Cal Controls 59621-1 Quick Reference
59621 MaxVU Rail Limiter Concise manual (EN)
1. INSTALLATION
Installation Guidance
Terminal Wir ing
CAUTION: Check information label on housing for correct operating
2. FRONT PANEL
Navigation & Editing
OPERATOR MODE
unit returns automatically to the first Operator Mode screen.
3. SETUP (& FIRST POWER UP)
Important N ote: When powered up for the first time, or after a factory reset (default) the
Setup Lock
Enter code & press
Default 10
Parameter
Description
Default Value
Type
J Thermocouple *
K Thermocouple
-200 – 1200ºC
-328 – 2192ºF
-128.8 – 537.7ºC
-199.9 – 999.9ºF
K Thermocouple *
-240 – 1373ºC
-400 – 2503ºF
-128.8 – 537.7ºC
-199.9 – 999.9ºF
PT100 *
-199 – 800ºC
-328 – 1472ºF
-128.8 – 537.7ºC
-199.9 – 999.9ºF
B Thermocouple
100 – 1824ºC
211 – 3315ºF
C Thermocouple
0 – 2320ºC
32 – 4208ºF
L Thermocouple *
0 – 762ºC
0.0 – 537.7ºC
N Thermocouple
0 – 1399ºC
R Thermocouple
0 – 1795ºC
S Thermocouple
0 – 1762ºC
T Thermocouple *
-240 – 400ºC
-128.8 – 400.0ºC
Linear dc
0 – 20mA
4 – 20mA
>Input
Units
°C
* Maximum of 1 decimal place for temperature inputs marked.
Decimal Place
0000 *
0000
Scaled Range only visible when input is a linear type.
Scale Range Maximum
Maximum for application working range.
1000
Scale Range Minimum
Minimum for application working range.
0
Type
High
Low -
High
>Limit
Value
The exceed value at which the Limit
-240
PV Retrans parameters only visible if Output 3 is Linear.
Type
0-10V
0-10V
>PV Retrans
Scale Range Maximum
Maximum PV value corresponding to
> PV Retrans
Scale Range Minimum
Minimum PV value corresponding to
Value
Range minimum to range maximum, or OFF
1373
Alarm 2 visible if Output 3 is Relay or SSR Drive.
Parameter
Description
Default Value
>Alarm 2
Value
Same options as Alarm 1.
PV Low
-240
>Coms Unit Address
Modbus address from 1 to 255
1
>Coms Baud Rate
1200, 2400, 4800, 9600, 19200 & 38400
9600
>Coms Parity
Odd, Even or None
None
Press & to exit.
When you exit, If necessary, press and to clear
Pop Up Alerts.
OPERATOR MODE
Name
Details
Alarm State
Alarm active
Latch State
Output Latched
Maximum PV
Minimum PV
Minimum PV
Warnings & Error Messages
Caution: Do not continue your process until any issues are resolved.
Name
Details
For example, Pop Up Alert for Alarm 1.
Alarm 1, Alarm 2, Alarm 1 & 2, Starting Calibration, Calibration Ongoing,
Calibration Fail, Setup not Completed & Limit Exceeded
LIMIT
Alternates with PV to show Limit is active.
ALARM
Alternates with PV to show Alarm is active.
LATCH
(Alternates with PV.) One or more outputs are latched on, and
no alarm is active.
HIGH
Process variable input > 5% over-range.
LOW
Process variable input > 5% under-range.
OPEN
Break detected in process variable input sensor, wiring or wrong
Shows OPEN until resolved, actives Limit exceed state..
ERROR
Selected input range is not calibrated.
5. SAFETY & WARNING SYMBOLS
Alternating or direct current
could be present.
Equipment protected through-out
by double insulation.
6. SPECIFICATIONS
PROCESS INPUT
Thermocouple
Calibration:
±0.25% of full range, ±1LSD & ±1°C for Thermocouple CJC.
BS4937, NBS125 & IEC584.
PT100 Calibration:
±0.25% of full range, ±1LSD.
BS1904 & DIN43760 (0.00385Ω/Ω/°C).
DC Calibration:
±0.25% of full range, ±1LSD.
Sampling Rate:
4 per second.
Impedance:
>1MΩ resistive, except dc mA (5Ω) and V (47kΩ)
Sensor Break
Detection:
Thermocouple, RTD, 4 to 20mA, 10 to 50mV, 2 to 10V and 1 to
5V ranges only.
detected.
DIGITAL INPUT (Isolated or Non-Isolated version)
Functions:
Reset Limits & Alarms only.
Signal:
Non
Isolated version
Closed to Open transition = Reset.
OUTPUTS
Relay
Contacts:
Limit (Output 1) Form C SPDT 2A @250vac or
Other (Output 2 or 3) Form A SPST relay, 2A @ 250Vac.
Lifetime:
>150,000 operations at rated voltage/current, resistive load.
SSR Driver
Capability:
SSR drive voltage >10V at 20mA
Output 3 option o nl y: DC (Linear) for PV Retransmit
Types:
0 to 20mA, 4 to 20mA, 0 to 5V, 0 to 10V or 2 to 10V
Load Resistance:
Current Output 500Ω max, Voltage Output 500Ω min.
Resolution:
8 bits in 250ms (10 bits in 1s typical, >10 bits in >1s typical).
RS485 SERIAL COMMUNICATIONS
Data Rate:
1200, 2400, 4800, 9600, 192 00 or 38 400 bps.
Protocol:
Modbus RTU.
OPERATING CONDITIONS
Usage:
For indoor use only, DIN-rail mounted in suitable enclosure
Ambient Temperature:
<95% humidity 0°C to 55°C (Operating), –10°C to 80°C
(Storage).
Relative Humidity:
20% to 95% non-condensing.
Altitude:
< 2000m
Supply Voltage &
Power:
Mains power version - 100 to 240Vac ±10%, 50/60Hz, 9VA
Low voltage version
+10/-15% 5W.
ENVIRONMENTAL
Standards:
CE, FM 3545, UL & cUL.
EMI:
EN61326-1:2013, Table 2 & Class A.
Warning: This is a Class A product. In a domestic environment this product may cause
radio interference in which case the user may be required to take adequate measures.
Safety:
UL61010-1 Edition 3, EN61010-1 Version 2010, Pollution
Degree 2 & Installation Class 2.
Protecti on Rating:
IP20.
PHYSICAL
Unit Size:
Height - 99mm; Width – 22.5mm; Depth - 121mm
Ventilation:
A minimum space of 80mm must be allowed above and below
each unit.
Weight:
0.20kg maximum
ISOLATION
Bus Connector
* Dedicated
* NEVER DIRECTLY CONNECT DEDICATED CONFIGURATION SOCKET TO A USB PORT.
A
Data A
Data B
RS485 Data A (Rx/Tx+)
Output 3
(Alarm2/Retx PV)
Alarm 1 output
Power
Digital Input
RS485 Data B (Rx/Tx-)
Relay COM / Linear +
Relay NO / Linear -
Relay COM / SSR -
Relay NO / SSR +
Relay COM / SSR -
Relay NO / SSR +
Relay NC
TC / RTD / Linear +
Volt-free or TTL
L +
N -
TC / RTD / Linear -
RTD
B
Alarm State
Limit
Alarm 1
Alarm 2
Latch State
Limit
Alarm 1
Alarm 2
Bus Connector (optional)
Mounting & Unmounting
Ok /
Select
Up
Down
LEDs show Limit, Exceed and Alarm state: LM EX AL
alarm/latch statuses, error & warning messages.
Non-Isolated
Digital Input
Isolated Digital
Input
Configuration
Port
Configuration
Port
NonIsolated
Digital
Input
Isolated
Digital
Input
RS485 Comms
Not Applicable
No Isolation
Reinforced
Isolation
RS485
Comms
Linear
Linear
SSR
SSR
Relay
Relay
Universal Input
Universal
Input
PSU
PSU
59621-1
MaxVU Rail Limiter Concise Manual
• Installation should only be performed by technically competent personnel.
• Standards compliance shall not be impaired when fitting into the final installation.
• It is the responsibility of the installing engineer to ensure that the configuration is safe.
• Local regulations regarding the electr ical insta l lation & safety must be observed.
• Impairment of protection will occur if the product is used in a manner not specified by the
manufacturer.
• Due to the low weight of this instrument there are no special lifting or carrying considerations.
• Designed to offer a minimum of Basic Insulation only.
• Ensure that supplementary insulation suitable for Installation Category II is achieved when fully
installed.
• To avoid possible hazards, accessible conductive parts of the final installation should be
protectively earthed in accordance with EN61010 for Class 1 equipment.
• Output wiring should be within a Protectively Earthed cabinet.
• Sensor sheaths should be bonded to protective earth or not be accessible.
• Live parts should not be accessible without the use of a tool.
• When fitted to the final installation, an IEC/CSA APPROVED disconnecting device should be used
to disconnect both LINE and NEUTRAL conductors simultaneously.
• Do not position the equipment so that it is difficult to operate the disconnecting device.
• Ventilation slots must not be covered and adequate air circulation must be allowed.
• Use conductor sizes 30-12 AWG, minimum temp rating of cables to be 80c.
voltage before connecting supply to Power Inputs.
Diagrams show all possible option combinations, check your exact
product speci fi ca t io n before connecting.
configuration port
pin-outs:
Display shows PV (process variable), units, LIM (Limit value),
Display turns off after 5, 15 or 30 minut es wit hou t key presses.
See
section for available screens in Operator Mode.
Press or keys to navigate between parameters or menu items.
Press to highlight and edit a parameter value.
Press or to change the parameter value, then press within 60 seconds to
confirm change.
Note: For security, no parameters can be changed from the Operator Mode.
Navigating to Setup Mode or Advance Configuration fr om Operator Mode:
Setup Mode - press & .
Advanced Configuration - press & .
Returning to Operator Mode:
Press & to move back one level. After 120 seconds without key presses the
Communications
Compatible
Limit output
Input
instrument enters Setup.
The device remains in Setup, or will keep powering up back into Setup, until all
parameters have been reviewed and the user exits Setup.
Some parameters may be hidden depending on configuration & hardware.
Alternatively press & to enter Setup from Operator screen and & to exit.
>Input
32 – 1403ºF
-400 – 752ºF
0 – 50mV
0 – 5V
0 – 10V
32 – 2551ºF
32 – 3198ºF
32 – 3204ºF
32.0 – 999.9ºF
-199.9 – 752.0ºF
10 – 50mV
1 – 5V
2 – 10V
°C or °F (hidden when a linear input is used)
>Input
000.0 *
00.00
0.000
>Input
>Input
– device will limit when PV is
>Limit
greater than the Limit value. (PV>Limit
Value)
device will limit when PV is less
than the Limit value. (PV<Limit value).
output will trip.
2-10V
>PV Retrans
0-20mA
4-20mA
0-5V
1-5V
maximum linear output.
minimum linear output.
>Alarm 1
(maximum +1). OFF disables alarm.
Default PV High alarm type.
Input type Max
Input type Min
4.
User Screen
Pop up Alerts:
Warnings and
Confirmations
Pop up Alerts:
Default
To clear press then to select
Yes. Press to accept.
Shows ERROR until resolved, actives Limit exceed state.
Risk of electric shock.
alarm type.
any
PV - top
LIM - bottom
Temperature Unit - right.
Alarm set, but not
To clear
latches press
then to select
Yes.
Press to
accept.
Alarm not set
Latch set, but output
not Latched
Latch not set
Screens show the
Maximum &
reached.
Pop Up Alerts need to be acknowledged.
Press and to clear Pop Up Alert.
.
input type selected.
Caution, refer to the manual.
active
Important: Check your product code for exact hardware fitted.
-isolated version - Open or Close only.
Limit output triggers when a sensor break is
- Open (2 to 24Vdc) or Closed (<0.8Vdc).
- 24Vac +10/-15% 50/60Hz 9VA or 24Vdc
59621 MaxVU Rail Limiter Concise manual (EN)
Advanced Configuration gives access to all possible parameters; however,
the device hides
specification & configuration.
Advanced Configuration Navigation
Enter by pressing & . Press or to navigate to the required menu, then press
Press
necessary to exit 2 or 3 levels for Operator Mode.
Advanced Configuration main menu
Advanced Lock
Enter code & press
Default 20
Menus
Description
Input
Configure the process input.
User Calibration
Single or two-point calibration adjustments for the process input.
Outputs
Configuration param et ers f o r the out put s and alarms.
Communication
Modbus communications settings.
Display
Lock codes and Factory Default.
Information
View serial number & manufacturing details.
Input
Parameter
Description
Default Value
Input Type
See Input Type table in SETUP (& FIRST
POWER UP).
K Thermocouple
Units
Display °C or °F (hidden when a linear input
is used)
°C
0000
0000
000.0
00.00
0.000
Scale Range
Maximum
Maximum for application working range
Max allowed for
Input Type.
Scale Range
Minimum
Minimum for application working range
Min allowed for
Input Type.
Filter Time
OFF or 0.5 to 100.0 seconds in 0.5
2.0
CJC Enable
Enable Enables the internal thermocouple
CJC (Cold Junction Compensation).
Enable
Disable Disables the internal CJC.
thermocouples.
User Calibration
Single-point offset or two-point calibration adj u stm ent for process input. Can be used
together
Parameter
Description
Default Value
Offset
Shifts the input value up or down by a single offset amount
across the entire range.
0
Low Point
Enter value at which the low point error was measured.
Lower Limit
Low Offset
Enter equal, but opposite offset value to the observed low
0
High Point
Enter value at which the high point error was measured.
Upper Limit
High Offset
Enter an equal, but opposite offset value to the observed
0
Outputs
Parameter
Description
Default Value
>Limit Output
Type
High = Limit output trips when PV over Limit
Low
High
Value
The exceed value at which the Limit output will
-240
Output Latching
OFF – Limit Output doesn’t latch
ON - Limit Output latches & needs to be cleared.
ON
Startup latch
Reset Latch
Always Latch
Last Latch
Last Latch
>Alarm 1
Type
None
PV High
PV Low
Deviation
Annunciator
PV High
Parameter
Description
Default Value
Value
Range minimum to range maximum, or OFF
Default PV High alarm type.
1373
Hysteresis
0 to full span.
1
Action
Direct - Output active when alarm is active.
Reverse
Direct
Output Latching
OFF - Alarm doesn’t latch
ON -
* Default when Annunciator is ON.
OFF *
Startup latch
Reset Latch
Always Latch
Last Latch
Last Latch
>Alarm 2
Alarm 2 visible if Output 3 is Relay or SSR Drive.
Type
PV Low
Value
-240
Hysteresis
Off
Action
Direct
Output Latching
OFF
Startup latch
Reset Latch
Always Latch
Last Latch
Last Latch
>PV Retrans
PV Retrans parameters only visible if Output 3 is Linear.
Output type
0-10V
0-5V
2-10V
0-20mA
4-20mA
1-5V
0-10V
Scale Range Maximum
Display value for maximum output, -1999 to
9999
Input type
Max
Scale Range Minimum
Display value for minimum output, -1999 to 9999
Input type Min
>Alarm Options
> Alm Options
Start-up Inhibit
Inhibit Alarms on Start up.
Alarm 1 & 2
None
> Alm Options
Sensor Break
OFF or ON
is detected.
ON
Communications
Only shown when RS485 option is fitted.
Parameter Name
Description
Default Value
Unit Address
Modbus address from 1 to
255
1
Baud Rate
Coms data rate in kbps
9600
Parity
Parity checking: Odd, Even
or None
None
Display
Lock codes & Factory Defaults.
Parameter Name
Description
Default Value
Setup Unlock
Code
View & adjust Setup lock code.
From 1 to 9999 or Off for no lock code.
10
Advanced Unlock
Code
View & adjust Advanced lock code.
9999
Off
20
Screen Timeout
Screensaver time 5, 15 or 30 mins.
5
Selected language
Display language, 2 available – English plus
either German or French.
English
Reset to Defaults
Reset parameters back to factory defaults.
Press to accept.
Information (Read-Only)
Parameter Name
Description
PRL
DOM
The hardware/software revision level.
FW Version
FW Type
The firmware version number & code type.
Serial
Instrument serial number.
Out1
Out2
Out3
Relay
Comm
DI
Comms option - Fitted or None.
isolated)
Please refer to the full manual for further information on any topic.
What is a Limiter / Limit Controller?
7. ADVANCED CONFIGURATION
parameters that are irrelevant to your exact product
to enter.
& to exit up 1 level. Depending upon w hich menu you enter it may be
(maximum +1). OFF disables alarm.
- Output active when alarm is not
active.
Alarm latches & needs to be cleared.
Same options as Alarm 1.
A protective device that will shut down a process at a preset Exceed Condition, in order to prevent possible damage to equipment or products. A ‘fail-safe’ latching relay is used, which cannot be reset
by the operator until the process is back in a safe condition. This signal may be applied from the instrument keypad, digital input or command via Serial Communication.
Limit controllers work independently of the normal process controller. Limit Controllers have specific approvals for safety critical applications. They are recommended for any process that could
potentially become hazardous under fault conditions.
What does Exceed Condition mean?
A state that occurs when the Process Variable exceeds the Limit Setpoint value. E.g. if the PV is above the Limit SP when set for high limit action, or below the Limit SP for low limit action. The Limit
Controller can be used to shut down the process when this condition occurs, and cannot be reset until the Exceed Condition has passed.
What does ‘Latching’ mean?
An output that once it becomes active requires a reset signal before it will deactivate. This output is available on Limit controllers and indicator alarms. To successfully deactivate a latched output, the
alarm or limit condition that caused the relay to become active must first be removed, then a reset signal can be applied. This signal may be applied from the instrument keypad, Digital Input or
command via Serial Communication.
What is the PV Retransmit Output?
A linear DC Voltage or mA output signal proportional to the Process Variable (e.g. process temperature), for use by external devices, such as a Data Recorder or PLC. This output can be scaled to
transmit any portion of the input, but it is normally scaled so the reading matches on the device receiving the signal.
What is an Annunciator?
A special type of alarm output that is linked to a Limit Controller’s main Limit Output. An Annunciator output will activate when an Exceed condition occurs, and will remain active until a reset instruction
is received, or the Exceed condition has passed. Unlike the Limit Output, an Annunciator can be reset even if the Exceed condition is present.
Decimal Place
, if required.
External compensation must be provided for
point error.
high point error.
Not for temperature.
increments
Alarm 1
Alarm 2
None
ON - triggers Alarm outputs when sens or bre ak
1200, 2400, 4800, 9600,
19200 & 38400.
From 1 to
or
for no lock code.
value. (PV>Limit Value).
= Limit output trips when PV under Limit
value. (PV<Limit value).
trip. Variable within the Scaled Range set in
Input.
To clear press then to select Yes.
Date of manufacture (mmyy).
SSR (SSR driver) or Relay.
None, SSR (SSR driver), Relay or Linear.
Digital Input options – Iso (isolated) or NonIs (non-
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