and there is no smoke or combustion risk when heated to 300 ° F (150 ° C) for the first time.

Auxiliary function options

High emissivity coating: Black surface coating (part number CFBSC) with an emissivity close to 1.0, improving radiative heat transfer efficiency.

Thermocouple installation: Supports embedded ceramic tubes (0.140-0.265 in inner diameter), can be arranged close to components, and accurately monitors hot spot temperatures.

Lead protection: Provides options such as ribbon leads (601 alloy 600), flexible leads (nickel material), etc. The lead length can be adjusted from 0-42 inches, and is equipped with ceramic sleeves to protect against high temperature oxidation.

Installation and usage specifications

（1） Key installation requirements

Fixed method: Priority should be given to mechanical fixation such as pins, clamps, and overlapping edge clamping to avoid adhesion (which cannot adapt to the thermal expansion and contraction of metal structures).

Heat dissipation and insulation: A backing insulation blanket (recommended density of 6 lb/ft ³, part number CFBLKT series) is required to improve energy efficiency and reduce external surface temperature (external temperature can be controlled within 450 ° F under 2200 ° F conditions).

Space reservation: When installing multiple units, a shrinkage gap should be reserved, and the gap should be filled with loose ceramic fibers after the first use.

Environmental protection: Avoid contact with pollutants such as oil and lubricants. Ceramic fiber porosity is greater than 90%, and the infiltration of pollutants can damage heating elements.

（2） Wiring and safety regulations

Lead wire treatment: The lead wire should be kept away from high temperature areas and connected by crimping. Regularly check for looseness caused by thermal expansion and contraction.

Temperature control: Low quality fast response thermocouples must be used (recommended distance from heating surface ≤ 1/16 in) to avoid self damage of the heater due to lack of temperature control.

Fault protection: Equipped with semiconductor fuses (such as Bussmann 170M series), with a short-circuit current rating (SCCR) of 200kA, in compliance with UL 508 safety standards.

（3） Maintenance and Repair

Cleaning: Regularly clean the surface dust with compressed air to avoid accumulation that affects heat dissipation.

Repair: Minor mechanical damage can be repaired using a specialized repair kit (CFPATCHKIT), which includes ceramic fiber powder and black coating. The use of non original adhesives is prohibited.

Replacement: If the heating element is damaged, the entire heater needs to be replaced, and the built-in element cannot be repaired separately.

Selection and Accessories

（1） Selection of core dimensions

Temperature and power density matching: Under high temperature conditions (>1800 ° F), the power density needs to be reduced to avoid exceeding performance limits (refer to the product performance curve to ensure that the operating conditions fall within a safe zone).

Form adaptation: Select flat/cylindrical/customized type according to the shape of the equipment chamber. For semi cylindrical equipment with an inner diameter greater than 5 inches, V-shaped sine elements are preferred.

Voltage and wiring: The 240V standard model adopts dual element parallel connection, and can be customized with 480V/277V or three-phase internal wiring schemes.

（2） Key accessories

Accessory type, function, usage, recommended model

Insulation blanket enhances insulation effect and reduces external temperature CFBLKT1/4 (6mm thick) and CFBLKT1 (25mm thick)

Thermowell fixed thermocouple, electrically isolated CC405 series (inner diameter 3.6-13.1mm)

Hardening agent repairs cutting edges, enhances surface hardness CFRGPPT (pint pack), CFRGDGAL (gallon pack)

Ceramic sleeve protection lead or fixing pin CC405-1 (3.6mm inner diameter), CC405-9 (13.1mm inner diameter)

Repair kit for small area damage CFPATCHKIT (including ceramic powder and coating)

Typical application scenarios

Recommended Configuration Core Value for Industry Application Scenarios

Metal processing melting furnace, insulation furnace, metal transmission line semi cylindrical/customized forming heater, high emissivity coating, high temperature resistance, fast heating, suitable for metal high-temperature processing needs

Semiconductor wafer processing equipment, CVD reactor flat embedded coil components, precise temperature control, low pollution, strong thermal stability, avoiding affecting process accuracy

Glass ceramic glass forming furnace, ceramic sintering furnace, fully cylindrical/multi-faceted integrated molding, high power density bonding chamber structure, uniform radiation, improving product consistency

Laboratory and R&D small-scale experimental furnaces, analytical instruments, small-sized fully cylindrical (inner diameter 3/4-2 in) rapid heating and cooling, suitable for frequent start stop test scenarios

Product Core Overview

The Watlow Power Series is a microprocessor based silicon controlled rectifier (SCR) power controller designed specifically for industrial heater control. It supports various configurations such as single-phase, three-phase two bridge arm, three-phase three bridge arm, and single-phase multi zone. The current rating is 65-250A (at 50 ° C environment), and the voltage is compatible with 24-600V AC. It has multiple control methods such as zero crossing trigger and phase angle control. It integrates heater diagnosis, current limitation, alarm and other functions, and is widely used in industrial heating, heat treatment, semiconductor manufacturing and other scenarios. The product complies with UL 508, CE certification, IP00 protection level, pollution level 3, provides a 3-year warranty, supports Modbus RTU communication and signal retransmission function, and balances stability and flexibility.

Core advantages:

Multi configuration adaptation: covering single-phase, three-phase, and multi zone control, meeting the needs of different load types (resistive, transformer coupled loads).

Intelligent control function: supports zero crossing (fixed/variable time base), phase angle control, built-in soft start, current limit, heater drying and other functions to protect the load and optimize the control effect.

Comprehensive diagnosis and alarm: equipped with multiple alarms such as heater open circuit, over temperature, phase imbalance, etc., supporting locked/non locked modes, combined with SCR short circuit detection and fuse protection, to enhance system safety.

Flexible expansion: optional communication module (RS-232/485), signal retransmission function, supports remote monitoring and parameter configuration.

Core functions and features

（1） Control method

Zero crossing control (Burst Firing)

Fixed time base: 1-second or 4-second cycle, output power is distributed based on the complete power cycle, low noise, suitable for resistive loads (such as nickel chromium heaters).

Variable time base: dynamically adjusts the on-off cycle, with fast response speed, supports line voltage compensation, and adapts to scenarios that require precise power regulation.

DC contactor mode: Only 0% or 100% output, trigger threshold 2.0V/3.5V (voltage input), 5.0mA/8.0mA (current input), suitable for simple switch control.

Phase Angle Control

Based on partial conduction of the power cycle, power regulation is achieved, with built-in soft start (adjustable from 0-120 seconds) and support for current limitation (requiring heater diagnostic function). It is suitable for transformer coupled loads and nonlinear loads that require soft start.

The maximum rate of change can be adjusted (0.1-100%/0.1 seconds) to avoid load damage or fuse tripping caused by sudden changes in current.

（2） Key functions

Heater diagnosis and protection

Heater drying: suitable for single-phase and three-phase three bridge arm configurations, slowly heating to remove heater moisture, avoiding damage caused by direct full power start-up, and supporting overcurrent trip protection.

Current limitation: Effective in phase angle control mode, the maximum allowable current can be set to prevent overload.

Fault detection: Detect faults such as open circuit, short circuit, out of tolerance, SCR short circuit, phase imbalance, etc. of the heater, and trigger corresponding alarms.

Alarm and safety functions

Alarm types: including 10+types of alarms such as heater open circuit, over temperature, line voltage loss, frequency abnormality, communication watchdog, etc., supporting four configurations: standard, lockout, mute, lockout+mute.

Alarm output: Single channel electromagnetic relay (Form C contact), rated 3A@250V AC or 30V DC, supports energized or de energized state configuration when powered on.

Hardware protection: Built in semiconductor fuse (to be matched with specified models, such as Bussmann 170M series), supporting 200kA short-circuit current rating (SCCR).

Communication and signal retransmission

Communication: Supports RS-232/485 interface, Modbus RTU protocol, baud rate 1200-19200bps, can connect up to 247 devices (requiring repeaters).

Signal retransmission: optional 0-10V DC or 4-20mA output, adjustable load current, power and other parameters, suitable for external devices such as recorders and PLCs.

​

Installation and wiring

（1） Installation requirements

Installation method: Panel installation (N20-F30 model) or bolt fixation (F35 model), must be installed vertically to ensure heat dissipation. When multiple units are installed in parallel, heat dissipation space must be reserved.

Environmental restrictions: Working environment temperature 0-60 ° C (fan cooling)/0-65 ° C (natural cooling), relative humidity 0-90% (no condensation), avoid corrosive and high humidity environments.

Cooling requirements: Calculate the cooling demand based on power loss (1.25W/ampere/control bridge arm), and use fans, eddy current coolers, or air conditioners for cooling to ensure that the temperature inside the chassis does not exceed 50 ° C.

（2） Wiring specifications

Power and load wiring

Wire specifications: Select 6 AWG-250 MCM copper wire based on the current, with a terminal torque of 180 in lbs (20 Nm) and a wire bending radius of 2.0-8.5 inches (depending on the current specifications).

Fuse selection: Semiconductor fuses (such as Watlow 0808 series) should be used, and the specific model should be matched according to the rated current of the controller (such as 65A corresponding to 100A fuses).

Grounding requirements: The specifications of the grounding wire should be consistent with the power line, connected to a grounding terminal with sufficient current carrying capacity, and comply with NEC and local electrical regulations.

Signal wiring

Input signal: Supports 0-10V DC voltage input (input impedance 11k Ω) or 4-20mA current input (input impedance 100 Ω), and high and low trigger points can be configured through parameter settings.

Communication wiring: RS-485 uses differential signals (485 T/R+, 485 T/R -), RS-232 supports signal transmission and reception, and shielded wires are grounded at one end to reduce interference.

Retransmission signal: 4-20mA output load maximum 800 Ω, 0-10V output load minimum 1k Ω, separate wiring is required to avoid signal interference.

（3） Typical configuration wiring

Single phase: L1 is connected to the power supply, the load is connected to the output terminal and internal busbar, and the reference terminal is connected to the neutral wire or another phase wire as needed.

Three phase two bridge arm: Only switch between L1 and L3 phases, L2 is directly connected through an internal busbar, suitable for delta or ungrounded wye loads.

Three phase three bridge arm: Switch all three phases, support grounded wye loads, and ensure that the phase rotation is clockwise from A-B-C.

Multi zone: Each zone is independently wired and shares alarm output, avoiding phase conflicts between different zones (such as 180 ° inversion).

Operation and Configuration

（1） Operation interface

Display and buttons: dual four digit display (parameter values displayed on the upper screen and parameter names displayed on the lower screen), including increase and decrease keys, left and right keys, and home keys, supporting menu navigation, parameter adjustment, and alarm clearing.

Menu structure: divided into display loop (monitoring parameters), settings page (configuration control mode, alarm, communication), factory page (calibration, data backup), supporting menu locking function to prevent misoperation.

（2） Core parameter configuration

control parameters

Control algorithm: Choose zero crossing (fixed/variable time base), phase angle control, or DC contactor mode.

Soft start time: adjustable from 0-120 seconds, phase angle control mode is enabled by default to avoid starting surge current.

Current limit: Only the phase angle control mode is effective, and it needs to be paired with a heater diagnostic function to set the maximum allowable current (0-load rated current).

Heater diagnostic parameters

Drying time: 0-9999 minutes. Exceeding the set current (HbOC parameter) during the drying process will trigger a trip.

Load tolerance: Set high and low current thresholds (effective for power above 20%), triggering an alarm if the range is exceeded.

Alarm and communication parameters

Alarm configuration: Select the global alarm mode (standard/lockout/mute) or configure each alarm type separately, and set the alarm relay status (triggered by power on/off).

Communication parameters: Configure device address (1-247), baud rate, watchdog timeout (0-9999 seconds). If enabled, no communication will trigger an alarm.

（3） Calibration and maintenance

Analog input calibration: Calibrate the high and low points of voltage/current input on the factory page to ensure signal accuracy.

Retransmission calibration: Calibrate 4-20mA or 0-10V output signals to match the range of external devices.

Data backup: Supports configuration parameter backup, recovery, and factory reset, and can be backed up by system and region classification to avoid parameter loss.

Troubleshooting and Maintenance

（1） Common fault handling

Possible causes and solutions for the fault phenomenon

No output, no display. The power supply is not connected, the fuse is blown, and the display module has poor contact. Check the power wiring and fuse, unplug the display module again, and if it is ineffective, return it to the factory for repair

The heater does not generate heat, the load wiring is disconnected, the control algorithm is set to “OFF”, and the input signal is abnormal. Check the load and input wiring, confirm the control algorithm configuration, and monitor the input signal ([In] parameter) through display loop monitoring

Frequent tripping of fuses due to mismatched rated values, insufficient heat dissipation, and short circuits in the heater. Replace the corresponding type of fuse, optimize the heat dissipation of the chassis, and check the insulation and wiring of the heater

Phase angle control error [hCYL] caused by inductive load resulting in half cycle loss, low reactance delay setting increasing [rdLy] parameter (0-500) until the error disappears

Communication failure address/baud rate mismatch, wiring error, watchdog timeout. Unified communication parameters, check RS-485 differential wiring to shorten communication interruption time

（2） Daily maintenance

Regular inspection: Re tighten the terminals every 3-6 months (to avoid looseness caused by cold flow), clean the heat sink fins, and ensure no dust accumulation.

Fuse replacement: Only use designated models (such as Watlow 0808 series or Bussmann 170M series), disconnect the power and tighten according to the specified torque during replacement.

Calibration cycle: It has been calibrated at the factory and does not require frequent calibration on site. If the sensor or input module is replaced, the analog input needs to be recalibrated.

Typical application scenarios

Recommended configuration for application areas, matching core functions

Industrial resistive heater control single-phase/three-phase zero crossing control with low noise and stable power output, suitable for nickel chromium, iron chromium aluminum heaters

Transformer coupling load (such as silicon carbide rod heater) three-phase three bridge arm phase angle control soft start+current limitation to avoid load impact damage

Multi zone heating system (such as oven multi temperature zone) single-phase multi zone configuration independently controls the power of each zone, shares alarms and communication, saving installation space

Remote monitoring scenario (such as chemical reaction kettle) with communication and retransmission function Modbus remote configuration, retransmitting load current/power to the monitoring system

Wet environment heater (such as food processing) single-phase+heater drying function to dry and remove moisture, avoiding short circuit when the heater is started

Product Core Overview

The Watlow thermocouple product line covers multiple scenarios such as general industry, high temperature, and precision measurement. It adopts ASTM standard calibration types (J/K/E/T/N/R/S/B, etc.) and is based on structural designs such as mineral insulation (MI), metal sheath, and fiberglass/PFA insulation. It has characteristics such as fast response, corrosion resistance, and high temperature resistance. The temperature measurement range covers -40 ° C to 1700 ° C and is suitable for various fields such as food processing, heat treatment, semiconductor manufacturing, and diesel engine post-processing.

Core advantages:

Diversified structure: including universal tube wire type, mineral insulation type, and micro coil (MICROCOIL) ™）、 Radio frequency compatible (TR), multi-point temperature measurement, etc., suitable for different installation and environmental requirements.

Accurate and stable: Following ASTM E230 calibration tolerances, some models have an accuracy of ± 1 ° C and a repeatability of 1% -2%. It supports three types of junctions: grounded/ungrounded/bare.

Durable protection: Sheath material can be selected from 304/316 stainless steel Alloy 600、Haynes ®  230, some products come with PFA coating or fiberglass weaving protection, which is corrosion-resistant and resistant to electromagnetic interference.

Classification and Characteristics of Key Products

（1） Universal thermocouple (Tube and Wire)

Application scenarios: Food processing, medical equipment, oven/refrigerator temperature control, pipeline tracking, and other routine temperature measurements.

Core features: Temperature range -200 ° C to 900 ° C, using SERV-RITE ®  The wire is made of insulation materials such as fiberglass and PFA, and supports straight and 45 °/90 ° bending designs. The installation methods include adjustable springs, flanges, pipe clamps, and ring terminals.

Typical models: Style 10/11 (spring adjustable), Style 20/21/22 (rigid shear), Style 72 (clamp type), Style 74/75 (gasket type).

（2） Mineral Insulated (MI) Thermocouples

Application scenarios: Extreme environments such as high-temperature furnaces, turbines, nuclear reactors, semiconductor manufacturing, etc.

Core feature: Adopting XACTPAK ®  Mineral insulated metal sheathed cable, compacted MgO insulation, temperature range -40 ° C to 1200 ° C (some up to 1700 ° C), minimum sheath diameter of 0.02 inches, fast response time (0.02 inch sheath grounding response time<0.02 seconds).

Typical models: Style AB (cutting and stripping type), Style AC (plug terminal type), Style AR (connector type), Style AT (thermowell adaptation type).

（3） Special function thermocouple

EXACTSENSE ®  Series: Integrated electronic components, convert thermocouple signals into 0-5V analog signals or LIN/CAN digital signals, compatible with diesel engine aftertreatment systems (DPF/DOC/SCR), temperature range -40 ° C to 1100 ° C, accuracy ± 7 ° C – ± 12.5 ° C, immersion depth 25-200mm.

MICROCOIL ™  Series: Micro spiral design, suitable for surface temperature measurement, isothermal measurement area ensures accuracy, temperature range -40 ° C to 700 ° C, coil diameter 0.125 inches, spring loaded design suitable for uneven surfaces.

TR RF compatible type: designed for plasma applications, resistant to electromagnetic interference, dielectric strength of 3000VDC, temperature range of 260 ° C-500 ° C, tip material can be silver plated copper or aluminum nitride.

Multi point temperature measurement type: The single sheath is equipped with multiple temperature measurement points, suitable for scenarios such as distillation towers and furnaces that require gradient temperature measurement. The diameter of the sheath is 0.125-0.25 inches, supporting 2 to multiple temperature measurement points, and the spacing can be customized.

Core technical parameters

（1） Calibration type and temperature range

Calibration Type Measurement Range (° C) Typical Application Scenarios Key Characteristics

J-200 to 760 general industrial, moisture free environment iron constantan material, commonly used for medium and low temperatures

K-200 to 1260 high temperature furnace, heat treated nickel chromium nickel silicon material, corrosion-resistant, widely used

E-200 to 900 vacuum, inert environment nickel chromium copper nickel material, with the highest EMF output

T-200 to 350 low temperature, cryogenic scene copper copper nickel material, good low-temperature stability

N -200 to 1260 sulfur containing environment NiCrSi NiSi material, anti-aging

R/S 0 to 1480 high temperature precision measurement of platinum rhodium alloy, resistant to high temperature oxidation

B 870 to 1700 ultra-high temperature furnace platinum rhodium 30- platinum rhodium 6 material, excellent high temperature stability

（2） Key performance parameters

Response time: Depending on the diameter of the sheath and the type of junction, a 0.032-inch mineral insulated grounding junction takes less than 0.02 seconds, while a 1-inch rigid sheath without grounding junction takes about 4 seconds.

Wire resistance: The resistance per foot of the 24 gauge double wire is 0.3-1.5 Ω (depending on the calibration type), and it is recommended to use a thick wire gauge for long-distance wiring.

Voltage resistance and protection: Some models are resistant to electromagnetic interference (100V/m 20MHz-2GHz), with a waterproof rating of IP65 (NEMA 4X), and some are equipped with explosion-proof connectors.

Key points for installation and selection

（1） Selection of core dimensions

Temperature range: Select the calibration type based on the highest/lowest temperature of the operating conditions (such as B/R/S type for ultra-high temperature and T type for low temperature).

Environmental medium: Choose PFA coating or 316 stainless steel sheath for corrosive environments; Choose N-type for sulfur-containing environments; Choose K-type oxidation environment.

Installation method: Choose micro curved type (Style 12) for narrow spaces; Pipeline temperature measurement using clamp type (Style 72); Choose pad type (Style 74) or MICROCOIL for surface temperature measurement ™。

Signal requirement: Select EXACTSENSE for digital signal ®； Choose thick wire gauge or shielded wire for long-distance transmission.

（2） Installation precautions

Wiring: The thermocouple extension wire should be matched with the calibration type (such as J-type iron constantan wire) to avoid polarity reversal. For long-distance wiring, the influence of wire resistance should be considered.

Junction selection: Grounding junction for corrosive environments (welded with sheath to prevent medium intrusion); Avoid using ungrounded connections for grounding loops; The fastest response is required to select a bare junction (without sheath protection).

Interference protection: TR type for RF environment; Choose twisted pair cables and shielding layer for strong electromagnetic environment, with the shielding layer grounded at one end.

Typical application scenarios

Industry recommended product types, core requirement matching

Food processing universal tube wire type (Style 20/72) sanitary grade, easy to install, medium and low temperature measurement

Heat treatment/high temperature furnace mineral insulation type (Style AR/AT), high temperature resistance, thermal shock resistance, long-term stability

Semiconductor Manufacturing MICROCOIL ™/ True SURFACE precision surface temperature measurement, installation in narrow spaces

Diesel engine EXACTSENSE ® Exhaust gas temperature measurement, digital signal compatible with ECM

Chemical/petroleum multi-point temperature measurement type, Alloy 600 sheath type corrosion environment, gradient temperature measurement requirements

Plasma application TR RF compatible anti electromagnetic interference, precise temperature measurement

Product Core Information

The Watlow Series 965 is a 1/16 DIN microprocessor based temperature controller with a single input dual output design, suitable for industrial temperature control scenarios. The product complies with ISO 9001 standards, has a NEMA 4X (IP65) protection level, supports UL, CE and other certifications, provides a 3-year warranty, and is equipped with dual four digit red/green LED displays. It is easy to operate and balances stability and flexibility.

Core specification highlights:

Input type: compatible with J/K/T/N/S thermocouples, 2/3 wire RTD (100 Ω/1k Ω, supporting DIN/JIS curves), 0-5V DC voltage/4-20mA DC current process signal.

Output configuration: Dual outputs can be independently configured, with output 1 supporting heating/cooling and output 2 supporting heating/cooling/alarm/shutdown. Output types include mechanical relay (5A), solid-state relay (0.5A), switch DC, 4-20mA process output.

Control accuracy: Calibration accuracy ± 0.1% range (± 1 least significant bit @ 25 ° C environment), sampling rate 2.5Hz, display update rate 1Hz, temperature stability ± 0.2 ° C/° C environment change.

Key functions and features

（1） Control and tuning functions

Control mode: Supports PID (proportional integral derivative), P, PI, PD, and switch control. When the proportional band is set to 0, it automatically switches to switch control, and the switching difference is defined by HSC parameters.

Self tuning function: Supports heating/cooling output self-tuning, providing three thermal response modes: slow, medium, and fast. Based on 90% of the set value for “learning”, if the temperature crossover is not completed four times within 80 minutes, it will automatically exit and maintain the original parameters.

Manual tuning: Parameters such as proportional band, integral (reset), derivative (rate), and cycle time can be manually adjusted to adapt to the characteristics of complex thermal systems. The cycle time can be adjusted according to the output type (for mechanical relays, it is recommended to extend the cycle to reduce wear).

（2） Alarm and safety functions

Alarm type: Supports process alarm (absolute temperature threshold) and deviation alarm (relative to set value), output 2 can be configured as an alarm mode with/without display, and high/low threshold can be independently set.

Alarm auxiliary function: supports locking/non locking mode (locking needs to be manually cleared), alarm mute (only deviation alarm support), customizable alarm lag (HSA parameter) to avoid frequent alarms.

Fault protection: equipped with sensor open/short circuit detection, A/D conversion error detection. When the sensor fails, it can be switched to manual mode (maintain power) or turn off the output according to the lock level (LOC), and supports undisturbed switching.

（3） Auxiliary functions

Slope heating: Supports heating during startup or when the set value changes, with a rate of 0-9999 °/hour. During the heating process, the display screen alternately flashes “rP” and the target set value.

Data storage: non-volatile memory, parameters are not lost after power failure, supports calibration offset adjustment (± 180 ° F/± 100 ° C), and can compensate for sensor errors.

Locking function: 5-level locking level (LOC 0-4), restricting parameter access and operation permissions, adapting to the security management needs of different scenarios.

Installation and wiring

（1） Installation requirements

Panel incision size: 55mm (width) × 55mm (height), panel thickness 1.5-9.7mm, fixed with snap on installation ring, ensuring that the sealing gasket is not twisted and installed in place to achieve IP65 protection.

Environmental restrictions: Operating temperature 0-65 ° C, storage temperature -40-85 ° C, relative humidity 0-90% (no condensation), suitable for industrial general environments.

（2） Wiring specifications

Power wiring: Supports 100-240V AC (high voltage type) or 12-24V AC/DC (low voltage type), with built-in slow melting fuses (high voltage type 1A, low voltage type 2A), and must comply with NEC electrical standards.

Input wiring:

Thermocouple: The extension wire should be made of the same material as the thermocouple, and the positive and negative poles should be distinguished (red is usually the negative pole) to avoid polarity reversal.

RTD: The 3-wire system can compensate for lead resistance, and the three leads need to have the same specifications (same wire diameter, same length). If the total lead resistance is too high, it will cause measurement errors.

Process signal: 0-5V input impedance of 10k Ω, 4-20mA input impedance of 5 Ω, ensuring that the signal source and controller are grounded together.

Output wiring: Inductive loads (such as relay coils) need to be paired with RC suppressors (Watlow part number 0804-0147-0000) to avoid electromagnetic interference causing equipment damage.

Operation and Configuration

（1） Menu Structure and Navigation

Menu Type Entry Method Core Functions

Operation menu: Press the MODE key to switch and adjust settings, PID parameters, alarm thresholds, start self-tuning, etc

Simultaneously press and hold the up and down arrow keys for 3 seconds in the setup menu to configure input types, output functions, alarm logic, lock levels, slope parameters, etc

Calibration Menu: Continue to long press the up and down arrow keys from the settings menu to input/output calibration, restore factory calibration values, and switch between US/SI unit systems

（2） Core configuration steps

Input type configuration: Open the controller chassis and select the input type (thermocouple/RTD/process signal) through the internal DIP switch. It should be consistent with the In parameter in the settings menu, otherwise an error will be triggered.

Self tuning start: Set the AUt parameter (1=slow/2=medium/3=fast) in the operation menu, press the MODE key to start, and during the self-tuning process, the display screen alternately displays “At” and normal information. After completion, the optimal PID parameters are automatically saved.

Alarm configuration: Set the Ot2 parameter in the settings menu to select the alarm type (process/deviation), configure parameters such as ALO (low alarm threshold), AHI (high alarm threshold), HSA (hysteresis), LAt (lockout mode), etc.

（3） Keys and Display

Key functions: The MODE key is used to switch menus, the up and down arrow keys adjust parameter values (long press to quickly increase or decrease), and the A/M key is used to switch between automatic/manual modes and clear lock alarms.

Display screen: The upper screen displays the process value (PV), the lower screen displays the set value (SP)/parameter name/alarm/error code, flashes “LO”/”HI” when an alarm occurs, and displays “—-” when a sensor fails.

Troubleshooting and Maintenance

（1） Handling common error codes

Steps for handling error code reasons

Er2 RTD under range or A/D circuit fault check RTD wiring and resistance value, confirm input type configuration matches

Er4 microprocessor configuration error. Contact the manufacturer for after-sales repair

Er5 non-volatile memory verification error, power off and restart. If it is invalid, contact the manufacturer to replace the memory

Er6/Er7 A/D conversion overflow/undercurrent check sensor wiring (open circuit/reverse polarity), confirm that the input type is consistent with the DIP switch

（2） Maintenance points

Regular calibration: It is recommended to calibrate the input/output accuracy once a year, using precision millivolt sources, resistance boxes, and other equipment. Before calibration, the current parameters should be recorded.

Terminal maintenance: Check the tightness of the wiring to avoid poor contact caused by vibration. The lifespan of mechanical relays is about 100000 cycles, and it is recommended to use solid-state relays for high-frequency switching.

Noise protection: The input signal line should be separated from the power line (with a minimum distance of 305mm), using shielded wire/twisted pair, and inductive loads should be paired with RC suppressors.

Product Core Information

Watlow PM3 LEGACY ™  PID is a 1/32 DIN panel mounted high-precision temperature controller that adopts universal input and multi output configurations, supports PID/switch control modes, and is suitable for industrial temperature regulation, process monitoring, and other scenarios. The product complies with the ISO 9001 standard, has an IP65 (NEMA 4X) protection level, supports multi country certifications such as CE, UL, CSA, etc., provides a 3-year warranty, and is equipped with dual four digit red and green LED displays. It is easy to operate and compatible with multiple communication protocols.

Core specification highlights:

Input type: compatible with J/K/T/N/E/R/S/B thermocouples, 2/3 wire RTD (100 Ω/1k Ω), thermistor, potentiometer, 0-10V voltage/0-20mA current and other process signals.

Output configuration: Supports switch DC, mechanical relay (5A), solid-state relay (0.5A), 4-20mA process output, and can be configured with heating, cooling, alarm, retransmission and other functions.

Control accuracy: Calibration accuracy ± 0.1% range (± 1 ° C @ 25 ° C environment), sampling rate 10Hz, display update rate 1Hz, temperature stability ± 0.1 ° C/° C environmental changes.

Key functions and features

（1） Control and tuning functions

PID control: supports P, PI, PD, PID, and switch control, with parameters including proportional band, integral (reset), and derivative (rate), which can be optimized through self-tuning or manual calibration; The switching difference of the switch control can be customized.

Self tuning and adaptive tuning:

Autotune: Based on 90% of the set value as a reference, the system characteristics are “learned” through 5 temperature cross tests. If not completed within 60 minutes, it will automatically exit. It supports three response modes: under damping, critical damping, and over damping.

TRU-TUNE+ ®  Adaptive tuning: Real time monitoring of process values, automatic adjustment of PID parameters to adapt to load changes, support for bandwidth and gain customization, suitable for dynamic process control.

Ramp/Soak: Supports 4 configuration files, with up to 40 steps per file. The heating rate (℃/minute/hour) and constant temperature time can be set, and the step types include heating, constant temperature, waiting for events/processes, jump cycles, etc., to meet the requirements of complex temperature control processes.

（2） Alarm and safety functions

Alarm type: Supports process alarm (absolute temperature threshold) and deviation alarm (relative to set value), 4 independent alarm channels, configurable high/low threshold and hysteresis (to avoid frequent alarms).

Alarm auxiliary function: supports locking/non locking mode (locking needs to be manually cleared), alarm mute, alarm blocking when starting/setting value changes. The alarm output logic can be set to “energize when alarm” or “de energize when alarm”.

Fault protection: equipped with sensor open/short circuit detection, open-loop detection (monitoring process value deviation when output is 100%), input error handling (configurable to switch to manual mode or turn off output without disturbance).

（3） Auxiliary functions

Data storage: non-volatile memory, parameters are not lost after power failure, supports saving and restoring 2 sets of user configurations, and can quickly reuse parameter settings.

Display customization: Users can customize homepage parameters (up to 20), support display switching, automatic scrolling, and adapt to different operational scenarios.

Communication compatibility: Supports EIA-485, Modbus RTU, Bluetooth (optional), can be remotely configured and monitored through PC software (EZ-ZONE Configurator), supports networking with 247 Modbus nodes.

Installation and wiring

（1） Installation requirements

Panel incision size: 53.3mm (width) × 30.9mm (height), panel thickness: 1.53-9.52mm, fixed with snap on installation ring, IP65 protection needs to ensure that the sealing gasket is not twisted and installed in place.

Environmental restrictions: Operating temperature 0-65 ° C, storage temperature -40-85 ° C, relative humidity 0-90% (no condensation), suitable for Class I, Div.2 hazardous areas (some models).

（2） Wiring specifications

Power wiring: Supports 85-264V AC, 12-40V DC, or 20-28V AC, with built-in slow melting fuses (high voltage type 1A, low voltage type 2A), and must comply with NEC electrical standards.

Input wiring:

Thermocouple: The extension wire should be made of the same material as the thermocouple, and the positive and negative poles should be distinguished (red is usually the negative pole) to avoid polarity reversal.

RTD: The 3-wire system can compensate for lead resistance, and the three leads must have the same specifications (same wire diameter, same length), with a total lead resistance of ≤ 20 Ω.

Process signal: 0-20mA current input impedance of 100 Ω, 0-10V voltage input impedance of 20k Ω, ensuring that the signal source and controller are grounded together.

Output wiring: Inductive loads (such as relay coils) need to be paired with RC suppressors (Watlow part number 0804-0147-0000); It is recommended to extend the cycle of mechanical relays to reduce contact wear, while solid-state relays can shorten the cycle and improve control accuracy.

Operation and Configuration

（1） Menu Structure and Navigation

Menu Type Entry Method Core Functions

Home: Power on default or press and hold the infinite key for 2 seconds to view/modify commonly used parameters such as settings, control modes, and self-tuning startup

Press and hold the up and down arrow keys for 3 seconds in the Operations menu to monitor process values, adjust PID parameters, alarm thresholds, and view operating status

Press and hold the up and down arrow keys for 6 seconds in the Setup menu to configure basic parameters such as input type, output function, communication parameters, alarm logic, etc

Program menu (Profiling): Long press the forward button for 3 seconds to edit the slope/constant temperature program, step parameters, and number of cycles

Factory Menu: Long press the forward button and infinite button for 6 seconds to calibrate, password lock, restore factory settings, and customize the homepage

（2） Core configuration steps

Input type configuration: Select the sensor type (such as thermocouple J type, 100 Ω RTD) from the “Analog Input” menu in the settings, and match the wiring method (such as RTD 2/3 wire system).

PID self-tuning start: Set “Autotune” to “YES” in the operation menu, and the controller will automatically enter the tuning mode. The homepage will display the prompt “tUN1”, and the optimal PID parameters will be automatically saved after completion.

Slope/constant temperature program configuration: Create steps in the program menu (such as heating rate of 5 ℃/min, constant temperature of 30 minutes), support jump loop (up to 4 nested layers), and can be started/stopped through digital input or panel operation.

Alarm configuration: Select the alarm type (process/deviation), threshold, and hysteresis in the settings menu, configure the lockout/mute function, and display normal parameters and alarm information alternately on the homepage when the alarm is triggered (such as “AL. h1” indicating high alarm 1).

（3） Keys and Display

Key functions: forward key (switch parameters), infinite key (return to home page/clear alarm), up and down arrow keys (adjust values), support parameter self input (automatic confirmation after 3 seconds without operation).

Display screen: The upper screen displays the process value (PV), the lower screen displays the set value (SP)/parameter name, flashes the alarm code when an alarm is triggered, and displays “—-” when a sensor fails.

Troubleshooting and Maintenance

（1） Common fault handling

Possible causes and steps for troubleshooting

No display power not connected, fuse blown, wiring error. Check the power voltage, replace the fuse, and verify the power wiring (terminals 98/99)

Sensor malfunction (Er. i1): Sensor open/short circuit, reverse polarity, type mismatch. Check the wiring and integrity of the sensor, and confirm that the sensor type in the settings menu is consistent with the actual one

No output action output function configuration error, load fault, control mode is “Off”. Check the output function in the settings menu (such as heating/cooling), check the load and fuse, and switch the control mode to “Auto”

Temperature overshoot/large fluctuation. Improper PID parameters, incomplete self-tuning. Restart self-tuning, or manually adjust the proportional band (increase to reduce fluctuations) and derivative (increase to suppress overshoot)

Communication failure: baud rate/address mismatch, wiring error. Check the communication parameters (Modbus address, baud rate) in the settings menu and verify the EIA-485 wiring (T+/T -/common terminal)

（2） Maintenance points

Regular calibration: It is recommended to calibrate the input/output accuracy once a year using precision millivolt sources, resistance boxes, and other equipment. Offset and slope adjustments can be made through the “Calibration” menu in the factory.

Terminal maintenance: Check the tightness of the wiring (torque 0.56 Nm) to avoid poor contact caused by vibration; The lifespan of mechanical relays is about 100000 cycles, and it is recommended to use solid-state relays for high-frequency switching scenarios.

Software update: The EZ-ZONE Configurator software can be used to upgrade firmware, backup/restore configuration parameters, and avoid parameter loss caused by misoperation.

Product Core Information

The Watlow Series 93 is a 1/16 DIN microprocessor based temperature controller with a single input dual output design. It supports J, K, T, N, S-type thermocouples, RTDs, or process signal (0-5V DC, 4-20mA) inputs, and outputs can be configured for heating, cooling, alarm, or shutdown functions. It has both PID and switch control modes and is suitable for industrial temperature control scenarios. The product complies with ISO 9001 standards, has an IP65 (NEMA 4X) protection level (optional), supports CE certification, provides a 3-year warranty, and is equipped with dual four digit red or green display screens by default, making it easy to operate.

Core functions and technical details

（1） Control mode and algorithm

PID control

Proportional band (Pb): The range can be set to 0-555 ° C (or ° F/unit), and it automatically switches to switch control when Pb=0; Under the SI unit, it is displayed in “% range” (0.0-999.9%), with a default value of 3%. The smaller the value, the higher the control sensitivity.

Integral/Reset (It/rE): Integral time 0.1-99.9 minutes/time (SI), reset frequency 0.01-99.9 times/minute (US), default 0, used to eliminate static deviation (droop) and avoid deviation from the set value after temperature stabilization.

Differential/Rate (dE/rA): 0.01-99.9 minutes, default 0, suppresses overshoot by predicting temperature trends, suitable for thermal systems with fast heating rates and high inertia.

Cycle time (Ct): 0.1-999.9 seconds, default 5 seconds. It is recommended to extend the cycle for mechanical relays to reduce contact wear, while solid-state relays can shorten the cycle to improve control accuracy.

Self tuning function

Trigger method: Set the [AUt] parameter in the operation menu (0=off, 1=slow, 2=medium, 3=fast), press the forward button to start, and after starting, the lower display screen will alternate between “[AUt]” and the current parameter.

Working principle: Based on 90% of the set value, the system’s thermal characteristics are “learned” through 4 cross temperature points, and the optimal PID parameters are automatically calculated; If 4 crosses are not completed within 80 minutes, automatically exit and maintain the original parameters.

Applicable scenarios: Slow mode is suitable for scenarios where heating is slow and overshoot is not allowed (such as laboratory reactors), while fast mode is suitable for industrial heating furnaces and other scenarios where the set value needs to be quickly reached.

switch control

When the PID proportional band is set to 0, it is enabled, and the switching difference is defined by the [` HSC] parameter (1-55 ° C/1-99 ° F, default 2 ° C/3 ° F). When the temperature is below the set value – difference, the output is turned on, and when it is above the set value+difference, the output is turned off. It is suitable for scenarios with low control accuracy requirements (such as warehouse insulation).

（2） Alarm and safety functions

Alarm type configuration

**Process alarm ([PrA]/[Pr]) * *: Based on absolute temperature triggering, [ALO] (low alarm threshold, default range low limit) and [AHI] (high alarm threshold, default range high limit) need to be set in the operation menu. [PrA] will flash the alarm information, and [Pr] will only trigger the output without display.

**Deviation alarm (dEA/dE) * *: triggered based on the deviation of the set value, [ALO] range -999-0 (deviation below the set value), [AHI] range 0-999 (deviation above the set value), the alarm threshold automatically follows when the set value changes (e.g. set value of 100 ° F, deviation+7 ° F, alarm trigger point is 107 ° F).

Alarm auxiliary function

**Locked ([LAt]) * *: [LAt] (locked) needs to be manually cleared by pressing the infinite key, [` nLA] (non locked) will automatically clear when the temperature returns to the safe range, default is non locked.

**Silent (SIL) * *: Only deviation alarm is supported. When set to “On”, press the infinite key to activate the alarm output when powered on. Even if the temperature exceeds the difference after activation, the alarm output will remain closed until the temperature returns to the safe range and the triggering ability is restored.

Hysteresis (HSA): 1-5555 ° C (or ° F/unit), default 2 ° C/3 ° F, to avoid frequent alarms caused by temperature fluctuations near the alarm threshold (e.g. alarm threshold of 100 ° C, hysteresis of 2 ° C, temperature drops below 98 ° C before the alarm is released).

（3） Auxiliary control function

Slope heating (rP)

Supports two modes: [Str] (only slopes from the current temperature to the set value when powered on), [On] (also slopes when the set value changes), with a ramp rate range of 0-9999 °/hour (default 100 °/hour), and the lower display screen alternately flashes “rP” and the target set value during the ramp process.

Applicable scenarios: To avoid damage to heating elements due to instantaneous high temperatures (such as glass melting furnaces), and to prevent deformation of workpieces due to excessive temperature differences (such as metal heat treatment).

Power Limit ([PL])

Only heating output is available, with a range of 0-100% (default 100%), limiting the maximum power of heating output to avoid load overload (such as when a small heater is adapted to a high-power controller, power should be limited to prevent burnout).

Calibration offset (CAL)

Range ± 100 ° C/± 180 ° F (or ± 180 units), default 0, used to compensate for measurement deviations caused by sensor installation errors or environmental interference (if the sensor is installed in a heat dissipation area and the actual temperature is 5 ° C higher than the measured value, a+5 ° C offset can be set).

Automatic/manual undisturbed switching

Switching mode: Press the infinite key twice to enter manual mode, the percentage indicator light remains on, and the lower display screen shows the output power (-100% to 100%, negative sign represents cooling); Press the infinite key again to return to automatic mode.

Non disruptive logic: When switching from automatic to manual mode, the output power remains at the PID calculated value before switching; When manually switching to automatic mode, transition to PID control starting from the current manual power to avoid sudden temperature changes.

Sensor fault handling: When the lock level [LOC] is 0/1/2, the sensor will automatically switch to manual mode after an open circuit (maintain the power before the fault, set to 0% if the power is unstable); Directly turn off the output at level 3/4.

Installation and wiring specifications

（1） Installation process

Panel preparation: Cut according to the size of 44.96-45.47mm (width x height). It is recommended to use Greenlee 60287 type 1/16 DIN punch, with a panel thickness of 1.5-9.7mm. When installing multiple units, the distance between adjacent cuts should be ≥ 20mm (to avoid heat dissipation interference).

Sealed installation (IP65 model):

Confirm that the housing gasket (circular with rounded corners) is facing the panel, without distortion or damage, and is embedded in the groove of the housing frame.

Insert the controller into the incision, press the panel side shell, insert the installation ring from the back, ensure that the installation ring buckle is aligned with the shell protrusion, press the buckle with your thumb until you hear a “click” sound, and check that the distance between the panel and the shell is ≤ 0.483mm (ensure sealing).

Dismantling method: Use a thin screwdriver or putty knife to gently pry open the 6 buckles of the installation ring, detach them one by one, and then shake the installation ring back and forth to remove it, avoiding pulling and damaging the shell with force.

（2） Wiring Details

Power wiring

High voltage type (93_ -1 0-00): Terminal 11 is connected to L1 (100-240V AC, actually compatible with 85-264V), terminal 12 is connected to L2, built-in 1A slow melting fuse (250V), cannot be replaced with fast melting fuse.

Low voltage type (93_ -1 1-00 _): Terminal 11 is connected to positive (12-24V AC/DC, actually compatible with 10-26V), terminal 12 is connected to negative, with built-in 2A slow melting fuse. It is strictly prohibited to connect high voltage (which may cause irreversible damage).

Input wiring

Thermocouple: Terminal 3 is connected to the positive pole (if the red color of the J-type thermocouple is negative, pay attention to the polarity), terminal 5 is connected to the negative pole, and the extension wire should be made of the same material as the thermocouple (if the J-type thermocouple uses iron constantan material) to avoid errors; If the external device is not isolated, an isolated thermocouple should be used.

3-wire RTD: Terminal 2 is connected to S1, Terminal 3 is connected to S2, and Terminal 5 is connected to S3. The three leads must have the same specifications (same wire diameter and length), and the total lead resistance should be ≤ 20 Ω to avoid measurement errors caused by resistance differences; 2-wire RTD requires short circuiting terminals 3 and 5, resulting in low accuracy (+2 ° F error per 1 Ω lead resistance).

4-20mA signal: Terminal 2 is connected to the negative pole, terminal 5 is connected to the positive pole, and the input impedance is 5 Ω. It is necessary to ensure that the signal source and controller are grounded together to avoid grounding loops.

Output wiring

Mechanical relay (Output 1: Terminals 8/9/10): Terminal 8 is normally closed (NC), 9 is common terminal (COM), 10 is normally open (NO), maximum load 5A@240V Communication, inductive loads (such as relay coils) require parallel RC suppressors (Watlow 0804-0147-0000), minimum load 100mA@5V DC (to avoid contact oxidation).

4-20mA output (Output 1: Terminal 9/10): Terminal 9 is connected to the positive pole and 10 to the negative pole, with a maximum load impedance of 800 Ω. It is used to control actuators such as frequency converters and valves. Shielded wire is required for wiring, and the shielding layer is grounded at one end (controller end).

Safety Specifications

All wiring must comply with NEC and local electrical standards, with wire diameter of 20-14AWG and terminal torque of 1.4Nm (12in lb), to avoid poor contact caused by looseness and damage to terminals caused by tightness.

Disassembling the controller after power failure may result in residual voltage at the casing terminals, and insulated gloves should be worn during operation; When installing in high temperature environments, insulation pads should be added between the controller and the heat source to avoid ambient temperatures exceeding 65 ° C (rated operating limit).

Operation and Configuration

Buttons and Display: Equipped with forward key, infinite key, up and down arrow keys, the upper display screen displays process values, the lower display screen displays set values/parameters/alarm codes, and the percentage indicator light indicates manual mode (constantly on) or mode switching (flashing).

Menu navigation:

Settings menu (press and hold the up and down arrow keys for 3 seconds to enter): Configure input type, range, output mode, alarm parameters, lock level (0-4 levels, restrict parameter access permissions), etc.

Operation menu (press the forward button to enter): adjust PID parameters, alarm threshold, calibrate offset, start self-tuning, etc.

Calibration menu (enter by long pressing the up and down arrow keys from the settings menu): Supports thermocouples RTD、 The input/output calibration of process signals can restore the factory calibration values.

Core parameter configuration: The input type must be consistent with the internal DIP switch; The set value range is limited by [rL] (low range) and [rH] (high range); Output 1 defaults to heating, output 2 defaults to the opposite action of output 1, and can be changed to alarm function as needed.

Troubleshooting and Maintenance

Common error codes: [Er2] (RTD under range), [Er4] (configuration error), [Er5] (non-volatile memory verification error), [Er6]/[` Er7] (analog-to-digital conversion overflow/undercurrent, mostly due to sensor open circuit or polarity reversal). Error handling should be carried out according to the locking level, with manual mode switchable at lower levels and output directly turned off at higher levels.

Maintenance points: Regularly check the tightness of wiring and the status of sensors; The lifespan of mechanical relays is about 100000 cycles, and it is recommended to use solid-state relays for high-frequency switching; Non defective products must be returned in their original packaging within 120 days, with a 20% restocking fee. An RMA number must be obtained before repair.