Watlow PM PLUS™ PID & Integrated Limit Controllers

Watlow PM PLUS controllers from Watlow 
and Anderson-Bolds

Watlow’s PM PLUS™, the enhanced EZ-ZONE® PM, is now more intuitive and features an enhanced interface for easier programming and readability with a SMOOTH-TOUCH™ keypad creating an industry leading user experience. The Watlow PM PLUS is backwards compatible with legacy EZ-ZONE PM controllers but offers many user upgrades including an intuitive menu flow allowing the controller to be easily configured. It also continues to offer the industry leading Bluetooth® connectivity with the EZ-LINK™ mobile app for remote access capability and full descriptions of parameters and error codes. The PM PLUS improves the user experience by reducing the complexity at the front of the control while eliminating the dependency of cables when configuring the product.

Like the original Watlow EZ-ZONE PM, the PM PLUS can be ordered as a PID controller, or an integrated controller with multiple functions combined into one. Now Watlow’s PM PLUS is available through Watlow SELECT®, a program that enables you to quickly identify, configure and receive your thermal products faster and easier than ever before. With SELECT, you use a variety of tools to guide your decision, configure products for an exact fit and quickly receive your order. 

For a Watlow PM-PLUS quote, Please click HERE!

Watlow PM-PLUS Temperature Controller

Features and Benefits 

Intuitive menu flow • Reduces menu structure to a list of lists allowing the controller to be easily configured • Offers easy to read characters and color coding making the display visible from many angles 

SMOOTH TOUCH keypad • Eliminates contamination points on the front of the controller • No mechanical components will wear out • Creates a better seal on front panel • Easy to clean

Bluetooth® compatible with EZ-LINK™ mobile app • Provides full descriptions of parameters and error codes • Allows remote access capabilities without the use of cables or converters • Provides the ability to configure the product and save parameter sets 

Integrated PID and limit controller • Reduces wiring time and termination complexity compared with connecting discrete products • Decreases required panel space • Lowers installation costs • Increases user and equipment safety for over/under temperature conditions 

High amperage power control output • Drives 15 ampere resistive loads directly • Reduces component count • Decreases cost of ownership 

Current monitoring • Detects heater current flow and provides alarm indication of a failed output device or heater load • Drives output on open or shorted heater 

Serial communication capabilities • Provides a wide range of protocol choices including Modbus® RTU, EtherNet/IP™, Modbus® TCP, PROFIBUS DP, DeviceNet™ and J1939 CAN bus • Supports network connectivity to a PC or PLC 

Enhanced control options • Easily handles complex process problems such as ratio, differential, square-root, motorized valve control without slidewire feedback, wet-bulb/dry-bulb, compressor control and peltier loads

Countdown timer option • Provides batch process control • Supports set point change during countdown 10-point linearization curve • Improves sensor accuracy 

EZ-LINK™ mobile application for iPhone® and Android™ • Expedites controller setup with intuitive navigation • Simplifies setting parameters with plain text names and descriptions • Connects quickly and easily via Bluetooth® wireless communications 

Configuration communications with software • Includes Watlow standard bus communications used by COMPOSER® or EZ-ZONE configurator software 

Advanced PID control algorithm • Offers TRU-TUNE®+ adaptive control to provide tighter control for demanding applications • Provides auto-tune for fast, efficient start-up 

Built-in sensor compensation curves • Saves cost of buying compensated sensors • Includes Vaisala RH and altitude (pressure) curves 

Remote set point operation • Supports convenient set point manipulation from a remote device such as a master control or PLC 

Profile capability • Offers pre-programmed process control • Allows ramp/soak programming with 40 total steps 

Retransmit output • Supports industry needs for recording 

Factory Mutual (FM) approved over/under limit with auxiliary outputs • Increases user and equipment safety for over/under temperature conditions 

Memory for saving and restoring parameter settings • Decreases service calls and time down 

Agency approvals: UL® listed, CSA, CE, RoHS, W.E.E.E., FM, SEMI F47-0200, Class 1, Div. 2 rating on selected models • Assures prompt product acceptance • Reduces end product documentation costs

Touch-safe package • Increases safety for installer/operator • Complies with IP2X requirements

Programmable function key • Enables simple, one-touch operation of user-defined, repetitive activities 

Programmable menu system • Reduces setup time and increases operator efficiency 

Three-year warranty • Provides product support and reliability

Watlow PM-PLUS Controller 

For a Watlow PM-PLUS quote, Please click HERE!

Specifications:

Controller • User-selectable heat/cool, on-off, P, PI, PD, PID or alarm action • Auto-tune with TRU-TUNE+ adaptive control algorithm • Control sampling rates: input = 10Hz, outputs = 10Hz 

Profile Ramp/Soak • 4 profiles, 40 total steps • Accuracy (typical): ±30 PPM at 77°F (25°C) +30/-100 PPM at -4 to 149°F (-20 to 65°C) 

Isolated Serial Communications • EIA 232/485, Modbus® RTU • EtherNet/IP™/Modbus® TCP • DeviceNet™ • PROFIBUS DP • SAE J1939 CAN bus 

Wiring Termination—Touch-Safe Terminals • Input, power and controller output terminals are touch safe, removable, 12 to 22 AWG 

Universal Input • Thermocouple, grounded or ungrounded sensors greater than 20MΩ input impedance, 3µA open sensor detection, 2kΩ source resistance max. • RTD 2- or 3-wire, platinum, 100Ω and 1000Ω @ 32°F (0°C) calibration to DIN curve (0.00385 Ω/Ω/°C) • Process, 0-20mA @ 100Ω, or 0-10VDC @ 20kΩ, 0-50mV at 20MΩ, 0-1000Ω potentiometer; scalable; inverse scaling 

Functional Operating Range Type J: -346 to 2192°F (-210 to 1200°C) 

Type K: -454 to 2500°F (-270 to 1371°C) 

Type T: -454 to 750°F (-270 to 400°C) 

Type E: -454 to 1832°F (-270 to 1000°C) 

Type N: -454 to 2372°F (-270 to 1300°C) 

Type C: 32 to 4200°F (0 to 2315°C) 

Type D: 32 to 4200°F (0 to 2315°C) 

Type F: 32 to 2449°F (0 to 1343°C) 

Type R: -58 to 3214°F (-50 to 1767°C) 

Type S: -58 to 3214°F (-50 to 1767°C) 

Type B: 32 to 3300°F (0 to 1816°C) 

RTD (DIN): -328 to 1472°F (-200 to 800°C) Process: -1999 to 9999 units 

Accuracy • Calibration accuracy and sensor conformity: ±0.1% of span, ±1°C @ the calibrated ambient temperature and rated line voltage • Types R, S, B; 0.2% • Type T below -50°C; 0.2% • Calibration ambient temperature @ 77°F ±5°F (25°C ±3°C) • Accuracy span: 1000°F (540°C) min. • Temperature stability: ±0.1°F/°F (±0.1°C/°C) rise in ambient max. 

Thermistor Input • 0 to 40kΩ, 0 to 20kΩ, 0 to 10kΩ, 0 to 5kΩ • 2.252kΩ and 10kΩ base at 77°F (25°C) • Linearization curves built-in

Current Transformer Input • Accepts 0-50mA signal (user-programmable range) • Displayed operating range and resolution can be scaled and are user-programmable 

Digital Inputs (DC Voltage) • Max. input: 36V at 3mA • Logic: min. high state 3V at 0.25mA, max. low state 2V 

Digital Inputs (Dry Contact) • Logic: min. open resistance 10kΩ, max. closed resistance 50Ω • Max. short circuit: 20mA 

2 Digital I/O (ordered with power supply option) • Update rate: 10Hz • Input type: user-selectable, dc voltage or dry contact • Output type: switched dc • Output voltage: 24V • Output 5: 24mA max. or drive one 3-pole DIN-A-MITE® • Output 6: 10mA max. 

Output Hardware • Switched dc: 22 to 32VDC @ 30mA max. per single output and 40mA max. total per paired outputs (1 & 2, 3 & 4) 

• Open collector: 30VDC max. @ 100mA max. 

• SSR, Form A, 24 to 240VAC, 1A at 50°F (10°C) to 0.5A at 149°F (65°C) resistive load, 264VAC max., opto-isolated, without contact suppression, 120/240VAC @ 20VA pilot duty 

• Electromechanical relay, Form A, 24 to 240VAC or 30VDC max., 5A resistive load, 100,000 cycles at rated load, 120/240 @ 125VA or 24VAC @ 25VA pilot duty 

• Electromechanical relay, Form C, 24 to 240VAC or 30VDC max., 5A resistive load, 100,000 cycles at rated load, 120/240 @ 125VA or 24VAC @ 25VA pilot duty 

• NO-ARC relay, Form A, 85 to 264VAC, 15A @ 122°F (50°C), resistive load, no VDC, 2,000,000 cycles at rated load 

• Universal process output: range selectable; 0 to 10VDC ±15mV into a min. 1,000Ω load with 2.5mV nominal resolution; 0 to 20mA ±30μA into max. 800Ω load with 5μA nominal resolution; temperature stability 100ppm/°C

Operator Interface • LCD display • SMOOTH TOUCH keypad • Programmable function key

Line Voltage/Power • High voltage option: 85 to 264VAC, 47 to 63Hz • Low voltage option: 20 to 28VAC, +10/-15%; 50/60Hz, ±5% or 12 to 40VDC • Max. power consumption: 10VA (1/32 and 1/16 DIN); 14VA 

Environment • Operating temperature: 0 to 149°F (-18 to 65°C) • Storage temperature: -40 to 185°F (-40 to 85°C) • Relative humidity: 0 to 90% RH, non-condensing 

Agency Approvals • cULus® UL®/EN/CSA C22.2 No 61010-1 Listed, File E185611 • CSA C22.2 No. 24, File 158031 (1/32 and 1/16 DIN sizes) • IP 67, IP 66 front seal • UL® Type 4X front seal indoor locations • cULus® ANSI/ISA 12.12.01-2012, CSA-C22.2 No. 213-1987, Class 1, Div. 2, Groups A, B, C and D, Temperature Code T4A, File E184390 (optional) • FM Class 3545 (limit controls) • CE, RoHS by design, W.E.E.E. • EtherNet/IP™ and DeviceNet™ ODVA Conformance Tested displays

For a Watlow PM-PLUS quote, Please click HERE!

Anderson-Bolds
Cleveland, Ohio
www.anderson-bolds.com
216-360-9800

Watlow F4T Process Controller

The F4T High End Watlow Process Controller from Anderson-Bolds

BUY the Watlow F4T HERE!

Watlow F4T Process Contoller

The Watlow F4T with INTUITION temperature & process controller offers a wide range of field removable I/O modules for maximum design flexibility. Configurations can be custom tailored to meet the scaling needs of a tremendous range of equipment and applications while providing exactly the hardware types required for compatibility. The F4T controller also features a 4.3 inch, color, graphical touch panel. Combining power, flexibility and functionality, this new controller offers unmatched versatility, and its best-in-class ease of use could very well make user manuals a thing of the past.
The F4T's batch processing feature can help with regulatory compliance, achieving data integrity in the plant, reducing warranty exposure, and even avoiding a potential recall scenario without significantly raising production costs. Download the specification sheet below to learn more.

Features and Benefits

4.3-inch, color touch panel with high-resolution, graphical

user-interface

• Shortens learning curve and reduces operator errors

• Allows channels, profiles, alarms, inputs and outputs to be

personalized with user defined names

Temperature PID, data logger, trend chart,

over/under-temperature limit, power switching,

math, logic, timers and counters combined into an

integrated system

• Lowers ownership costs

• Eliminates the need for separate discrete components

• Reduces complexity

• Simplifies design, ordering and installation

• Saves money

Robust algorithms for temperature, cascade, altitude,

humidity and compressor

• Improves process control

• Offers one to four channels of control

• Provides multiple PID sets

• Enables TRU-TUNE(R)+ adaptive control algorithm

• Offers 40 ramp and soak profiles with real-time clock and

battery backup

COMPOSER® graphical configuration PC software

• Speeds up and simplifies commissioning

• Archives and documents controller setup

• Connects with controller easily via Ethernet

Batch processing with bar code data entry

• Easily collects and manages data records

• Inputs information from bar code scan for fast and easy

data entry

• Offers foolproof processing via smart profile to part linkage

• Provides data security through password and data log

encrypted file options

• Improves manufacturing robustness via reminder screens

ensuring all data is entered during processing

• Helps ensure compliance with growing regulations and

minimizes warranty exposure

• Eliminates part processing skips or walk arounds due to

improved quality control

• Produces formatted data record report for easy receipt or

record management uses

Many communications options available including Ethernet

Modbus® TCP and SCPI and EIA-232/485 Modbus® RTU

• Offers two USB host ports and one device port

• Simplifies file transfers

• Connects easily

Modular design

• Adapts quickly to evolving requirements

• Offers numerous types of field pluggable modules for

maximum flexibility and easiest compatibility

• Features scalable and modular firmware functions

• Delivers scalable input/output quantities from 1 to 36

Agency certifications include UL®, FM, CE, RoHS, W.E.E.E.,

NEMA 4X/IP65

• Ensures high quality and reliability

• Verifies performance in installations worldwide

SERIES F4S/F4D/F4P backward compatible

• Provides easy retrofit with minimum pain and disruption

• Ensures proper fit in existing SERIES F4 panel cutout

Off-the-shelf solution

• Provides cost-effective “make versus buy”

• Offers preconfigured touch-panel screens

• Assures quicker time to market

Common Specifications

Line Voltage/Power

• Data retention upon power failure via nonvolatile memory

Functional Operating Range

• Type J: -346 to 2192ÅãF (-210 to 1200ÅãC)

• Type K: -454 to 2500ÅãF (-270 to 1371ÅãC)

• Type T: -454 to 750ÅãF (-270 to 400ÅãC)

• Type E: -454 to 1832ÅãF (-270 to 1000ÅãC)

• Type N: -454 to 2372ÅãF (-270 to 1300ÅãC)

• Type C: 32 to 4200ÅãF (0 to 2315ÅãC)

• Type D: 32 to 4200ÅãF (0 to 2315ÅãC)

• Type F: 32 to 2449ÅãF (0 to 1343ÅãC)

• Type R: -58 to 3214ÅãF (-50 to 1767ÅãC)

• Type S: -58 to 3214ÅãF (-50 to 1767ÅãC)

• Type B: 32 to 3300ÅãF (0 to 1816ÅãC)

• RTD (DIN): -328 to 1472ÅãF (-200 to 800ÅãC)

• Process: -1999 to 9999 units

Calibration Accuracy

• Calibration accuracy and sensor conformity: Å}0.1% of

span, Å}1ÅãC at the calibrated ambient temperature and

rated line voltage

• Types R, S, B: Å}0.2%

• Type T below -50ÅãC: Å}0.2%

• Calibration ambient temperature at 77ÅãF Å}5ÅãF (25ÅãC Å}3ÅãC)

• Accuracy span: 1000ÅãF (540ÅãC) min.

• Temperature stability: Typical Å}0.1ÅãF/ÅãF (Å}0.1ÅãC/ÅãC) rise in

ambient max.

Configuration Diagnostics

• Indicates if modules present match the expected

configuration settings

USB Host Port

• Total of 2 available

• Version: USB 2.0 hi-speed

• Connector: USB Type A, high-retention

• Flash drive must be FAT32 file system

• Max. current 0.5A/port

System Configuration Requirements

• F4T has 6 slots for flex modules (FM)

• EIA-232/485 Modbus(R) RTU flex module, if used, must occupy

slot 6 location

• A maximum of two 10A SSR FM modules can be used in the F4T

and each will require space for 2 slots. Valid in slots 1, 2, 4 or 5

Wiring Termination—Touch-Safe Terminals

• Right-angle and front-screw terminal blocks for input, output

and power supply connections

• Input, output and power terminals: touch safe, removable,

12 to 30 AWG

F4T Base Specifications

Line Voltage/Power

• High voltage option: 100 to 240VAC +10/-15%, 50/60Hz Å}5%

• Low voltage option: 24 to 28VAC/VDC+10/-15%, 50/60Hz Å}5%

• Power consumption: 23 W, 54VA

Environment

• NEMA 4X/IP65 front panel mount configuration only

• Operating temperature: 0 to 122ÅãF (-18 to 50ÅãC)

• Storage temperature: -40 to 185ÅãF (-40 to 85ÅãC)

• Relative humidity: 0 to 90%, non-condensing

Agency Approvals

• UL(R)/EN 61010 Listed, File E185611 QUYX

• UL(R) 508 Reviewed

• CSA CC.C#14, File 158031

• FM Class 3545 (configurations with limit modules)

• AMS 2750 E compliant: Analog input process values. Tip: Maximize

field calibration accuracy and uniformity by using advanced F4T

features such as Calibration Offset and Linearization Function

Blocks. Refer to user manual for details.

• RoHS by design, China RoHS Level 2, W.E.E.E.

• CE

• Windows(R) Hardware Certification

User Interface

• 4.3 inch TFT PCAP color graphic touch screen

• LED backlife >50K hours

• 4 keys: Home, Main Menu, Back, Help

• Multiple languages

• English, German, French, Italian, Spanish, Japanese, Korean

and Chinese

• USB wired or wireless mouse functionality

• Right click for 4 keys: Home, Main Menu, Back, Help

Control Loops

• 1 to 4 PID or ON-OFF control loops

• 0 to 6 Limit loops

• User-selectable action: heat, cool or heat/cool

• Auto-tune with TRU-TUNE+ adaptive control

Control Loops and Over-temperature Limits

• Input sampling: 10Hz

• Output update: 10Hz

Communications

• Ethernet Modbus(R) TCP

• Isolated communications

Profile Ramp and Soak Option

• Profile engine affects 1 to 4 loops in sync

• 40 profiles with 50 steps per profile

Data Logging

• User selectable parameters: Up to a maximum of 128 active

parameters depending on configuration

• Logging interval: Programmable increments between 0.1 seconds

and 60 minutes if logging to internal memory. Logging directly to

USB; 1.0 seconds to 60 minutes

• File types: .CSV for standard data logging or proprietary format for

encrypted data log option

• Storage: 80MB internal memory or to USB memory stick

• File transfer: Internal memory to USB host port or to Ethernet

Modbus(R) TCP

• Transfer options: On demand by user or user programmable based

on when a new data log file record is available. Utilizes TFTP and

Samba protocols

• Record: Date and time stamped

For a Watlow Quote on the F4T or other Watlow Products, click HERE!

Anderson-Bolds
216-360-9800
www.anderson-bolds.com

Watlow Process Controller F4T with Ramp Soak, Batches, 1-4 loops and communications.

Maximize Electric Heater Performance

Ten Tips to Maximize Heater Performance

Electric Heating elements are very durable and can last a png time with some preventative care for the elements. In the industrial world some heaters are put ito abusive environments so using some of these tis could add life to your electrical heating elements and heaters. 

Contact Anderson-Bolds HERE!

Watlow Heaters from Anderson-Bolds

Watlow Firebar Elements

Many plant engineers do not give much thought to the heaters operating within their processes and applications - unless those heaters fail, require significant maintenance or cause other problems. Unfortunately, heaters play an integral role in many applications. Therefore, heater problems can easily snowball and lead to much larger headaches.

Following a few simple guidelines will not only reduce the likelihood of heater-related issues, but can actually have a significant positive impact on the efficiency of systems and reduce maintenance requirements and costs. Below are 10 ways to maximize a heater's service life and performance.

Tip 1: Guard against heater contamination

Contamination is the most frequent cause of heater failure (see images). As heaters expand and contract during cycling, they often draw in organic or conductive materials. This can lead to an arcing failure between individual heater windings or between heater windings and the electrically grounded outer heater sheath. When allowed to collect at the lead end of a heater, contaminants can also cause electrical shorts between power pins or terminals. Therefore, it is important to keep lubricants, oils, low-temperature tapes or processing materials out of contact with the lead end of the heater. Employing seals will help.

Tip 2: Protect leads and terminations from high temperatures and excessive movement

Standard fiberglass-insulated lead wire may be used in applications with ambient temperatures up to approximately 260°C (500°F). If a lead is exposed to higher temperatures, high-temperature lead wire or ceramic bead insulation should be used. An unheated section of the heater, extending away from the heated region of the system, enables the leads to run at a beneficially cooler temperature.

When heaters are mounted in moving machinery, it is essential to anchor the leads to prevent them from being damaged. A lead protection option should be specified and used for optimum protection against lead damage.

Tip 3: Heater selection and sizing are important

A heater's wattage should be matched as closely as possible to the application's actual load requirements to limit ON/OFF cycling (see tip 6). For fitted-part applications, specify the hole or an alternative application feature size to ensure an optimal fit between the heater and application feature. A tight fit minimizes air gaps and reduces the instances of hot spotting.

Tip 4: Ground the equipment

It is common sense and safe practice to electrically ground all equipment on which the heater is used. Grounding equipment helps protects plant and personnel in the event of an electrical failure in the heating system.

Tip 5: Regulating voltage ensures the rated heater voltage matches voltage supply

It is essential to ensure a heater's rated voltage matches the available voltage supply because wattage increases (or decreases) at the square of the change in voltage applied to a heater. For example, if a heater is rated for 120V/1000W and is connected to a 240V supply, it will generate four times the rated wattage output or 4000W. This will cause a heater to fail relatively quickly and can also cause significant damage the attached equipment.

Tip 6: Prevent excessive heater cycling

Excessive temperature cycling is very detrimental to the life of a heater. The most detrimental is the cycle rate that allows full expansion and contraction of the heater resistance wire at a high rate (30 to 60 seconds' power ON and power OFF). This causes severe stress and oxidation of the resistance wires inside a heater. A bad temperature cycle is typically found when thermostats are used. Thermostats respond slowly to temperature changes and have large switch ON/OFF temperature differentials. An improvement, but a somewhat more expensive solution, is to use ON/OFF or PID controllers with mechanical relays. It is crucial to not switch the frequency or cycle time too rapidly (somewhere between 3 to 10 seconds), because the relay contacts can wear out quickly.

The most effective way to minimize heater element temperature cycling, and the most expensive solution, is to use solid state relays (SSRs) and SCR power controllers coupled to PID temperature controllers. This combination provides the best performance for both your thermal system as well as for the heater itself. Solid state switching devices cycle power to the heater very rapidly (from one second with a SSR, down to milliseconds with phase-angle fired SCRs). This fast-power cycling dramatically reduces heater element wire temperature excursions and substantially extends heater life.

Tip 7: Ensure that the sheath material and watt density ratings are compatible with the material being heated

This is absolutely critical to ensure long heater life and healthy processing equipment. When heating solids, such as metals, the operating temperature and heater-to-part fit drive sheath material and watt density choices. Carbon steels, aluminum, silicone rubber sheath materials are fine for lower temperatures (a few hundred degrees). However, as temperatures increase beyond this point, sheath material choices become limited to galvanized or stainless steels and other higher temperature metal alloys. As temperature also increases, the watt density must decrease accordingly to prevent internal resistance wires from oxidizing quickly and failing prematurely. A good heater-to-part fit ensures proper heat transfer and does not force the resistance wires to overheat.

When heating gases, the operating temperature and flow rates dictate what sheath material and watt density can be used. For example, you can run higher watt densities when heating hydrogen versus nitrogen, but hydrogen requires Alloy 800 sheaths, whereas 304 Stainless Steel will work for many nitrogen applications.

Increasing flow and turbulence across the heater elements means better heat transfer, which raises watt density values. For liquid heating, the prime driver for materials and watt density selection is the fluid material and flow rate. Water can easily handle 42.52 to 70.87W/cm2 (60 to 100W/in2) using a copper sheath, whereas a 50/50-water/glycol mix can only handle 21.26 W/cm2 (30 W/in2) and must use a steel sheath.

Tip 8: Mount immersion tank heaters horizontally near the tank bottom

Heaters should be placed horizontally and near tank bottoms to maximize convective circulation. Vertical mounting is only advisable when limitations, such as space restrictions, prohibit horizontal placement. Regardless of whether a heater is mounted horizontally or vertically, it is essential to place it high enough to avoid any sludge and debris buildup in the bottom of the tank. Likewise, for both mounting methods, the entire heated length of the heater must be immersed at all times - one reason vertical mounting is rarely recommended. It is also important to avoid placing heaters in restricted spaces that limit convective flow and/or where free boiling or steam traps can occur.

Tip 9: Prevent build-up and sludge on the heater elements

Scale, coking and sludge build-up on heater sheaths must be minimized. Any accumulation should be periodically removed or at least minimized, to avoid inhibiting heat transfer to the liquid. Periodic cleaning prevents heater elements being forced to operate at higher temperatures, which can lead to early heater failure. Extreme care should also be taken to avoid getting silicone lubricant on the heated section of a heater. Silicone will prevent the "wetting" of the sheath by the liquid, act as an insulator, and possibly cause the heater to fail.

Tip 10: Ensure proper, tight temperature control and safety limit protection

Matching the appropriate temperature control system to the heater is imperative to strong heater performance and life. Each process application should, at the very least, include a process temperature sensor (to sense the material being heated) and a limit sensor (to sense the heater sheath temperature). The process sensor should be directly immersed into the material to be heated, or snugly inserted into a thermowell inside the fluid itself. For safety reasons, two separate control systems should be used - one for process temperature control and one for high limit control. PID type process temperature controllers offer more stable control and faster response than ON/OFF switching controls or thermostats. The trade off is that PID control is often more expensive than ON/OFF types and not always necessary for applications that do not require highly accurate temperature control.

Anderson-Bolds

216-360-9800

www.anderson-bolds.com

Watlow Heaters and Controls - Process Technology - Chromalox - Process Heat

Process Ovens Over 40 years Old

Anderson-Bolds and Grieve Ovens

Safety Updates for Older Ovens.

 
Most Process ovens made over 40 years ago did not include an excess temperature controller or separate heating element contactors to protect the oven from overheating if the main temperature controller or contactors fail.  Any ovens like this should not be used until this safety equipment is installed.  Failure to install this safety equipment could result in the oven overheating and a fire that could result in oven damage, loss of the product load, building damage and injury to personnel.
 
A field kit to add the excess temperature controller and separate contractors should be ordered from the MFG.

The excess temperature controller and separate contactors are now standard equipment on all Grieve ovens.  Also standard is a recirculating blower airflow safety switch to shut down the oven heat if the recirculating blower fails.  This is a pressure differential switch that senses the pressure created when the blower wheel is turning.  This switch protects the oven heating elements by preventing them from heating when air is not being recirculated over them.  A field kit for installation of the recirculating blower airflow safety switch should be purchased from the oven MFG.

When installing new safety equipment it can be a good idea to add other new electronics to the oven for better performance.  New electronics could be a digital temperature controller, programmable digital temperature controller, new thermocouples or a digital timer.  Grieve can provide a field kit to add a digital temperature controllers as well as and a field kit for a digital shut down timer. For electric Ovens new elements can be ordered as well along with pin and sleeve disconnect switches for added electrical safety for personnel. We can provide Gas meters for gas ovens to measure gas flow at the oven and shut the oven down in a dangerous situation.

Grieve's field kits include installation instructions, wiring diagram showing items to be removed, wiring diagram showing items to be added and revised wiring diagram for your records.  Our kits will be based on how the ovens were constructed when they left our factory.  If there have been changes made to the oven in the field they will not be included in our revised wiring diagram.   

Grieve will provide all parts except for standard wire, conduit and conduit fittings.  These items are better provided in the field as necessary to connect the components being added.  Conduit would only be required for the air flow safety switch as the other items are mounted in the oven control panel.

Please contact Anderson-Bolds with the oven serial number, job # and model number all of which can be found on the name plate of the oven.  We can also provide new wiring schematics for old ovens and instruction manuals.  Grieve and Anderson-Bolds want our products to be operated in the safest manner possible. 

Meltric deContactor Plugs

Elster American Meter Gas Meters

Watlow Temperature Controllers

Contact Anderson-Bolds at:

216-360-9800 

grieve@anderson-bolds.com

Watlow 1/4 DIN Temperature Controllers

Watlow Process 1/4 DIN Controllers from Anderson-Bolds

The Watlow SERIES F4 1⁄4 DIN temperature process controller offers performance features to meet a wide range of industrial processing needs. The F4 process controller is ideal for semiconductor manufacturing equipment, plastic processing and packaging equipment and industrial process control applications.

The F4 Watlow process controller features a four line, high definition LCD interface display, in addition to an information key that enables easy set up and control operation, minimizing the chance for error. Its 16-bit microprocessor ensures accuracy and delivers performance advantages you can count on from a Watlow controller.

Four digital inputs remotely modify the F4’s operation or enable display of pre-defined operator messages. Advanced process controller features include cascade, ratio, differential, duplex slide wire and retransmit options.

Serial communication and dual alarm relays are included in the base unit. The WATLOW SERIES F4 is packaged with a
NEMA 4X front face to withstand harsh environments anda four-inch (101.6 mm) deep case with removable connectors for wiring convenience. It is manufactured by Watlow, ISO 9001 registered and protected by a three-year warranty.

Use our Watlow Parts form to get a quote.

Watlow F4 Process Controller

Features and Benefits

Guided setup

• Removes “guess work” from the setup process 
• Saves time by reducing programming errors 
• High definition four-line LCD display 

• Simplifies setup process and operations 
• Quickly and easily identifies process, alarm and
  set point values 
• Information “I” Key 

• Displays essential elements from the user manual on board

Customized menuing

• Quickly displays up to 16 parameters 
• Allows users to create custom messaging and easily
  identify key events or alarms 
• High performance 16-bit microprocessor 

• Provides precise process control with 20Hz update rate on input 1. (10Hz on inputs 2 and 3) 
• Calibration accuracy of ±0.1 percent of span 
• Universal input 
• • Embedded software provides application versatility 
• • Eliminates the need for dip switches 
• Modbus® communications ready 

• Equipped to handle RS232 or EIA485 communications

Example Watlow F4P Temperature Controller Part numbers:

F4PH-EEA-01RG - Watlow Process Temperature Controller

Controller with 2 relay outputs and standard control operation.

F4PH-EEB-01RG - Watlow Process Temperature Controller

Controller with 2 relay outputs and enhanced control operation (dual universal inputs, cascade, ratio, duplex, differential, slide wire)

F4PH-FEA-11RG - Watlow Process Temperature Controller

Controller with analog output and a relay output and standard control operation and retransmit analog signal.

F4PH-FEB-11RG - Watlow Process Temperature Controller

Controller with analog output and a relay output and enhanced control operation (dual universal inputs, cascade, ratio, duplex, differential, slide wire) and retransmit analog signal.

The Watlow EZ-ZONE®PM panel mount 1/4 DIN controller offers control options that reduce system complexity and thermal loop ownership cost. It can be ordered as a PID controller, an over/under limit controller or its functions can be combined into an integrated controller. An option to integrate a high amperage power controller output with a high-performance PID controller and an over/under limit controller in one space-saving, panel mount package is also available. Many communications options are offered to support connectivity needs.

Because the Watlow EZ-ZONE PM panel mount controller is highly scalable, you pay only for what is needed. This controller is available in 1⁄32,1⁄16,1⁄8 and1⁄4 DIN panel mount packages. The Watlow EZ-ZONE PM controller is easy to use and is ideal for PID controller, over/under limit controller or integrated controller needs.

Watlow PM EZ-Zone Controllers

Features and Benefits

Integrated PID and limit controller

• Reduces wiring time and termination complexity

compared with connecting discrete products

• Decreases required panel space

• Lowers installation costs

• Increases user and equipment safety for over/under

temperature conditions

High amperage power control output

• Drives 15 ampere resistive loads directly

• Reduces component count

• Decreases cost of ownership

Current monitoring

• Detects heater current flow and provides alarm indication

of a failed output device or heater load

• Drives output on open or shorted heater

Serial communication capabilities

• Provides a wide range of protocol choices including

Modbus(R) RTU, EtherNet/IP™, Modbus(R) TCP, PROFIBUS

DP and DeviceNet™

• Supports network connectivity to a PC or PLC

Dual-channel controller

• Provides two PID controllers in one space-saving package

Enhanced control options

• Easily handles complex process problems such as

cascade, ratio, differential, square-root, motorized valve

control without slidewire feedback, wet-bulb/dry-bulb,

compressor control and peltier loads

Countdown timer option

• Provides batch process control

• Supports set point change during countdown

Advanced PID control algorithm

• Offers TRU-TUNE(R)+ adaptive control to provide tighter

control for demanding applications

• Provides auto-tune for fast, efficient start-up

Configuration communications with software

• Includes Watlow standard bus communications and

EZ-ZONE configurator software

• Saves time and improves reliability of controller setup

Ten-point linearization curve

• Improves sensor accuracy

Built-in sensor compensation curves

• Saves cost of buying compensated sensors

• Includes Vaisala RH and altitude (pressure) curves

Remote set point operation

• Supports convenient set point manipulation from a

remote device such as a master control or PLC

Profile capability

• Offers pre-programmed process control

• Allows ramp/soak programming with 40 total steps,

battery backup and real time clock

Retransmit Output

• Supports industry needs for recording

Factory Mutual (FM) approved over/under limit with

auxiliary outputs

• Increases user and equipment safety for over/under

temperature conditions

Memory for saving and restoring parameter settings

• Decreases service calls and time down

Agency approvals: UL® listed, CSA, CE, RoHS, W.E.E.E.,

FM, SEMI F47-0200, Class 1, Div. 2 rating on selected

models

• Assures prompt product acceptance

• Reduces end product documentation costs

Touch-safe package

• Increases safety for installer/operator

• Complies with IP2X requirements

Consistent termination labeling connection system

• Simplifies switching between products

• Speeds up user’s system documentation

EZ-KEY

• Enables simple, one-touch operation of user-defined,

repetitive activities

Programmable menu system

• Reduces setup time and increases operator efficiency

Three-year warranty

• Provides product support and reliability

Watlow EZ-ZONE PM PM4C1EA-AAAAAAA Integrated PID Digital Display Temperature Control, 1/4 DIN, PID Control, Two 4 digit digital displays, Universal input, 100-240 VAC

Output 1: 5 amp Form C Mechanical Relay

Watlow EZ-ZONE PM PM4C1EJ-AAAAAAA Integrated PID Digital Display Temperature Control, 1/4 DIN, PID Control, Two 4 digit digital displays, Universal input, 100-240 VAC

Output 1: 5 amp Form C Mechanical Relay 

Output 2: 5 amp Form A Mechanical Relay

Watlow EZ-ZONE PM PM4R1EJ-AAAAAAA PID Digital Display Temperature Control, 1/4 DIN, PID Control with RAMP SOAK capability, Two 4 digit digital displays, Universal Sensor input, 100-240 VAC

Output 1: 5 amp Form C Mechanical Relay 

Output 2: 5 amp Form A Mechanical Relay

Watlow EZ-ZONE PM PM4C1EJ-AAEAAAA Integrated PID Digital Display Process/Temperature Control, 1/4 DIN, PID Control, Two 4 digit digital displays, Universal input, 100-240 VAC

Output 1: 5 amp Form C Mechanical Relay 

Output 2: 5 amp Form A Mechanical Relay

Output 3: 5 amp Form C Mechanical Relay

Watlow EZ-ZONE PM PM4C1EJ-AAEKAAA Integrated PID Digital Display Temperature Control, 1/4 DIN, PID Control, Two 4 digit digital displays, Universal Sensor input, 100-240 VAC

Output 1: 5 amp Form C Mechanical Relay 

Output 2: 5 amp Form C Mechanical Relay

Output 3: 5 amp Form C Mechanical Relay

Output 4: SSR Form A, 0.5A

Watlow EZ-ZONE PM PM4C4KH-ALEJAAA Integrated PID Digital Temperature Control, 1/4 DIN, PID Control, Two 4 digit digital displays, Universal input, 20-28 VAC and 12-40 VDC

Output 1: SSR Form A, 0.5A

Output 2: NO-ARC 15 A power control

Output 3: 5 amp Form C Mechanical Relay

Output 4: 5 amp Form A Mechanical Relay

Watlow EZ-ZONE PM PM4C1KK-ALEJAAA Integrated PID Digital Display Temperature Control, 1/4 DIN, PID Control, Two 4 digit digital displays, Universal input, 100-240 VAC

Output 1: SSR Form A, 0.5A

Output 2: SSR Form A, 0.5A

Output 3: 5 amp Form C Mechanical Relay

Output 4: 5 amp Form A Mechanical Relay

Watlow EZ-ZONE PM PM4C4FJ-6AAAAAA Integrated PID Digital Temperature Control, 1/4 DIN, PID Control, Two 4 digit displays, Universal input, 20-28 VAC and 12-40 VDC

Output 1: Universal Process - 4-20mA, 0-10vdc, 0-20mA

Output 2: None

Output 3: None

Output 4: None

Communications: PROFIBUS DP

Watlow EZ-ZONE PM PM4C4FJ-3AAAAAA Integrated PID Digital Display Temperature/Process Control, 1/4 DIN, PID Control, Two 4 digit digital displays, Universal input, 20-28 VAC and 12-40 VDC

Output 1: Universal Process - 0-10vdc, 0-20mA, 4-20mA

Output 2: 5 amp Form A Mechanical Relay

Output 3: None

Output 4: None

Communications: EtherNet/IP/Modbus TCP

For questions/quotes/comments email to wallow@anderson-bolds.com

216-360-9800 / 614-885-3933