Watlow PM Plus 1/4 DIN Controller - Quick Start Guide

Controller Interface

The controller features an interface with navigation buttons (Home, Right, Left, Up/Down, F1/F2) for accessing menus, parameters, and functions. The 'Home' button returns to the main screen, 'Right' advances through lists, 'Left' goes back, 'Up/Down' adjusts values and scrolls, and 'F1/F2' perform user-defined functions.

1 - Mount to Panel

Panel Cutout: Refer to Figure 1 for panel cutout dimensions (92 to 93mm width and height).

Mounting Procedure:

1. Remove green terminal connectors and mounting collar.
2. Insert controller into the panel cutout from the front.
3. Orient the collar base with the flat side facing front and screw openings on the sides (Figure 2), then slide it over the controller's back.
4. Slide the mounting bracket over the controller, aligning screws with the collar base. Push until hooks snap into case slots.
5. Tighten the four #6-19 x 1.5 in. screws (two on each side) with a Phillips screwdriver until the device is flush with the panel (3-4 in-lbs torque) (Figure 3).
6. Reinstall terminal connectors. Field wiring can be connected before or after reinstalling connectors.

Note: Access to the back of the panel is required for mounting.

2 - Connect the Sensor Input

Connect sensors according to the diagram for your specific sensor type. Figure 4 shows a thermocouple connection.

Thermocouple: Connect S1 and S2 to R1 and R2 respectively.

Platinum 1000 or 10000 RTD: Connect S1, S2, and S3. Ensure lead resistance is 200 max. round trip.

Process Voltage or Current: Connect S1 and S2 for voltage (0-50 mV or 0-10V) or current (4-20 mA).

3 - Wire Output 1

Wire Output 1 based on your model number:

• Switched DC or Open Collector: Connect to terminals C (Common) and W1 (for Load).
• Universal Process (0-20 mA or 0-10V): Connect to terminals C (Common), W1 (for Load), and Y1 (for Power Supply +). Note load resistance requirements (800 Ω max for mA, 1kΩ min for V).

Output specifications: [5A @ 240 V(ac) or 30 V(dc)]

4 - Wire Output 2

Wire Output 2 based on your model number:

• Form A Relay: Connect to terminals C (Common), L2 (Load), and K2 (Internal Circuit Common).
• Switched DC: Connect to terminals C (Common) and W2 (for Load).
• Form C Relay: Connect to terminals C (Common), L2 (Load), and K2 (Internal Circuit Common).
• No-Arc Relay: Connect to terminals C (Common), J1 (Load), and K2 (Internal Circuit Common).

Output specifications: [5A @ 240 V(ac) or 30 V(dc)]

5 - Connect Power

Connect power to terminals 98 and 99.

Power Source:

• PM4_[1, 2, 3, 4]
• 1 or 2: 120-240 V (ac)
• 3 or 4: 24 V (ac or dc)

CAUTION: Do not connect high voltage to a controller that requires low voltage.

6 - Set Up the Sensors

Repeat for other sensors.

Steps:

1. Tap 'Home'.
2. Tap 'Right' to open the Operations list.
3. Select 'Setup' and tap 'Right'.
4. Select 'Analog Input' and tap 'Right'.
5. Select 'Analog Input 1' or 'Analog Input 2' and tap 'Right'.
6. Select 'Sensor Type' and tap 'Right'.
7. Scroll to the desired sensor type (Thermocouple, Millivolts, Volts, Milliamp, RTD 100 Ohm, RTD 1000 Ohm, Potentiometer) and tap 'Left' after selection.

For a thermocouple: Select 'Thermocouple', then the specific type (J, K, N, R, S, or T).

For an RTD: Select 'RTD 100 Ohm' or 'RTD 1000 Ohm', then select '2' or '3' wires as needed.

For other sensor types, refer to the PM PLUS User's Guide.

7 - Set Up Outputs

Repeat for all outputs.

Steps:

1. Tap 'Home'.
2. Tap 'Right' to open the Operations list.
3. Select 'Setup' and tap 'Right'.
4. Select 'Output' and tap 'Right'.
5. Select the desired Output (1 or 2) and tap 'Right'.
6. Select 'Function' and tap 'Right'.
7. Scroll to the desired function and tap 'Left'.
8. Set the specific settings for that output function.

Output Functions include: Heat Power, Cool Power, Event A, Event B, Alarm, Setup.

Example for a 4-20 mA process output: Set Output Type to 'Milliamps', Output Function to 'Heat Power', Output Function Instance to '1', Scale Low to '4.00', Scale High to '20.00', Range Low to '0.0' and Range High to '100.0'.

8 - Set Up Alarms

Repeat for other alarms.

Alarm Types:

• Process: Alarm set points are set directly.
• Deviation: Alarm set points are relative to the control loop's set point.
• Off: No alarm occurs.

Alarm Sides:

• Both: High and low alarms are active.
• High: Alarm when process is above the high alarm set point.
• Low: Alarm when process is below the low alarm set point.

Steps:

1. Tap 'Home'.
2. Tap 'Right' to open the Operations list.
3. Select 'Setup' and tap 'Right'.
4. Select 'Alarm' and tap 'Right'.
5. Select the desired Alarm (1, 2, 3, or 4) and tap 'Right'.
6. Select 'Type' and tap 'Right'.
7. Select 'Off', 'Process Alarm', or 'Deviation Alarm' and tap 'Left'.
8. Scroll to 'Alarm Sides' and tap 'Right'.
9. Scroll to the desired option (Both, High, or Low) and tap 'Left'.
10. Set the alarm setpoint(s) (Low Set Point and/or High Set Point) as necessary. Note: Enter negative values for low deviation alarms.

9 - Control Loop Mode, Set Point, Autotune

NOTES: By default, the control loop Heat algorithm is enabled for PID control and the Cool algorithm is OFF. To enable, go to Control Loop.

CAUTION: Autotune turns on the loop's heat output until the process value exceeds 90% of the set point, then turns the output off and repeats this. When finished, the loop controls at the set point. Before starting Autotune, consider if it is safe to do so. The system must be operational for autotuning to select PID settings.

Steps:

1. Tap 'Home'.
2. Tap 'Right' to open the Operations list.
3. Select 'Setup' and tap 'Right'.
4. Select 'Control Loop' and tap 'Right'.
5. Select the control loop (if more than one) and tap 'Right'.
6. Scroll to 'Control Mode' and tap 'Right'.
7. Select 'Off', 'Auto', or 'Manual' and tap 'Right'.
   • Auto: Loop adjusts output so process matches set point.
   • Manual: User sets control loop output in percent power.
   • Off: No control loop output.

Control Loop Set Point: Tap 'Home' or the Home screen. Use Up/Down to set the set point.

Autotune:

1. On the Setup list, scroll to and select 'Control Loop'.
2. Scroll to and select 'AutoTune'.
3. Select 'Yes'.