Archives

This manual describes how to install, setup, and operate a 

CAS200. Included are six chapters and a glossary of terms. 

Each chapter covers a different aspect of the alarm scanner 

and may apply to different users. The following describes 

the chapters and their purpose.

• Chapter 1: System Overview provides a component 

list and summary of features for the CAS200 series 

alarm scanners.

• Chapter 2: Installation provides detailed 

instructions on installing the CAS200 and its 

peripherals.

• Chapter 3: Using the CAS200 provides an overview 

of operator displays used for system monitoring and 

job selection.

• Chapter 4: Setup provides detailed descriptions of all 

menus and parameters for scanner setup.

• Chapter 5: Troubleshooting and 

Reconfiguration provides some basic guidelines for 

solving operational problems and provides procedures 

for changing some of the hardware options (e.g. 

installing special input resistors and changing EIA/

TIA-232 to EIA/TIA-485).

• Chapter 6: Linear Scaling Examples provides 

three examples where linear scaling is used.

• Chapter 7: Specifications lists detailed 

specifications of the scanner and optional components.

Product Features

The CAS200 is a modular monitoring system with 16 

analog inputs. It can function as a stand-alone system; the 

CAS200 1/8 DIN front panel has a Vacuum Fluorescent 

Display (VFD) and touch keypad for local display and local 

parameter entry. You can also use it as the key element in 

a computer supervised data acquisition system; the 

CAS200 can be locally or remotely controlled via an EIA/

TIA-232 or EIA/TIA-485 serial communications interface.

Features include:

Direct Connection of Mixed Thermocouple Sensors:

Connect most thermocouples to the scanner with no 

hardware modifications. Thermocouple inputs feature 

reference junction compensation, linearization, process 

variable offset calibration to correct for sensor 

inaccuracies, detection of broken, shorted or reversed 

thermocouples, and a choice of Fahrenheit or Celsius 

display.

Automatic Scaling for Linear Analog Inputs: The 

CAS200 series automatically scales linear inputs used with 

industrial process sensors. Enter two points and all input 

values are automatically scaled in your units. Scaling 

resistors must be installed.

Flexible Alarm Outputs: Independently set high/low 

process alarms and a high/low deviation band alarm for 

each channel. Alarms can activate a digital output by 

themselves, or they can be grouped with other alarms to 

activate an output. 

Alarm Outputs: You can set high/low deviation and high/

low process alarm setpoints to operate digital outputs as 

latched or unlatched functions. 

Global Alarm Output: When any alarm is triggered, the 

global alarm output is also triggered, and it stays on until 

you acknowledge it.

CPU Watchdog: The CAS200 series CPU watchdog timer 

output notifies you of system failure. Use it to hold a relay 

closed while the system is running, so you are notified if the 

microprocessor shuts down.

Front Panel or Computer Operation: Set up and run 

the scanner from the front panel or from a local or remote 

computer. Watlow Anafaze offers WatView, a Windows® 

compatible Human Machine Interface (HMI) software 

package that includes data logging and graphing features 

in addition to process monitoring and parameter setup 

screens.

Multiple Job Storage: Store up to eight jobs in protected 

memory, and access them locally by entering a single job 

number or remotely via digital inputs. Each job is a set of 

alarm conditions.

Pulse Counter Input: Use the pulse counter input for 

precise monitoring of motor or belt speed.

 System Diagram

The illustration below shows how the parts of the CAS200 

are connected. When unpacking your system, use the 

diagram and parts list below to ensure all parts have been 

shipped. Please don’t hesitate to call Watlow Anafaze if you 

have problems with your shipment, or if any CAS200 

components are missing or damaged. 

Figure 1.1 System Components

• CAS200 Scanner

• Mounting Kit

• TB50 Terminal Board

• 50-Pin SCSI Cable

• DC Power Supply

Mounting Scanner Components

Install the scanner in a location free from excessive heat 

(>50°C), dust, and unauthorized handling. 

Electromagnetic and radio frequency interference can 

induce noise on sensor wiring. Select locations for the CAS 

200 and TB50 such that wiring can be routed clear of 

sources of interference such as high voltage wires, power 

switching devices and motors.

∫

WARNING! To reduce the risk of fire or electric shock, install 

CAS200 in a controlled environment, relatively 

free of contaminants.

 Safety

Watlow Anafaze has made efforts to ensure the reliability 

and safety of the CAS200 and to recommend safe uses in 

systems applications. Note that in any application failures 

can occur. 

Good engineering practices, electrical codes, and insurance 

regulations require that you use independent external 

safety devices to prevent potentially dangerous or unsafe 

conditions. Assume that the CAS200 can fail or that other 

unexpected conditions can occur.

Install high or low temperature protection in systems 

where an overtemperature or undertemperature fault 

condition could present a fire hazard or other hazard. 

Failure to install temperature control protection where a 

potential hazard exists could result in damage to 

equipment and property, and injury to personnel.

For additional process safety, program a computer or other 

host device to automatically reload your desired operating 

parameters after a power failure. However, this safety 

feature does not eliminate the need for other external, 

independent safety devices in dangerous conditions.

The CAS200 should never be used as a safety 

shutdown device. It should only be used with 

other approved independent safety shutdown 

devices.

Contact Watlow Anafaze immediately if you have any 

questions about system safety or system operation.

This chapter describes how to install the CAS200 series 

scanner and its peripherals. Installation of the scanner 

involves the following procedures:

• Determining the best location for the scanner

• Mounting the scanner and TB50

• Power Connection

• Input Wiring

• Communications Wiring (EIA/TIA-232 or EIA/TIA485)

• Output Wiring

Typical Installation

The illustrations below show typical installations of the 

scanner with the TB50 terminal block. Observe the 

illustration below to determine potential space 

requirements.

We recommend that you read this entire chapter first 

before beginning the installation procedure. This will help 

you to carefully plan and assess the installation. 

Figure 2.1 System Components

Safety

∫

WARNING! Ensure that power has been shut off to your entire 

process before you begin installation of the 

scanner

Watlow Anafaze has made every effort to ensure the 

reliability and safety of this product. In addition, we have 

provided recommendations that will allow you to safely 

install and maintain this scanner. 

∫

WARNING! In any application, failures can occur. These 

failures can result in full control output (100% 

power), or the occurrence of other output failures 

which can cause damage to the scanner, or to the 

equipment or process connected to the scanner. 

Therefore, always follow good engineering 

practices, electrical codes, and insurance 

regulations when installing and operating this 

equipment. 

 External Safety Devices

External safety devices should be used to prevent 

potentially dangerous and unsafe conditions upon 

equipment failure. Always assume that this device can fail 

with outputs full-On, or full-Off, by the occurrence of an 

unexpected external condition.

∫

WARNING! Always install high or low temperature protection 

in installations where an overtemperature or 

undertemperature fault will present a potential 

hazard. Failure to install external protection 

devices where hazards exist can result in damage 

to equipment, property, or human life.

Mounting 

We recommend you mount the scanner in a panel not more 

than 0.2 inches thick. 

∫

WARNING! To reduce the risk of fire or electric shock, install 

the CAS200 in a controlled environment, 

relatively free of contaminants.

 Location

Install the scanner in a location free from excessive (>50°C) 

heat, dust, and unauthorized handling. 

Ensure there is enough clearance for mounting brackets, 

terminal blocks, and cable and wire connections; the 

scanner extends 7.0 in. behind the panel face and the screw 

brackets extend 0.5 in. above and below it. Allow an 

additional 1 to 3 inches for the SCSI cable.

Figure 2.2 Clearance Recommendations

Other Tools: 

You will also need these tools:

• Phillips head screwdriver

• Flathead screwdriver for wiring

• Multimeter

 Mounting the Scanner

Mount the scanner before you mount the TB50 or do any 

wiring. The scanner’s placement affects placement and 

wiring considerations for the other components of your 

system.

You receive one of two types of mounting brackets with 

your scanner, the mini-bracket or the collar bracket. Refer 

to the corresponding sections below for instructions.

 Steps Using the Mini-Bracket

1. Cut a hole in the panel to the dimensions shown in the 

illustration below. To do this, use a punch, nibbler, or 

jigsaw, and file the edges of the hole.

2. Insert the scanner into the hole through the front of 

the panel.

3. Screw the top and bottom clips in place: insert the 

clip’s lip into the cutout in the scanner’s metal housing 

just behind the front panel. Tighten the screws. 

4. If you expect much panel vibration, use a rear support 

for the scanner and its interconnecting cables.

Figure 2.3 Mounting with the Mini-Bracket

Steps Using the Collar Bracket

Installing and mounting requires access to the back of the 

panel. 

NOTE! Removing the scanner chassis from its case

makes mounting easier.

1. Make a panel cutout. Refer to Figure 2.3 on page 11 for 

dimensions of the cutout.

2. Slide the scanner into the panel cutout. 

3. Slide the mounting collar over the back of the scanner, 

making sure the mounting screw indentations face 

toward the back of the scanner.

4. Loosen the mounting bracket screws enough to allow 

for the mounting collar and panel thickness. Place 

each mounting bracket into the mounting slots (head 

of the screw facing the back of the scanner). Push each 

bracket backward then to the side to secure it to the 

scanner case. 

5. Make sure the case is seated properly. Tighten the 

installation screws firmly against the mounting collar 

to secure the unit. Ensure that the end of the mounting screws fit into the indentations on the mounting 

collar.

Figure 2.4 Mounting with the Collar Bracket

Mounting the TB50

There are two ways you can mount the TB50, by using the 

pre-installed DIN rail mounting brackets provided or by 

using the plastic standoffs. Follow the procedures for each 

to mount the board.

This paper describes the use of cascade control utilized for processes with long lag times between a change in the 

control output level and a change in the process variable such as temperature. A lag time period of 10 to 30 minutes 

or longer would be suitable conditions for considering cascade control. A commonly used process that is described 

as needing cascade control is the water tank example. Another common process that uses cascade control is 

aluminum melt furnaces. 

It is not the type of process; rather the qualifying condition is the long lag time of a slow process that is always out 

of control. The PV will be lagging so far behind the change in the output so that no amount of PID tuning will 

correct the condition. The water tank example is using the input (cold) water temperature and looking at the outlet 

(hot) water temperature that is the controlling point. The outlet temperature may always lag behind the heating of the 

inlet water thus providing a variance of the outlet water temperature that is out of tolerance no matter the PID 

settings. 

The aluminum melt furnace has a problem in the melting of cold aluminum bars as the bars are introduced into the 

melt furnace. The temperature of the heating zone will rise so high due to a “cooler” condition of the melt pot and to 

the long lag time that it will overheat the melt furnace. Cycling will be very severe and the melt pot will be out of 

control. 

The use of two TC or other types of temperature sensors at two different locations can provide for control of long 

lag time response process. By placing one sensor to measure the outlet of the process temperature and another one to 

measure the process product inlet temperature, we can now measure the process for cascade control. 

The outlet sensor as it measures the process product outlet temperature will provide for the desired product 

temperature. This is known as the temperature Setpoint Control and has other labels as well such as Outer Loop. 

This loop will provide the SP level for the temperature Heat Control zone also known as the Inner Loop. 

The inlet sensor will measure the process product inlet temperature and using the SP level from the Setpoint Control 

of the outlet sensor provide the heat control required for controlling the inlet temperature to meet the desired 

temperature for the outlet temperature. It does this by using the control output level of the SP Control Loop to set the 

SP level of the Control Loop. 

As the outlet temperature decreases it will increase the SP level for control of the inlet temperature control zone. As 

the outlet temperature increases it will decrease the SP level for control of the inlet temperature control zone. In 

providing this cascade of control it overcomes the long lag time of the process. By looking at the difference between 

the two sensors and making corrections as to the heat control level, the output level can be maintained at a closer 

level of control. 

CLS200 and MLS300 Cascade Control Terms

Nominal heat only control cascade has two parameters for adjustments. Dual heat and cool control would have four 

parameters. 

The Control Loop Setpoint (Inner Loop) for heat or cool outputs has a parameter for setting the desired SP value 

when the SP Control Loop (Outer Loop) output level is at 0%. It also has a parameter for setting the desired SP 

value when the SP Control output level is at 100%. Full PID control modes of the Control Loop will be used for 

controlling the control output level. 

Watlow Winona OH 07/28/06 

1241 Bundy Blvd 

Winona, MN 55987 

Telephone (507) 494-5656 

1

© 2005 Watlow Electric Manufacturing Company 

CLS200 and MLS300 Cascade Control 

 Setup and Tuning of Cascade Functions 

The Setpoint Loop will use the loop’s SP as set by the operator for the desired temperature of the product or process. 

The Setpoint Loop PID control modes will only use P and I control modes. 

There is a possibly of six parameters that will need to be set for using cascade control when using the CLS200 or 

MLS300 Dual Control Outputs. There are five when only using the Heating Control Output. 

Follow User Guide instructions for changing parameters from the front panel keys. 

First, the assignment as to which loop will be the temperature SP control loop (Primary Loop) and which loop will 

be the cascade temperature Control Loop (Secondary Loop). 

In the front panel display, select the Cascade Menu while in the loop number that the inlet sensor is connected to, 

which is the heat control loop or Secondary Loop. For instance if Loop 2 is the heat control loop with an output to 

the heat control device, the display should show Loop 2 before going into the Cascade Menu. 

While in the Cascade Menu and using the keys select the PRIM. Loop or the SP Control Loop. Select any number, 

but number 2. The number selected should be the output sensor loop. For instance if the outlet sensor is connected to 

Loop 1, select Loop 1. 

Second, the Base SP, Min SP, Max SP, and Heat Span, and Cool Span parameters need to be set. All parameters are

in the engineering units of the Control Loop or Secondary Loop.

If the process is controlling a process with a SP at 140°F and at -22°F while not wanting any control output at 

ambient, which is consider to be 75°F, the following will apply. 

BASE SP = 75, this is the base value at which all other values will be referenced from. This value must be set 

whenever using heat, cool, or heat and cooling control outputs. 

Min SP = -35, this is the value at which the lower SP value cannot exceed and must be greater than the cooling SP 

of -30. This value can be set to the input range lowest value, if desired so that it would not need to be included in 

any future resetting of cascade parameters. 

Max SP = 145, this is the value at which the higher SP value cannot exceed and must be greater than the heating SP 

of 140. This value can be set to the input range highest value, if desired so that it would not need to be included in 

any future resetting of cascade parameters. 

Heat Span = 65, this is the value which is the span between the Base SP and the desired heat SP. i.e. 140 – 75 = 65. 

This is the value that must be set if using heat only or heat and cooling outputs as well as the Base SP. 

Cool Span = 105, this is the value which is the span between the Base SP and the desired cool SP i.e. -75 + -30 = 

105. This value must be set when using heat and cooling or cooling only outputs as well as the Base SP. 

Heat only example: Low SP = 1200 and High SP =1600. 

Base SP = 1200 and Heat Span = 400. 

Cool only example: High SP = 50 and Low SP = 30. 

Base SP = 50 and Cool Span = 20 

Watlow Winona OH 07/28/06 

1241 Bundy Blvd 

Winona, MN 55987 

Telephone (507) 494-5656 

2

© 2005 Watlow Electric Manufacturing Company 

CLS200 and MLS300 Cascade Control 

 Setup and Tuning of Cascade Functions 

Tuning Cascade Loops

The proper procedure for tuning cascade control loops is to first tune the secondary (inner) heat or cool control loop 

using all three of the PID modes. This loop must first be tuned to good PID control parameters before doing any 

tuning of the SP temperature control loop. Do not try tuning both loops at the same time unless you are an expert in 

tuning PID loops and have experience with cascade control systems. 

If cooling is in use and there is a proportional component to the cooling control such as using a TP output with a 

solenoid valve, then the PID modes can be tune as well. 

The use of autotuning or adaptive tuning can be used to achieve the PID control parameters. If these tuning 

functions are not available then use manual PID tuning methods. After a satisfactory control is achieved with the 

heat control loop, take note of the P and I values. 

To tune the primary (outer) SP control loop, first check the actual range of the SP of the secondary loop by placing 

the SP loop control into manual mode. With a heat output of 0%, the SP of the heat control loop should be at the low 

SP value as set in the cascade menu. Change the output to 100%, the SP of the heat control loop should be at the 

high SP value as set in the cascade menu. If using cooling control do the same thing with the heat output at 0% and 

then changing the cooling output to achieve the same values as set in the cascade menu. 

Use the values as noted in the PB mode and TI or RM of the Integral/Reset mode of the heat control loop and place 

them in the PID parameters of the heat control output. If PID values are obtained for the cooling, use them for the 

cooling PID parameters. DO NOT USE THE DERIVATIVE MODE. IT MUST BE TURNED OFF. 

Place the control mode of the SP loop into Auto control mode. The SP loop control output should start changing 

which in turn will be changing the SP of the secondary or heat control loop. Allow the process to settle down. If 

there is any unwanted cycling of the temperature, use and change the PID parameters of the SP control loop for 

changing any unwanted control deviations from SP. Do not use the heat control loop for making any changing to the 

PID parameters. 

A slow process will take time to see how the tuning is doing so don’t be in a hurry. A space of 20 to 30 minutes is 

not too long in most cases. 

If you are not knowledgeable or trained and have experience with PID and tuning be sure to see the instructions on 

PID and PID tuning before attempting to tune cascade loops. 

Watlow TRU-TUNE+ can do the tuning for you. First, perform an auto tune of the heat control loop by placing the 

control mode into Tune. After the adaptive mode has been active for a while such as 1 or 2 hours, use the P and I 

values as obtained in the adaptive mode for the P and I values of the SP loop. Place the SP loop directly into 

Adaptive Mode for final tuning of the SP PID values. 

TRU-TUNE+ is not available in the CLS200 or MLS300 Series controllers, but is available in the CPC400. Also 

cascade is standard firmware in the CPC400 as well. Order option “EF” in the CLS200 and MLS300 to use cascade 

control. 

Watlow Winona OH 07/28/06 

1241 Bundy Blvd 

Winona, MN 55987 

Telephone (507) 494-5656 

3

© 2005 Watlow Electric Manufacturing Company 

This reference guide is designed to help applications software

programmers with the following tasks:

• Interface to Watlow Anafaze MLS300, CLS200, MLS and CLS controllers, and the CAS200 and CAS scanners via serial communications.

• Modify the communications Anafaze protocol driver in the Watlow 

Anafaze Communications Driver Kit. (If you have the communications driver kit, you don’t need to read this manual unless you want 

to modify the communications driver.)

In This Manual

The following sections are included in this guide: 

Chapter 1: Anafaze/AB Protocol. Gives an overview and explanation

of the Anafaze/Allen Bradley communications protocol.

Chapter 2: Modbus-RTU Protocol. Gives an overview and

explanation of the Modbus-RTU communications protocol

Chapters 1 and 2: Data Table Summary. Provides standard controller

data table maps for the parameters (one for each protocol).

Chapter 3: Parameters Description. Describes each parameter.

Appendix A: Communications driver.

Glossary: Explanation of commonly used terms and acronyms.

NOTE

This reference guide is not a tutorial. It does not explain

how to use the controller; it is not a programming reference; it also does not explain PID control, alarms, linear

scaling, or other topics that are explained in detail in the

controller manuals. If you need additional information

about a topic covered in this reference guide, consult the

documentation included with your controller.

Chapter 1: ANAFAZE/AB Protocol

This section explains the ANAFAZE/Allen Bradley protocol used in

Watlow Anafaze MLS, CLS, and CAS devices. These controllers

operate on serial communications links (EIA/TIA-232 or EIA-TIA-485)

at either 2400 or 9600 baud. They use 8 data bits, one or 2 stop bits, and

no parity.

Protocol Syntax

The controllers use a half-duplex (master-slave) protocol to interface to

high-level software. The host software is considered the “master” and

the controller is considered the “slave.” In other words, the software can

request information from the controller or download information to the

controller. The controller can only respond to communications

transactions initiated by the host software. The controller cannot initiate

communications.

The controller and host software communicate by sending and receiving

information in a “packet” format. A packet consists of a sequence of

bytes in a specific format; it can be as large as 256 bytes of data. (For

more information about packets, see the Packet Format section later in

this chapter.)

The numbers in the packet are sent in binary format. However, our

examples show bytes in hexadecimal format.

Control Codes

Watlow Anafaze abbreviates control codes this way

Chapter 1: ANAFAZE/AB Protocol

Transaction Sequence

Here are the four steps in a transaction between the host software and

the controller. The following example shows the transaction as an

exchange of packets. The example also assumes that there are no

communication errors in the exchange.

(1) The host software sends a packet that contains a read command or 

write command.

(2) The controller sends a DLE ACK to the host software.

(3) The host software receives a reply packet from the controller. 

(4) The host software sends a DLE ACK.

The following flowchart shows a transaction with no error handling.

NOTE

Due to the difference between the processing speeds of the

controller and PCs, it may be necessary to delay the computer’s acknowledgement (ACK) in order for the controller

to receive it. A delay of 200 ms should suffice

Packet Format

Messages are transmitted in the form of packets. Command and reply

packets specify the source and destination addresses, whether to read or

write, the block of data to read or write, etc.

A packet contains a sequence of binary bytes formatted this way:

Sending Control Codes

To send a control code, send a DLE before the control code to

distinguish it from data.

Sending a DLE as Data

When you send a byte with an x10, (a DLE), the controller and software

interpret it as a command. Therefore, to send a DLE as data, send

another DLE immediately before it (DLE DLE). 

Codes in a Packet

This section describes the sequence of bytes in a packet, in the order the

host software or controller sends them.

DLE STX

• The DLE STX byte signals the beginning of a transmission. Every 

packet of information starts with the control codes DLE STX. 

DST

• The DST byte is the address of the destination device (usually a controller; the first Watlow Anafaze controller is at x08).

NOTE

When host software communicates with an MLS, a CLS, or

a CAS in ANAFAZE or AB protocol, it does not send the

controller’s actual address. Since the protocol reserves

device addresses 0 to 7, the host software sends the value

(controller address + 7), instead of the actual device

address.

SRC

• The SRC byte is the device address of the packet’s source. The host 

software is usually designated address x00.

DLE STX DLE ETX BCC/CRC

DST SRC CMD STS TNSL TNSH ADDL ADDH DAT

CMD

• The CMD byte indicates the command that the host software sends 

to the controller. The software sends a read (x01) or write (x08). 

When the controller replies, it returns the read or write command 

with the 7th bit set—in other words, it sends an x41 or x48.

STS (The Status Byte)

• The controller uses the status byte, or STS, to return general status 

and error flags to the host software. (The controller ignores the status 

byte in the host software’s command packet.) The next table shows 

status byte values and definitions. 

• An “x” in the status bytes below indicates that the associated nibble 

may contain additional information. In most cases, the status byte is 

composed of two independent nibbles. Each nibble is independent 

so that two codes can return at once. For example, status code F1 

indicates that data has changed (Fx) and the controller is being 

updated through the front panel (x1).

Status

in Hex Description

00 The controller has nothing to report, or AB protocol is selected.

01 Access denied for editing. The controller is being updated through the 

front panel.

02 AIM Comm failure.

A0 A controller reset occurred.

Cx The controller received a command that was not a block read or block 

write. (Command Error)

Dx The block write command attempted to write beyond a particular parameter block boundary, or the host software attempted to access a data table 

block that does not exist. (Data Boundary Error)

Ex The Alarm_Status variable has changed. The software should query the 

alarm status block to determine the particular alarm flag that changed.

Fx The controller altered shared data, either internally (from the firmware) or 

externally (from the keyboard). The host software should read the Data 

Changed Register to determine which data has been altered and update 

its own run-time memory

TNSL

• Least significant byte of the transaction number. This is the first half 

of a “message stamp.”

• The controller sends back the TNSL and TNSH exactly as it received 

them, so host software can use the TNSL and TNSH bytes to keep 

track of message packets.

TNSH 

• Most significant byte of the transaction number. This is the second 

half of the “message stamp.” 

ADDL

• The low byte of the beginning data table address of the block of data 

to read or write.

ADDH

• The high byte of the beginning data table address of the block of data 

to read or write.

DATA

• The new values to be set with a write command, or the requested data 

in a response to a read command.

DLE ETX

• Every packet of information must end with the codes DLE ETX. 

These codes signal the end of a transmission.

BCC or CRC

• Communications packets include a one- or two-byte error check at 

the end of the packet. There are two error check methods: Block 

Check Character (BCC), which requires 1 byte, and Cyclic Redundancy Check (CRC), which requires 2 bytes.

Watlow Anafaze recommends that you use the default error check

method, BCC. It is easier to implement than CRC, and it is acceptable

for most applications.

Select one error check method and configure both software and

controller for that method, or they will be unable to communicate.

The error check methods work this way:

Block Check Character (BCC)

BCC checks the accuracy of each message packet transmission. It

provides a medium level of security. The BCC is the 2’s complement of

the 8-bit sum (modulo-256 arithmetic sum) of the data bytes between

the DLE STX and the DLE ETX. (1’s complement +1)

• BCC does not detect transposed bytes in a packet. 

• BCC cannot detect inserted or deleted 0 values in a packet.

• If you have sent an x10 as data (by sending DLE x10) only one of the 

DLE data bytes is included in the BCC’s sum (the DLE = x10 also).

For instance, the block read example shown in the examples section, 

adds x08 00 01 00 00 80 02 10. Note that the x10 representing DLE 

has been left out of the calculation. The sum should come to x9B.

Cyclic Redundancy Check (CRC)

CRC is a more secure error check method than BCC. It provides a very

high level of data security. It can detect:

• All single-bit and double-bit errors.

• All errors of odd numbers of bits.

• All burst errors of 16 bits or less.

• 99.997% of 17-bit error bursts.

• 99.998% of 18-bit and larger error bursts.

The CRC is calculated using the value of the data bytes and the ETX

byte. At the start of each message packet, the transmitter must clear a

16-bit CRC register. 

When a byte is transmitted, it is exclusive-ORed with the right 8 bits of

the CRC register and the result is transferred to the right 8 bits of the

CRC register. The CRC register is then shifted right 8 times by inserting

0’s on the left. 

Each time a 1 is shifted out on the right, the CRC register is ExclusiveORed with the constant value xA001. After the ETX value is

transmitted, the CRC value is sent, least significant byte (LSB) first.

Below is a structured English procedure from AB Manual:

data_byte = all application layer data, ETX

CLEAR CRC_REGISTER

FOR each data_byte

GET data_byte

XOR (data_byte, right eight bits of CRC_REGISTER)

PLACE RESULT in right eight bits of CRC_REGISTER

DO 8 times

Shift bit right, shift in 0 at left

IF bit shifted =1

XOR (CONSTANT, CRC_REGISTER)

PLACE RESULT in CRC_REGISTER

END IF

END DO

END FOR

TRANSMIT CRC_REGISTER as 2-byte CRC field

The host software sends two kinds of commands: block reads and block

writes. This section shows examples of both commands.

NOTE

If you read data from a loop set to SKIP, the controller will

send an empty packet for that loop.

This section does not show how to calculate the error check value

included with every packet. For help calculating the error check value,

see the section on BCC or CRC earlier in this chapter.

Block Read

This example shows the block read command the host software sends,

the controller’s responses, and the software’s acknowledgment. 

Situation: Read process variables for loops 1 to 8. 

• 8 process variables 2 bytes each = 16 bytes from data table address 

x0280.

• Character values are represented in hex. 

• The sender is device address 0. 

• The destination is device address 8 (controller address 1). 

• The software sends transaction number 00

Data for a Write Command

For a block write command, the block contains the bytes to write (up to

242 bytes of data). The controller sends back a message packet without

data.

Two-Byte Data Types

For two-byte data types, like process variable and setpoint, the

controller or host software sends the data in two-byte pairs with the least

significant byte first.

Figuring Block Size

In order to read parameter values, you must know how many bytes to

request. Parameter values are stored contiguously such that the setpoints

for all the loops are stored together and in loop number order. For

example, to read the deviation alarm deadband value for loops one to

five, you would read five bytes starting at x05A0. Some parameters,

such as setpoint, require two bytes of memory to store. So, for example,

if you want to read the setpoint for four loops, you must read eight

bytes.

Figure total block size in bytes for most loop parameters this way (do

not forget the pulse loop):

(Data Size) * (Number of Loops)

Some parameters have values for both heat and cool. Figure block size

for such a parameter this way:

2 * (Data Size) * (Number of Loops)

One exception is the units for each loop. Figure the data size for the

units this way:

3 * (Number of Loops)

Parameters that are not loop parameters (like system status, digital

inputs, or digital outputs) have specific data sizes. These data sizes are

listed in the data table in the next section

Anafaze/AB Data Table Summary

Each address holds one byte of data. Each parameter value requires one

or two addresses to store depending on the type of data. The table below

indicates the number of bytes for each data type. The data type for each

parameter is indicated in the tables on the following pages.

Because each loop is individually configurable, the number of instances

of many parameters depends on the number of loops in the controller.

Therefore, the number of bytes for these parameters is listed in the

tables on the following pages in terms of the number of loops in the

controller.

The storage requirements for some parameters depend on the number of

digital inputs or digital outputs in the controller (MAX_DIGIN_BYTES

and MAX_DIGOUT_BYTES). The storage of ramp-soak profile

parameters depend on the number of profiles (MAX_RSP), the number

of segments per profile (MAX_SEG), the number of triggers per

segment (MAX_TRIG) and the number of events per segment

(MAX_EVENT).

The table below shows the values for each of these factors. Use them to

calculate the number of bytes for each parameter.

Data Type and Symbol Data Size

Unsigned char (UC) 1 byte

Signed char (SC) 1 byte

Unsigned int (UI) 2 bytes

Signed int (SI) 2 bytes

Ordering of Heat and Cool Channel Parameters

For parameters that have both heat and cool settings the heat values are

stored in the first registers and the cool values are stored in the registers

starting at the listed address plus MAX_CH.

NOTE

Data table parameters 46 to 60 and 100 are ramp-soak

parameters. They are only used in controllers with the

ramp-soak option. Parameters 81 to 95 are enhanced features and only available in controllers with the enhanced

features option.

Ordering of Ramp-Soak Profile Parameters

Ramp-soak profile parameters are ordered first by profile, then by

segment where applicable. So, for example, the first eight bytes of the

Ready Events parameter are the ready segment event states for the first

profile (profile A) and the next eight bytes are for profile B and so on. In

the case of the segment triggers, the first byte contains the first trigger

setting for the first segment of profile A, the second byte contains the

settings for the second trigger for the first segment of profile A, the third

byte contains the settings for the first trigger for the second segment of

profile A and so on.

Anafaze/AB Protocol Data Table

Number Description Address 

in Hex Type Number of Bytes

0 Proportional Band/Gain 0020 UC MAX_CH * 2

1 Derivative Term 0060 UC MAX_CH * 2

2 Integral Term 00A0 UI MAX_CH * 4

3 Input Type 0120 UC MAX_CH

4 Output Type 0180 UC MAX_CH * 2

5 Setpoint 01C0 SI MAX_CH * 2

6 Process Variable 0280 SI MAX_CH * 2

7 Output Filter 0340 UC MAX_CH * 2

8 Output Value 0380 UI MAX_CH * 4

9 High Process Alarm Setpoint 0400 SI MAX_CH * 2

10 Low Process Alarm Setpoint 04C0 SI MAX_CH * 2

11 Deviation Alarm Band Value 05A0 UC MAX_CH 

12 Alarm Deadband 0600 UC MAX_CH

13 Alarm Status 0660 UI MAX_CH * 2

14 Not used 06A0 128

Copy feature speeds up configuration.

COMPOSER®

COMPOSER® is Watlow’s new, easy-to-use software for 

configuring and customizing controllers. Use it to optimize 

Watlow’s F4T®, D4T™ and EZ-ZONE® PM and RM 

controllers for specific applications. Task-specific views 

simplify all aspects of commissioning new controllers 

including managing the inputs and outputs from pluggable 

flex modules, setting up functions such as control loops 

and alarms and creating and editing profiles. COMPOSER 

software is included on the “Watlow Support Tools” DVD 

and available for download at www.watlow.com.

Illustrations from COMPOSER

Features and Benefits

Function block diagram with live data and error 

indication

• Enables application-specific configuration of 

controllers

• Depicts the configuration visually making it easy 

to understand and explain to others

• Speeds up application testing and troubleshooting 

Multi-language support

• Prevents errors by communicating with users in their 

own languages

System image files contain complete configuration

• Makes it fast and easy to duplicate settings from one 

system to another

• Simplifies sending configurations to remote sites

• Provides backup of settings to restore if settings are 

changed or controller is replaced

Dashboard view

• Makes it easy to connect to controllers

• Clearly indicates when there are configuration errors 

that need to be addressed

• Allows downloading configuration files without allowing 

access to setup and configuration views

Opens and displays saved configuration image files

• Simplifies supporting remote users

• Makes it easy to inspect configuration files

Configurable interface

• Lets users adjust window sizes and positions to work 

efficiently

Integrated video tutorials and help

• Speed up commissioning by demonstrating 

configuration steps

• Simplifies access to function block and parameter 

descriptions

• Reduces configuration errors

• Helps the user take full advantage of available features

COMPOSER

Technical Data

Additional Features and Benefits for F4T

Profile editor

• Speeds up profile creation and editing

• Allows maintenance of profile list in controllers from a 

remote PC

• Makes it easy to move profiles from one controller to 

another

• Exports profiles to PC files for backup and portability

Fast, reliable Ethernet support

• Easily connects to 1 or more controllers

• Minimizes time to read and write configuration settings

Pluggable flex module management

• Simplifies configuration by clearly indicating which 

hardware is present

• Shortens commissioning by allowing user to configure 

controller for flex modules prior to installing them

Security configuration

• Allows OEMs and supervisors to limit permissions to 

specific features

• Controls access via COMPOSER and controller

• Prevents errors and reduces downtime by preventing 

undesired configuration changes

Calibration view with on-screen instructions and 

automation

• Reduces downtime by simplifying the calibration 

verification procedure

Features by Supported Product

Specifications

Supported Products

Compatible Operating Systems

• Windows® 10

• Windows® 8.1

Minimum System Requirements

• Microprocessor: 1 gigahertz (GHz) or faster 32-bit or 

64-bit 

• Memory: 1 gigabyte (GB) RAM (32-bit) or 2 GB RAM 

(64-bit) 

• Disk space: 250 megabytes (MB) 

• Video: 1280 x 720 or higher 

• Port for controller communications: Ethernet for F4T or 

EIA-485 half duplex (2-wire) for EZ-ZONE RM and PM

Illustrations from COMPOSER for F4T

EZ-LINK™ Mobile App

Watlow’s EZ-LINK™ mobile app allows users to easily set 

up and monitor Watlow PM PLUS™ and EZ-ZONE PM 

controllers via Bluetooth® wireless technology. The app is 

available free-of-charge from the app stores for phones 

and tablets, and provides access to the controller’s 

parameters with fully spelled out names in plain text with 

help topics that explain each parameter and option.

When connected to a controller, the app’s dashboard 

view displays up to 20 parameters. Users can configure 

which parameters appear on the dashboard view with the

controller’s custom home page. The all parameters 

feature in the app allows users set up the controller’s 

inputs, control settings, alarms, outputs and other 

features and functions.

In addition to controller setup, monitoring and adjusting,

the EZ-LINK mobile app provides many benefits to the 

user including password protection, alarm and error 

indicators, connection to Watlow for feedback and 

support and accessing device information such as 

firmware version, part number and serial number.

The app works with all PM PLUS and 1/16 DIN EZ-ZONE 

PM controllers and limits with Bluetooth® wireless 

technology. This option is approved for use in the U.S., 

Australia, Canada, Colombia, the European Union, Japan 

and New Zealand with more locations coming soon. 

Features and Benefits

Wireless communication

• Connect to controllers up to 70 feet (21.3 meters 

away)

• Eliminates need to access the back of the controller, 

USB-to-485 converter and error-prone wiring

Save and import system image files via Bluetooth®

• Makes a complete record of controller settings in a 

file

• Accurately copies or restores saved settings from a 

file to a controller

Portable system image files

• Send and receive files via email, messaging and other 

sharing methods

• View the controller configuration by opening the file on 

a PC with Watlow’s COMPOSER software

• Create a file with COMPOSER and email it to a phone 

to support updating controllers in the field with the 

app

All parameters feature

• Allows user to interactively set up the controller’s 

inputs, control settings, alarms, outputs and other 

functions

Uses controller’s custom home page and 

password security settings

• Adapts to the application by presenting the same 

parameters as found on the controller’s custom home 

page

• Allows full access, read-only access or no access 

to home page and all parameters feature based 

controller’s password protection settings

Visual device ping and controller naming

• Identifies which controller is connected when several 

controllers are within range

• Allows user to name the controller and easily find it 

again the next time

Compatibility

The EZ-LINK mobile application is compatible with all 

PM PLUS and 1/16 DIN EZ-ZONE PM controllers and 

limits that have the Bluetooth® communications option.

System Requirements

Android™

• Compatible versions: 6, 7, 8 and 9

Apple®

• Compatible versions: 10, 11 and 12

Supported devices

• Designed for phones, compatible with tablets. Download 

the EZ-LINK App at for Android™ or

 for iPhone®.

ASPYRE® Configurator

ASPYRE® Configurator is Watlow’s easy-to-use 

software for configuring and customizing ASPYRE 

power controllers. Use it to optimize Watlow’s ASPYRE 

products for specific applications. Task-specific views 

simplify all aspects of commissioning new controllers 

including configuring the use of digital and analog inputs, 

setting options such as maximum voltage and maximum 

current, setting up features including feedback, firing 

mode and communication options and uploading, saving 

and downloading recipe files that include the complete 

configuration of a power controller.

ASPYRE Configurator software is included on the 

“Watlow Support Tools” DVD and available for download 

at www.watlow.com.

System Requirements

• Microprocessor: 1 gigahertz (GHz) or faster, 32-bit or 

64-bit

• Memory: 1 gigabyte (GB) RAM (32-bit) or 2 GB RAM 

(64-bit)

• Disk Space: 250 megabytes (MB)

• Video: 1400 x 1050 or higher

• Operating System: Microsoft® Windows® 10, 8.1 

or 7

• Port for controller communications: USB 1.0 or 

EIA-485 half duplex (2-wire)

EZ-ZONE® Configurator 

EZ-ZONE® Configurator software allows Watlow®

EZ-ZONE products to be configured in one simple 

process. Its interface is flexible and easier to read than 

the basic remote user interface (RUI). It operates without 

requiring purchase of communications options as it uses 

the standard bus communications protocol that is 

included with all EZ-ZONE products. 

The EZ-ZONE Configurator software is available as a 

free download at www.watlow.com.

Features and Benefits

Communicates with EZ-ZONE products via 

standard bus protocol

• Works regardless of which communications option is 

purchased or even when no communication option 

is purchased

Detects EZ-ZONE devices and reads up 

configuration

• Allows easy access to any setting

Presents pages and menus as they are in the 

controller’s display, RUI and manuals

• Enables the user to easily locate what they are 

looking for

Wizard-style editor with menu explorer

• Allows for easy examination of each menu 

• Enables the user to skip directly to the parameters 

they want to work with

On-screen parameter help

• Reduces configuration errors

• Helps the user take full advantage of available features

Copies parameter settings

• Decreases configuration time especially for 

multi-loop controllers

Saves configuration files on the computer with all 

the information required to set up a controller

• Preserves settings to archive and recover or 

simplify setting up of another EZ-ZONE product

• Enables set up files to be emailed or made available 

to users on a network or via the internet to aid them 

with set up

View or modify configuration files saved during 

online editing sessions

• Allows users to get a jump on setting up EZ-ZONE 

products

• Aids in supporting remote users

Downloads saved configuration files

• Simplifies configuration of EZ-ZONE products

Flexible and smart compatibility checking

• Ensures configuration files are only loaded into devices 

that are similar enough to the original that the settings 

make sense

EZ-ZONE Configurator

Technical Data

Illustrated Features

Detects EZ-ZONE devices connected to the computer’s 

communications ports.

Safety Information

We use note, caution and warning symbols throughout this book to draw your attention to 

important operational and safety information.

• A “NOTE” marks a short message to alert you to an important detail.

• A “CAUTION” safety alert appears with information that is important for protecting your 

equipment and performance. Be especially careful to read and follow all cautions that 

apply to your application.

• A “WARNING” safety alert appears with information that is important for protecting you, 

others and equipment from damage. Pay very close attention to all warnings that apply 

to your application.

• The electrical hazard symbol, Ó (a lightning bolt in a triangle) precedes an electric 

shock hazard CAUTION or WARNING safety statement.

Symbol Explanation

CAUTION – Warning or Hazard that needs further explanation than label on 

unit can provide. Consult User’s Guide for further information.

ESD Sensitive product, use proper grounding and handling techniques 

when installing or servicing product.

Unit protected by double/reinforced insulation for shock hazard prevention.

Do not throw in trash, use proper recycling techniques or consult manufacturer for proper disposal.

Enclosure made of Polycarbonate material. Use proper recycling techniques or consult manufacturer for proper disposal.

Unit can be powered with either alternating current (ac) voltage or direct 

current (dc) voltage.

Unit is a Listed device per Underwriters Laboratories®. It has been evaluated to United States and Canadian requirements for Process Control 

Equipment. UL 61010 and CSA C22.2 No. 61010. File E185611 QUYX, 

QUYX7. See: www.ul.com

Unit is a Listed device per Underwriters Laboratories®. It has been evaluated to United States and Canadian requirements for Hazardous Locations 

Class 1 Division II Groups A, B, C and D. ANSI/ISA 12.12.01-2007. File 

E184390 QUZW, QUZW7. See: www.ul.com

Unit is compliant with European Union directives. See Declaration of 

Conformity for further details on Directives and Standards used for 

Compliance.

Warranty

The EZ-ZONE® PM is manufactured by ISO 9001-registered processes and is backed by a 

three-year warranty to the first purchaser for use, providing that the units have not been 

misapplied. Since Watlow has no control over their use, and sometimes misuse, we cannot guarantee against failure. Watlow’s obligations hereunder, at Watlow’s option, are limited to replacement, repair or refund of purchase price, and parts which upon examination 

prove to be defective within the warranty period specified. This warranty does not apply to 

damage resulting from transportation, alteration, misuse or abuse. The purchaser must use 

Watlow parts to maintain all listed ratings.

Technical Assistance

If you encounter a problem with your Watlow controller, review your configuration information to verify that your selections are consistent with your application: inputs, outputs, 

alarms, limits, etc. If the problem persists, you can get technical assistance from your local 

Watlow representative (see back cover), by e-mailing your questions to wintechsupport@watlow.com or by dialing +1 (507) 494-5656 between 7 a.m. and 5 p.m., Central Standard Time 

(CST). Ask for for an Applications Engineer. Please have the following information available 

when calling:

• Complete model number 

• All configuration information

• User’s Guide 

• Factory Page

Return Material Authorization (RMA)

1. Call Watlow Customer Service, (507) 454-5300, for a Return Material Authorization (RMA) 

number before returning any item for repair. If you do not know why the product failed, 

contact an Application Engineer or Product Manager. All RMA’s require:

• Ship-to address

• Bill-to address

• Contact name 

• Phone number

• Method of return shipment

• Your P.O. number

• Detailed description of the problem 

• Any special instructions

• Name and phone number of person returning the product.

2. Prior approval and an Return Merchandise Authorization number from the Customer 

Service Department is required when returning any product for credit, repair or evaluation. Make sure the Return Merchandise Authorization number is on the outside of the 

carton and on all paperwork returned. Ship on a Freight Prepaid basis.

3. After we receive your return, we will examine it and try to verify the reason for returning it.

4. In cases of manufacturing defect, we will enter a repair order, replacement order or 

issue credit for material returned. In cases of customer misuse, we will provide repair 

costs and request a purchase order to proceed with the repair work.

5. To return products that are not defective, goods must be in new condition, in the original boxes and they must be returned within 120 days of receipt. A 20 percent restocking 

charge is applied for all returned stock controls and accessories.

6. If the unit cannot be repaired, you will receive a letter of explanation and be given the 

option to have the unit returned to you at your expense or to have us scrap the unit.

7. Watlow reserves the right to charge for no trouble found (NTF) returns.

This EZ-ZONE® PM User’s Guide is copyrighted by Watlow Electric, Inc., © August 2016 with 

all rights reserved. 

EZ-ZONE PM is covered by U.S. Patent Numbers: 6005577; D553095; D553096; D553097; 

D560175; D55766; and OTHER PATENTS PENDING

Chapter 1: Overview 1

Available EZ-ZONE PM Literature and Resources

The DVD described above ships with the product and as stated contains all of the literature 

above as well as much more. If the DVD is not available one can be acquired by contacting 

Watlow Customer Service at 1-507-454-5300.

As an alternative to the DVD, all of the user documentation described above can also be 

found on the Watlow website. Click on the following link to find your document of choice: 

http://www.watlow.com/literature/index.cfm. Once there, simply type in the desired part 

number (or name) into the search box and download free copies. Printed versions of all user 

documents can also be purchased here as well.

Your Comments are Appreciated

In an effort to continually improve our technical literature and ensure that we are providing 

information that is useful to you, we would very much appreciate your comments and suggestions. Please send any comments you may have to the following e-mail address: 

TechlitComments@watlow.com

Introduction

The EZ-ZONE® PM takes the pain out of solving your thermal loop requirements. Watlow’s 

EZ-ZONE PM controllers offer options to reduce system complexity and the cost of control 

loop ownership. You can order the EZ-ZONE PM as a PID controller or an over-under limit 

controller, or you can combine both functions in the PM Integrated Controller. You now have 

the option to integrate a high-amperage power controller output, an over-under limit controller and a high-performance PID controller all in space saving, panel-mount packages. You 

can also select from a number of industrial serial communications options to help you manage system performance.

Standard Features and Benefits

Advanced PID Control Algorithm

• TRU-TUNE+® Adaptive tune provides tighter control for demanding applications.

• Auto Tune for fast, efficient start ups

High-amperage Power Control Output

• Drives 15 amp resistive loads directly

• Reduces component count

• Saves panel space and simplifies wiring

• Reduces the cost of ownership

EZ-ZONE configuration communications and software

• Saves time and improves the reliability of controller set up

Parameter Save & Restore Memory

• Reduces service calls and down time

Agency approvals: UL Listed, CSA, CE, RoHS, W.E.E.E. FM

• Assures prompt product acceptance

• Reduces end product documentation costs

• Semi F47-0200

P3T Armor Sealing System

• NEMA 4X and IP65 offers water and dust resistance, can be cleaned and washed down (indoor use only)

• Backed up by UL 50 independent certification to NEMA 4X specification

Three-year warranty

• Demonstrates Watlow’s reliability and product support

Touch-safe Package

• IP2X increased safety for installers and operators

Removable cage clamp wiring connectors 

• Reliable wiring, reduced service calls

• Simplified installation 

EZ-Key/s 

• Programmable EZ-Key enables simple one-touch operation of repetitive user activities

Programmable Menu System

• Reduces set up time and increases operator efficiency 

Full-featured Alarms

• Improves operator recognition of system faults

• Control of auxiliary devices

Heat-Cool Operation 

• Provides application flexibility with accurate temperature and process control 

Profile Capability

• Pre-programmed process control

• Ramp and soak programming with four files and 40 total steps

Getting Started Quickly

The PM control has a page and menu structure that is listed below along with a brief description of its purpose.

The default PM loop configuration from the factory is shown below: 

• Analog Input functions set to thermocouple, type J

• Heat algorithm set for PID, Cool set to off

• Output 1 set to Heat

• Control mode set to Auto

• Set point set to 75 °F

If you are using the input type shown above, simply connect your input and output devices 

to the control. Power up the control and push the up arrow ¿ on the face of the control to 

change the set point from the default value of 75°F to the desired value. As the Set Point 

increases above the Process Value, output 1 will come on and it will now begin driving your 

output device. The PV function as shown in the graphic below is only available with PM4/8/9 

models. 

Note: 

The output cycle time will have a bearing on the life of mechanical relay outputs and can 

be different based on the type of output ordered. The output cycle time can be changed 

in the Setup Page under the Output Menu.

A Conceptual View of the PM

The flexibility of the PM’s software and hardware allows a large range of configurations. Acquiring a better understanding of the controller’s overall functionality and capabilities while 

at the same time planning out how the controller can be used will deliver maximum effectiveness in your application.

It is useful to think of the controller in three parts: inputs; procedures; and outputs. Information flows from an input to a procedure to an output when the controller is properly 

configured. A single PM controller can carry out several procedures at the same time, for 

instance closed-loop control, monitoring for several different alarm situations and operating 

switched devices, such as lights and motors. Each process needs to be thought out carefully 

and the controller’s inputs, procedures and outputs set up properly.

Inputs

The inputs provide the information that any given programmed procedure can act upon. In a 

simple form, this information may come from an operator pushing a button or from a sensor 

monitoring the temperature of a part being heated or cooled.

Each analog input typically uses a thermocouple or RTD to read the process temperature. It 

can also read volts, current or resistance, allowing it to use various devices to read a wide 

array of values.

A PM with digital input/output (DIO) hardware includes two sets of terminals where each of 

which can be used as either an input or an output. Each pair of terminals must be configured 

to function as either an input or output with the direction parameter in the Digital Input/

Output Menu (Setup Page). Each digital input reads whether a device is active or inactive. 

The Function or EZ Key/s (PM4/6/8/9 only) on the front panel of the PM also operates as a 

digital input by toggling the function assigned to it in the Digital Input Function parameter in 

the Function Key Menu (Setup Page).

Internal Functions

The controller will use input signals to calculate a value and then perform an operation. A 

sample of some functions may be as simple as:

• Compare an input value to the set point and calculate the optimal power for a heater

• Detect a failure of the primary sensing device and trip a contactor to remove power from 

the heating element

• Reading a digital input to set a state to true or false

• Evaluate an incoming temperature to determine an alarm state (on or off)

To set up a function, it’s important to define the source, or instance, to use. For example, if 

the control is equipped with DIO they can be configured to respond to an alarm. If configured 

as such, the digital output must be tied to the desired alarm instance (1 to 4). Using this as 

an example, the Function for the digital output would be defined as an Alarm where the Instance would be selected as 1, 2, 3, or 4 corresponding to the alarm instance that will drive 

the output.

Keep in mind that a function is a user-programmed internal process that does not execute 

any action outside of the controller. To have any effect outside of the controller, an output 

must be configured to respond to a function..

Outputs

Outputs can perform various functions or actions in response to information provided by a 

function such as, removal of the control voltage to a contactor; operating a heater, turning a 

light on or off, unlocking a door, etc…

Assign a Function to any available output on the Setup Page within the Output Menu or Digital Input/Output Menu. Then select which instance of that function will drive the selected 

output. For example, you might assign an output to respond to alarm 4 (instance 4).

You can assign more than one output to respond to a single instance of a function. For example, alarm 2 could be used to trigger a light connected to output 1 and a siren connected 

to digital output 5.

Input Events and Output Events

Input and output events are internal states that are used exclusively by profiles. The source 

of an event input can come from a real-world digital input or an output from another function. Likewise, event outputs may control a physical output such as an output function block 

or be used as an input to another function.

What is a Profile

A profile is a set of instructions consisting of a sequence of steps. When a profile runs, the 

controller automatically executes its steps in sequence. The step type determines what action the controller performs. Steps can change temperatures and other process values gradually over time, maintain the temperatures and process values for specific periods, or repeat 

a sequence of steps numerous times. At each step the profile can activate or deactivate 

outputs that control other equipment. Also a step can have the controller wait for specific 

conditions before proceeding such as, waiting for a switch closure and/or a specific process 

value to be detected by a sensor.

EZ-ZONE® PM PID Model System Diagram

Universal Sensor Input, Configuration Communications,

Red/Green 7-Segment Display

Chapter 2: Install and Wire

Installation

1. Make the panel cutout using the mounting template dimensions in this chapter. Insert the 

case assembly into the panel cutout.

2. While pressing the case assembly firmly 

against the panel, slide the mounting collar 

over the back of the controller.

Note:

If the installation does not require a NEMA 4X 

seal, simply slide together until the gasket is 

compressed.

3. For a NEMA 4X (UL50, IP65) seal, alternately 

place and push the blade of a screwdriver 

against each of the four corners of the mounting collar assembly. Apply pressure to the face 

of the controller while pushing with the screwdriver. Don’t be afraid to apply enough 

pressure to properly install the controller. The seal system is compressed more by mating 

the mounting collar tighter to the front panel (see pictures above). If you can move the 

case assembly back and forth in the cutout, you do not have a proper seal.

The tabs on each side of the mounting collar have teeth that latch into the ridges on the 

sides of the controller. Each tooth is staggered at a different depth from the front so that 

only one of the tabs, on each side, is locked onto the ridges at a time.

Note: 

There is a graduated measurement difference between the upper and lower half of the 

display to the panel. In order to meet the seal requirements mentioned above, ensure 

that the distance from the front of the top half of the display to the panel is 16 mm 

(0.630 in.) or less, and the distance from the front of the bottom half and the panel is 

13.3 mm (0.525 in.) or less.

Removing the Mounted Controller from Its Case

1. From the controller’s face, pull out the tabs on each side until you hear it click
2. 

2. On a PM6 control once the sides are released grab the unit above and below the face with 

two hands and pull the unit out. On the PM4/8/9 controls slide a screwdriver under the 

pry tabs and turn.

WARNING! ç

• This equipment is suitable for use in class 1, div. 2, Groups A, B, C and D or Non-Hazardous 

locations only. Temperature Code T4A.

• WARNING – EXPLOSION HAZARD. Substitution of component may impair suitability for class 1, 

div. 2.

• WARNING – EXPLOSION HAZARD. Do not disconnect equipment unless power has been 

switched off or the area is known to be nonhazardous.

Returning the Controller to its Case

1. Ensure that the orientation of the controller is correct and slide it back into the housing.

Note:

The controller is keyed so if it feels that it will not slide back in do not force it. Check the 

orientation again and reinsert after correcting.

2. Using your thumbs push on either side of the controller until both latches click.

Chemical Compatibility

This product is compatible with acids, weak alkalis, alcohols, gamma radiation and ultraviolet radiation. This product is not compatible with strong alkalis, organic solvents, fuels, 

aromatic hydrocarbons, chlorinated hydrocarbons, esters and keytones.

WARNING! ç

All electrical power to the controller and controlled circuits must be disconnected before 

removing the controller from the front panel or disconnecting other wiring. Failure to follow 

these instructions may cause an electrical shock and/or sparks that could cause an explosion 

in class 1, div. 2 hazardous locations.

Default Home Page Parameters

Watlow’s patented user-defined menu system improves operational efficiency. The userdefined Home Page provides you with a shortcut to monitor or change the parameter values 

that you use most often. The default Home Page is shown on the following page. When a parameter normally located in the Setup Page or Operations Page is placed in the Home Page, 

it is accessible through both. If you change a parameter in the Home Page, it is automatically 

changed in its original page. If you change a parameter in its original page it is automatically 

changed in the Home Page. 

Use the Advance Key ‰ to step through the other parameters. When not in pairs, the parameter prompt will appear in the lower display, and the parameter value will appear in the 

upper display. You can use the Up ¿ and Down ¯ keys to change the value of writable parameters, just as you would in any other menu.

Note:

If a writable value is placed on the upper display and is paired with another read only 

parameter on the lower display, the arrow keys affect the setting of the upper display. If 

two writable parameters are paired, the arrow keys affect the lower display.

• The Attention attn parameter appears only if there is an active message. An example of 

an active message could be a Input Error Er.i1, or it could be for information only like 

Autotune tUn1 taking place.

• If Control Mode is set to Auto, the Process Value is in the upper display and the Set Point 

(read-write) is in the lower display.

• If a profile is running, the process value is in the upper display and the Target Set Point 

(read only) is in the lower display. If Control Mode is set to Manual, the Process Value is in 

the upper display and Manual Power (read-write) is in the lower display.

• If Control Mode is set to Off, the Process Value is in the upper display and off (read only) 

is in the lower display.

• If a sensor failure has occurred, dashes —- will be displayed in the upper display and 

the Manual Power (read-write) is in the lower display

Safety Information

We use note, caution and warning symbols throughout this book to draw your attention to 

important operational and safety information.

• A “NOTE” marks a short message to alert you to an important detail.

• A “CAUTION” safety alert appears with information that is important for protecting your 

equipment and performance. Be especially careful to read and follow all cautions that 

apply to your application.

• A “WARNING” safety alert appears with information that is important for protecting you, 

others and equipment from damage. Pay very close attention to all warnings that apply 

to your application.

• The electrical hazard symbol, Ó (a lightning bolt in a triangle) precedes an electric 

shock hazard CAUTION or WARNING safety statement.

Symbol Explanation

CAUTION – Warning or Hazard that needs further explanation than label on 

unit can provide. Consult User’s Guide for further information.

ESD Sensitive product, use proper grounding and handling techniques 

when installing or servicing product.

Unit protected by double/reinforced insulation for shock hazard prevention.

Do not throw in trash, use proper recycling techniques or consult manufacturer for proper disposal.

Enclosure made of Polycarbonate material. Use proper recycling techniques or consult manufacturer for proper disposal.

Unit can be powered with either alternating current (ac) voltage or direct 

current (dc) voltage.

Unit is a Listed device per Underwriters Laboratories®. It has been evaluated to United States and Canadian requirements for Process Control 

Equipment. UL 61010 and CSA C22.2 No. 61010. File E185611 QUYX, 

QUYX7. See: www.ul.com

Unit is a Listed device per Underwriters Laboratories®. It has been evaluated to United States and Canadian requirements for Hazardous Locations 

Class 1 Division II Groups A, B, C and D. ANSI/ISA 12.12.01-2007. File 

E184390 QUZW, QUZW7. See: www.ul.com

Unit is compliant with European Union directives. See Declaration of 

Conformity for further details on Directives and Standards used for 

Compliance.

Warranty

The EZ-ZONE® PM is manufactured by ISO 9001-registered processes and is backed by a 

three-year warranty to the first purchaser for use, providing that the units have not been 

misapplied. Since Watlow has no control over their use, and sometimes misuse, we cannot guarantee against failure. Watlow’s obligations hereunder, at Watlow’s option, are limited to replacement, repair or refund of purchase price, and parts which upon examination 

prove to be defective within the warranty period specified. This warranty does not apply to 

damage resulting from transportation, alteration, misuse or abuse. The purchaser must use 

Watlow parts to maintain all listed ratings.

Technical Assistance

If you encounter a problem with your Watlow controller, review your configuration information to verify that your selections are consistent with your application: inputs, outputs, 

alarms, limits, etc. If the problem persists, you can get technical assistance from your local 

Watlow representative (see back cover), by e-mailing your questions to wintechsupport@watlow.com or by dialing +1 (507) 494-5656 between 7 a.m. and 5 p.m., Central Standard Time 

(CST). Ask for for an Applications Engineer. Please have the following information available 

when calling:

• Complete model number 

• All configuration information

• User’s Guide 

• Factory Page

Return Material Authorization (RMA)

1. Call Watlow Customer Service, (507) 454-5300, for a Return Material Authorization (RMA) 

number before returning any item for repair. If you do not know why the product failed, 

contact an Application Engineer or Product Manager. All RMA’s require:

• Ship-to address

• Bill-to address

• Contact name 

• Phone number

• Method of return shipment

• Your P.O. number

• Detailed description of the problem 

• Any special instructions

• Name and phone number of person returning the product.

2. Prior approval and an Return Merchandise Authorization number from the Customer 

Service Department is required when returning any product for credit, repair or evaluation. Make sure the Return Merchandise Authorization number is on the outside of the 

carton and on all paperwork returned. Ship on a Freight Prepaid basis.

3. After we receive your return, we will examine it and try to verify the reason for returning it.

4. In cases of manufacturing defect, we will enter a repair order, replacement order or 

issue credit for material returned. In cases of customer misuse, we will provide repair 

costs and request a purchase order to proceed with the repair work.

5. To return products that are not defective, goods must be in new condition, in the original boxes and they must be returned within 120 days of receipt. A 20 percent restocking 

charge is applied for all returned stock controls and accessories.

6. If the unit cannot be repaired, you will receive a letter of explanation and be given the 

option to have the unit returned to you at your expense or to have us scrap the unit.

7. Watlow reserves the right to charge for no trouble found (NTF) returns.

This EZ-ZONE® PM User’s Guide is copyrighted by Watlow Electric, Inc., © August 2016 with 

all rights reserved. 

EZ-ZONE PM is covered by U.S. Patent Numbers: 6005577; D553095; D553096; D553097; 

D560175; D55766; and OTHER PATENTS PENDING

Chapter 1: Overview 1

Available EZ-ZONE PM Literature and Resources

The DVD described above ships with the product and as stated contains all of the literature 

above as well as much more. If the DVD is not available one can be acquired by contacting 

Watlow Customer Service at 1-507-454-5300.

As an alternative to the DVD, all of the user documentation described above can also be 

found on the Watlow website. Click on the following link to find your document of choice: 

http://www.watlow.com/literature/index.cfm. Once there, simply type in the desired part 

number (or name) into the search box and download free copies. Printed versions of all user 

documents can also be purchased here as well.

Your Comments are Appreciated

In an effort to continually improve our technical literature and ensure that we are providing 

information that is useful to you, we would very much appreciate your comments and suggestions. Please send any comments you may have to the following e-mail address: 

TechlitComments@watlow.com

Introduction

The EZ-ZONE® PM takes the pain out of solving your thermal loop requirements. Watlow’s 

EZ-ZONE PM controllers offer options to reduce system complexity and the cost of control 

loop ownership. You can order the EZ-ZONE PM as a PID controller or an over-under limit 

controller, or you can combine both functions in the PM Integrated Controller. You now have 

the option to integrate a high-amperage power controller output, an over-under limit controller and a high-performance PID controller all in space saving, panel-mount packages. You 

can also select from a number of industrial serial communications options to help you manage system performance.

Standard Features and Benefits

Advanced PID Control Algorithm

• TRU-TUNE+® Adaptive tune provides tighter control for demanding applications.

• Auto Tune for fast, efficient start ups

High-amperage Power Control Output

• Drives 15 amp resistive loads directly

• Reduces component count

• Saves panel space and simplifies wiring

• Reduces the cost of ownership

EZ-ZONE configuration communications and software

• Saves time and improves the reliability of controller set up

Parameter Save & Restore Memory

• Reduces service calls and down time

Agency approvals: UL Listed, CSA, CE, RoHS, W.E.E.E. FM

• Assures prompt product acceptance

• Reduces end product documentation costs

• Semi F47-0200

P3T Armor Sealing System

• NEMA 4X and IP65 offers water and dust resistance, can be cleaned and washed down (indoor use only)

• Backed up by UL 50 independent certification to NEMA 4X specification

Three-year warranty

• Demonstrates Watlow’s reliability and product support

Touch-safe Package

• IP2X increased safety for installers and operators

Removable cage clamp wiring connectors 

• Reliable wiring, reduced service calls

• Simplified installation 

EZ-Key/s 

• Programmable EZ-Key enables simple one-touch operation of repetitive user activities

Programmable Menu System

• Reduces set up time and increases operator efficiency 

Full-featured Alarms

• Improves operator recognition of system faults

• Control of auxiliary devices

Heat-Cool Operation 

• Provides application flexibility with accurate temperature and process control 

Profile Capability

• Pre-programmed process control

• Ramp and soak programming with four files and 40 total steps

Getting Started Quickly

The PM control has a page and menu structure that is listed below along with a brief description of its purpose.

The default PM loop configuration from the factory is shown below: 

• Analog Input functions set to thermocouple, type J

• Heat algorithm set for PID, Cool set to off

• Output 1 set to Heat

• Control mode set to Auto

• Set point set to 75 °F

If you are using the input type shown above, simply connect your input and output devices 

to the control. Power up the control and push the up arrow ¿ on the face of the control to 

change the set point from the default value of 75°F to the desired value. As the Set Point 

increases above the Process Value, output 1 will come on and it will now begin driving your 

output device. The PV function as shown in the graphic below is only available with PM4/8/9 

models. 

Note: 

The output cycle time will have a bearing on the life of mechanical relay outputs and can 

be different based on the type of output ordered. The output cycle time can be changed 

in the Setup Page under the Output Menu.

A Conceptual View of the PM

The flexibility of the PM’s software and hardware allows a large range of configurations. Acquiring a better understanding of the controller’s overall functionality and capabilities while 

at the same time planning out how the controller can be used will deliver maximum effectiveness in your application.

It is useful to think of the controller in three parts: inputs; procedures; and outputs. Information flows from an input to a procedure to an output when the controller is properly 

configured. A single PM controller can carry out several procedures at the same time, for 

instance closed-loop control, monitoring for several different alarm situations and operating 

switched devices, such as lights and motors. Each process needs to be thought out carefully 

and the controller’s inputs, procedures and outputs set up properly.

Inputs

The inputs provide the information that any given programmed procedure can act upon. In a 

simple form, this information may come from an operator pushing a button or from a sensor 

monitoring the temperature of a part being heated or cooled.

Each analog input typically uses a thermocouple or RTD to read the process temperature. It 

can also read volts, current or resistance, allowing it to use various devices to read a wide 

array of values.

A PM with digital input/output (DIO) hardware includes two sets of terminals where each of 

which can be used as either an input or an output. Each pair of terminals must be configured 

to function as either an input or output with the direction parameter in the Digital Input/

Output Menu (Setup Page). Each digital input reads whether a device is active or inactive. 

The Function or EZ Key/s (PM4/6/8/9 only) on the front panel of the PM also operates as a 

digital input by toggling the function assigned to it in the Digital Input Function parameter in 

the Function Key Menu (Setup Page).

Internal Functions

The controller will use input signals to calculate a value and then perform an operation. A 

sample of some functions may be as simple as:

• Compare an input value to the set point and calculate the optimal power for a heater

• Detect a failure of the primary sensing device and trip a contactor to remove power from 

the heating element

• Reading a digital input to set a state to true or false

• Evaluate an incoming temperature to determine an alarm state (on or off)

To set up a function, it’s important to define the source, or instance, to use. For example, if 

the control is equipped with DIO they can be configured to respond to an alarm. If configured 

as such, the digital output must be tied to the desired alarm instance (1 to 4). Using this as 

an example, the Function for the digital output would be defined as an Alarm where the Instance would be selected as 1, 2, 3, or 4 corresponding to the alarm instance that will drive 

the output.

Keep in mind that a function is a user-programmed internal process that does not execute 

any action outside of the controller. To have any effect outside of the controller, an output 

must be configured to respond to a function..

Outputs

Outputs can perform various functions or actions in response to information provided by a 

function such as, removal of the control voltage to a contactor; operating a heater, turning a 

light on or off, unlocking a door, etc…

Assign a Function to any available output on the Setup Page within the Output Menu or Digital Input/Output Menu. Then select which instance of that function will drive the selected 

output. For example, you might assign an output to respond to alarm 4 (instance 4).

You can assign more than one output to respond to a single instance of a function. For example, alarm 2 could be used to trigger a light connected to output 1 and a siren connected 

to digital output 5.

Input Events and Output Events

Input and output events are internal states that are used exclusively by profiles. The source 

of an event input can come from a real-world digital input or an output from another function. Likewise, event outputs may control a physical output such as an output function block 

or be used as an input to another function.

What is a Profile

A profile is a set of instructions consisting of a sequence of steps. When a profile runs, the 

controller automatically executes its steps in sequence. The step type determines what action the controller performs. Steps can change temperatures and other process values gradually over time, maintain the temperatures and process values for specific periods, or repeat 

a sequence of steps numerous times. At each step the profile can activate or deactivate 

outputs that control other equipment. Also a step can have the controller wait for specific 

conditions before proceeding such as, waiting for a switch closure and/or a specific process 

value to be detected by a sensor.

EZ-ZONE® PM PID Model System Diagram

Universal Sensor Input, Configuration Communications,

Red/Green 7-Segment Display

Chapter 2: Install and Wire

Installation

1. Make the panel cutout using the mounting template dimensions in this chapter. Insert the 

case assembly into the panel cutout.

2. While pressing the case assembly firmly 

against the panel, slide the mounting collar 

over the back of the controller.

Note:

If the installation does not require a NEMA 4X 

seal, simply slide together until the gasket is 

compressed.

3. For a NEMA 4X (UL50, IP65) seal, alternately 

place and push the blade of a screwdriver 

against each of the four corners of the mounting collar assembly. Apply pressure to the face 

of the controller while pushing with the screwdriver. Don’t be afraid to apply enough 

pressure to properly install the controller. The seal system is compressed more by mating 

the mounting collar tighter to the front panel (see pictures above). If you can move the 

case assembly back and forth in the cutout, you do not have a proper seal.

The tabs on each side of the mounting collar have teeth that latch into the ridges on the 

sides of the controller. Each tooth is staggered at a different depth from the front so that 

only one of the tabs, on each side, is locked onto the ridges at a time.

Note: 

There is a graduated measurement difference between the upper and lower half of the 

display to the panel. In order to meet the seal requirements mentioned above, ensure 

that the distance from the front of the top half of the display to the panel is 16 mm 

(0.630 in.) or less, and the distance from the front of the bottom half and the panel is 

13.3 mm (0.525 in.) or less.

Removing the Mounted Controller from Its Case

1. From the controller’s face, pull out the tabs on each side until you hear it click
2. 

2. On a PM6 control once the sides are released grab the unit above and below the face with 

two hands and pull the unit out. On the PM4/8/9 controls slide a screwdriver under the 

pry tabs and turn.

WARNING! ç

• This equipment is suitable for use in class 1, div. 2, Groups A, B, C and D or Non-Hazardous 

locations only. Temperature Code T4A.

• WARNING – EXPLOSION HAZARD. Substitution of component may impair suitability for class 1, 

div. 2.

• WARNING – EXPLOSION HAZARD. Do not disconnect equipment unless power has been 

switched off or the area is known to be nonhazardous.

Returning the Controller to its Case

1. Ensure that the orientation of the controller is correct and slide it back into the housing.

Note:

The controller is keyed so if it feels that it will not slide back in do not force it. Check the 

orientation again and reinsert after correcting.

2. Using your thumbs push on either side of the controller until both latches click.

Chemical Compatibility

This product is compatible with acids, weak alkalis, alcohols, gamma radiation and ultraviolet radiation. This product is not compatible with strong alkalis, organic solvents, fuels, 

aromatic hydrocarbons, chlorinated hydrocarbons, esters and keytones.

WARNING! ç

All electrical power to the controller and controlled circuits must be disconnected before 

removing the controller from the front panel or disconnecting other wiring. Failure to follow 

these instructions may cause an electrical shock and/or sparks that could cause an explosion 

in class 1, div. 2 hazardous locations.

Default Home Page Parameters

Watlow’s patented user-defined menu system improves operational efficiency. The userdefined Home Page provides you with a shortcut to monitor or change the parameter values 

that you use most often. The default Home Page is shown on the following page. When a parameter normally located in the Setup Page or Operations Page is placed in the Home Page, 

it is accessible through both. If you change a parameter in the Home Page, it is automatically 

changed in its original page. If you change a parameter in its original page it is automatically 

changed in the Home Page. 

Use the Advance Key ‰ to step through the other parameters. When not in pairs, the parameter prompt will appear in the lower display, and the parameter value will appear in the 

upper display. You can use the Up ¿ and Down ¯ keys to change the value of writable parameters, just as you would in any other menu.

Note:

If a writable value is placed on the upper display and is paired with another read only 

parameter on the lower display, the arrow keys affect the setting of the upper display. If 

two writable parameters are paired, the arrow keys affect the lower display.

• The Attention attn parameter appears only if there is an active message. An example of 

an active message could be a Input Error Er.i1, or it could be for information only like 

Autotune tUn1 taking place.

• If Control Mode is set to Auto, the Process Value is in the upper display and the Set Point 

(read-write) is in the lower display.

• If a profile is running, the process value is in the upper display and the Target Set Point 

(read only) is in the lower display. If Control Mode is set to Manual, the Process Value is in 

the upper display and Manual Power (read-write) is in the lower display.

• If Control Mode is set to Off, the Process Value is in the upper display and off (read only) 

is in the lower display.

• If a sensor failure has occurred, dashes —- will be displayed in the upper display and 

the Manual Power (read-write) is in the lower display

Safety Information

We use note, caution and warning symbols throughout this book to draw your attention to 

important operational and safety information.

• A “NOTE” marks a short message to alert you to an important detail.

• A “CAUTION” safety alert appears with information that is important for protecting your 

equipment and performance. Be especially careful to read and follow all cautions that 

apply to your application.

• A “WARNING” safety alert appears with information that is important for protecting you, 

others and equipment from damage. Pay very close attention to all warnings that apply 

to your application.

• The electrical hazard symbol, Ó (a lightning bolt in a triangle) precedes an electric 

shock hazard CAUTION or WARNING safety statement.

Symbol Explanation

CAUTION – Warning or Hazard that needs further explanation than label on 

unit can provide. Consult User’s Guide for further information.

ESD Sensitive product, use proper grounding and handling techniques 

when installing or servicing product.

Unit protected by double/reinforced insulation for shock hazard prevention.

Do not throw in trash, use proper recycling techniques or consult manufacturer for proper disposal.

Enclosure made of Polycarbonate material. Use proper recycling techniques or consult manufacturer for proper disposal.

Unit can be powered with either alternating current (ac) voltage or direct 

current (dc) voltage.

Unit is a Listed device per Underwriters Laboratories®. It has been evaluated to United States and Canadian requirements for Process Control 

Equipment. UL 61010 and CSA C22.2 No. 61010. File E185611 QUYX, 

QUYX7. See: www.ul.com

Unit is a Listed device per Underwriters Laboratories®. It has been evaluated to United States and Canadian requirements for Hazardous Locations 

Class 1 Division II Groups A, B, C and D. ANSI/ISA 12.12.01-2007. File 

E184390 QUZW, QUZW7. See: www.ul.com

Unit is compliant with European Union directives. See Declaration of 

Conformity for further details on Directives and Standards used for 

Compliance.

Warranty

The EZ-ZONE® PM is manufactured by ISO 9001-registered processes and is backed by a 

three-year warranty to the first purchaser for use, providing that the units have not been 

misapplied. Since Watlow has no control over their use, and sometimes misuse, we cannot guarantee against failure. Watlow’s obligations hereunder, at Watlow’s option, are limited to replacement, repair or refund of purchase price, and parts which upon examination 

prove to be defective within the warranty period specified. This warranty does not apply to 

damage resulting from transportation, alteration, misuse or abuse. The purchaser must use 

Watlow parts to maintain all listed ratings.

Technical Assistance

If you encounter a problem with your Watlow controller, review your configuration information to verify that your selections are consistent with your application: inputs, outputs, 

alarms, limits, etc. If the problem persists, you can get technical assistance from your local 

Watlow representative (see back cover), by e-mailing your questions to wintechsupport@watlow.com or by dialing +1 (507) 494-5656 between 7 a.m. and 5 p.m., Central Standard Time 

(CST). Ask for for an Applications Engineer. Please have the following information available 

when calling:

• Complete model number 

• All configuration information

• User’s Guide 

• Factory Page

Return Material Authorization (RMA)

1. Call Watlow Customer Service, (507) 454-5300, for a Return Material Authorization (RMA) 

number before returning any item for repair. If you do not know why the product failed, 

contact an Application Engineer or Product Manager. All RMA’s require:

• Ship-to address

• Bill-to address

• Contact name 

• Phone number

• Method of return shipment

• Your P.O. number

• Detailed description of the problem 

• Any special instructions

• Name and phone number of person returning the product.

2. Prior approval and an Return Merchandise Authorization number from the Customer 

Service Department is required when returning any product for credit, repair or evaluation. Make sure the Return Merchandise Authorization number is on the outside of the 

carton and on all paperwork returned. Ship on a Freight Prepaid basis.

3. After we receive your return, we will examine it and try to verify the reason for returning it.

4. In cases of manufacturing defect, we will enter a repair order, replacement order or 

issue credit for material returned. In cases of customer misuse, we will provide repair 

costs and request a purchase order to proceed with the repair work.

5. To return products that are not defective, goods must be in new condition, in the original boxes and they must be returned within 120 days of receipt. A 20 percent restocking 

charge is applied for all returned stock controls and accessories.

6. If the unit cannot be repaired, you will receive a letter of explanation and be given the 

option to have the unit returned to you at your expense or to have us scrap the unit.

7. Watlow reserves the right to charge for no trouble found (NTF) returns.

This EZ-ZONE® PM User’s Guide is copyrighted by Watlow Electric, Inc., © August 2016 with 

all rights reserved. 

EZ-ZONE PM is covered by U.S. Patent Numbers: 6005577; D553095; D553096; D553097; 

D560175; D55766; and OTHER PATENTS PENDING

Chapter 1: Overview 1

Available EZ-ZONE PM Literature and Resources

The DVD described above ships with the product and as stated contains all of the literature 

above as well as much more. If the DVD is not available one can be acquired by contacting 

Watlow Customer Service at 1-507-454-5300.

As an alternative to the DVD, all of the user documentation described above can also be 

found on the Watlow website. Click on the following link to find your document of choice: 

http://www.watlow.com/literature/index.cfm. Once there, simply type in the desired part 

number (or name) into the search box and download free copies. Printed versions of all user 

documents can also be purchased here as well.

Your Comments are Appreciated

In an effort to continually improve our technical literature and ensure that we are providing 

information that is useful to you, we would very much appreciate your comments and suggestions. Please send any comments you may have to the following e-mail address: 

TechlitComments@watlow.com

Introduction

The EZ-ZONE® PM takes the pain out of solving your thermal loop requirements. Watlow’s 

EZ-ZONE PM controllers offer options to reduce system complexity and the cost of control 

loop ownership. You can order the EZ-ZONE PM as a PID controller or an over-under limit 

controller, or you can combine both functions in the PM Integrated Controller. You now have 

the option to integrate a high-amperage power controller output, an over-under limit controller and a high-performance PID controller all in space saving, panel-mount packages. You 

can also select from a number of industrial serial communications options to help you manage system performance.

Standard Features and Benefits

Advanced PID Control Algorithm

• TRU-TUNE+® Adaptive tune provides tighter control for demanding applications.

• Auto Tune for fast, efficient start ups

High-amperage Power Control Output

• Drives 15 amp resistive loads directly

• Reduces component count

• Saves panel space and simplifies wiring

• Reduces the cost of ownership

EZ-ZONE configuration communications and software

• Saves time and improves the reliability of controller set up

Parameter Save & Restore Memory

• Reduces service calls and down time

Agency approvals: UL Listed, CSA, CE, RoHS, W.E.E.E. FM

• Assures prompt product acceptance

• Reduces end product documentation costs

• Semi F47-0200

P3T Armor Sealing System

• NEMA 4X and IP65 offers water and dust resistance, can be cleaned and washed down (indoor use only)

• Backed up by UL 50 independent certification to NEMA 4X specification

Three-year warranty

• Demonstrates Watlow’s reliability and product support

Touch-safe Package

• IP2X increased safety for installers and operators

Removable cage clamp wiring connectors 

• Reliable wiring, reduced service calls

• Simplified installation 

EZ-Key/s 

• Programmable EZ-Key enables simple one-touch operation of repetitive user activities

Programmable Menu System

• Reduces set up time and increases operator efficiency 

Full-featured Alarms

• Improves operator recognition of system faults

• Control of auxiliary devices

Heat-Cool Operation 

• Provides application flexibility with accurate temperature and process control 

Profile Capability

• Pre-programmed process control

• Ramp and soak programming with four files and 40 total steps

Getting Started Quickly

The PM control has a page and menu structure that is listed below along with a brief description of its purpose.

The default PM loop configuration from the factory is shown below: 

• Analog Input functions set to thermocouple, type J

• Heat algorithm set for PID, Cool set to off

• Output 1 set to Heat

• Control mode set to Auto

• Set point set to 75 °F

If you are using the input type shown above, simply connect your input and output devices 

to the control. Power up the control and push the up arrow ¿ on the face of the control to 

change the set point from the default value of 75°F to the desired value. As the Set Point 

increases above the Process Value, output 1 will come on and it will now begin driving your 

output device. The PV function as shown in the graphic below is only available with PM4/8/9 

models. 

Note: 

The output cycle time will have a bearing on the life of mechanical relay outputs and can 

be different based on the type of output ordered. The output cycle time can be changed 

in the Setup Page under the Output Menu.

A Conceptual View of the PM

The flexibility of the PM’s software and hardware allows a large range of configurations. Acquiring a better understanding of the controller’s overall functionality and capabilities while 

at the same time planning out how the controller can be used will deliver maximum effectiveness in your application.

It is useful to think of the controller in three parts: inputs; procedures; and outputs. Information flows from an input to a procedure to an output when the controller is properly 

configured. A single PM controller can carry out several procedures at the same time, for 

instance closed-loop control, monitoring for several different alarm situations and operating 

switched devices, such as lights and motors. Each process needs to be thought out carefully 

and the controller’s inputs, procedures and outputs set up properly.

Inputs

The inputs provide the information that any given programmed procedure can act upon. In a 

simple form, this information may come from an operator pushing a button or from a sensor 

monitoring the temperature of a part being heated or cooled.

Each analog input typically uses a thermocouple or RTD to read the process temperature. It 

can also read volts, current or resistance, allowing it to use various devices to read a wide 

array of values.

A PM with digital input/output (DIO) hardware includes two sets of terminals where each of 

which can be used as either an input or an output. Each pair of terminals must be configured 

to function as either an input or output with the direction parameter in the Digital Input/

Output Menu (Setup Page). Each digital input reads whether a device is active or inactive. 

The Function or EZ Key/s (PM4/6/8/9 only) on the front panel of the PM also operates as a 

digital input by toggling the function assigned to it in the Digital Input Function parameter in 

the Function Key Menu (Setup Page).

Internal Functions

The controller will use input signals to calculate a value and then perform an operation. A 

sample of some functions may be as simple as:

• Compare an input value to the set point and calculate the optimal power for a heater

• Detect a failure of the primary sensing device and trip a contactor to remove power from 

the heating element

• Reading a digital input to set a state to true or false

• Evaluate an incoming temperature to determine an alarm state (on or off)

To set up a function, it’s important to define the source, or instance, to use. For example, if 

the control is equipped with DIO they can be configured to respond to an alarm. If configured 

as such, the digital output must be tied to the desired alarm instance (1 to 4). Using this as 

an example, the Function for the digital output would be defined as an Alarm where the Instance would be selected as 1, 2, 3, or 4 corresponding to the alarm instance that will drive 

the output.

Keep in mind that a function is a user-programmed internal process that does not execute 

any action outside of the controller. To have any effect outside of the controller, an output 

must be configured to respond to a function..

Outputs

Outputs can perform various functions or actions in response to information provided by a 

function such as, removal of the control voltage to a contactor; operating a heater, turning a 

light on or off, unlocking a door, etc…

Assign a Function to any available output on the Setup Page within the Output Menu or Digital Input/Output Menu. Then select which instance of that function will drive the selected 

output. For example, you might assign an output to respond to alarm 4 (instance 4).

You can assign more than one output to respond to a single instance of a function. For example, alarm 2 could be used to trigger a light connected to output 1 and a siren connected 

to digital output 5.

Input Events and Output Events

Input and output events are internal states that are used exclusively by profiles. The source 

of an event input can come from a real-world digital input or an output from another function. Likewise, event outputs may control a physical output such as an output function block 

or be used as an input to another function.

What is a Profile

A profile is a set of instructions consisting of a sequence of steps. When a profile runs, the 

controller automatically executes its steps in sequence. The step type determines what action the controller performs. Steps can change temperatures and other process values gradually over time, maintain the temperatures and process values for specific periods, or repeat 

a sequence of steps numerous times. At each step the profile can activate or deactivate 

outputs that control other equipment. Also a step can have the controller wait for specific 

conditions before proceeding such as, waiting for a switch closure and/or a specific process 

value to be detected by a sensor.

EZ-ZONE® PM PID Model System Diagram

Universal Sensor Input, Configuration Communications,

Red/Green 7-Segment Display

Chapter 2: Install and Wire

Installation

1. Make the panel cutout using the mounting template dimensions in this chapter. Insert the 

case assembly into the panel cutout.

2. While pressing the case assembly firmly 

against the panel, slide the mounting collar 

over the back of the controller.

Note:

If the installation does not require a NEMA 4X 

seal, simply slide together until the gasket is 

compressed.

3. For a NEMA 4X (UL50, IP65) seal, alternately 

place and push the blade of a screwdriver 

against each of the four corners of the mounting collar assembly. Apply pressure to the face 

of the controller while pushing with the screwdriver. Don’t be afraid to apply enough 

pressure to properly install the controller. The seal system is compressed more by mating 

the mounting collar tighter to the front panel (see pictures above). If you can move the 

case assembly back and forth in the cutout, you do not have a proper seal.

The tabs on each side of the mounting collar have teeth that latch into the ridges on the 

sides of the controller. Each tooth is staggered at a different depth from the front so that 

only one of the tabs, on each side, is locked onto the ridges at a time.

Note: 

There is a graduated measurement difference between the upper and lower half of the 

display to the panel. In order to meet the seal requirements mentioned above, ensure 

that the distance from the front of the top half of the display to the panel is 16 mm 

(0.630 in.) or less, and the distance from the front of the bottom half and the panel is 

13.3 mm (0.525 in.) or less.

Removing the Mounted Controller from Its Case

1. From the controller’s face, pull out the tabs on each side until you hear it click
2. 

2. On a PM6 control once the sides are released grab the unit above and below the face with 

two hands and pull the unit out. On the PM4/8/9 controls slide a screwdriver under the 

pry tabs and turn.

WARNING! ç

• This equipment is suitable for use in class 1, div. 2, Groups A, B, C and D or Non-Hazardous 

locations only. Temperature Code T4A.

• WARNING – EXPLOSION HAZARD. Substitution of component may impair suitability for class 1, 

div. 2.

• WARNING – EXPLOSION HAZARD. Do not disconnect equipment unless power has been 

switched off or the area is known to be nonhazardous.

Returning the Controller to its Case

1. Ensure that the orientation of the controller is correct and slide it back into the housing.

Note:

The controller is keyed so if it feels that it will not slide back in do not force it. Check the 

orientation again and reinsert after correcting.

2. Using your thumbs push on either side of the controller until both latches click.

Chemical Compatibility

This product is compatible with acids, weak alkalis, alcohols, gamma radiation and ultraviolet radiation. This product is not compatible with strong alkalis, organic solvents, fuels, 

aromatic hydrocarbons, chlorinated hydrocarbons, esters and keytones.

WARNING! ç

All electrical power to the controller and controlled circuits must be disconnected before 

removing the controller from the front panel or disconnecting other wiring. Failure to follow 

these instructions may cause an electrical shock and/or sparks that could cause an explosion 

in class 1, div. 2 hazardous locations.

Default Home Page Parameters

Watlow’s patented user-defined menu system improves operational efficiency. The userdefined Home Page provides you with a shortcut to monitor or change the parameter values 

that you use most often. The default Home Page is shown on the following page. When a parameter normally located in the Setup Page or Operations Page is placed in the Home Page, 

it is accessible through both. If you change a parameter in the Home Page, it is automatically 

changed in its original page. If you change a parameter in its original page it is automatically 

changed in the Home Page. 

Use the Advance Key ‰ to step through the other parameters. When not in pairs, the parameter prompt will appear in the lower display, and the parameter value will appear in the 

upper display. You can use the Up ¿ and Down ¯ keys to change the value of writable parameters, just as you would in any other menu.

Note:

If a writable value is placed on the upper display and is paired with another read only 

parameter on the lower display, the arrow keys affect the setting of the upper display. If 

two writable parameters are paired, the arrow keys affect the lower display.

• The Attention attn parameter appears only if there is an active message. An example of 

an active message could be a Input Error Er.i1, or it could be for information only like 

Autotune tUn1 taking place.

• If Control Mode is set to Auto, the Process Value is in the upper display and the Set Point 

(read-write) is in the lower display.

• If a profile is running, the process value is in the upper display and the Target Set Point 

(read only) is in the lower display. If Control Mode is set to Manual, the Process Value is in 

the upper display and Manual Power (read-write) is in the lower display.

• If Control Mode is set to Off, the Process Value is in the upper display and off (read only) 

is in the lower display.

• If a sensor failure has occurred, dashes —- will be displayed in the upper display and 

the Manual Power (read-write) is in the lower display

Manual Contents

This manual describes how to install, setup, and operate a 

MLS316 or MLS332 controller. Each chapter covers a 

different aspect of your control system and may apply to 

different users. The following describes each chapter’s 

purpose.

• Chapter 1: System Overview. Provides a component list 

and summary of features for the MLS300 controllers. 

• Chapter 2: Installation. Provides detailed instructions 

on installing the MLS300 controller and its peripherals.

• Chapter 3: Using the MLS300. Provides an overview of 

operator displays used for system monitoring and job 

selection.

• Chapter 4: Setup. Provides detailed descriptions of all 

menus and menu options for controller setup.

• Chapter 5: Extruder Options. Explains the additional 

features on an MLS300 controller equipped with Extruder 

Control Firmware.

• Chapter 6: Enhanced Features. Describes process 

variable retransmit, ratio, differential and cascade control 

features available with the enhanced features option.

• Chapter 7: Ramp/Soak. Explains how to setup and use 

the features of the ramp/soak option.

• Chapter 8: Tuning and Control. Describes available 

control algorithms and provides suggestions for 

applications.

• Chapter 9: Troubleshooting and Reconfiguring.

Includes troubleshooting, upgrading and reconfiguring 

procedures for technical personnel.

• Chapter 10: Linear Scaling Examples. Provides an 

example configuring a pressure sensor, a flow sensor, and 

an encoder using linear scaling.

• Chapter 11: Specifications. Lists detailed specifications 

of the controller and optional components.

Getting Started

The following sections provide information regarding product 

features, technical descriptions, safety requirements, and 

preparation for operation.

These symbols are used throughout this manual:

DANGER! Indicates potential for serious injury or loss

of human life.

WARNING! Indicates possible damage to property or

equipment.

NOTE! Indicates pertinent information in order to

proceed.

Initial Inspection

Accessories may or may not be shipped in the same container 

as the MLS300, depending upon their size. Check the 

shipping invoice carefully against the contents received in all 

boxes.

Product Features

The MLS300 series controllers provide 16 or 32 fully 

independent loops of PID control. When used as a stand-alone 

controller, you may operate the MLS300 via the two-line 16-

character display and touch keypad. You can also use it as the 

key element in a computer-supervised data acquisition and 

control system; the MLS300 can be locally or remotely 

controlled via an EIA/RS-232 or EIA/RS-485 serial 

communications interface. 

The MLS300 features include:

• Direct Connection of Mixed Thermocouple Sensors: 

Connect most thermocouples to the controller with no 

hardware modifications. Thermocouple inputs feature 

reference junction compensation, linearization, process 

variable offset calibration to correct for sensor 

inaccuracies, detection of broken, shorted or reversed 

thermocouples, and a choice of Fahrenheit or Celsius 

display.

• CIM300 Input Option: The CIM300 input module 

provides high density sensor termination with a smaller 

installation footprint and faster installation.

• Accepts Resistive Temperature Detectors (RTDs): Use 

3-wire, 100 ohm, platinum, DIN-curve sensors with two 

choices for range and precision of measurements. (To use 

this input, order a MLS316 or MLS332 controller with 

scaling resistors.)

• Automatic Scaling for Linear Analog Inputs: The 

MLS300 series automatically scales linear inputs used 

with other industrial process sensors. Enter two points, 

and all input values are automatically scaled in your units. 

Scaling resistors must be installed.

• Dual Outputs: The MLS300 series includes both heat 

and cool outputs for up to 16 loops. Independent control 

parameters are provided for each output.

• Independently Selectable Control and Output Modes:

You can set each control output to ON/OFF, Time 

Proportioning, Serial DAC, or Distributed Zero Crossing 

mode. Set up to two outputs per loop for ON/OFF, P, PI, 

or PID control with reverse or direct action.

• Control Outputs: Set high/low deviation and high/low 

process limits to operate digital outputs as on/off control 

functions or alarms.

• Flexible Alarm Outputs: Independently set high/low 

process alarms and a high/low deviation band alarm for 

each loop. Alarms can activate a digital output by 

themselves, or they can be grouped with other alarms to 

activate an output. 

• Global Alarm Output: When any alarm is triggered, the 

Global Alarm Output is also triggered, and it stays on until 

you acknowledge it.

• CPU Watchdog: The MLS300 series CPU watchdog 

timer output notifies you of system failure. You can use it 

to hold a relay closed while the controller is running, so 

you are notified if the microprocessor shuts down.

• Front Panel or Computer Operation: Set up and run the 

controller from the front panel or from a local or remote 

computer. WatView software is available to configure 

and monitor the MLS300 from a PC.

• Modbus RTU Protocol, EIA/TIA-232 and 485 

Communications: Connect to PLCs, operator interface 

terminals and third-party software packages using the 

widely supported Modbus RTU protocol.

• Multiple Job Storage: Store up to 8 jobs in memory, and 

access them locally by entering a single job number or 

remotely via digital inputs. Each job is a set of operating 

conditions, including set points and alarms.

• Non-Linear Output Curves: Select either of two nonlinear output curves for each control output.

• Autotuning Makes Setup Simple: Use the Autotune 

feature to set up your system quickly and easily. The 

MLS300 internal expert system table finds the correct 

PID parameters for your process.

• Pulse Counter Input: Use the pulse counter input for 

precise control of motor or belt speed.

• Low Power Shutdown: The controller shuts down and 

turns off all outputs when it detects the input voltage drop 

below the minimum safe operating level.

MLS300 Series User’s Guide Chapter 1: System Overview

Doc.# 0600-3070-2000 Watlow Anafaze 5

System Diagram

The illustration below shows how the parts of the MLS300 are 

connected. When unpacking your system, use the diagram and 

parts list below to ensure all parts have been shipped. Please 

don’t hesitate to call Watlow Anafaze’s Customer Service 

Department if you have problems with your shipment, or if the 

MLS300’s components are missing or damaged.

Parts List MLS316/MLS332

You may have received one or more of the following 

components. Refer to Figure 1.1 on page 5 and Figure 1.2 on 

page 6 for MLS300 configuration information.

• MLS300 Processor Module (PM)

• Controller Mounting Kit

• 16- or 32-Channel MLS300-AIM Module with 4-foot 

AIM cable

• 16- or 32-Channel CIM300 Module with 4-foot AIM 

cable.

• EIA/RS-232 or EIA/RS-485 Communication Cable

• TB50 with 50-pin SCSI Cable

• Power Supply with Mounting Bracket and Screws

• SDAC (Serial Digital-to-Analog Converter)

• Special Input Resistors (installed in MLS300 AIM)

• User Manual

Technical Description 

This section contains a technical description of each 

component of your MLS300 Controller. 

Processor Module 

The MLS300 Processor Module (MLS300-PM) is housed in 

an eighth-DIN panel mount package. It contains the CPU, 

RAM with a built-in battery, EPROM, serial communications, 

digital I/O, the screen and touch keypad.

The MLS300-PM has the following features:

• Keypad and 2-line, 16-character display.

• Screw terminals for the power inputs and outputs.

• Input power is 12 to 24 Vdc at 1 amp.

• The +5 Vdc output power supply of the processor module 

powers the MLS300-AIM. 

• The MLS300-PM interfaces with the MLS300-AIM with 

an 8-pin RJ-45 style connector.

• A 50-pin SCSI cable connects the digital inputs and 

outputs to the 50-pin terminal block (TB50). 

• The MLS300 uses 6-pin, telephone-style connectors for 

EIA/RS-232 and EIA/RS-485 external communications. 

The program that operates the MLS300 is stored in a socketed, 

flash, static-RAM chip, so it is easy to update or change the 

firmware. The MLS300 stores its operating parameters in 

battery-backed RAM, so if there’s a power loss the operating 

parameters are unchanged. The battery has a ten year shelf 

life, and it is not used when the unit is on. 

The microprocessor performs all calculations for input signal 

linearization, PID control, alarms, and communications. 

Front Panel Description 

The MLS300-PM’s display and touch keypad provide an 

intelligent way to operate the MLS300. The display has 16 

alphanumeric or graphic characters per line. The 8-key 

keypad allows you to change the MLS300’s operating 

parameters, controller functions, and displays. 

The MLS300’s information-packed displays show process 

variables, set points, and output levels for each loop. A bar 

graph display, single loop display, scanning display and an 

alarm display offer a real-time view of process conditions. 

Two access levels allow operator changes and supervisor 

changes. 

The TB50 is a screw terminal interface for control wiring 

which allows you to connect relays, encoders and discrete I/O 

devices to the MLS300. The screw terminal blocks accept 

wires as large as 18 AWG. A 50-pin SCSI cable connects the 

TB50 to the MLS300-PM

MLS300-AIM and AIM-TB 

The MLS300 Analog Input Module (MLS300-AIM), consists 

of the AIM-TB (AIM Terminal Board) and the AIM’s plug-in 

cards. The MLS300-AIM receives input signals from sensors 

and transmits this information to the MLS300-PM through the 

AIM cable.

The AIM-TB includes power supply terminals, input signal 

wiring screw terminals, input signal conditioning circuits, and 

terminal connections for the AIM’s plug-in cards. It also 

includes a cold junction temperature sensor and room for the 

input scaling resistors, if required. (RTDs, inputs greater than 

60 mVdc, and mAdc current inputs require input scaling 

resistors.) The AIM-TB has three slots for the plug-in AIM 

cards. 

There are two versions of the MLS300-AIM: the AIM-16 and 

AIM-32. The AIM-16 has one multiplexer (MUX) card, and 

the AIM-32 has two MUX cards. These cards multiplex the 16 

inputs each card receives. Each -10 to 60 mVdc input is 

converted to a voltage that is transmitted to the Voltage/

Frequency (V/F) card. (The MUX cards also automatically 

calibrate the zero and span of the analog amplifier and 

measure the cold junction compensation temperature for 

thermocouple inputs.) Both the AIM-16 and AIM-32 have a 

V/F card, which converts the input signal voltage to a 

frequency. The converted signal is then transmitted via the 

AIM cable to the MLS300-PM for processing.

The MLS300 Compact Input Module (CIM300) consists of 

two circuit boards that perform analog-to-digital conversion 

and data communications to the processor module. The 

CIM300 receives input signals from sensors and transmits this 

information to the MLS300-PM through the AIM cable.

The CIM300 includes power supply terminals, input signal 

connectors, a communications connector and input signal 

conditioning circuits. It also includes a cold-junction 

temperature sensor and room for the input scaling resistors, if 

required. (RTDs, inputs greater than 60 mV dc, and mA dc 

current inputs require input scaling resistors.) 

There are two versions of the CIM300: the CIM316 and 

CIM332. The CIM316 supports 16 inputs through a D-Sub 50 

female connector and the CIM332 supports 32 inputs through 

2 D-Sub 50 connectors (inputs 1 to 16 female, inputs 17 to 32 

male). The user supplies the mating D-Sub 50 connectors. The 

CIM300 has one or two multiplexer circuits that multiplex the 

16 inputs each card receives. Each -10 to 60 mV dc input is 

converted to a voltage that is transmitted to the Voltage/

Frequency (V/F) card. (The mulitplexer circuits also 

automatically calibrate the zero and span of the analog 

amplifier and measure the cold-junction compensation 

temperature for thermocouple (T/C) inputs.) A V/F circuit 

converts the input signal voltage to a frequency. The 

converted signal is then transmitted via the AIM cable to the 

MLS300-PM for processing

MLS300 Cabling

Watlow Anafaze provides cables required to install your 

MLS300. 

A 50-pin SCSI cable connects the TB50 to the MLS300-PM. 

The cable connecting the MLS300-PM to the AIM-TB is an 

8-conductor, shielded cable with RJ-45 connectors. 

The cables used to connect the MLS300 to EIA/RS-232 or 

EIA/RS-485 communications are 6-conductor, shielded cable 

with RJ-12 connectors on one end and a DB-9 connector or 

bare wires on the other end.

The pin numbering convention used for communications cables varies between suppliers. See Serial Communications, Cable

Connector Pin Outs on page 62.

Safety

Watlow Anafaze has made every effort to ensure the 

reliability and safety of this product. In addition, we have 

provided recommendations that will allow you to safely 

install and maintain this controller. 

Ensure that power has been shut off to your

entire process before you begin installation

of the controller.

WARNING! In any application, failures can occur. These

failures can result in full control output (100%

power), or the occurrence of other output failures which can cause damage to the controller, or to the equipment or process

connected to the controller. Therefore, always follow good engineering practices,

electrical codes, and insurance regulations

when installing and operating this equipment. 

External Safety Devices

External safety devices should be used to prevent potentially 

dangerous and unsafe conditions upon equipment failure. 

Always assume that this device can fail with outputs full-on, 

or full-off, by the occurrence of an unexpected external 

condition.

Always install high or low temperature protection in installations where an over-temperature or under-temperature fault will present

a potential hazard. Failure to install external

protection devices where hazards exist can

result in damage to equipment and property

as well as loss of human life.

Power-Fail Protection

In the occurrence of a sudden loss of power, this controller can 

be programmed to reset the control outputs to OFF (this is the 

default). Typically, when power is re-started, the controller 

restarts to data stored in memory. If you have programmed the 

controller to restart with control outputs ON, the memorybased restart might create an unsafe process condition for 

some installations. Therefore, you should only set the restart 

with outputs ON if you are certain your system will safely 

restart. (See Process Power Digital Input on page 98).

When using a computer or host device, you can program the 

software to automatically reload desired operating constants 

or process values on power-up. Keep in mind that these 

convenience features do not eliminate the need for 

independent safety devices. 

Contact Watlow Anafaze immediately if you have any 

questions about system safety or system operation.

This chapter describes how to install the MLS300 series 

controller and its peripherals. Installation of the controller 

involves the following procedures:

• Determining the best location for the controller

• Mounting the controller, the AIM and the TB50

• Power connection

• Testing the system

• Input wiring

• Output wiring

• Communications wiring (EIA/TIA-232 or EIA/TIA485)

Typical Installation

Figure 2.1 on page 18 illustrates a typical installation of the 

MLS300-PM (controller) with the MLS300-AIM (analog 

input module), TB50 terminal block, and power supply. 

Refer to Figure 2.15 on page 36 for a more detailed view of 

the power connections.

Read this entire chapter before beginning the installation 

procedure.

Mounting Controller Components 

Install the controller in a location free from excessive heat 

(more than 50°C), dust and unauthorized handling. 

Electromagnetic and radio frequency interference can induce 

noise on sensor wiring. Select locations for the MLS300-PM 

and MLS300-AIM and CIM300 such that wiring can be 

routed clear of sources of interference such as high voltage 

wires, power switching devices and motors

! The MLS300 system is for indoor use only. Install it in a controlled environment to reduce

the risk of fire or electric shock.

Recommended Tools

Use these tools to install the MLS300 series controller.

Panel Hole Cutters

Use any of the following tools to cut a hole of the appropriate 

size in the panel.

• Jigsaw and metal file, for stainless steel and heavyweight 

panel doors.

• Greenlee 1/8 DIN rectangular punch (Greenlee part # 

600-68), for most panel materials and thicknesses.

• Nibbler and metal file, for aluminum and lightweight 

panel doors.

Other Tools

You will also need these tools:

• Phillips head screwdriver

• Flathead screwdriver for wiring

• Multimeter

• A metal phone connector crimping tool (optional). 

Watlow Anafaze provides all the cabling for the Modular 

Loop System. If you have special cabling requirements and 

you make your own RJ-12 communications cable, use a metal 

crimping tool for the connectors. (A metal tool makes better 

connections than a plastic tool.)

Mounting the Processor Module

Mount the processor module before you mount the terminal 

block or do any wiring. The controller’s placement affects 

placement and wiring considerations for the other 

components of your system.

Ensure there is enough clearance for mounting brackets, 

terminal blocks, and cable and wire connections; the 

controller extends up to 9.0 in. (219 mm) behind the panel 

face and the collar and brackets extend 9/32 in. (7 mm) on the 

sides and 15/32 in. (12 mm) above and below it.

We recommend you mount the controller in a panel not more 

than 0.2 in. (5 mm) thick.

1. Choose a panel location free from excessive heat (more

than 50°C), dust, and unauthorized handling. (Make sure

there is adequate clearance for the mounting hardware,

terminal blocks, and cables. The controller extends 7.40

in. (178 mm) behind the panel. Allow for an additional

0.60 to 1.60 in. (15 to 41 mm) beyond the connectors. 

2. Temporarily cover any slots in the metal housing so that

dirt, metal filings, and pieces of wire do not enter the

housing and lodge in the electronics.

3. Cut a hole in the panel 1.80 in. (46 mm) by 3.63 in. (92

mm) as shown below. (This picture is NOT a template; it

is for illustration only.) Use caution; the dimensions given here have 0.02 in. (1 mm) tolerances.

4. Remove the brackets and collar from the processor module, if they are already in place.

5. Slide the processor module into the panel cutout.

Slide the mounting collar over the back of the processor

module, making sure the mounting screw indentations

face toward the back of the processor module.

Loosen the mounting bracket screws enough to allow for

the mounting collar and panel thickness. Place each

mounting bracket into the mounting slots (head of the

screw facing the back of the processor module). Push

each bracket backward then to the side to secure it to the

processor module case.

Make sure the case is seated properly. Tighten the installation 

screws firmly against the mounting collar to secure the unit. 

Ensure that the end of the mounting screws fit into the 

indentations on the mounting collar.

Mounting the MLS300-AIM 

!

NOTE! If you plan to install scaling resistors, mount

them on the AIM-TB before mounting the

AIM-TB in the panel. See Chapter 9, Troubleshooting and Reconfiguring.

If you ordered an MLS300-AIM-TB with scaling inputs from Watlow Anafaze, the scaling

resistors are already installed. 

Install the MLS300-AIM in a location free from excessive 

(more than 50°C) heat, dust, and unauthorized handling.

The MLS300-AIM measures 6.5 L x 5 W x 7 in. H. Leave 6 

in. of clearance above the MLS300-AIM, so you can remove 

the entire unit (or just the AIM cards) if necessary. 

1. Choose an appropriate place to install the MLS300-AIM.

2. Use the template shown in Figure 2.7 as a reference for

clearance and dimensions.

Figure 2.7 MLS300-AIM Template

3. Drill four holes for #6 or #8 screws in the chosen

location. 

4. Place the MLS300-AIM where you will mount it. Use

screws with internal star lock washers to ensure a good

Frame Ground connection. You may use self-tapping

screws. Insert the screws through the standoffs and

tighten them. 

5. Be sure to remove any loose metal filings after you are

finished mounting the MLS300-AIM.

Mounting the CIM300

!

NOTE! If you plan to install scaling resistors, mount

them on the CIM300 before mounting the

CIM300 in the panel. See Chapter 9, Troubleshooting and Reconfiguring.

If you ordered a CIM300 with scaling inputs from Watlow 

Anafaze, the scaling resistors are already installed. 

Install the CIM300 in a location free from excessive (more 

than 50ºC) heat, dust and unauthorized handling. The CIM300 

measures 7.5 L x 2.75 W x 3.75 inches D. Leave 1.5 inches of 

clearance above the CIM300, so that there will be enough 

space for power and communications wires.

DIN Mounting

1. Choose an appropriate place to install the CIM300. 

2. Snap the CIM300 on to the DIN rail by placing the hook 

side on the rail first, then pushing the snap latch side in place. 

(To remove the CIM300 from the rail, use a flat-head screw 

driver to unsnap the bracket from the rail.)

Direct Mounting

1. Choose an appropriate place to install the CIM300. 

2. Use the dimensions shown in Figure 2.8 as a reference for 

clearance and dimensions

Figure 2.8 CIM300 Template

3. Drill four holes for #6 or #8 screws in the chosen location.

4. Place the CIM300 where you will mount it. Use screws with 

internal star lock washers to ensure a good frame ground 

connection. You may use self-tapping screws. Insert the 

screws through the standoffs and tighten them.

5. Be sure to remove any loose metal filings after you are 

finished mounting the CIM300.

Do not connect power or sensors to the

MLS300 now. Test the unit first, as explained

in the Power Wiring and Controller Test section. 

Mounting the TB50

There are two ways you can mount the TB50: use the preinstalled DIN rail mounting brackets provided or use the 

plastic standoffs. Follow the corresponding procedures to 

mount the board

DIN Rail Mounting

Snap the TB50 on to the DIN rail by placing the hook side on 

the rail first, then pushing the snap latch side in place. Refer 

to Figure 2.10.

Figure 2.10 TB50 Mounted on a DIN Rail (Front)

To remove the TB50 from the rail, use a flat-head screw driver 

to unsnap the bracket from the rail. See Figure 2.11

Figure 2.11 TB50 Mounted on DIN Rail (Side)

Mounting with Standoffs

1. Remove the DIN rail mounting brackets from the TB50.

2. Select a location with enough clearance to remove the

TB50, its SCSI cable, and the controller itself.

3. Mark the four mounting holes. 

4. Drill and tap the 4, #6 (3.5 mm) mounting holes.

5. Mount the TB50 with 4 screws. 

There are four smaller holes on the terminal board. Use these 

holes to secure wiring to the terminal block with tie wraps.

Figure 2.12 Mounting a TB50 with Standoffs 

Mounting the Power Supply 

If you use your own power supply for the MLS300, please 

refer to the power supply manufacturer’s instructions for 

mounting information. Choose a power supply that supplies 

an isolated regulated 12 to 24 Vdc at 1 A. 

Mounting Environment 

Leave enough clearance around the power supply so that it 

can be removed.

Mounting DAC or SDAC Module

This section describes how to install the optional DAC and 

SDAC Digital-to-Analog Converters for use with a MLS300 

series controller.

Installation

Installation of the DAC and SDAC is essentially the same. 

The main differences are in the dimensions and the wiring. 

Follow this procedure to correctly install these devices.

Jumpers

The output signal range of the DAC and SDAC modules is 

configured with jumpers. See Configuring DAC Outputs on 

page 210 and Configuring SDAC Outputs on page 212 for 

information on setting these jumpers.

Mounting

1. Select a location for installation. The unit is designed for

wall mounting and should be installed as close to the controller as possible.

2. Mark and drill four holes for screw mounting. Holes

accommodate #6 size screws. Use the diagrams in Figure

2.14 on page 32 for the correct locations.

3. Install the unit with the four screws.

Figure 2.14 Dual DAC and SDAC Dimensions

System Wiring

Successful installation and operation of the control system can 

depend on placement of the components and on selection of 

the proper cables, sensors, and peripheral components.

Routing and shielding of sensor wires and proper grounding 

of components can insure a robust control system. This 

section includes wiring recommendations, instructions for 

proper grounding and noise suppression, and considerations 

for avoiding ground loops.

Never wire bundles of low power Watlow

Anafaze circuits next to bundles of high power ac wiring. Instead, physically separate

high power circuits from the controller. If

possible, install high voltage ac power circuits in a separate panel. 

Wiring Recommendations

Keep the following guidelines in mind when selecting wires 

and cables:

• Use stranded wire. (Solid wire can be used for fixed 

service; it makes intermittent connections when you 

move it for maintenance.) 

• Use #20 AWG thermocouple extension wire. Larger or 

smaller sizes may be difficult to install, may break easily, 

or may cause intermittent connections. 

• Use shielded wire. (The electrical shield protects the 

signals and the MLS300 from electrical noise.) Connect 

one end of the input and output wiring shield to earth 

ground.

• Use copper wire for all connections other than 

thermocouple sensor inputs.

See Table 2.1 on page 33 for cable recommendations.

Noise Suppression 

The MLS300’s outputs are typically used to drive solid state 

relays. These relays may in turn operate more inductive types 

of loads such as electromechanical relays, alarm horns and 

motor starters. Such devices may generate electromagnetic 

interference (EMI or noise). If the controller is placed close to 

sources of EMI, it may not function correctly. Below are some 

tips on how to recognize and avoid problems with EMI. 

For the AIM or CIM300 earth ground wire, use a large gauge 

and keep the length as short as possible. Additional shielding 

may be achieved by connecting a chassis ground strap from 

the panel to the case of the processor module.

Symptoms of RFI/EMI

If your controller displays the following symptoms, suspect 

EMI:

• The controller’s display blanks out and then re-energizes 

as if power had been turned off for a moment.

• The process variable does not display correctly.

EMI may also damage the digital output circuit—so digital 

outputs will not turn on. If the digital output circuit is 

damaged, return the controller to Watlow Anafaze for repair.

Avoiding Noise Problems

To avoid RFI/EMI noise problems:

• The MLS300 system includes noise suppression 

circuitry. Some of which is only effective when the 

components are properly grounded. Be sure the 

processor module and AIM (or CIM300) are connected 

to earth ground.

• Separate the 120 or 240 Vac power leads from the low 

level input and output leads connected to the MLS300 

series controller. Don’t run the digital I/O or control 

output leads in bundles with 120 Vac wires.

• Where possible, use solid-state relays (SSRs) instead of 

electromechanical (EM) relays. If you must use EM 

relays, try to avoid mounting them in the same panel as 

the MLS300 series equipment.

• If you must use EM relays and you must place them in a 

panel with MLS300 series equipment, use a 0.01 

microfarad capacitor rated at 1000 Vac (or higher) in 

series with a 47 Ω, 1/2 watt resistor across the NO 

contacts of the relay load. This is known as a snubber 

network and can reduce the amount of electrical noise. 

• You can use other voltage suppression devices, but they 

are not usually required. For instance, you can place a 

metal oxide varistor (MOV) rated at 130 Vac for 120 Vac 

control circuits across the load, which limits the peak AC 

voltage to about 180 Vac (Watlow Anafaze P/N 0802-

0826-0000). You can also place a transorb (back to back 

zener diodes) across the digital output, which limits the 

digital output voltage.

The above steps will eliminate most EMI/RFI noise problems. 

If you have further problems or questions, please contact 

Application Engineering

Avoiding Ground Loops

Ground loops occur when current passes from the process 

through the controller to ground. This can cause instrument 

errors or malfunctions.

A ground loop may follow one of these paths, among others:

• From one sensor to another.

• From a sensor to the communications port.

• From a sensor to the dc power supply.

The best way to avoid ground loops is to minimize 

unnecessary connections to ground. Do not connect any of the 

following terminals to each other or to earth ground:

• MLS300 PM: TB1, pin 2 (COM)

• MLS300-AIM: TB3, pin 1 to (PWR COM)

• All A COM terminals on the MLS300-AIM or CIM300

• Power Supply: (COM)

• Pin 3 on the RJ connector

Watlow Anafaze strongly recommends that you:

• Isolate outputs through solid state relays, where possible.

• Isolate RTDs or “bridge” type inputs from ground.

• Isolate digital inputs from ground through solid state 

relays. If you can’t do that, then make sure the digital 

input is the only place that one of the above pins connects 

to earth ground.

• If you are using EIA/TIA-232 from an un-isolated host, 

don’t connect any other power common point to earth 

ground, or use an optical isolator in the communications 

line. 

Personal Computers and Ground Loops

Many PC communications ports connect the communications 

common to chassis ground. When such a PC is connected to 

the controller, this can provide a path to ground for current 

from the process that can enter the controller through a sensor 

(such as a thermocouple). This creates a ground loop that can 

affect communications and other controller functions. To 

eliminate a ground loop, either use an optically isolated 

communications adapter or take measures to ensure that 

sensors and all other connections to the controller are isolated 

and not conducting current into the unit.

Power Connections

This section covers making the power connections between 

the MLS300 components and testing those connections before 

completing sensor and controller wiring in the following 

sections.

Figure 2.15 on page 36 and Figure 2.16 on page 36 illustrates 

the power connections.

Figure 2.15 Power Connections with MLS300-

AIM

Figure 2.16 Power Connections with CIM300

At this point you have isolated the parts of

the MLS300 that can be damaged by excess

voltage. 

4. With ac power on, use a voltmeter to measure the

following:

(a) The voltage between the COM and +V terminals

on TB 1 should be +12 to 24 Vdc

(b) The voltage between COM and EX should be 0

Vdc

5. If the voltages are not as described in Step 4, check the

installation of the power supply, troubleshoot or replace

the power supply. If the voltages are within the limits

described in Step 4, continue to Step 6.

6. Turn off the power and plug TB1 back into the MLS300-

PM. 

7. Turn the power back on. The Processor Module’s display

should light up, and after about a second the Bar Graph

display should appear, followed by the message AIM

COMM FAIL.

8. Verify power to the MLS300-AIM. With a voltmeter,

measure the following:

(a) The voltage between +5 IN and PWR COM terminals on TB-3 on the MLS300-AIM should be

+4.75 to +5.25 Vdc.

9. If the voltage is not as described in Step 8, check the

wiring from the MLS300-PM to the MLS300-AIM. If

the voltage is within the limit described in Step 8,

continue to Step 10.

10. Turn off the power and carefully insert the AIM cards

back into the AIM Terminal Block.

11. Reconnect the AIM communications cable. 

Watlow’s SERIES CLS200 is a powerful line of controllers, 

combining performance and flexibility with compact design. 

The 4, 8 and 16 loop versions provide complete controller 

solutions for a broad range of applications. Support for 

multiple types of sensor inputs is available, including 

thermocouples, RTDs, linear voltage, current and frequency. 

Each controller can operate as a stand-alone system, and 

includes built-in serial communications for computer interface 

and data acquisition. Optional programmable ramp and soak 

features allow complex batch processing and sequencing. 

An enhanced feature option offers cascade control, ratio 

control, differential control, process variable retransmit and 

remote analog set point.

The SERIES CLS200 controllers are UL® and C-UL® listed and 

meet the requirements of the European Community EMC 

Directive and carry the CE mark.

Features and Benefits

PID control of up to 16 heat and cool loops

• Minimizes panel space per loop 

• Reduces installation time

• Increases reliability: fewer parts means fewer failures

Auto-tune

• Requires less time tuning

• Achieves excellent control with less expertise

Menu-guided operation with full text display

• Allows quick setup of the controller

• Simplifies operation

Eight jobs stored and recalled

• Changes quickly from one process to another

Multiple and mixed inputs

• Accepts combinations of thermocouples, RTDs, linear 

dc voltage and linear dc current sensors

• Reduces learning curve and inventory

Sensor failure detection

• Reduces time troubleshooting reversed, shorted and 

open sensors

High/low process and deviation alarms for each input

• Integrates as needed to integrate with PLC and other 

control elements

34 digital outputs

• Provides flexible configuration

• Allows use of outputs as needed for control and alarms

EIA/TIA-232 and 485 communications

• Connects to software for easy configuration and operation

• Allows integration with controllers and software

DAC and SDAC Modules

The optional DAC and SDAC modules are available for

Watlow SERIES CLS200 controllers.

DAC

The DAC (digital to analog converter) converts one or two 

of the controller’s distributed zero crossing (DZC) output 

signals to analog signals. Each output is field configurable 

for 4-20mA(dc), 0-5VDC or 0-10VDC.

SDAC

The SDAC (serial digital to analog converter) converts 

one controller output to a precise analog voltage or 

current signal. The unit is typically used for process variable 

retransmit, open-loop control, motor or belt speed control, 

or phase-angle fired SCR power controllers. The SDAC bears 

the CE mark and is UL® and C-UL® listed.

Firmware Options

Choose firmware with the features needed for the 

application:

• Standard—includes closed-loop PID control, auto-tune, 

alarms, job memory and failed sensor detection.

• Ramp and soak—includes the standard firmware 

features with the addition of ramp and soak and process 

variable retransmit. Each channel can be configured for 

standard PID control or ramp and soak operation. Unused 

control outputs on any channel can be configured for 

retransmition.

• Enhanced features— includes the standard firmware 

features with the addition of process variable retransmit, 

remote analog set point, cascade control, ratio control 

and differential control algorithms. Each channel can be 

configured for standard PID controller or one of the other 

control algorithms. Each channel of cascade control or 

remote analog set point requires two controller channels. 

Unused control outputs on any channel can be 

configured for retransmit.

Because the SERIES CLS200 has no onboard analog 

outputs, applications that use process variable retransmit 

typically require one SDAC module per retransmitted 

signal.

CLS200 Specifications

Operator Interface

• 32-character vacuum fluorescent display 

• 8-key keypad to access guided menus and prompts, 

enter passkey sequence, set values, switch between 

single channel and multiple channel displays

• Controller configuration can be loaded through the 

standard serial port

Analog Inputs

• CLS204 4 differential

• CLS208 8 differential

• CLS216 16 single-ended 

Noise Rejection 

• 120dB at 60Hz

Temperature Coefficient 

• 40ppm/°C 

Sensors/Inputs

• Thermocouples: user-selectable type, direct connection, 

linearization, reference junction compensation, reversed 

and shorted thermocouple detection and upscale break 

protection with output averaging 

• RTD: (CLS204 and CLS208 only) 2- or 3-wire, platinum, 

100Ω @ 0°C, DIN 0.003850Ω/Ω/°C curve, user-selectable 

range. Two user-selectable ranges offer different 

resolutions. Requires scaling resistors. See special/linear 

inputs in ordering information.

• Linear: current and voltage signals from linear transmitters 

• Pulse input

Input Range and Accuracy 

Sensor Range (°F) Range (°C) Accuracy

Type B 150 to 3200°F 66 to 1760°C ±4.0°C

Type E -328 to 1448°F -200 to 787°C ±1.0°C

Type J -350 to 1400°F -212 to 760°C ±1.2°C

Type K -450 to 2500°F -268 to 1371°C ±1.3°C

Type R 0 to 3210°F -18 to 1766°C ±2.8°C

Type S 0 to 3200°F -18 to 1760°C ±2.8°C

Type T -450 to 750°F -268 to 399°C ±1.6°C

RTDs available on CLS204 and CLS208 only.

Sensor Range (°F) Range (°C) Accuracy

RTD1 -148 to 527˚F -100 to 275˚C ±1.1˚C

RTD2 -184 to 1544˚F -120 to 840˚C ±1.6˚C

Note: Accuracy @ 25˚C ambient. Valid for 10 to 100 percent 

of span except Type B, which is specified for 800˚F to 

3200˚F. RTD is for 100 percent of span.

Linear Voltage and Current Inputs

Requires scaling resistors. See special inputs in ordering 

information.

0-20mA(dc)/4-20mA(dc)

0-5VDC

0-10VDC

Other ranges available. Contact factory. 

Pulse Input 

• One TTL-level square wave input up to 2kHz

Input Sampling Rate at 60Hz 

Each channel has the following scans per second:

• CLS204: 6 samples per second (update time: 0.167 sec.)

• CLS208: 3 samples per second, (update time: 0.333 sec.)

• CLS216: 1.5 samples per second, (update time: 0.667 sec.)

Internal Measurement Resolution

• 0.006 percent, greater than 14 bits

Calibration

• Automatic zero and full scale

Digital Inputs 

• TTL-level used for selecting recipes or jobs, or R/S triggers

• 8 inputs and 1 pulse input with 50-pin terminal board 

option

• 2 inputs and pulse input or 3 inputs with 18-pin terminal 

block option

Digital Outputs

• 34 digital outputs are available with 50-pin terminal 

board option

• 10 control outputs with 18-pin terminal block option

• 1 or 2 control outputs are user assigned for each loop

• Each control output can be configured for on-off time 

proportioning, or distributed zero crossing

• Outputs sink up to 60mA each at 5VDC

• 350mA at 5VDC available from on-board supply 

Alarm Outputs 

• Independent process and deviation alarms for each 

channel

• Alarms can operate any output not used for control

• User-programmable deadband, delay and startup 

suppression

• Global alarm output activates when any alarm occurs

• Watchdog output indicates controller is functioning 

correctly

Serial Interface 

• EIA/TIA-232 or EIA/TIA-485 

Baud Rate

• 2400, 9600 or 19200, user-selectable

Communications Protocols

• Form of ANSI X3.28-1976, (D1, F1) compatible with 

Allen-Bradley PLC/2

• Modbus® RTU

Line Voltage/Power

• 15 to 24VDC ± 3VDC @ 1A (max.),

300mA (no load)

Agency Approvals

• UL®, C-UL® listed: UL®61010-1 safety requirements for 

measurement, control and laboratory equipment

• CE Mark: See Declaration of Conformity for details

• Shows up to 2 or 4 rows, 20 characters 

of information

• Choice of Vacuum Fluorescent or 

Monochrome LCD

• 5 user programmable function keys 

with slide-in legends

• 5 user programmable LED indicators

• Multilanguage project capability 

• Connection to industrial bus systems 

and Ethernet with optional modules 

• IP65 front panel protection

• Version with extended operating 

temperature available

The CP HMI panels is compact low cost products yet extremely rich in functionality. The product 

support the rich common functionality of the UniOP operator panels: 

• Powerful and intuitive programming with the UniOP Designer software 

• Dual-driver communication capability (only CP01) 

• Support of more than 130 communication drivers for industrial devices 

• Optional modules for fieldbus systems (Profibus DP, DeviceNet, CANopen, Interbus) and Ethernet 

• Display data in numerical, text and bargraph format

• Recipe data storage 

• Keyboard macro editor 

• Alarms and historical alarm list 

• Eight level password protection 

Technical Data 

PN# tn197-1.doc – 26.01.2012 – Ver. 1.01

Page 3 

Fuse 2 A (user replaceable) 

Weight ~ 1.1 Kg 

Operating temperature 0 ÷ +50 °C

Storage temperature -20 ÷ +70 °C 

Operating and storage humidity 5 ÷ 85 % RH non-condensing 

Protection class IP65 (front panel) 

The product is designed for installation in an industrial environment in compliance with the regulations: 

Emitted interference EN 61000-6-4 

Noise immunity EN 61000-6-2 

Front Dimensions and Cutout 

Faceplate LxH 138×186 mm 5.43×7.32 “

Cutout AxB 117×176 mm 4.61×6.50 “

Cutout depth C 74 mm 2.91 ”

Max panel thickness 5 mm 0.20

Connections 

The product is compatible with all standard TCM and SCM modules. 

To access the slot for the modules, remove the rear cover of the product 

The backup battery is accessible for replacement after removing the main module of the unit. 

The standard programming cable CA114 can be used with CP01 units.

Indicators and keypad 

There is one dedicated LED indicator on the front panel of the unit. Function is described in the table 

below. 

A customizable legend strip is included. 

Elements not listed in this chapter are reserved for future use. 

PN# tn197-1.doc – 26.01.2012 – Ver. 1.01

The RDA mapping of all keys and LEDs is standard. 

Function keys associated to keys 1 to 5 have a slide-in legend. Legend strips in laser printable form are 

available as accessories. 

Ordering Information 

CP01R-04-0045 Compact HMI with 4×20 LCD display 

R-PRINT2299 Printable legends (5 A4 foils, 16 sets of legends per foil)