Page 1
The CAL 9500P
Programmable
Profiling
Temperature &
Process Controller
SL000272 33061/01/0900
Ordering information codes
Code
Model 48 x 48 mm 95
Outputs SSd / relay 00
relay / relay 11
SSd / SSd 22
4-20mA / relay B1
4-20mA / ssd B2
0-5V / relay C1
0-5V / ssd C2
0-10V / relay D1
0-10V / ssd D2
Output 3 Always relay 1
Programmer P
Inputs Sensor A
4-20mA B
0-5V C
0-10V D
Communications None fitted 0
RS232 fitted 2
RS485 fitted 4
Unused 00
Ordering example 1
Model 9500P ssd/relay/relay outputs
4-20mA input, RS485 fitted
95 00 1 P B 4 00 95 B2 1 P A 0 00
Ordering example 2
Model 9500 with 4-20mA/ssd/relay
outputs, sensor input, no comms
Codes for additional software and hardware
CALCOMMS charting & logging software
CALCOMMS CD Rom demo-disk
Communications board RS232
Communications board RS485
RS232 to RS485 converter
CALopc OPC server
CALpoll
10 01 XX 3 0 0
000124
3C 00 00 2 0 0
3C 00 00 4 0 0
3C 24 00 0 0 0
10 01 GB S 0 0
Available on the web
Temperature Controllers
This low-cost range is dedicated for
temperature control and also has the
added options for RS232 & RS485
communications boards. All controllers
have P.I.D. control, autotune, heat-cool
strategy and a single ramp-soak profile.
Solid State Relays
This range of solid-state relays completes
the solution from sensors to control
output. This catalogue shows a range of
hockey-puck style SSRs and the Solitron
range with built-in heat sinks that are easy
to specify and install.
Ask for these brochures for our other product ranges
Temperature Sensors
This comprehensive catalogue is full of
useful information as well as a wide range
of thermocouples and RTDs for all
applications. Also included is a range of
accessories from cables, connectors, glands
to thermowells.
Page 2
The CAL 9500P Programmable Temperature / Process Controller with Communications & Software Support
CAL innovators in control
Established in 1963, CAL is a dynamic and
strong company leading the industry in
single-loop controllers. CAL’s pioneering
spirit established many of today’s world
standards for controllers such as the first
48mm x 48mm (
followed by the first digital controller of the
same size and then the first 24mm x 48mm
1
(
/32NDDIN) controller.
CAL’s range of easy-to-use controllers are
complemented by a suite of software
products for communications, data-logging
and supervisory control.
CAL has developed a reputation based on
product support, innovation and attractivelystyled controllers that enhance our
customers’ equipment, panels and machines.
Note:
Standard colour is Jade
Green, other colours
are subject to minimum
order quantities.
1
/16THDIN) analogue controller,
The CAL 9500P programmable process
controller
The CAL 9500P is a versatile programmable controller
for temperature and process control applications. It is
designed to offer the highest functionality in a 48mm
x 48mm (1/16
TH
DIN) package.
The 9500P can be factory configured in a range of
process control or temperature control options
making the controller dedicated to the application,
ideal for both OEM and manufacturing process
applications.
This combination of programmable ramp/soak profiles,
process control inputs and 3 outputs, together with
RS232 or RS485 comms makes the CAL 9500P a
unique and affordable package.
Controller functionality
●
Full P.I.D. operation
●
Autotune at 75% of set-point or at set-point
●
Heat-cool operation
●
RS232 or RS485 communications options
●
CE, UL & CSA compliant
Inputs
●
Thermocouples & RTD (PT100, 2 or 3 wire)
●
Analogue – 0-20mA, 4-20mA, 0-50mV, 0-5V, 0-10V
Easy to scale input signals
CAL has made the task of scaling inputs very simple:
example: 4-20mA = 60–260 units, where 4mA = 60 units
note: 4-20mA corresponds to an input range of 10-50mV
Step 1, enter scale max’ = 260,
Step 2, enter scale min’ = 60,
Step 3, enter input max’ = 50 (i.e. 50mV = 20mA)
Step 4, enter input min’ = 10 (i.e. 10mV = 4mA).
Outputs (total of three outputs)
●
Solid state relay drive (SSD) and Relays (2 amp)
●
Analogue – 4-20mA, 0-5V, 0-10V
3-year warranty
Programmer functionality
●
Up to 31 programs (profiles)
●
Up to 126 segments
●
Unlimited use of event outputs via the 2nd and 3rd
outputs
●
Copy/Paste/Edit/Delete functions to simplify program
building
●
Call another program as a sub-program segment
●
Up to 999 program loop cycles, or continuous loop
cycling
●
Hold back function, to ensure the next segment is not
started until the last segment reaches the set-point
●
3 power fail recovery options, (Hold, Continue or
Reset)
●
Front panel interrogation of the program position
●
Memory usage indication during programming.
(note: program capacity is a memory function and
different types of segment use more/less memory).
Profile of a single program
Set-point
Segment 1
Subset of the functions list:
●
hoLd Suspends program until run
●
on Run program
●
Edit Insert, delete or copy programs
Power failure modes
●
rSEt Reset to program start
●
Cont Continue from interruption
●
hoLd Hold at interruption
Segment types
●
SPr Ramp to next set-point
●
SoAK Hold set-point for set time
●
StEP Step to new set-point
●
LooP Repeat the program
●
CALL Call up another program
●
E.oP Generate an event output at end of segment
●
Edit Delete or insert a segment
Hold back function
●
hb.u Hold back, this function ‘holds back’ the
Segment 2
RAMP
SOAK
Segment 4
SOAK
Segment 3
STEP
Segment 5
RAMP
Segment 6
SOAK
ramping set-point until the measured value
catches up with the ramping set-point. This
function ensures that the time taken to ramp
does not reduce the next segment.
Segment 7
EVENT
OUTPUT
Time
Memory Allocation Table
Function Memory Usage
Ramp 4 Bytes
Ramp with Holdback 5 Bytes
Soak 2 Bytes
Step 3 Bytes
Loops (1-3) 1 Byte
Loop (4+) 2 Bytes
Call 1 Byte
Event Output 1 Byte
Program Header 1 Byte
Examples:
Maximum capacity; 351 Bytes, 126 segments per
program, 31 programs
Example 1 (349 Bytes)
One program of 116 segments
(58 ramps, 58 soaks)
Example 2 (340 Bytes)
4 programs of 28 segments
(14 ramps, 14 soaks)
Example 3 (341 Bytes)
31 programs of (ramp-soak-ramp)
The above ramps are without hold-back option
Set-point
Seg. 1
from 1 to 999 cycles
e.g. loop for 25 cycles
RAMP
Segment 4
Program LooP
Seg. 2
SOAK
Seg. 3
RAMP
Seg. 5
RAMP
Segment 6
Program CALL,
to call another program
e.g. Call Prog 5
Then go to 7
Seg. 7
SOAK
The CAL 9500P is potentially the most versatile and
flexible controller in its size and price range. The
above program shows what is possible from this
unique controller.
Seg. 8
Seg. 10
RAMP
E.oP Event Output
e.g. Trigger alarm on SP2
SOAK
CONTIN-
UOUS
Time
Segment 9
.
Page 3
Software and Connectivity
Using CAL controllers there’s a wide range of software support products designed to suit different applications.
Product
CALCOMMS
CALopc
CALpoll
CALCOMMSTMChart-recorder, Data-logging & Configuration software for Windows
CALCOMMSTMcharting and logging software is incredibly easy to use. It is designed to connect up to 128 controllers
by RS485 into a standard or industrial PC. This allows the user to program all functions of the controller and to
data-log the recorded process signals.
Description
Ideal for:
For use by:
Typical applications:
License cost
Development cost
Flexibility/versatility
Other comments
Easy to use and install
software application
requiring no design work.
Chart-recorders,
Data-logger,
Alarms
Plant/Process engineers,
Supervisors, Quality control,
System/Machine designers
Quality control, Process
optimisation, Lab equipment
$
$
✔
Only connect to CAL
Designed for simplicity with
many features
Software driver for OPC
client/server applications
such as SCADA.
Large SCADA applications
requiring many inputs other
than CAL
Process engineers,
Plant managers,
SCADA system builders.
Process control,
Manufacturing
$$$
$$$
✔✔✔
Connect to other h/w
User must also purchase the
SCADA software
Example demo program plus
source code to help you
build a custom application.
Custom software
applications dedicated to
one application.
Software engineers with
Visual C experience
OEM machines,
development projects
Gratis/web
$$$$$$
✔✔✔✔✔✔
As flexible as the s/w
For use with Visual C ++
Compiler
Functions
●
Data-logger for archiving process data
●
Chart-recorder for on-screen viewing of trends
●
Virtual instrument display
●
On-screen alarm displays
●
Configuration/programming tool for controllers
●
‘Cloning’ of instrument settings
●
Saving of applications of multiple controller set-ups
●
Remote set-point adjustment
Example of networked
controller configuration
into CALCOMMS
TM
FREE demo-disk
CD demo of CALCOMMS
charting & logging
software
®
Terminology:
SCADA Supervisory Control And Data Acquisition
OPC Object Linking and Embedding for Process Control
OEM Original Equipment Manufacturer
CALopc – OPC server
The CALopc server is a MODBUS RTU software product
designed for integration into OPC client/server
applications such as SCADA.
CALopc includes pre-configured templates for all CAL
controllers, together with controller bitmaps and the
7-segment LED true type font.
Using this OPC server allows ‘tags’ to be added to all
controller functions and built into the SCADA
application enabling the display and changing of any
parameters in a custom configured application for
complete process monitoring and control.
CALpoll – tools for custom software
engineers
CALpoll is a free of charge software product
available from www.cal-controls.com It includes an
example program and source code in Visual C++.
It is ideal for use by software engineers who wish to
create custom applications that need to
communicate with CAL controllers via the MODBUS
RTU protocol.
The source code includes routines for
communicating via MODBUS saving the software
engineer significant development time. The example
program also doubles as an ideal diagnostic tool for
proving that the communications hardware is set up
correctly.
For further details please contact CAL.
COM
port
RS 485 multidrop
connection from PC
to controllers
0
0
5
9
CAL
Relay
SSd
4-20mA
4-20mA
sensor
Flow Control
Ideal for:
Recording process data for manufacturing reporting,
quality control, health & safety purposes, or OEM
system development.
RS 485 – MODBUS RTU
– up to 128 controllers
CAL
Relay
Relay
4-20mA
sensor
Level Control
Applications:
Food industry, Dairy industry, Rubber & Plastics
manufacturing, Ovens, Furnaces, Kilns, Plastics
machines, Laboratory and Scientific equipment,
Bottling and beverage production and many other
process industries.
0
0
5
9
Relay
0
0
5
9
CAL
Relay
SSd
SSd
3-wire
PT100
Temperature Control
95
CAL
Relay
0-10V
0-10V
Pressure Control
0
0
Relay
.
.
Page 4
CAL 9500P Specifications
Thermocouple
9 types: B, E, J, K, L, N, R, S, T
Standards: IEC 584–1–1 : EN60584–1
CJC rejection: 20:1 (0.05°/°C) typical
External resistance: 100Ω maximum
Resistance thermometer
RTD/Pt100 2 or 3 wire
Standards: IEC751: EN60751 (100Ω 0°C/138.5Ω 100°C Pt)
Bulb current: 0.2mA maximum
Analogue process inputs 0 to 50mV, +/- 0.1%. 0-20mA, 4-20mA, +/- 0.1%. 0-5V, +/- 0.1%. 0-10V, +/- 0.1%
Applicable to all Thermocouple and RTD 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: 50ppm/°C SM typical
Reference conditions: 22°C +/- 2°C, rated voltage after 15 minutes settling time.
Output devices
SSd1 and SSd2: Solid state relay driver: To switch a remote SSR 6Vdc (nominal) 20mA non-isolated
Relay 1,2,3 Miniature power relay: Form A/SPST contacts (AgCdO): 2A/250Vac resistive load
Analogue output: 4–20mA 500Ω max +/- 0.1% full scale typical
(check configuration)
0–5Vdc 10mA (500Ω min) +/- 0.1% full scale typical
0–10Vdc 10mA (1KΩ min) +/- 0.1% full scale typical
Technical Specifications
Typical Application
In this example the load temperature is monitored by a
temperature transducer/transmitter which provides a
4–20mA input signal to the controller. The 4–20mA output
has been allocated to SP1 to drive an SCR power
controller providing a phase angle controlled output to
the heater.
F1 Fuse: 1A 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.
4–20mA
Transducer
Mains
Heater
Analogue
power
controller
(+)
L
N
S1
(–)
17 18 19
4–20mA
Model 95B11P
INPUT
(–)
123456 78
User configurable
alarms
20 21 22 23 24
B – – –
(+)
F1
F2
LN
General
Displays: Upper, 4 Digits, high brightness green LED. 10mm (0.4”) high.
Lower, 4 Digits, high brightness orange LED 9mm (0.35”) high.
Digital range -199 to 9999. Hi-res mode -199.9 to 999.9.
LED output indicators - SP1 square, green; SP2/SP3 round, red
Keypad: 3 elastomeric buttons
Programmer functions:
Segments: Total of 126 per program
Programs: Maximum of 31 programs
Program memory: 351 Bytes (see memory allocation table)
Environmental
Humidity: Max 95% non-condensing
Altitude: up to 2000M
Installation: Categories ll and lll
Pollution: Degree ll
Protection: NEMA 4X, lP66 (Front panel only)
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: 180g (6.4 oz)
Safety: EN61010–/CSA22.2 No 1010.1 92 (see users manual)
Dimensions
Front facia: 51.0 x 51.0mm (2.0” x 2.0”) (includes gasket)
Sleeve length: 106.7mm (4.2”) (with gasket fitted)
Instrument body: 44.8 x 44.8mm (1.76” x 1.76”)
Overall length: 116.2mm (4.57”)
Model 9500P
(48x48mm) 1/16 DIN
51.0
(2.0)
includes
gasket
51.0 (2.0)
includes gasket
Dimensions in mm (inches)
116.2
(4.57)
44.8
(1.76)
44.8
(1.76)
106.7 (4.2)
with gasket fitted
Supply Voltage: 100–240Vac, 50–60Hz +/- 10% maximum permitted fluctuation
Power Requirements: 6.0VA (nominal)
.
9500P with COMMS board fitted
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