Operating Manual
CAL Controls
Temperature Controllers
CAL 9400 Dual Display
Autotune Temperature
Controller
INDEX
SAFETY & WARRANTY A1
FUNCTIONS MENU A3
QUICK START
Quick Start Set-up 1a
INTRODUCTION 2
The controllers 2
OVERVIEW 3
Installation 3
Set-up 3
Autotune 3
Cycle-time 4
SET-UP 5
Power-up 5
Select input sensor 5
Select display units 5
Allocate output device 5
Enter initial configuration 5
Set main setpoint 5
MENU NAVIGATION 6
Using program mode 6
AUTOTUNE 7
Tune program 7
Tune at setpoint program 8
PROPORTIONAL CYCLE-TIME 9
Cycle-time selection methods 9
Cycle-time recommendations 9
Autotune calculated cycle-time 9
PROGRAMMER 11
Ramp-Soak 11
SECOND SETPOINT (SP2) 12
SP2 as an alarm 12
SP2 subsidiary mode 13
SP2 as a proportional output 13
SP2 alarm condition table 13
SP2 alarm annunciator 13
ERROR MESSAGES 14
Recommendations 14
Autotune data in
IMPROVING CONTROL ACCURACY 15
Using
ChEK
FUNCTION LIST 16
Level 1 16
Level 2 18
Level 3 19
Level 4 21
OUTPUT OPTIONS 22
ADVANCED SETTINGS 23
Heat Cool strategy 23
Calibration to other instrument 24
Linear input calibration 25
MECHANICAL INSTALLATION 27
DIN panel cut-outs 27
Minimum spacing 27
Mounting 28
ELECTRICAL INSTALLATION 29
General requirements 29
Connection diagrams 30
INPUT/SENSOR SELECTION 31
SPECIFICATION 32
tECH
accuracy monitor 15
14
Index
A2A1
SAFETY AND WARRANTY INFORMATION
INSTALLATION
Designed for use:
UL873 - only in products where the acceptability is determined by
Underwriters Laboratories Inc.
EN61010-1 / CSA 22.2 No 1010.1 - 92
To offer a minimum of Basic Insulation only.
Suitable for installation within Catagory II and III and Pollution
Degree 2.
SEE ELECTRICAL INSTALLATION P29 & P30
It is the responsibility of the installation engineer to ensure this
equipment is installed as specified in this manual and is in
compliance with appropriate wiring regulations.
CONFIGURATION
All functions are front selectable, it is the responsibility of the
installing engineer to ensure that the configuration is safe. Use the
program lock to protect critical functions from tampering.
ULTIMATE SAFETY ALARMS
Do not use SP2 as the sole alarm where personal injury or damage
may be caused by equipment failure.
WARRANTY
CAL Controls warrant this product free from defect in workmanship
and materials for three (3) years from date of purchase.
1 Should the unit malfunction, return it to the factory. If
defective it will be repaired or replaced at no charge.
2 There are no user-servisable parts in this unit. This
waranty is void if the unit shows evidence of being
tampered with or subjected to excessive heat, moisture,
corrosion or other misuse.
3 Components which wear, or damage with misuse, are
excluded e.g. relays.
4 CAL Controls shall not be responsible for any damage or losses
however caused, which may be experienced as a result of the
installation or use of this product. CAL Controls liability for any
breach of this agreement shall not exceed the purchase price
paid E. & O.E.
Safety and Warranty
FUNCTIONS MENU
nonE; LEV 3; LEV 2; ALL
LEVL 4
Security lock
LOCK
Disable program auto-exit
PROG NO.AL DIS.S DER.S
*
Auto; StAY
USER-PROTECTED SETTINGS
Off; on
Disable -AL- alarm display
Display averaging
*
dir; 1 to 32 (6)
0.1 to 1.0 x dEr.t (0.5)
Derivative sensitivity
Range of Adjustment shown in red under
description. If applicable, factory settings shown
in bold.
* Note: Dual Relay and Dual SSd Output Options
Models 9411 and 9422 have their outputs
pre-configured. (see page 22)
Setpoint 1
Output
indicator
(green)
Process temperature (PV) or Function (green)
Setpoint temperature (SP) or Option (orange)
Setpoint 2 Output indicator (red)
nonE; rlY; SSd
SP1 output device
LEVL 3
LEVL 2
Functions Menu
LEVL 1
Level C only visable
when COMMS
Option fitted
KEY ✱ ▼ OR ✱ ▲ TOGETHER TO CHANGE LEVELS OR OPTIONS
LEVL C
SP1.D
CONFIGURE OUTPUT SAFETY SETTINGS CALIBRATION PERFORMANCE DATA
0 to 100% read only
Read SP1 output %
SP1.P
oFF; on; tunE; ParK; At.Sp
Autotune or Park
TUNE
PROGRAM ENTRY
➔
0 to 255
Instrument address
ADDR
A3
nonE; SSd; rlY (read only)
SP2 output device
SP2.D BURN REU.D REU.L SPAN ZERO CHEK READ TECH UER RSET
0 to 100% proportional
SP1 manual output %
HAND PL.1 PL.2 SP2.A SP2.B DISP HI.SC LO.SC INPT UNIT
MANUAL ADJUSTMENTS SP2 MODES RANGING CONFIGURE INPUT
0.1 deg to 25% sensor f/s
SP1 Prop band (gain)/hyst
BAND INT.T DER.T DAC CYC.T OFST SP.LK SPRR SPRN SOAK SET.2 BND.2 CYC.2
1200: 2400: 4800:
Baud rate
BAUD DATA DBUG
COMMS SETTINGS
Sensor burn-out
mode only
Limit SP1 output %
(10°C/18°F)
Integral time (reset)
9600: 19k2
Data format
uP.SC; dn.SC; 1u.2d; 1d.2u
100 to 0%
Off; 0.1 to 60 min (5 min)
18n1:18E1:18O1
1r.2d; 1d.2d; 1r.2r; 1d.2r
Reverse outputs
100 to 0%
Limit SP2 output %
Off; 1 to 200 sec (25 sec)
Derivative time (rate)
SP1 SETTINGS
Off; on
Tx/Rx activity
1n.2n; 1i.2n; 1n.2i; 1i.2i
Reverse O/P LEDs
nonE; dV.hi; dV.Lo; bAnd;
FS.hi; FS,Lo; Cool
Main SP2 mode
0.5 to 5.0 x bAnd (1.5)
Derivative approach
0.0 to 25% sensor f/s
Span adjustment
nonE; LtCH; hold; Lt.ho;
nLin
Second SP2 mode
(20 sec)
On.off; 0.1 to 81 sec
Cycle time or on/off
sensor full scale
0.0 to 25%
Zero Adjustment
1 or 0.1 degree
Display resolution
(In.t = off)
0 to 50% x bAnd
Offset (manual reset)
Off; on
Set Monitor
sensor full scale
0.0 Sensor max to
Set scale maximum
Off; on
Setpoint lock (SP1)
Read Monitor
Set scale minimum
Setpoint Ramp rate
KEY ▼ ▲ TO VIEW FUNCTIONS
VAr; hi; lo deg
full scale
0.0 Sensor min to sensor
CtA; Ctb; Ct1; Ct2; Ct3;
Read Tune Data
nonE
Select input sensor
Ct4; oS1; uS; oS2
Consult unit
Software version
PSi; Ph; rh; SEt
nonE; °C; °F; bAr;
Select display units
RESET
nonE; ALL
➔
QUICK START ENTRY
0 to 9990 deg/hour
PROGRAMMER SETTINGS SP2 SETTINGS
On; off; hold
Ramp off/on
Off; 0 to 1440 min
Soak time
Adjust SP2 setpoint
full scale
+/– sensor full scale or
0.1 deg to 100% sensor
SP2 prop band/Gain/Hyst
f/s (2°C/3.6°F)
SP2 Cycle on/off
On.off; 0.1 to 81 sec
INSTRUMENT ADJUSTMENTS
To enter or exit program mode: Press ▲ ▼ together for 3 seconds
To scroll through functions: Press ▲ or ▼
To change levels or options: Press ✱ ▲ together or ✱ ▼ together
To view setpoint: Press ✱
To increase setpoint: Press ✱ ▲ together
To decrease setpoint: Press ✱ ▼ together
To reset an alarm or fault condition: Press ▲ ▼ together briefly
Notes: If in difficulty by becoming “lost” in program mode, press ▲ and ▼
together for 3 seconds to return to display mode, check the
INSTRUMENT ADJUSTMENTS above and try again.
When in program mode, after 60 seconds of key inactivity
the display will revert to either
or, if the initial configuration has been completed, the
measured value. Any settings already completed will be retained.
INPT
NONE
2 Select unit.
Press and hold ✱ and use the ▲ or ▼ buttons to scroll
through the unit selection list until the
correct unit is displayed. Release the
buttons.
The display will read selected unit e.g.
Press ▲ once The display will now read
3 Select SP1 (Main setpoint output device)
Note: Dual Relay and Dual SSd Output Options
Models 9411 and 9422 have their outputs
pre-configured. (see page 22)
Press and hold ✱ and use the ▲ or ▼ buttons to select
SSd
or
rLY
as required.
The controller will now read selected output device e.g.
Quick Start
QUICK START
1b
4 To enter initial configuration into
controller memory
Press and hold both ▲ and ▼ buttons for 3 seconds.
The upper display will now alternate
ParK
and measured variable (temperature)
(eg. 23)
ParK
is displayed because
a setpoint has not yet been entered as
shown by the lower display
To display setpoint
Press and hold ✱ The displays will now read
unit
(eg. °C) and
0
To enter setpoint
Press and hold ✱ and use ▲ button to increase or ▼
button to decrease the reading and
scroll to required setpoint value. (The
digit roll-over rate increases with time).
THE CONTROLLER IS NOW OPERATIONAL
WITH FACTORY SETTINGS
Note: For precise control of an application the controller
may need to be TUNED. Please study section
headed FUNCTIONS and OPTIONS before moving
to the section on AUTOTUNE.
UNIT
*C
SPI.D
NONE
SPI.D
SSD
PARK
0
*C
0
Introduction
INTRODUCTION
The CAL 9400 is a 1/16 DIN dual display, dual output miniature
controller with PID control strategy.
Control can be optimised with a single shot autotune either on
initial warm-up or at setpoint. The second setpoint can be
configured in a variety of alarm modes or PID Heat-Cool strategy. A
programmer offers a single ramp to setpoint with a choice of timed
soak period before switching off the output.
Control of non temperature processes is achieved by the provision
of linear input ranges and scaling in commonly used engineering
units.
Serial communication is available as an option, and the easy to use
CALCOMMS
TM
is a graphic WINDOWSTMbased software package
designed for PC supervision of up to 32 instruments, for remote
adjustment, configuration, cloning, saving and retrieving settings to
files and logging and charting in real time.
CALCOMMSTMuses the MODBUS®protocol via either a fully isolated
RS232 or RS485 link depending on the number of instruments and
the transmission distances involved in the application.
A users manual is supplied with the comms option. For more
information contact CAL. For details, see rear cover.
It is suggested that users read the OVERVIEW section of this manual
before any installation or setting-up procedures are undertaken.
Note: The controller will not be operational until either the
QUICK-START or SET-UP procedure has been completed.
NB: Please note that in program mode, functions
are shown in the upper display (green) and options
in the lower display (orange)
2
CAL 9400
TUNE
PARK
Overview
OVERVIEW
INSTALLATION
The Model 9400 controller is designed to be mounted in a 1/16 DIN
panel cut-out. See the INSTALLATION section.
SET-UP
After installation the controller requires programming with the
following information:
Type of Input Sensor
Operating unit (C or F etc)
Type of Output Device
Temperature Setpoint
Note: The controller will not be operational until this
information is entered.
When the above information has been programmed into the
controller it will be operational with the following factory PID
(proportional band, integral time, derivative time) settings.
Proportional band/Gain 10°C/18°F
Integral time/Reset 5 mins
Proportional cycle-time 20 secs
Derivative time/Rate 25 secs
DAC Derivative approach control 1.5
AUTOTUNE
To precisely control an application the controller will need to be
‘tuned’ using the built-in ‘AUTOTUNE’ feature. Autotune ‘teaches’
the controller the main characteristics of the process and ‘learns’ by
cycling the output on and off. The results are measured and used to
calculate optimum PID values which are automatically entered in the
controller memory.
During AUTOTUNE the optimum cycle-time is calculated but is not
automatically implemented. The cycle-time requires manual
acceptance unless pre-selected.
To ensure good control over a wide range of applications two
versions of the Autotune program are provided, TUNE and TUNE AT
SETPOINT.
The TUNE method normally achieves the best results. Starting with
the load cool, tuning occurs during warm-up preventing overshoot.
This method of tuning is recommended.
The TUNE AT SETPOINT method is used for specialist applications.
eg. Heat-cool, multizones and processes below 100°C/200°F. During
the tuning cycle some overshoot occurs because the tuning cycle is
at set point.
The DAC setting is not re-calculated.
3
Overview
CYCLE-TIME
The choice of cycle-time is influenced by the external switching
device or load. e.g. contactor, SSR, Valve. A setting that is too long
for the process will cause oscillation and a setting that is too short
will cause unnecessary wear to an electro-mechanical switching
device.
Cycle-time selection methods
The following methods of cycle-time selection may be used:
Autotune calculated
After Autotune has been run and completed the calculated cycletime can be manually accepted or adjusted to suit the switching
device. For selection method see Select Autotune Calculated
Cycle-time.
Pre-select autotune cycle-time
The controller can be programmed to automatically accept the
calculated Autotune cycle-time. For selection method see Pre-
Select Automatic Acceptance of Any Autotune Cycle-time.
Pre-select before autotune
The controller can be programmed manually with any cycle-time
between 0.1 and 81 sec. This cycle-time will not be changed by any
Autotune functions. For selection method see Pre-Select Cycletime Before Autotune.
Factory set
To use the 20 sec factory set cycle-time no action is needed
whether Autotune is used or not.
Further information can be programmed into the controller, see
SECOND SETPOINT, RANGING AND SETPOINT LOCK, IMPROVING
CONTROL ACCURACY
Functions and options
The facilities of the controller are selected from the multi-level menu
using the front panel mounted buttons.
Note: It is advisable to study this section before any
programming is undertaken.
Each level within the multi-level menu offers different functions, see
FUNCTIONS MENU for menu of main functions. Each function has a
range of user selections or options, see FUNCTION LIST for
functions and options details.
The controller has two modes, program mode and operating mode.
When in program mode the controller can be programmed with
settings and functions to suit the application. When in operating
mode the controller uses the setting and functions entered in the
program mode to control the application and also displays both the
process variable and setpoint temperatures. For full details on how
to program the controller see VIEWING AND SELECTING
FUNCTIONS.
Note: In this manual the letter k is represented by the
character K
4
Set-up
SET-UP
5
This section details the four step initial configuration that
enables control with factory PID settings to start, once the
setpoint has been entered.
POWER-UP
On power-up the controller will display the self test
sequence and brief display blanking
1 SELECT INPUT SENSOR
Press and hold ✱ and use either the ▲ or ▼ buttons to
scroll through the sensor selection (see table p.31).
When the correct sensor is displayed, release the
buttons. The controller will now display selected sensor
type e.g.
2 TO SELECT °C/°F
Press and release the ▲ button, the controller will now
display
Press and hold the ✱ button and using the ▲ button
select °C, °F, Bar, PSI, Ph, Rh or SEt as required. Release the
buttons when the correct unit is displayed.
The controller will now display
unit
and e.g. ºC
3 TO SELECT SP1
(Main setpoint output device)
Note: Dual Relay and Dual SSd Output Options Models
9411 and 9422 have their outputs pre-configured.
(see page 22)
Press and release the ▲ button, the controller will now
display
Press and hold the ✱ button and using the ▲ button
select
SSd
or
rLY
as required. Release the buttons when
the correct device is displayed. The controller will now
display
SPI.d
and selected output device e.g.
SSd
.
4 To enter initial configuration into
controller memory
Press and hold both ▲ and ▼ buttons for 3 seconds.
The upper display will now alternate
ParK
and measured variable (temperature)
(eg. 23)
ParK
is displayed because
a setpoint has not yet been entered as
shown by the lower display
TO SET THE MAIN SETPOINT
To display the setpoint, press and hold the ✱ button. °Cand
0
or °Fand 32will be displayed. Press and hold the ✱
button. Press ▲ to increase or ▼ to decrease the setpoint.
The main setpoint LED will flash indicating that SP1 output is
ON. The controller will now be set with the factory PID
settings.
INPT
NONE
SP1>D
NONE
SP1>D
SSD
INPT
TCS
UNIT
NONE
UNIT
*C
PARK
0
Menu Navigation
MENU NAVIGATION
To change an option value or setting
Press and hold the ✱ button, then press ▲ to increase or ▼ to
decrease the value or select the next option.
Note: Check the new option value before moving to
another function or exiting program mode.
To change levels
Press and hold ▼ to scroll through the functions until
LEUL
is
displayed. Release ▼ to display current level. Press and hold the ✱
button, then press ▲ to increase or ▼ to decrease the level.
Release buttons when required level is obtained.
To exit program mode
Press and hold both ▲ and ▼ buttons for at least 3 seconds.
Note: Control commences with any new instructions now
entered in the memory.
REMINDER OF INSTRUMENT ADJUSTMENTS
Press ▲ ▼ together for 3 seconds for program entry or exit.
Press ▲ or ▼ to scroll through functions.
Press ✱ ▲ together or ✱ ▼ together to change levels or alter
options.
Note: If in difficulty by becoming “lost” in program mode,
press ▲ and ▼ together for 3 seconds to return
to display mode, check the Menu Navigation
summary above and try again.
The facilities of the controller are selected from the multi-level menu
using the front panel mounted buttons.
Each level within the multi-level menu offers different functions, see
FUNCTIONS MENU page A3. Each function has a range of user
selections or options, see FUNCTION LIST pages 16–22
In operating mode, the upper (green) display reads process
temperature (PV) and the lower (orange) display reads setpoint
temperature (SP).
When in program mode, settings of each function, shown in the
upper display, can be made by selecting an appropriate option
from the lower display.
USING PROGRAM MODE
Note: The controller will auto-exit program mode after
60 seconds of inactivity.
To enter program mode from normal operating mode
Press and hold both ▲ and ▼ buttons for at least
3 seconds.
Release the buttons together and the controller will
now display the function and option (setting of that
function), e.g.
To view function on the same level and display current option
Press ▲ or ▼ button once to view the next function.
Press and hold ▲ or ▼ buttons to scroll through functions. The
current option or function value is shown in the lower display.
6
TUNE
OFF
Autotune
AUTOTUNE
Select the most appropriate method of Autotune , Tune or
Tune at Setpoint, to suit the application.
Note: The proportional cycle-time can be pre-selected
before starting Autotune, see PROPORTIONAL
CYCLE-TIME.
The TUNE program should be run with the load cool. The output is
cycled at 75% of the setpoint value to avoid any overshoot during
the tuning cycle. The warm-up characteristics are monitored and set
DAC which minimises overshoot on subsequent warm-ups.
The TUNE AT SETPOINT program is recommended:
when the setpoint is below 100°C/200°F, where
TUNE’s tuning cycle at 75% setpoint may be too
close to ambient to produce good results;
when the process is already hot and the cooling
rate is slow;
when controlling multi-zone or heat-cool
applications;
to re-tune if the setpoint is changed substantially
from previous Autotune.
Note: dAC is not re-tuned by TUNE AT SETPOINT.
TUNE PROGRAM
Enter program mode
and from the display
press and hold ✱ and press ▲ once,
the controller will now display
Exit program mode.
The TUNE program will now start. The upper display will
alternate between
tune
and the process temperature as it
climbs to setpoint.
The lower display will read the setpoint value e.g.
Note: During tuning, the main setpoint (SP1) LED will flash.
Temp
Setpoint
Cycle
75% SP
Start
TUNE
TUNE
Tuning DAC
PID
1
1
/4 on/off tuning
cycles
New PID
values
entered
Time
(100% output)
7
TUNE
OFF
TUNE
ON
TUNE
232
Autotune
The TUNE AT SETPOINT program will now start. The upper display
will alternate
tune
and the process temperature.
The lower display will read the setpoint value.
Note: During tuning the main setpoint (SP1) LED will flash.
When the TUNE AT SETPOINT program is complete the upper
alternating display stops and only the process temperature is
displayed. The PID values are entered automatically. The
process temperature will rise to setpoint and control should
be stable. If not, this may be because optimum cycle time
is not automatically implemented. To set the cycle time see
PROPORTIONAL CYCLE-TIME.
When the TUNE program is complete the upper alternating
display stops and only the process temperature is displayed. The PID
values are entered automatically. The process temperature will rise
to setpoint and control should be stable. If not, this may be
because optimum cycle time is not automatically implemented. To
set the cycle time see PROPORTIONAL CYCLE-TIME.
TUNE AT SETPOINT PROGRAM
Enter program mode and select
And from the display select
Exit program mode.
Temp
Setpoint
Start
TUNE
Tuning
PID
1
3
/4 on/off tuning
cycles
New PID
values
entered
Time
(100% output)
AT.SP
Overshoot
during tuning
Prop band
REMINDER OF INSTRUMENT ADJUSTMENTS
Press ▲ ▼ together for 3 seconds for program entry or exit.
Press ▲ or ▼ to scroll through functions.
Press ✱ ▲ together or ✱ ▼ together to change levels or alter
options.
Note: If in difficulty by becoming “lost” in program mode,
press ▲ and ▼ together for 3 seconds to return
to display mode, check the Menu Navigation
summary above and try again.
8
TUNE
OFF
TUNE
AT.SP
Proportional cycle-time
The choice of cycle-time is influenced by the external switching
device or load. eg. contactor, SSR, valve. A setting that is too long
for the process will cause oscillation and a setting that is too short
will cause unnecessary wear to an electro-mechanical switching
device.
CYCLE-TIME SELECTION METHODS
The following methods of cycle-time selection may be used:
Autotune calculated
After Autotune has been run and completed the calculated
cycle-time can be manually accepted or adjusted to suit the
switching device. For selection method see Select Autotune
Calculated Cycle-time.
Pre-select Autotune cycle-time
The controller can be programmed to automatically accept
any calculated Autotune cycle-time. For selection method
see Pre-Select Automatic Acceptance of Any Autotune
Cycle-time, page 10.
Pre-select before Autotune
The controller can be programmed manually with any
cycle-time between 0.1 and 81 sec. This cycle-time will not be
changed by any Autotune functions. For selection method see Pre-
Select Cycle-time Before Autotune, page 10.
Factory set
To use the 20 sec factory set cycle-time no action is needed
whether autotune is used or not.
CYCLE-TIME RECOMMENDATIONS
To Select AUTOTUNE CALCULATED CYCLE-TIME
On completion of Autotune enter program mode.
Select
The controller will display
CYC.t
and
20
(the factory
setting) in seconds
To view the calculated optimum cycle-time press and hold
the ✱ button then press and hold ▼ until indexing stops.
The controller will display the calculated cycle-time in the
lower display e.g.
A16
. This indicates that the calculated
cycle-time is 16 seconds
PROPORTIONAL CYCLE-TIME
9
Output
Device
Load max
(resistive)
Factory
Setting
Recommended
Minimum
Internal relay
rLY/rLY1
Internal relay
rLY2
20 seconds
20 seconds
20 seconds
10 seconds
2A/250 Vac
1A/250 Vac
Externally
fitted SSR
(n/a)
Solid state
drives
SSd/SSd1/SSd2
10 seconds
0.1 seconds
CYC.T
CYC.T
20
CYC.T
A16
If this cycle-time is suitable press and hold both ▲ and ▼
buttons for 3 seconds to enter it into the controllers
memory.
If the calculated cycle-time is not compatible with the
switching device press and hold the ✱ button then press
and hold ▲ or ▼ until a more suitable cycle-time is
displayed. Release the buttons, then press and hold both
▲ and ▼ buttons for 3 seconds to enter it into the controllers
memory.
Pre-Select Automatic Acceptance of Any Autotune
Cycle-time
Before selecting Autotune, enter program mode.
Select CYC.T
Press and hold the ✱ button then press and hold ▼
until indexing stops and
A- -
is displayed in the
lower display
Note:
A- -
indicates that no cycle-time exists.
Press and hold ▼ to scroll to
tunE
The controller will now display
Press and hold the ✱ button and use ▲ to select
either onor
At.SP
. Release ▲.
The controller will now run Autotune and will accept the
calculated cycle-time.
To Pre-Select Cycle-time Before Autotune
Before selecting Autotune, enter program mode.
Select
Press and hold the ✱ button, then press ▲ to increase
or ▼ to decrease the displayed cycle-time. Release
buttons when required value is displayed.
Select
or index to another function then exit program mode.
Proportional cycle-time
10
81
ON.OF
0.1
20
A --
Factory setting
ON/OFF
Autotune calculated
cycle-time
Manual settings
Seconds
✱ ▼
✱ ▲
Proportional Cycle-time (continued)
CYC.T
CYC.T
A--
TUNE
OFF
CYC.T
TUNE
Programmer
RAMP-SOAK
This feature enables the controller to ramp up or down from current
temperature to a target setpoint at a pre-determined rate. It then
controls at the target setpoint for an adjustable soak period before
switching off the heat output.
Set Ramp rate (0 to 9995 deg/hour)
Press ▲ and ▼ buttons for 3 seconds to enter
program entry point
Press ▲ to scroll to
Press and hold ✱, then press ▲ or ▼ to scroll to
required ramp value in the lower display
Set Soak (if required) 0 to 1440 minutes
Press ▲ to scroll to
Press and hold ✱, then press ▲ or ▼ to scroll to
required soak period in the lower display.
Set Ramp On (Off) : On : hold
Press ▲ to scroll to
Press and hold ✱, then press ▲ to select On
Exit program to enter settings into memory and commence ramp to
target setpoint.
Notes
In Ramp on configuration, if power is removed from the controller,
the Ramp will re-start when power is restored.
The Ramp hold option suspends the ramp at its last value.
If no Soak period has been set, control at target setpoint continues
indefinitely.
SP2 deviation alarms follow the ramp setpoint and can be used to
alarm “out of limits” ramp rate.
WARNING
The Soak timer is triggered when the ramp setpoint reaches the
target setpoint. If the ramp rate is set too fast for the process, the
Soak timer will be triggered before the process temperature reaches
the target setpoint.
PROGRAMMER
Target
setpoint
Deg.
Ramp °/hour
Time
Soak
Target
setpoint
Deg.
Ramp °/hour
Time
Soak
11
TUNE
OFF
SPRR
0
SOAK
--
SPRN
OFF
The second setpoint SP2 can be used to trigger an alarm
or as a proportional control output.
TO CONFIGURE SP2 AS AN ALARM
Enter program mode.
Select level 2
then followed by the required option below:
dV.hi
sets off alarm signal when temperature rises above a
pre-set temperature above the setpoint.
dV.Lo
sets off alarm signal when temperature falls below a pre-set
temperature below the setpoint.
bAnd
sets off alarm signal when temperature rises above or falls
below a pre-set temperature above or below the setpoint.
FS.hi
sets off alarm signal when the temperature rises above
setpoint to a pre-set temperature above scale minimum.
FS.Lo
sets off alarm signal when the temperature falls below
setpoint to a pre-set temperature above scale minimum.
Select level 1
and set the required setpoint value (y°).
If the factory set hysteresis 2.0°C/3.6°F is unsuitable:
Index to
and adjust the setting.
Check
is set to
on.oF
(for alarm).
Exit program mode. SP2 is now operational as an alarm.
CooL
see heat-cool configuration, page 23.
Second Setpoint
SECOND SETPOINT (SP2)
Y°
✱
✱
✱
✱
Deviation
high alarm
Deviation
low alarm
Deviation
band alarm
Alarm
state
SP
setpoint
Y°
Y°
Y°
SP
setpoint
SP
setpoint
Y°= SP2
set value
Y°
✱
✱
Full scale
high alarm
Full scale
low alarm
SP
setpoint
SP
setpoint
Y°
12
SP2.A
NONE
SET.2
0
BND.2
CYC.2
Second Setpoint
SUBSIDIARY SP2 MODE:
Latch/sequence or non-linear cool.
Latch alarm
LtCh
When activated, the alarm latches until manually reset, even
though the alarm condition may have disappeared.
Sequence alarm
hoLd
When
hoLd
is selected, in any alarm mode, it prevents an
alarm signal on power-up. The alarm is enabled only after
the process temperature has reached setpoint.
TO CONFIGURE SP2 AS A PROPORTIONAL
CONTROL OUTPUT
In level 2 select
then select the required option.
In level 1 select
and then set the required proportional band.
In level 1 select
and then set the setpoint (SP2) value (y°).
SP2 OUTPUT AND LED INDICATION STATES - IN
ALARM CONDITION
SP2 ALARM ANNUNCIATOR
When an SP2 alarm mode is selected in SP2.A the alarm
annunciator
-AL-
is displayed, alternating with the process
temperature, during alarm condition.
Note: The annunciator may be disabled by selecting
function
and option onin level 4.
SP2 in cool strategy
(See heat-cool configuration in ADVANCED SETTINGS page 23).
✱
Without sequence
alarm
Alarms on
power up
SP
setpoint
Y°
✱
Y°
SP
setpoint
SP
setpointSPsetpoint
No alarm on
power up
With sequence alarm
Alarm
enabled
Alarm operates
normally
Alarm type ON-OFF
operating mode
Proportional
operating mode
FS.HI
COOL
FS.LO
BAND
DV.LO
DV.HI
Deviation
Full scale
Strategy
SP2
Output state
SP2
LED state
SP2
Output state
SP2
LED state
BAND
: on-off mode only
Output ON
(Relay or SSd energised)
Output OFF
(Relay or SSd de-energised)
LED ON
Temperature above setpoint
13
SP2.B
SP2.A
BND.2
SET.2
NO.AL
ON
Error Messages
ERROR MESSAGES
Temp
Setpoint
Cycle
75% SP
Start
TUNE
TUNE
Tuning
DAC
PID
New PID
values
entered
Time
(100% output)
oS 1
oS 2
Ct A
Ct b
Ct 3
Ct 4
uS
Ct 1
Ct 2
SENSOR FAULT
Upper display alternates:
inPt
and
FAiL
Indicates: thermocouple burnout RTD/Pt100 open or
short circuit or negative over-range.
Action: Check sensor/wiring
NON-VOLATILE MEMORY ERROR
Upper display alternates:
dAtA
and
FAiL
Action: De-power briefly. Replace unit if problem
persists
MANUAL POWER ERROR
Upper display alternates:
hAnd
and
FAiL
SP1 set to ON/OFF in
CYC.t
Action: Select proportional mode
IMMEDIATE FAIL ON AUTOTUNE START
Upper display alternates:
PV tunE
and
FAiL
Lower display 0
1. No setpoint entered.
Action: Enter setpoint
2. SP1 set to ON/OFF in
Action: Select proportional mode
Note: To reset and clear error press ▲▼ together
briefly to cancel message.
FAIL LATER DURING AUTOTUNE CYCLE
The thermal characteristics of the load exceed the
Autotune algorithm limits. The failure point indicated
by any display 0.0 in
e.g. Ctb = 0.0 see adjacent diagram.
Action: 1. Change the conditions. eg. raise setpoint
2. Try
3. Check SP1.P percentage power
(see IMPROVING CONTROL ACCURACY)
4. If the error message persists, call CAL
for advice.
READING AUTOTUNE TUNING CYCLE
RESULTS IN
tECh
1. Index to
release ▲ or ▼, lower display will alternate
Ct.A
and value
2. Keep ✱ pressed and press ▲ once, the lower
display will alternate
Ct.b
and value (eg. 19.6)
3. Repeat step 3 above to view:
Ct 1, Ct 2, Ct 3, Ct 4, oS 1, uS and oS 2.
Autotune tuning data and limits
14
INPT
DATA
HAND
FAIL
0
CYC.T
ON.OF
TECH
TUNE
AT.SP
TECH
CT.A
Improving Control Accuracy
IMPROVING CONTROL ACCURACY
Temp
Maximum
Time
Variance
VAr°
hi°
±0.1°
Minimum
Lo°
The following functions are to assist engineers with
machine development, commissioning and troubleshooting.
READ SP1 OUTPUT PERCENTAGE POWER
Poor control may be due to incorrectly sized heaters.
SP1.P
(Level 2) constantly displays the output
percentage power applied, which at normal setpoint
should ideally be within 20 - 80% to achieve stable
control.
CONTROL ACCURACY MONITOR
This measures the control stability, to within 0.1 °C/°F.
The monitor is started using
CheK
(Level 3) and the
variance (deviation), maximum and minimum temperature
are displayed and constantly updated in
Using the
CheK
Control accuracy monitor
To start the monitor select
Note: During monitoring either return to normal operation
or remain in program mode.
To view monitor readings: index to
The lower display will alternate between
Var°
and the variance displayed in degrees (e.g. 0.6)
Press and hold ✱ and press ▲ once, the lower display will
alternate between
VAr°
and the maximum
hi°
displayed
in degrees (e.g. 320.3)
Press and hold ✱ and press ▲ once, the lower display will
alternate between
VAr°
and the minimum
Lo°
displayed
in degrees (e.g. 319.7)
CheK oFF
stops monitor retaining readings
CheK on
resets readings.
On de-powering
CheK
resets to
oFF
and
rEAd
is zeroed.
15
SP1.P
CHEK
CHEK
ON
READ
CHEK
OFF
CHEK
ON
READ
Function List
FUNCTION LIST (Levels 1 to 4)
BAND
Too narrow
(oscillates)
increase
Too wide
(slow warm up and response)
decrease
BAND
Note: A Functions Menu is shown on the cover fold-out A3
LEVEL 1
Function Options
[Factory settings] shown in brackets
SELECT AUTOTUNE
[oFF] on ParK At.Sp
Used to switch the Autotune feature on and off, to
select
ParK
or Autotune at setpoint.
ParK
temporarily turns the output(s) off. To use select
ParK
and exit program mode. To disable re-enter
program at
tunE
and select
oFF
.
SP1 OPERATING PARAMETERS
0.1 to * °C/°F [10ºC/18ºF]
SP1 proportional band/Gain or Hysteresis
* 25% sensor maximum
Proportional control eliminates the cycling of on-off
control. Heater power is reduced, by time
proportioning action, across the proportional band.
Function Options
[Factory settings] shown in brackets
oFF 0.1 to 60 minutes [5.0]
SP1 integral time/reset
Auto-corrects proportional control offset error
oFF 1 - 200 seconds [25]
SP1 derivate time/rate
Suppresses overshoot and speeds response to
disturbances
0.5 - 5.0 x bAnd [1.5]
SP1 derivative approach control dAC
Tunes warm-up characteristics, independent of normal
operating conditions, by controlling when derivative
action starts during warm-up (smaller dAC value =
nearer setpoint).
Too short
(overshoots and oscillates)
Too long
(slow warm up and response)
Too short
(slow warm up and response,
under corrects)
Too long
(oscillates and over corrects)
*
*
disturbance
Too small
(overshoots)
Too large
(slow stepped warm up)
16
TUNE
BAND
INT.T
DER.T
DAC
Function List
Function Options
[Factory settings] shown in brackets
A - - on.oF 0.1 - 81 sec [20]
SP1 proportional cycle-time (see pages 9/10)
Determines the cycle rate of the output device for
proportional control. Select
on.oF
for ON/OFF mode.
[0] to * °C/°F
SP1 offset/manual reset
* ±50%
bAnd
. Applicable in proportional and ON/OFF
mode with integral disable:
Int.t oFF
.
[oFF] on
Lock main setpoint
Locks the setpoint preventing unauthorised
adjustment.
PROGRAMMER SETTINGS (see page 11)
[0] to 9995 deg/hour
Sets the ramp rate
on [oFF] hoLd
Switches the ramp on or off, or hold at last ramp value
[oFF] 0 to 1440 min
Sets the soak time
SP2 OPERATING PARAMETERS (see pages 12/13)
Function Options
[Factory settings] shown in brackets
0 to * °C/°F [0]
Adjust SP2 setpoint
* Deviation Alarms
DV.hi, DV.Lo, bAnd
25% sensor maximum (see figure 7).
* Full scale alarms
FS.hi, FS.Lo
sensor range f/s (see figure 8)
0.1 - * °C/°F [2.0 °C/3.6°F]
Adjust SP2 hysteresis or proportional band/gain
(see
CyC.2
setting)
* 25% sensor f/s
[on.oFF] 0.1–81 seconds
Select SP2 ON/OFF or proportional cycle-time
Select on.oFF for ON/OFF mode, or the cycle rate of
SP2 output device for proportional mode.
17
LEVEL 1 (continued)
CYC.T
OFST
SP>LK
SPRR
SPRN
SOAK
SET.2
BND.2
CYC.2
Function List
LEVEL 2
Function Options
[Factory settings] shown in brackets
MANUAL CONTROL MODES
0 to 100 % ‘read only’
Read SP1 output percentage power
[oFF] 1 to 100 % (not in ON/OFF)
SP1 manual percentage power control
For manual control should a sensor fail.
Record typical
SP1.P
values beforehand.
100 to 0 % duty cycle [100]
Set SP1 power limit percentage
Limits maximum SP1 heating power during warm-up
and in proportional band.
100 to 0 % duty cycle [100]
Set SP2 percentage power limit (cooling)
SP2 OPERATING MODES (see page 12/13)
[nonE] dV.hi dV.Lo bAnd FS.hi FS.Lo Cool
Main SP2 operating mode
Function Options
[Factory settings] shown in brackets
[nonE] LtCh hoLd nLin
Subsidiary SP2 mode: latch/sequence
Non-linear cool proportional band
INPUT SELECTION AND RANGING
[1] 0.1
Select display resolution: for display of process
temperature, setpoint,
OFSt, Set.2, hi.SC, LoSC
.
sensor minimum [sensor maximum]
°C/°F
Set full scale
[sensor minimum] sensor maximum
°C/ºF
Set scale minimum (default 0°C or 32°F)
Select input sensor
[nonE]
(See SENSOR SELECTION table, page 31)
[nonE] °C °F bAr Psi Ph rh SEt
Select °C/°F or process units
18
SP1.P
HAND
PL.1
PL.2
SP2.A
DISP
HISC
LO.SC
INPT
UNIT
SP2.B
Function List
Sensor burn-out/break protection
Caution: Settings affect fail safe state.
SP1 SP2
[uP.SC]
Upscale Upscale
dn.SC
Downscale Downscale
1u.2d
Upscale Downscale
1d.2u
Downscale Upscale
Select output modes: Direct/Reverse
Caution: Settings affect fail safe state.
SP1 SP2
[1r.2d]
Reverse Direct
1d.2d
Direct Direct
1r.2r
Reverse Reverse
1d.2r
Direct Reverse
Select Reverse on SP1 for heating and Direct for
cooling applications.
19
LEVEL 3
OUTPUT CONFIGURATION
Note: ‘Read only’ after initial configuration.
rSET ALL
full reset to
factory settings required to change subsequently.
Function Options
[Factory settings] shown in brackets
[nonE] rLY SSd rLY1 rLY2 SSd1
Select SP1 output device
[nonE] SSd rLY rLY2 rLY1 SSd2
Read SP2 output device
(read only)
Dual Relay and Dual SSd output options Models 9411
and 9422 are factory set. See page 22
Note: (when in initial configuration only)
Hold ✱ and ▲ or ▼ for 10 seconds to move to or from
output devices in shaded portion.
SP1.D
BURN
REU.D
SP1.D
SP2.D
Function List
Function Options
[Factory settings] shown in brackets
Select SP1/2 LED indicator modes
SP1 SP2
[1n.2n]
Normal Normal
1i.2n
Invert Normal
1n.2i
Normal Invert
1i.2i
Invert Invert
[0.0] to ±25% sensor maximum
Sensor span adjust
For recalibrating to a remote standard e.g. External
Meter, data logger. See ADVANCED SETTINGS page
24,25.
[0.0] to ±25% sensor f/s
Zero sensor error, see SPAn
[oFF] on
Select control accuracy monitor
[Var] hi Lo
Read control accuracy monitor
20
LEVEL 3 (continued)
F
unction Options
[Factory settings] shown in brackets
[Ct A] CT b Ct 1 Ct 2 Ct 3
Ct 4 oS 1 uS oS 2
Read Autotune tuning cycle data (see figure, page 14)
Software version number
[nonE] ALL
Resets all functions to factory settings
Caution: Note current configuration before using this
function, otherwise initial configuration and
OEM settings must be re-entered.
REU.L
TECH
VER
RSET
SPAN
ZERO
CHEK
READ
Function List
LEVEL 4
Access to level 4 is gained through in level 3.
Press and hold ▲ and ▼
for 10 seconds.
Enter level 4 at
Lock
, release ▲ and ▼ together.
Display reads
Program security using Lock
Select from three
Lock
options:
Press and hold ✱, press ▲ to index.
LEV.3
locks level 3 and 4 only- Technical Functions.
LEV.2
locks levels 2, 3 and 4 only - Configuration and
Technical Functions.
ALL
locks all functions
Note: Locked functions and options may be read.
Function Options
[Factory settings] shown in brackets
Press ▼ to access following functions
[Auto] StAY
Program mode auto-exit switch
Auto-exit returns display to normal if 60 seconds of
key inactivity, select
StAY
to disable
[oFF] on
Disable SP2 alarm annunciator -ALSelect on to disable -AL-
dir 1 to 32 [6]
Display sensitivity
dir
= direct display of input
1
= maximum, 32= minimum sensitivity
0.1 to 1.0 [0.5]
Derivative sensitivity
21
IMPORTANT NOTE FOR OEM’s: For safety and to protect settings from tampering
USE THE SOFTWARE SECURITY LOCK.... THEN REMOVE THIS SECTION.
✂
VER
PROG
NO.AL
DIS.S
DER.S
LOCK
NONE
LOCK
ALL
FACTORY SET OUTPUT OPTIONS
22
DUAL RELAY OR DUAL SSd OUTPUT MODELS
The table below details the factory set output options. rLY2 is a 1A
electromechanical relay, and SSd1/SSd2 is an identical second SSR
drive output.
QUICK START (page 1a) or SET-UP (page 5) follow steps 1
and 2 ignore step 3 and proceed straight to step 4.
Factory Option 9411 offers the ability to change the allocation of
SP1 to terminals 5 and 6.
To make this selection during the initial configuration in either
QUICK START (page 1b) or SET-UP (page 5), start from step 3.
3 TO SELECT SP1 (Main setpoint output device)
From the display
press and hold ✱ button then press the ▲ once
to display
rLY2
in the lower display.
Product
Code
Terminals
34 56
9411
9422
rLY1 (2A) rLY2 (1A)
SSd1 SSd2
(+) (-) (+) (-)
Factory Options 9411 and 9422 pre-allocate SP1 to
terminals 3 and 4.
Note: Output device rLY/rLY1 is rated 2A
Output device rLY2 is rated 1A
SP1D
RLY1
Advanced Settings
Before embarking on the Advanced Settings, please
familiarise yourself with the basic operation of the controller
as described in this manual. The following instructions
assume that the user understands how to make the initial
configuration, can navigate through the Function Menu and
successfully Autotune the controller in heating mode.
HEAT COOL STRATEGY CONFIGURATION
Using
Cool
option
Heat-Cool strategy is a feature that improves control of processes
that need heating and cooling, depending on the conditions, for
example:
Environmental test chambers used in rooms where the
ambient temperature swings above and below the test
temperature.
Plastics extruders where the material initially needs
heating, then cooling, when it begins to heat itself
exothermically due to pressure and friction applied by the
process.
The purpose of cool strategy is to maintain smooth control
of the process during transition from heating to cooling.
This is achieved by using PID control for heating and cooling with the
proportioning bands linked by an adjustable deadband.
From cold (normal procedure on a new installation)
Enter setpoint and allow the process to reach the setpoint using
factory settings for heating only.
Autotune at setpoint
Make the following pre-settings:
Level 1 set to
1.0
to 10and to
10
Level 2 set to
Cool
Level 1 set to
At.SP
Autotune will cause a temporary disturbance. Check that the
temperature has stabilised in heating mode before running the
process in cooling mode.
If regular temperature oscillations occur, change
CYC.t
to optimum
value. See page 9. To select Autotune Calculated Cycle-time
Further adjustments – Cooling
Autotune uses the same calculated
bAnd
value for both
SP1
(heating) and
SP2
(cooling). In some processes, regular temperature
oscillations occur when cooling.
Make the following manual adjustment:
In level 1 double the value of
ADVANCED SETTINGS
23
SP2.A
DAC
SP2.A
TUNE
CYC.T CYC.2
BND.2
Advanced Settings
Heat Cool Strategy Configuration (continued)
If no improvement, return to the original value and;
In level 1 halve the value of
If the process hunts between heating and cooling, a
deadband setting may be needed. Enter a small value,
eg. 1 and observe the process. Increase the setting until
hunting stops.
Level 1 adjust value
Water cooled applications
Water cooled applications operating at temperatures greater than
100°C may suffer from the non linear effect caused by water turning
to steam. This can be countered by the non linear setting for SP2;
In level 2 set to
nL in
Multi zone applications
When tuning multi zone applications like extruders, distortions due
to thermal interaction between adjacent zones can be minimised by
running autotune on all controllers at the same time.
CALIBRATION TO ANOTHER INSTRUMENT
If the controller and instrument readings are different, the
and/or function in Function Menu Level 3
will require adjustment.
Adjust
to make an equal adjustment across the full scale
of the controller and
to make a correction when the error increases/
decreases across the scale.
1 To adjust using the function
1.1 Substitute measured values in the expression:
Instrument reading – controller reading =
Example:
Instrument reading = 396°
Controller reading = 400°
396 – 400 = (-)4°
1.2 Adjust to (-) 4° to correct error.
24
CYC.2
ZERO
SPAN
ZERO
ZERO
ZERO
ZERO
SPAN
SET.2
SP2.B
Advanced Settings
2.5 Therefore adjust
SPAn
to (-) 18 to correct error.
Notes: (1) After making the adjustment the reading will
immediately change. Allow time for the temperature
to stabilise at T2before making any further adjustment.
At this point, a
ZEro
adjustment may be needed, refer
to step 1 above.
(2) Check that the temperature correctly stabilises at T
2
and then adjust setpoints to T1. If an error is present
at T1repeat from step 2.
LINEAR INPUT CALIBRATION
In addition to the ten temperature inputs, the controller has five
linear input ranges which can be calibrated to display a range of
engineering units. This procedure involves making adjustments to
the controller’s
hi.SC, ZEro
and
SPAn
adjustments found in
function menu levels 2 and 3.
Note: The controllers linear inputs are in mV. If your transducer
provides an output in mA this should be converted to mV
by feeding the controller input via a high stability one ohm
resistor, see figure page 26. Other low Vdc signals can be
connected via a suitable voltage divider network to match
the controller input requirements.
Calibration to Another Instrument (continued)
To make a correction when there are different errors across the scale.
2 Adjust using the function
2.1 Chose a temperature near the bottom and
another near the top of the scale.
2.2 Run the process at the lower temperature (T
1
).
Note the error (E1) between the controller and the
instrument readings.
2.3 Repeat at the upper temperature (T2) and note
error (E2).
2.4 Substitute the values for T1, T2, E1and E2in the
expression below to calculate
E2-E1X
hi.SC = SPAn
T2-T
1
For
hi.SC
settings see level 2.
Example: T
1
T
2
Instrument reading 58° 385°
Controller reading 60° 400°
Error E1(-) 2° E2(-) 15°
(-15) - (-2) x 450 = (-13) x 450 = (-)17.9
385 - 58 327
25
SPAN
SPAN
Advanced Settings
3 Allocate the output devices at function
as described in
SET-UP
, enter the configuration
into the memory and proceed as follows:
Calculate the values for the controller settings
for and using the example below
as a guide:
4 to 7mV input from transducer is required to
display 0 - 110 units
Chose Linear Range Lin4 4-20mV = 0 to 1000 units.
HI.SC = Nominal Signal Span x required span
actual signal span
(20-4) x (110-0) = 587
(7-4)
SPAN = (
hi.SC
- nominal scale span) x
hi.SC
Nominal Scale Span
(587-1000) x 587 = -242
1000
These settings should provide the correct scaling adjustment, but a
value for
ZEro
may need to be established by applying the lowest
and highest mV input signal and recording the display offset. Check
that this is the same at each end, and enter this plus or minus value
as a
ZEro
adjustment. Should there be a difference between the
two readings, a further adjustment of the
SPAn
setting can be made.
1 Power up the controller, and in response to
the prompt
select an appropriate Linear Range from
the table below.
Ensure that the Nominal Signal Span chosen is wider
than the transducer’s actual signal span, and the
Nominal Scale is wider than the full scale of the
engineering units to be displayed.
2 Select
then select the process unit,
°C,°F,Bar,PSI
,
Ph
, orrh. If the required unit is not shown
select
Set
.
Linear Range
Lin 1
Lin 2
Lin 3
Lin 4
Lin 5
Nom. Signal
Span
0–20 mV
4–20 mV
0–20 mV
4–20 mV
0–20 mV
Nom. Scale
Span
0 – 100
0 – 100
0 –1000
0 – 1000
0 – 2000
Max. Scale
Settings
0 – 400
-25 to 400
0 to 3000
-250 to 3000
0 to 3000
26
1 2 3 4 5 6 7 8
LN
5Vdc
15mA
+
–
+
–
9 10 11 12 13 14 15 16
Supply
1 ohm
4–20 mA
from transducer
Outputs
Linear Input Calibration (continued)
INPT
NONE
SP1.D
HI.SC
HI.SC
SPAN
SPAN
UNIT
Mechanical Installation
The 9400 Controller is designed to be mounted in a 1/16 DIN panel
cutout.
The unit is sleeve mounted with the front bezel assembly rated
NEMA4/IP66 provided that:
● the panel is smooth and the panel cutout is accurate;
● the mounting instructions are carefully followed.
DIN PANEL CUTOUT
1/16 DIN panel cutout size
45.0mm +0.6mm -0.0mm (1.77in. +0.02in. -0.0in.) wide
45.0mm +0.6mm -0.0mm (1.77in. +0.02in. -0.0in.) wide
9.5mm (0.374in) maximum panel thickness.
MINIMUM SPACING
MECHANICAL INSTALLATION
27
10 mm
(0.39)
20 mm
(0.79)
Mechanical Installation
MOUNTING
To mount a Controller proceed as follows:
1 Check that the controller is correctly orientated and
then slide the unit into the cutout.
2 Slide the panel clamp over the controller sleeve
pressing it firmly against the panel until the controller is
held firmly.
3 The controller front bezel and circuit board assembly
can be unplugged from the sleeve. Grasp the bezel
firmly by the recesses on each side and pull. A
screwdriver can be used as a lever if required.
4 When refitting the bezel assembly it is important to
press it firmly into the sleeve until the latch clicks in
order to compress the gasket and seal to NEMA4X/IP66.
Cleaning
Wipe down with damp cloth (water only)
28
44.8
(1.76)
44.8
(1.76)
106.7 (4.2)
with gasket fitted
51.0 (2.0)
includes gasket
51.0
(2.0)
includes
gasket
116.2
(4.57)
Model 9400
Dimensions in mm (inches)
Note: The controller should be isolated
before removing or refitting it in the sleeve,
and electrostatic precautions should be
observed when handling the controller
outside the sleeve.
Electrical Installation
OUTPUT DEVICES
Two of the following output devices are fitted to the controllers,
depending on the model.
1 Solid state relay drive (SSd/SSd1/SSd2)
5Vdc +0/-15%, 15mA non isolating
To switch a remote SSR (or logic)
2 Miniature power relay (rLY/rLY1)
2A/250V resistive, Form A/SPST contacts.
3 Sub miniature power relay (rLY2)
1A/250V resistive, Form A/SPST contacts.
OUTPUT DEVICE ALLOCATION
Either of the available outputs may be chosen for the main setpoint
(SP1), the remaining device being automatically allocated to the
second setpoint (SP2).
See example illustrated on page 30.
STANDARD MODEL 9400
Output Device 1 + Output Device 2
DUAL RELAY MODEL 9411
Output Device 2 + Output Device 3
DUAL SSd MODEL 9422
Output Device 1 + Output Device 1
Dual relay or dual SSd model options 9411/9422 are fully detailed
on page 22.
ELECTRICAL INSTALLATION
29
Designed for use with the following supply voltages:
100 - 240V 50-60 Hz 4.0 VA (nominal)
+/-10% maximum permitted fluctuation
12V - 24V (AC/DC) +/-20% 4.5 VA Polarity not required
WIRING THE CONNECTOR
Prepare the cable carefully, remove a maximum of 8mm insulation
and ideally tin to avoid bridging. Prevent excessive cable strain.
Maximum recommended wire size: 32/0.2mm 1.0mm2(18AWG).
INDUCTIVE LOADS
To prolong relay contact life and suppress interference it is
recommended engineering practice to fit a snubber
(0.1uf/100 ohms), refer to illustration on page 30.
CAUTION:
Snubber leakage current can cause some electro-mechanical
devices to be held ON. Check with the manufacturers
specifications.
Electrical Installation
30
ELECTRICAL INSTALLATION
(continued)
EN61010 - /CSA 22.2 No 1010.1 92
Compliance shall not be impaired when fitted to the final
installation.
Designed to offer a minimum of Basic Insulation only.
The body responsible for the installation is to ensure that
supplementary insulation suitable for Installation Category II or III is
achieved when fully installed.
To avoid possible hazards, accessible conductive parts of the final
installation should be protectively earthed in accordance with
EN6010 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.
A clear instruction shall be provided not to position the equipment
so that it is difficult to operate the disconnecting device.
MODEL 9400
TYPICAL CONNECTION DIAGRAM
The ssr driver output is allocated to SP1 and wired to switch the
load (heater) using an SSR
F1 Fuse: time lag type to IEC127. CSA/UL rating 250Vac
F2 Fuse: High Rupture Capacity (HRC) Suitable for
maximum rated load current
S1 Switch: IEC/CSA/UL Approved disconnecting Device
Comms option
(when fitted)
1 2 3 4 5 6 7 8
LN
5Vdc
15mA
+
–
+
–
12 13 14 15 16
Sensor
Output
SP1
SP2
Output
SSR
+
–
S1
Sensor
Supply
Line
Open in
alarm
state
9 10 11
Load
F2
F1
Neutral
Sensor Selection
Option/Sensor type Sensor range Linearity
Thermocouples
tc b B 0 to 1800 °C 32 to 3272 F Pt-30%Rh/Pt-6%Rh 2.0 *
tc E E 0 to 600 °C 32 to 1112 F Chromel/Con 0.5
tc J J 0 to 800 °C 32 to 1472 F Iron/Constantan 0.5
tc K K -50 to 1200 °C -58 to 2192 F Chromel/Alumel 0.25*
tc L L 0 to 800 °C 32 to 1472 F Fe/Konst 0.5
tc n N -50 to 1200 °C -58 to 2192 F NiCrosil/NiSil 0.25*
tc r R 0 to 1600 °C 32 to 2912 F Pt-13%Rh/Pt 2.0*
tc s S 0 to 1600 °C 32 to 2912 F Pt-10%Rh/Pt 2.0*
tc t T -200 / 250 °C -273 / 482 F Copper/Con 0.25*
Resistance thermometer
rtd -200 / 400 C -273 / 752 F Pt100/RTD-2 0.25*
Linear process inputs (Input mV range: 0 to 50mV)
Displays 0 - 20mV 4 - 20mV setpoint limits
Lin1
0 - 100 0 - 400 ± 0.5%
Lin2
0 - 100 -25 - 400 ± 0.5%
Lin3
0 - 1000 0 - 3000 ± 0.5%
Lin4
0 - 1000 -250 - 3000 ± 0.5%
Lin5
0 - 2000 0 - 3000 ± 0.5%
Notes: 1 Linearity: 5-95% sensor range
2* Linearity B:5° (70º - 500°C) K/N:1° >350°C exceptions: R/S: 5°<300°C T:1° <- -25° >150°C RTD/Pt100: 0.5° <-100°C
SENSOR SELECTION
31
Specification
Thermocouple
9 types
Standards: IPTS/68/DIN 43710
CJC rejection: 20:1 (0.05°/°C) typical
External resistance: 100Ω maximum
Resistance thermometer
RTD-2/Pt100 2 wire
Standards: DIN 43760
(100Ω 0°C/138.5Ω 100°C Pt)
Bulb current: 0.2mA maximum
Linear process inputs
mV range: 0 to 50mV
Applicable to all inputs SM = sensor maximum
Calibration accuracy: ±0.25%SM ±1°C
Sampling frequency: input 10Hz, CJC 2 sec.
Common mode rejection: Negligible effect up to 140dB,
240V, 50-60Hz
Series mode rejection: 60dB, 50-60Hz
Temperature coefficient: 150ppm/°C SM
Reference conditions: 22°C ±2°C, rated voltage after 15
minutes settling time.
Output devices
SSd/SSd1/SSd2: solid state relay driver: To switch a
remote SSR 5Vdc +0/-15% 15mA
non-isolated
Miniature power relay: form A/SPST contacts (AgCdO)
rLY and rLY1: 2A/250ac resistive load
rLY2: 1A/250ac resistive load
General
Displays: Upper, 4 Digits, high brightness
green LED. 10mm (0.4”) high.
Lower, 4 Digits, Orange LED. 9mm
(0.35”) high
Digital range -199 to 9999
Hi-res mode -199.9 to 999.9
LED output indicators - flashing
SP1 square, green; SP2 round, red
Keypad: 3 elastomeric buttons
Environmental
Humidity: Max 80%
Altitude: up to 2000M
Installation: Categories ll and lll
Pollution: Degree ll
Protection: NEMA 4X, lP66
EMC emission: EN50081-1 FCC Rules 15 subpart J
Class A
EMC immunity: EN50082-2
Ambient: 0-50ºC (32-130°F)
Mouldings: flame retardant polycarbonate
Weight: 130g (4.2 oz)
SPECIFICATION
32
Copyright CAL Controls Ltd. 1997
Not to be reproduced without prior written permission from
CAL Controls Ltd. Whilst every effort has been made to ensure
the accuracy of the specifications contained in this manual,
due to our policy of continuous develpment, CAL Controls Ltd
reserves the right to make changes without prior notice.
CAL Controls
Temperature Controllers
CAL Controls
Temperature Controllers
CAL Controls Ltd
Bury Mead Road, Hitchin, Herts, SG5 1RT. UK
Tel: + 44 (0)1462-436161 Fax: + 44 (0)1462-451801
email: support@cal-controls.co.uk
http://www.cal-controls.com
CAL Controls Inc
1580 S.Milwaukee Avenue, Libertyville, IL 60048. USA
Tel: (847) 680-7080 Fax: (847) 816-6852
000M06/33014/1/0798
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