CAL Controls 9500P Operating Manual

Users Manual

CAL 9500P

Programmable

Process Controller

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CAL Controls

INDEX INSTRUMENT PANEL FEATURES

INSTRUMENT PANEL FEATURES 2 FUNCTIONS MENU 3 GETTING STARTED 4

Initial Set-up 4

AUTOTUNE 4

Tune or tune at setpoint program 5

PROPORTIONAL CYCLE-TIME 5

Cycle-time recommendations 5

SECOND AND THIRD SETPOINTS (SP2 and SP3) 5

Error messages 6

LINEAR INPUT 6

Set-up procedure 6

FUNCTION LIST 7

Level 1 7
Level 2 7
Level 3 8
Output Options Table 8
Re-transmission 8
Level 4 9
Level A 10

PROGRAMMER 11

Function overview 11
Getting started (Programmer) 12
Program run mode 12
Display functions 12
Example program 13
Function map 14
Function list 16
Memory allocation table 17
Memory full indicator 17
Programming example 18
Program edit example 18

MECHANICAL INSTALLATION 19

DIN panel cut-out 19
Mounting 19
Cleaning 19

ELECTRICAL INSTALLATION 19

Typical application 20
Input options (diagrams) 21
Output options (diagrams) 21

INPUT SENSOR SELECTION 22

Temperature sensors 22
Linear input 22

SPECIFICATION 22
SAFETY AND WARRANTY 23

2

Right Red LED:

Program Holdback
indicator

Orange Display:

Setpoint value or
program selection

Green LED:

Setpoint 1 output indicator

Upper Red LED:

Setpoint 2 output
indicator

Lower Red LED:

Setpoint 3 output
indicator

Green Display:

Process variable or

Function/Option

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 units: Press ✱
To increase setpoint: Press ✱ ▲ together
To decrease setpoint: Press ✱ ▼ together
To reset latched alarm or tune fail: Press ▲ ▼ together briefly
To run or Hold a program: Press ✱ ▼ together for 3 seconds

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

inPt : nonE

or, if the initial configuration has been completed, the measured
value. Any settings already completed will be retained. During Program Configuration it
is recommended that this feature is inhibited. Select

ProG StAY

in Level 4.

This page can be photocopied and
used as a visual aid and bookmark when
working in other parts of the manual.

!

English

SINT PCYC SUB.P

Call sub-program number

nonE; 1 to number

of programs

Soak time interval

Cont; 0.1 to 1400

(10) min

Program re-cycle count

Cont; 1 to 999

DER.S DI.SS NO.AL PROG LOCK SET.L

Derivative sensitivity

0.1 to 1.0 x dEr.t (0.5)

Display averaging

dir; 1 to 32 (6)

Disable -AL- alarm

display

; on

Disable program auto-exit

Auto; StAY

Security lock

nonE; LEV 3; LEV 2; ALL

Change program entry point

Off; on

USER-PROTECTED SETTINGS

LEVL 4

SP2 output device

none; SSd; rly; (read only)

Sensor burn-out

uP.SC; dn.SC; 1u.2d; 1d.2u

Zero adjustment

0.0 to 25% sensor

full scale

Set Monitor

Off; on

Read Monitor

VAr; hi; lo deg

Read Tune Data

CtA; Ctb; Ct1; Ct2; Ct3; Ct4;

oS1; uS; oS2

Software version

Consult unit

RESET

nonE; ALL

SP1.D SP2.D BURN REU.D REU.L SPAN ZERO CHEK READ TECH UER RSET

SP1 output device

none; rly; SSd; AnLG

Reverse outputs

1r.2d; 1d.2d; 1r.2r; 1d.2r

Reverse O/P LEDs

1n.2n; 1i.2n; 1n.2i; 1i.2i

Span adjustment

0.0 to 25% sensor

full scale

LEVL 3

CONFIGURE OUTPUT SAFETY SETTINGS CALIBRATION PERFORMANCE DATA

Read SP1 output %

0 to 100% read only

SP1 manual output %

0 to100% proportional

mode only

Limit SP1 output %

100 to 0%

Limit SP2 output %

100 to 0%

Main SP2 mode

nonE; dV.hi; dV.Lo; bAnd;

FS.hi; FS.Lo; Cool; EoP

Second SP2 mode

nonE; LtCH; hold; Lt.ho;

nLin

Display resolution

1 or 0.1 degree

Set scale maximum

0.0 Sensor max to sensor

full scale

Set scale minimum

0.0 Sensor min to sensor

full scale

Select input sensor

nonE

Select display units

nonE;°C; °F; bAr;

PSi; Ph; rH; SEt

\\

SP1.P HAND PL.1 PL.2 SP2.A SP2.B DISP HI.SC LO.SC INPT UNITLEVL 2

MANUAL ADJUSTMENTS SP2 MODES CONFIGURE INPUT

RANGING

TUNE BAND INT.T DER.T DAC CYC.T OFST SP.LK SET.2 BND.2 CYC.2LEVL 1

SP1 SETTINGS SP2 SETTINGS

Autotune or Park

Off; on; ParK; At.SP

SP1 Prop band (gain)/

hyst 0.1 deg to 100%

sensor f/s (10°C/18°F)

Integral time (reset)

Off; 0.1 to 60 min

(5 min)

Derivative time (rate)

Off; 1 to 200 sec

(25 sec)

Derivative approach

0.5 to 5.0 x bAnd

(1.5)

Cycle time or on/off

On.off; 0.1 to 81 sec

(20 sec)

Offset (manual reset)

0 to 50% x bAnd

(In.t = off)

Setpoint lock (SP1)

Off; on

Adjust SP2 setpoint

+/– sensor full scale or

full scale

SP2 prop band/Gain/

Hyst 0.1 deg to 100%

sensor f/s (2°C/3.6°F)

SP2 Cycle on/off

On.off; 0.1 to 81 sec

Program number

1 to 31

Run program

oFF; on; hoLd; dEL

inS; CoPY; PStE

Power failure

recovery mode

rSEt; Cont; hoLd

Program start value

PV; SP

Setpoint ramp time units

hour; 60s

Holdback value

oFF; 0.1 to 150

Event output (SP2A or SP3A)

nonE; 2d; 2E; 3d; 3E; 2d.3d;

2E.3d; 2d.3E; 2E.3E

PROG RUN FAIL ST.U SPRU SEG TYPE SPRR T.SP HB.V EO.PLEVL P

PROGRAMMER SETTINGS

S

egment number

1 to 126 max.

Define segment type

SPr; SoAK; StEP; LooP;

Call; EoP; dEL; inS

Setpoint ramp rate

1 to 9990 (100)

units/time

Adjust target setpoint

+/– sensor full scale or

full scale

Instrument address

0 to 255

Baud rate

1200; 2400; 4800

9600; 19k2

Data format

18n1; 18E1; 1801

TxRx activity

Off; on

ADDR BAUD DATA DBUCLEVL C

COMMS SETTINGS

High scale 1000

-1999 to 9999

Low scale 0

-1999 to 9999

Input high 50.0

0.1 to 50.0

Input low 10.0

0.0 to 49.9

Decimel 0000

000.0 or 00.00

Burnout SP3 - uPSC

dhSC

R

everse O/P3 3D

3r

AN.HI ANLO HI.IN LO.IN DECP SP3.A SP3.B SET.3 HYS.3 BRN.3 REV.3LEVL A

SP3 SAFETY SETTINGS

Main mode nonE

dv.hi; dVLo; bAnd; Fshi;

FSLo; EoP

Second mode nonE

LtCh; hoLd; Lt.ho

Set SP3 0

0 to 2500

Hysteresis SP3 20

1–100% sensor

full scale

SP3 ADJUSTMENTSSP3 MODESLINEAR SCALING AND INPUT SETTINGS

➔

INITIAL
SET-UP
ENTRY

➔

PROGRAM ENTRY (DEFAULT)

Level C only visible
when COMMS
Option fitted

KEY ✱ ▼ OR ✱ ▲ TOGETHER TO CHANGE LEVELS OR OPTIONS

KEY ▼ OR ▲ TO VIEW FUNCTIONS

3

FUNCTIONS MENU

Range of Adjustment shown
under description.

If applicable, factory settings
shown in bold.

For a full description of menu
functions refer to pages 7 to
10, and 16/17 in Programmer
section.

Note: The letter K appears in
the instrument display as the
character K

This page can be photocopied and
used as a visual aid and bookmark when
working in other parts of the manual.

!

English

Press and hold ✱ and use the ▲ or ▼ buttons to select from the choices

Rly,SSd

or

AnLG

depending on the model supplied. SP2 and SP3 outputs will be automatically

allocated. (See output options table on page 8).

4 To enter initial configuration into controller memory

Press and hold both ▲ and ▼ buttons for 3 seconds. The display will now read

PArK

and measured variable (e.g. ambient temperature 23°).

PArK

is displayed because a

setpoint has not yet been entered.

To display setpoint units

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 THE FOLLOWING FACTORY SETTINGS

Proportional band/Gain 10ºC/18ºF/100 units
Integral time/Reset 5 mins
Derivative time/Rate 25 secs

Proportional cycle-time 20 secs
(Typical setting for relay output)
DAC Derivative approach control 1.5
(Average setting for minimum overshoot)

Note: For more precise control or for non temperature applications where a Linear input

transducer is being used, the controller may need to be tuned to the process.
Please refer to the following section on AUTOTUNE.

AUTOTUNE

This is a single shot procedure to match the controller to the process. Select either Tune or
Tune at Setpoint from the criteria given below.

The Tune program should be used for applications other than those listed under Tune at
Setpoint below. The procedure will apply disturbances when the temperature or process

reaches 75% of the setpoint value, causing overshoot which is monitored in order to adjust
the DAC overshoot inhibit feature. Care should be taken to ensure that any overshoot is safe
for the process.

The Tune at Setpoint program is recommended when:

●

The process is already at setpoint and control is poor

●

The setpoint is less than 100°C in a temperature application

●

Re-tuning after a large setpoint change

●

Tuning multi-zone and/or heat-cool applications.

Notes: DAC is not re-adjusted by Tune at setpoint. Proportional Cycle Time can be pre-

selected before running the Autotune program. (see page 5).

GETTING STARTED

After power-up the controller requires programming with the following information:

Type of Sensor (See list of sensors p.22)
Operating unit

°C °F bAr PSi Ph rh SEt

Allocation of Output Device to SP1/SP2 (Relay / SSd) or analogue. SP3 is always relay.
Setpoint

When the above information has been programmed into the controller it will be
operational with factory PID settings.

INITIAL SET-UP

On power-up the controller will display the self test sequence followed by the initial
display

inPt : nonE

1 Select input sensor.

Press and hold ✱ and use the ▲ or ▼ buttons to scroll through the sensor selection

list until the correct sensor is displayed. Release the buttons. The display will now read
selected sensor type e.g.

inPt : tCS

(type S thermocouple).

Press ▲ once The display will now read

unit : nonE

LINEAR INPUT

When Linear Input is selected, the display resolution of the setpoint and many other
functions will be changed from the setting previously made at

di.SP

in Level 2, to that set

at

dECP

in Level A.

It is therefore recommended that on completion of the Initial Set-up the Linear Input
settings in Level A be completed before moving on to configure Levels 1, 2 and 3. (see
Set-up Procedure page 6).

2 Select operating 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.

unit : °C

Press ▲ once The display will now read

SP1.d : nonE

3 Select SP1 (Main setpoint output device)

Analogue output

The allocation of the analogue output to SP1 automatically overrides the default
proportional cycle time setting of 20 seconds. Where the analogue output is
allocated to SP2, the default

CyC.2

setting on/off must be manually changed in
Level 1 to a time proportioning setting to enable the analogue output to operate in
proportional control mode.

4

English

AUTOTUNE (continued)

TUNE OR TUNE AT SETPOINT PROGRAM

Enter program (▲▼) and from the display

tunE : oFF

press and hold ✱ and press ▲ to

display

tunE : on

or

tunE : At.SP

Exit program mode (▲▼).

The TUNE program will now start. The display will show

tunE

as the process variable

climbs to setpoint.
Note: Avoid tuning while running a program as SP1 may be different from the target

setpoint..

When the TUNE or TUNE AT SETPOINT program is complete the PID values are entered
automatically. The process 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.

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.

Factory set

To use the 20 sec factory set cycle-time no action is needed whether autotune is used or
not.

To Manually Select AUTOTUNE Calculated CYCLE-TIME

When AUTOTUNE is completed, enter program (▲▼) and select

CYC.t

in Level 1. The

display will read

CYC.t : 20

(the factory setting).

To view the new calculated optimum value, press and hold both ✱ and ▼ buttons until
indexing stops. The calculated value will be displayed eg.

A16

. If acceptable, exit program

(▲▼) to implement this setting.

To Pre-select Automatic Acceptance of AUTOTUNE Calculated CYCLE-TIME

Before AUTOTUNE is initiated select

CYC.t

in Level1, press and hold both ✱ and ▼ buttons

until indexing stops at

A

– – . Exit program (▲▼) to accept calculated value automatically.

To Manually Pre-select Preferred CYCLE-TIME

Before AUTOTUNE is initiated select

CYC.t

in Level 1, press and hold both ✱ and ▲ or ▼

buttons until indexing stops at preferred value then exit program (▲▼) to accept.

CYCLE-TIME RECOMMENDATIONS

SECOND AND THIRD SETPOINTS (SP2 and SP3)

PRIMARY ALARM MODES

Configure SP2 output to operate as an alarm from

SP2.A

in Level 2 and set the alarm

setting in

SEt.2

Level 1.

Configure SP3 alarm mode

SP3.A

and setting

SEt.3

in Level A. The alarms will be
individually triggered when the process value changes according to the options listed
below.

dV.hi

Rises above the main setpoint by the value inserted at

SEt.2/3.

dV.Lo

Falls below the main setpoint by the value inserted at

SEt.2/3.

BAnd

Rises above or falls below the main setpoint by the value inserted at

SEt.2/3.

FS.hi

Rises above the full scale setting of

SEt.2

or

SEt.3.

FS.Lo

Falls below the full scale setting of

SEt.2

or

SEt.3.

EoP

Event Output (See Programmer section pages 11 to 18)

SUBSIDIARY SP2 / SP3 MODES

The following additional Subsidiary alarm functions can be added to any Primary alarm
configurations using the settings found at

SP2.b

in Level 2 and

SP3.b

in Level A.

LtCh

Once activated, the alarms will latch and can be manually reset when the alarm
condition has been removed.

Hold

This feature inhibits alarm operations on power-up and is automatically disabled
once the process reaches the alarm setting.

Lt.ho

Combines the effects of both

LtCh

and

hoLd

and can be applied to any Primary

alarm configuration.

SECOND SETPOINT (SP2) Proportional control output
Configure in Level 1 using

CyC.2

to select proportional cycle time and

bnd.2

to adjust

proportioning band. For Heat/Cool operation see Operating Manual.
Additional in depth information on controller operation is available in the CAL 9400.PDF

available for down load from www

.cal-controls.com

In on–off mode,

bnd.2

adjusts SP2 hysterisis.

5

Output Device

Factory Setting

Recommended Minimum

Internal relays

20 seconds
20 seconds

10 seconds

Solid state drives

0.1 seconds

Hereafter in the Manual the symbol (▲▼) signifies both buttons are held pressed

for 3 seconds to ENTER or EXIT Program mode.

Alarm type On-Off operating mode SP2 and SP3 Proportional operating mode SP2 only

FS.HI

COOL

FS.LO

BAND

DV.LO

DV.HI

Deviation

Full scale

Strategy

Output state LED state Output state 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

Legend

English

SP2 / SP3 OUTPUT AND LED STATUS IN ALARM CONDITION

SP2 / SP3 ALARM ANNUNCIATOR

If a Primary Alarm mode has been configured, when an alarm condition occurs the alarm
annunciator

-AL-

will be displayed alternating with the process variable. The alarm
together with the display, will be automatically reset as soon as the alarm condition has
been cleared.

The annunciator may be disabled by selecting

no.AL: on

, in Level 4.

ERROR MESSAGES

SENSOR FAULT

Display flashes:

inPt: FAiL

Indicates: sensor open or short circuit or linear input over-range.
Action: Check sensor/wiring/connectors

NON-VOLATILE MEMORY ERROR

Display flashes:

dAtA:FAiL

Action: De-power briefly. Replace unit if problem persists

MANUAL POWER ERROR

Display flashes:

hAnd :FAiL

SP1 set to on–off in

CYC.t

Action: Select proportional mode

IMMEDIATE FAIL ON AUTOTUNE START

Display flashes:

tunE :FAiL

Setpoint display 0

1. No setpoint entered.

Action: Enter setpoint

2. SP1 set to ON/OFF in

CyC.t

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

tech

e.g.

Ctb

= 0.0

Action: 1. Change the conditions. eg. raise setpoint

2. Try

tunE : At.SP

3. If the error message persists, call local CAL representative for advice.

6

LINEAR INPUT

Set-up Procedure

The 4–20mA input model converts current into voltage using an internal resistor which
spreads the signal across the input range 10 to 50 mV. using multiplier of 2.5. When using a
transducer with an output less than 4–20mA, the input maximum and minimum mV values
can be calculated using the same multiplier.

Models with 0 to 5V input use an internal resistor to spread the signal across the input
range 0 to 50 mV using a divider of 100. Where a transducer provides a smaller
output, the input maximum and minimum values can be similarly calculated.

Decide what scale minimum and maximum will be required, and whether the scale needs
inverting. (See Level A; Linear Input Scaling for list of settings and limits, page 10).

The example below shows how a 4–20mA linear Input should be configured.

# e.g. 4–20mA = 60 to 260 units where 4mA = 60 units

Follow INITIAL SET-UP procedure (also see page 4).

1. Select input sensor Select

inPt:Lin

2. Select unit Select required unit, if not available Select

unit:SEt

3. Select SP1 output Select from:

Rly,SSd

or

AnLG

Enter initial configuration into controller memory
DO NOT ENTER SETPOINT until Linear Input has been configured in Level A

See functions menu page 3
and functions list page 10.

Configure Linear Input Enter level A

(Then using example given # above)

4. Enter scale maximum Select

An.hi:260

5. Enter scale minimum Select

An.Lo:60

6. Enter input maximum Select

hi.in:50.0

7. Enter input minimum Select

Lo.in:10.0

8. Enter display resolution Select

dECP:0000

(WARNING – otherwise settings

marked may be altered)

Enter Linear Input configuration into controller memory and enter setpoint.
Now configure Levels 1, 2 and 3 and if required proceed with AUTOTUNE.
Note: Any apparent calibration errors can be removed using the

ZEro

and

SPAn

adjustments in Level 3.

✢

Will be affected by dECP settings in Level A

✢

English

7

FUNCTION LIST (LEVELS 1 to 4 and A)

Note: A Functions Menu is shown on page 3.

LEVEL 1

Function Options

[Factory settings] shown in brackets

SELECT AUTOTUNE (see pages 4/5)

tunE [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

bAnd 0.1 to * C/°F [10ºC/18ºF/100 units]

SP1 proportional band/Gain or Hysteresis

* 100% (

Hi.Sc

) sensor maximum Proportional control eliminates the cycling of on-off
control. Output power is reduced, by time proportioning action, across the proportional
band.

int.t oFF 0.1 to 60 minutes [5.0]

SP1 integral time/reset

Auto-corrects proportional control offset error

dEr.t oFF 1 - 200 seconds [25]

SP1 derivate time/rate

Suppresses overshoot and speeds response to disturbances

dAC 0.5 - 5.0 x bAnd [1.5]

SP1 derivative approach control dAC

Tunes warm-up characteristics, independent of normal operating conditions, by adjusting
when derivative action starts during start-up (smaller dAC value = nearer setpoint).

CyC.t 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.

oFSt 0 to * °C/°F/units [0]

SP1 offset/manual reset

* ±50%

bAnd

. Applicable in proportional and ON/OFF mode with integral disable:

Int.t : oFF

.

SP.LK [oFF] on

Lock main setpoint

Locks the setpoint preventing unauthorised adjustment.

SP2 OPERATING PARAMETERS (see page 6)

Function Options

[Factory settings] shown in brackets

SEt.2

[

0] to * °C/°F/units

Adjust SP2 setpoint

* Deviation Alarms

DV.hi, DV.Lo, bAnd

25% sensor maximum.

* Full scale alarms

FS.hi, FS.Lo

sensor range f/s

bnd.2 0.1 - * °C/°F/units [2.0 °C/3.6°F 2 units]

Adjust SP2 hysteresis or proportional band/gain

(see

CyC.2

setting)

* 100% sensor f/s (

Hi.Sc

)

CyC.2 [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.

LEVEL 2

MANUAL CONTROL MODES
Function Options

[Factory settings] shown in brackets

SPI.P 0 to 100 % ‘read only’

Read SP1 output percentage power

hAnd [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.

PL.1 100 to 0 % duty cycle [100]

Set SP1 power limit percentage

Limits maximum SP1 heating power during start-up and in proportional band.

PL.2 100 to 0 % duty cycle [100]

Set SP2 percentage power limit (cooling)

SP2 OPERATING MODES (see page 5)

SP2.A [nonE] dV.hi dV.Lo bAnd FS.hi FS.Lo Cool EoP

Main SP2 operating mode

SP2.b [nonE] LtCh hoLd nLin

Subsidiary SP2 mode: latch/sequence
Non-linear cool proportional band

LEVL 1

✢

✢

Will be affected by dECP settings in Level A

✢

LEVL 2

✢

✢

English

8

INPUT SELECTION AND RANGING

dI.SP [1] 0.1

Select display resolution: for display of process value, setpoint,

OFSt, Set.2, hi.SC, LoSC

.

hi.SC

[sensor maximum] sensor maximum

°C/°F/units

Set full scale

Lo.SC

[sensor minimum] sensor minimum

°C/ºF/units

Set scale minimum (default 0°C/32°F or 0 units)

inPt

Select input sensor

[nonE]

(See SENSOR SELECTION table, page 22)
NB. If Linear Input selected, start configuration from Level A.

unit [nonE] °C °F bAr Psi Ph rh SEt

Select required operating unit from above options

LEVEL 3

OUTPUT CONFIGURATION

Note 1: ‘Read only’ after initial configuration.

rSET ALL

full reset to factory settings

required to change

SP1.d

subsequently.

Note 2: Depending on the Model, SP1 and SP2 may be fitted with any of three output

types, RLY, SSd or Analogue (Specification on page 11/12) where appropriate,
these must be allocated during initial configuration. SP3 is always fitted with RLY.

Output Options Table

Model SP1 Output SP2 Output SP3 Output

95111P

RLY RLY RLY

95001P

SSd RLY RLY
RLY SSd RLY

95221P

SSd SSd RL

Y

*95X11P

AnLG RLY RLY

RLY AnLG RLY

*95X21P

AnLG SSd RLY

SSd AnLG RLY

* Substitute for X in table above, Analogue options B = 4–20mA, C = 0–5V, D = 0–10V

Will be affected by dECP settings in Level A

✢

✢

✢

Re-transmission

* These models above offer the option of using the analogue output for Re-transmission.

Select

bAndorbnd.2

value in

LEVL 1

to equal the full range setting in

LEVL A

and if

using SP1 output, set

int.t

and

dErt.t

in

LEVL 1

to off.

Example: Set-Up using a Model 95B11P to Re-transmit the 4-20 mA input, scaled 0 to 100
units. SP1 relay is used as the control output and SP2 analogue output is used for re­transmission.

Note: Read in conjunction with Linear Input Set-up Procedure on page 6.

Function Options

[Factory settings] shown in brackets

From initial power-up;

Set

inPt nonE

to

inPt Lin

unit nonE

to

unit SEt

(for example)

SP1.d nonE

to

SP1.d rLY

To scale the input, select

LEVL A

, then:

Set

dECP

to

000.0

(e.g. required resolution)

An.hi

to

100.0

An.Lo

to

0.0

hi.in

to

50

(ie 20mA)

Lo.in

to

10

(ie 4mA)

To align SP2 analogue re-transmission with SP1 control output, select LEVL 2 then:

Set

SP2.A

to

FS.hi

And in LEVL.1

Set

SEt.2

to

50

(ie 50% of display range)

bnd.2

to

100

(ie 100% of display range)

Finally, set SP1 setpoint value as required for process to start.

Using SP1 output for re-transmission

Set

int.t

to off

dErt

to off

rev.d

to

1d.2d

to invert SP1 output

SP1 Setpoint to midscale

burn

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

Retransmission range is limited to the sensor full scale value (Example RTD = 400C/752F).

LEVL 3

LEVEL 2 CONTINUED

English

9

Function Options

[Factory settings] shown in brackets

rEu.d

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.

rEu.L

Select SP1/2 LED indicator modes

SP1 SP2

[1n.2n]

Normal Normal

1i.2n

Invert Normal

1n.2i

Normal Invert

1i.2i

Invert Invert

SPAn [0.0] to ±25% sensor maximum -1999–2500 in Linear

Sensor span adjust
For recalibrating to align readings with another instrument e.g. External Meter, data logger.
See Full Operating Manual (ADVANCED SETTINGS).

ZEro [0.0] to ±25% sensor f/s -1999–2500 in Linear

Zero sensor error (see Sensor span adjust above).

ChEK [oFF] on

Select control accuracy monitor

rEAD [Var] hi Lo

Read control accuracy monitor

tECh [Ct A] CT b Ct 1 Ct 2 Ct 3 Ct 4 oS 1 uS oS 2

Read Autotune tuning cycle data (see Operating Manual)

UEr

Software version number

rSET [nonE] ALL

Resets all functions to factory settings

Caution: This selection will lose all of the current settings.

LEVEL 4

Access to level 4 is gained through

UEr

in level 3. Press and hold ▲ and ▼ for 10 seconds.

Enter level 4 at

Lock

, release ▲ and ▼ together. Display reads

LoCK nonE

Program security using

Lock [nonE]

Select from three

Lock

options: Press and hold ✱, press ▲ to index.

LEV.3

locks level 3, 4, A (and C when fitted)

LEV.2

locks level 2, 3, 4, A (and C when fitted)

ALL

locks all functions (including C when fitted)

Note: Any locked functions and options can still be read.
Press ▼ to access following functions.

Function Options

[Factory settings] shown in brackets

ProG [Auto] StAY

Program mode auto-exit switch
Auto-exit returns display to normal if 60 seconds of key inactivity, select

StAY

to disable

no.AL [oFF] on

Disable SP2 alarm annunciator -AL­Select on to disable -AL-

di.SS dir 1 to 32 [6]

Display sensitivity

dir

= direct display of input 1= maximum, 32= minimum sensitivity

dEr.S 0.1 to 1.0 [0.5]

Derivative sensitivity

SEt.L (oFF) on

Remember next menu exit point and use as new
menu entry point, except when exit is in Level 1.

LEVEL P See PROGRAMMER Section, page 11.

LEVEL C COMMS SETTINGS; visible only when Comms option

fitted.

Additional in depth information on controller operation is available in the APPGUIDE.PDF
available for down load from www

.cal-controls.com

LEVL 4

✢

✢

✢

✢

Will be affected by dECP settings in Level A

✢

LEVEL 3 CONTINUED

LEVL P

LEVL C

English

LEVEL A

Function Options

[Factory settings] shown in brackets

Linear Input Scaling

Please read in conjunction with Linear Input Set-up Procedure on page 6.

An.hi -1999 to 9999 [1000]

Adjusts required scale maximum

An.Lo -1999 to 9999 [0]

Adjusts required scale minimum

hi.in 0.1 to 50.0 [50.0]

Configure input maximum

Lo.in 0.0 to 49.9 [10.0]

Configure Input minimum
This setting must be at least 0.1 less than the setting for

hi.in

above.

Note: Refer to Linear Input conversion factors detailed in the Set-up Procedure on page 6.

dECP 000.0 to 00.00 [0000]

Scale resolution
NB. Once the Linear Input option has been selected, the setting here over-rides the scale
resolution setting

di.SP

in Level 2 and will affect the following display readings:

Level A:

An.hi;An.Lo;Set.3; hYS.3

Level 1:

bAnd; ofSt;SPrr;SEt2;bnd.2

Level 2:

hiSC;LoSC

Level 3:

SPAn;ZEro;rEAd;tECh

SP3 SETTINGS

SP3.A [nonE] dV.hi dV.lo bAnd FS.hi FS.Lo EoP

Main SP3 operating mode

SP3.b [nonE] LtCh hoLd Lt.ho

Subsidiary SP3 operating mode

SEt.3 0 to 2500 [0]

SP3 setpoint adjustment

hyS.3 0.1 to 100% of hiSC [20]

Set SP3 hysteresis

10

LEVL A

✢

✢

Function Options

[Factory settings] shown in brackets

brn.3 [uPSC] uPSC or dnSC

Sensor burn-out / break protection
Select upscale or downscale

rEV.3 [3d] 3d or 3r

Reverse SP3 output mode
Select direct or reverse operation

Will be affected by dECP settings in Level A

✢

English

11

PROGRAMMER

INDEX

Function overview 11
Getting started 12
Program run mode 12
Display functions 12
Example program 13
Function map 14
Function list 16
Memory allocation table 17
Memory full indicator 17
Programming example 18
Program edit example 18

FUNCTION OVERVIEW

The Programmer function in Level P enables the Model 9500P to control applications
needing Setpoint changes over time. Examples of this are Ramp changes where a gradual
Rate of change can be set, or Step changes which are instantaneous. These can be
separated by Soak periods during which the process is held at a constant value. Each
individual time interval of the program or Segment, together with it’s associated moving
setpoint value can be stored as a unique Program and for example be represented by the
diagram below.

In addition to those settings that determine the segment profile, it is also necessary to set
program start values, together with the preferred ramp rate time units for each individual
program.

At the end of a sequence, a Program can be arranged to repeat (Loop), either a specified
number of Cycles, or continuously. Only one Loop can be included in a Program. When
the program is running, the Display indicates progress through the sequence of segments,
and can additionally be interrogated for further segment information.

It is also possible to CALL an already existing program as a sub program that can be
inserted as a segment of another program.

To speed up Program configuration, several Edit functions have been provided so that
individual Segments and Programs may be Deleted or Inserted, and an entire Program
may be Copied and then Pasted into another that it will replace.

For safety reasons, three modes of recovery from a power failure are available. These either
automatically Re-start the Program from the beginning, Continue it from where it stopped,
or Hold it waiting for a user re-start.

Either one or both of the two auxiliary outputs can be configured as Event outputs.
Engaging the Holdback feature will temporarily halt Setpoint ramping to allow the process
temperature to catch up should it deviate by more than a pre-set amount during a Ramp
segment.

To afford maximum programming flexibility, memory is allocated dynamically, and not pre­allocated. This allows the user the freedom to configure a small number of long programs
or a larger number of shorter ones, up to the permitted maximum of 126 Segments per
program, and a limit of 31 Programs. Should these limits be exceeded, or the Programmer
memory become fully used, the display will read ProG FULL. Programs can be planned
using the Memory Allocation Table which details the memory requirements of individual
segment types. During configuration a check can be kept on memory usage by
interrogating the USEd feature of the display to give an instant reading of ‘percentage
memory used’.

Finally, once a program has been configured, it can be run from the run off/on/hold
controls in Level P, and in addition a quick access run/hold toggle is directly available from
the front panel.

The Programmer Functions List describes the full range of available Settings for each
Programmer Function together with their display mnemonic. The Model 9500P is supplied
with a suite of Factory Settings for each Function. These are shown in bold type.

The Functions Map illustrates the relationship between the Functions and their Settings
and provides a guide to the Keying Operations required to navigate around the menu
when configuring or running a Program.

English

Setpoint

Soak

Ramp

Step

Time (Segments)

12

GETTING STARTED (PROGRAMMER)

For users with previous experience of configuring programmers, the

13

TYPE

SPR

SPRR

105

T.SP

137

TYPE

SOAK

SINT

45

TYPE

STEP

T.SP

85

TYPE

SPR

SPRR

55

T.SP

30

TYPE

LOOP

PCYC

1

TYPE

SPR

SPRR

105

T.SP

137

TYPE

SOAK

SINT

45

TYPE

STEP

T.SP

85

TYPE

SPR

SEG

1

SEG2SEG3SEG4SEG

5

PROG

3

SEG

1

SEG2SEG3SEG

4

STOP

30

SPRR

55

T.SP

30

EXAMPLE PROGRAM

Temp

Time

See segment configuration of this
program detailed on page 18.

Ramp Function

Rate, 105 deg/hour
Target setpoint: 137 deg

Ramp Function

Rate, 55 deg/hour
Target setpoint: 30 deg

Loop Function

Number of repeat
program cycles: 1

Step Function

Target setpoint: 85 deg

Soak Function

Interval: 45 mins

English

14

PROGRAMMER FUNCTION MAP

TUNE

OFF

START HERE

Press and hold

▼ ▲

for 3 seconds

ENTER

PROGRAM

LEVL

1

LEVL

P

▼

▼

✱

▲

LEVL

A

LEVL

C

If COMMS option
fitted, LEVEL C
appears between
LEVEL P and LEVEL A

PROG

1

RUN
OFF

FAIL
RSET

ST.V

PV

SPRU
HOUR

▲

▲

▲

▲

USED

0

▼

RUN

ON

▲

✱

RUN

HOLD

EDIT

DEL

EDIT

INS

EDIT
COPY

EDIT
PSTE

FAIL
CONT

▲

✱

FAIL
HOLD

Hold the
program at
the point it
stopped

Continue the
program
from where
it stopped

Reset the
program at
beginning

Program
‘off’ state

▲

✱

PROG

2

PROG

3

PROG

ADD

RUN
OFF

▲

▼

Program 3
now appears
in list

Start program when ‘on’
selected. This locks
other options out

Hold the
program at
current position

Program
editing
functions.
Insert

Program
editing
functions.
Delete

Copies the
selected
program

Paste only appears
after a program is
copied

To add new
program,
press ▲ once

Add new
programs at
top of existing
menu

▼

Select the required
program number.

Default: 1

Memory used (%)

Select program mode
of operation

Default: off

Power failure recovery
position

Default: reset

Select the starting point of
program after power up

Default: PV

Ramp rate time units
adjustment

Default: hour

▲

ST.V

SP

▲

✱

Options: start
program at main
SP or process
variable

SPRU

60 S

▲

✱

Options:
hours
minutes

SURE

NO

✱

SURE

YES

PROG

2

3 secs

✱

▲

✱

3 secs

PROG

2

✱

3 secs

PROG

1

✱

3 secs

SURE

NO

✱

SURE

YES

PROG

3

3 secs

✱

▲

✱

3 secs

Another program has been
inserted into PROG 2
re-numbering existing
PROG 2 to 3

A copy of program 1 can be
pasted into another program

Program 1 has
been copied to
program 3

To view existing
programs 1 to 31
or full?

✱

✱

Program 3 has been
deleted. Display
shows next program
down from top of list

English

15

E.OP

2D

E.OP

2E

E.OP

3D

E.OP

3E

E.OP

2D3D

E.OP

2E3D

E.OP

2E3E

E.OP

2D3E

E.OP

NONE

▲

✱

TYPE
SOAK

TYPE
STEP

TYPE
LOOP

TYPE
CALL

TYPE

E,OP

EDIT

DEL

EDIT

INS

TYPE

SPR

▲

✱

Insert new
segment in
the menu

Delete a
segment

Event
output

Call up
another
program

Program
re-cycles

Step

Soak

Ramp

SEG

1

▲

▲

✱

SEG

2

SEG

3

SEG
ADD

TYPE

SPR

▲

▼

Segment 3
now appears
in menu

To add new
segments
press ▲ once

Add new
segments at
top of existing
list

To view existing
segments 1 to 126
or full?

Set the segment to be
adjusted

Default: 1

SURE

NO

✱

SURE

YES

SEG

2

3 secs

✱

▲

✱

3 secs

Segment 3
deleted

SEG

2

✱

3 secs

New segment now
inserted into 2. Old
segment 2 becomes 3

To select operational
mode of each segment

Default: Ramp

SINT

10

PCYC

1

SUB.P

NONE

SPRR

100

Important note

Up ▲ button must be
used after selecting the
segment type to
confirm it’s selection

Adjusts ramp
rate

Default: 100

Soak time in minutes
or continue

Default: 10

Define the program
number called

Default: none

Set Numbers of
re-cycles 1 to 999 unless
full. Or continuous

Default: 1

Returns to

SEG

T.SP

9999

T.SP

0.0

Target set point adjustable
over the unit’s range

Default: Current main SP

▲

✱

HB.V

150

HB.V

OFF

▲

✱

▲

▲

‘Hold back’ this function only
appears for ramp operational
once a value is set

Default: off

▲

Event output – options only
appear when SP2A or SP3A
modes set to E.OP

Default: de-energise

▲

▲

Event output options
energise and de-energise
for all combinations of
SP2 & SP3.

‘Hold back band
size adjustable

0.1 to 150 units

English

16

Function Sub-functions Settings

[Factory settings] shown

in brackets

Press ▲ or ▼ to change Press ✱ ▲ or ✱ ▼ to change

TyPE

Define segment type

SPr

Ramp to next target setpoint

SPrr

[100] Setpoint ramp rate Units per
hour/minute (0-9990) (as set at

Spru

above)

t.SP

(Segment target setpoint)
adjustable over instrument’s
configured range

hb.u

Hold back

[oFF]

sets the
permitted band size for the
measured value to deviate from
the ramp setpoint before the
program is ‘held back’ waiting for
the measured value to catch up.
(0.1 to 150 units)

SoAK

Hold setpoint for pre-set time

[10]

Sint

Soak time, adjust in minutes
(cont.-1440) x 0.1

StEP

Step to new target setpoint (Set

tSP

as above)

LooP

Re-cycle program

PCYC [1]

Set number of program loops

up to 999, or continuous loop

CALL

Call up another program by
number to import into this
program

Sub.P (nonE)

Number of Program called

at

Call

above

Edit dEL

Delete segment

Edit inS

Insert new segment

❋

❖

†

†

FUNCTION LIST (LEVEL P) PROGRAMMER

LEVEL P

Access Level P from Level 1. Press and hold ✱ ▼

Function Settings

[Factory settings] shown in brackets

Press ▲ or ▼ to change Press ✱ ▲ or ✱ ▼ to change

ProG

Program number

[1]

Add new programs (1 to 31)

run

Run Program

[oFF]

Program not running

on

Run program

hoLd

Pause program

Edit dEL

Delete program

Edit inS

Insert new program

Edit CoPy

Copy another program

Edit PStE

Paste copied program

Fail

Power failure recovery mode

[rSEt]

Reset to program start

Cont

Continue from interruption

hoLd

Hold at interruption (User re-start)

St.V

Program start value

[PV]

Process value

SP

Setpoint value

SPru

Ramp rate time units

[hour]

Ramp rate adjust in hours

60 s

Ramp rate adjust in minutes

SEG

Segment number

[1]

Add new segments (1 to 126)

❋

❖

†

†
†
†

See examples of EDIT procedures (page 18)
Deleting a Program automatically re-numbers those programs with higher numbers
Until memory full. See page 11 for further explanation and memory allocation table

on page 17.

❋

LEVL P

❖

†

English

17

Function Settings

[Factory settings] shown in brackets

Press ▲ or ▼ to change Press ✱ ▲ or ✱ ▼ to change

E.oP

Event output

[nonE]

Function can be applied to each
segment independently to trigger
an output at the start of that
segment for the duration of that
segment. Setting blocked unless
either or both outputs SP2A or
SP3A have been configured as an
Event Output in Level 2 or Level A
respectively.

2d

SP2A de-energised to mark event

2E

SP2A energised to mark event

3d

SP3A de-energised to mark event

3E

SP3A energised to mark event

2d.3d

SP2A and SP3A de-energised to
mark event

2E.3d

SP2A energised SP3A de-energised
to mark event

2E.3E

SP2A and SP3A energised to mark
event

2d.3E

SP2A de-energised SP3A energised
to mark event

To Return to:

LEVL P

Press and hold ▼

To Read % Programmer memory used:

USEd

Press ✱ and ▼ together in LEVL P / ProG 1
1–100%

Memory Allocation Table

Segment type Memory required

Ramp 4 Bytes
Ramp with Holdback 5 Bytes
Soak 2 Bytes
Step 3 Bytes
Loops (1–3) 1 Byte
Loops (4+) 2 Bytes
Call 1 Byte
Event Output 1 Byte
Program Header 1 Byte

Maximum capacity: 351 Bytes

31 Programs
126 Segments

Examples:

1. 1 program of 58 Ramps and 58 Soaks 349 Bytes

2. 4 programs of 14 Ramps and 14 Soaks 340 Bytes

3. 31 programs of 2 Ramps and 1 Soak 341 Bytes

4. 2 programs of 10 Ramps, 10 Soaks, 2 Steps and 1 loop 136 Bytes

Memory Full Indication

Should the programmer memory capacity be reached during program configuration, the
display will show ‘FULL’

English

18

PROGRAMMING EXAMPLES

PROG

1

RUN
OFF

EDIT
COPY

PROG

1

RUN
OFF

ADD

PROG

(next)

3 secs

✱

EDIT
PSTE

3 secs

SURE

NO

SURE

YES

PROG

2

Program 1
now pasted
as Program 2

✱

3 secs

✱

SEG

1

SEG

2

SEG

3

SEG

4

SEG

5

SEG
ADD

TYPE

SPR

TYPE
SOAK

TYPE
STEP

TYPE

SPR

TYPE
LOOP

SPRR

10 S

SINT

45

SPRR

55

PCYC

1

T.SP

137

T.SP

85

T.SP

30

HB.V

OFF

E.OP

NONE

PROG

3

Program settings for functions:
run; FAiL; St.U and SPru
not shown, are all set to Default

Program Segment Configuration

See Program 3 illustrated on page 13

KEY ▼ OR ▲ TO VIEW FUNCTIONS

Program Edit Function

Make copy of Program 1 and paste as
new Program 2

KEY ✱ ▼ OR ✱ ▲ TOGETHER TO VIEW OR CHANGE SETTINGS

Arrows drawn thus
signify several key
operations

Programmer functions
shown as white
characters on black
background have
Default settings

KEY

English

19

MECHANICAL INSTALLATION

The Controller is designed to be sleeve mounted in a 1/16 DIN panel cutout with only the
front panel rated to 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: 45.0mm +0.6 / -0.0 wide, 45.0mm +0.6 / -0.0 high
Maximum panel thickness 9.5mm
Minimum spacing 20mm vertical, 10mm horizontal

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)

CAUTION: The controller should be isolated before removing or refitting it
in it’s sleeve. Live circuits can hold a charge for short periods after isolation
from voltage supply. Electrostatic precautions should be observed when
handling the controller outside it’s sleeve.

DIMENSIONS

Bezel* Behind Panel Overall Behind panel

Width Height Width Height Length Length*

51.0 51.0 44.8 44.8 116.2 106.7

Dimensions in mm
* includes gasket

ELECTRICAL INSTALLATION

(See important Safety Information page 20)

OUTPUT DEVICES

WARNING:

Three types of output device may be factory fitted to the controllers, and users must choose
how to allocate these to outputs SP1 and SP2. (SP3 is always RLY). Check the model number
and output configuration against the Output Options Table on page 8 before wiring the
instrument and applying power.

1 Solid state relay drive (SSd1/SSd2)

6Vdc (nominal) 20mA max.
To switch remote SSR (or logic)

2 Miniature power relay (rLY/rLY1/rLY3)

2A/250V AC resistive, Form A/SPST contacts.

3 Analogue Output (

AnLG

) (isolated)

Specify; 4–20mA 500Ω max +/- 0.1% fs typical

0–5Vdc 10mA (500Ω min) +/- 0.1% fs typical
0–10Vdc 10mA (1KΩ min) +/- 0.1% fs typical

SUPPLY VOLTAGE

100–240V 50–60HZ 6.0VA (nominal)
+/- 10% maximum permitted fluctuation

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 1.0mm

2

(18AWG).

INDUCTIVE LOADS

To prolong relay contact life and suppress interference it is recommended engineering practice
to fit a snubber (0.1uf/100 ohms) between relay output terminals.

CAUTION:
Snubber leakage current can cause some electro-mechanical devices to be held ON.
Check with the manufacturers specifications.

English

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 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.
A clear instruction shall be provided not to position the equipment so that it is difficult to

operate the disconnecting device.

* EMC Immunity

EMC immunity may be improved by fitting large Ferrite cores around the sensor cables at the
point where they enter the cabinet and an earth bond is recommended.

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.

20

1234 56 78

LN

4–20mA

INPUT

(–)

(+)

20 21 22 23 24

Mains

S1

L

17 18 19

F2

N

Model 95B11P

B – – –

F1

4–20mA

Transducer

User configurable

alarms

(–)

(+)

Analogue

power

controller

Heater

*

TYPICAL APPLICATION

English

21

INPUT OPTIONS

OUTPUT: HARDWARE OPTIONS & TERMINATIONS

20 21 22 23 2417 18 19

20 21 22 23 2417 18 19

20 21 22 23 2417 18 19

20 21 22 23 2417 18 19

20 21 22 23 2417 18 19

(–)

(+)

SSd

(–)

(+)

SSd

(–)

(+)

SSd

(–)

(+)

AnLG

(–)

(+)

AnLG

(–)

(+)

SSd

Model Output Codes

95111P

95001P

95221P

95B11P
95C11P
95D11P

= 4–20mA
= 0–5V
= 0–10V

95B21P
95C21P
95D21P

= 4–20mA
= 0–5V
= 0–10V

Relay = 1 SSd = 2 Analogue = B/C/D

The analogue output always replaces the output on terminals 19 & 20.

English

(+)

(+)

RTD/PT100 2 wire

(+)

RTD/PT100 3 wire

(+)

Spare

Spare

Spare

Spare

Input

(+)

(–)

1234 56 78

Thermocouple

Input

(+)

(–)

1234 56 78

Wire link

Input

(+)

(–)

1234 56 78

Input

(+)

(–)

1234 56 78

Linear (transducer) input

Supply

LN

Supply

LN

Supply

LN

Supply

LN

Standard Input Code

95

–––

Linear Input Codes

95

–––

95

–––

95

–––

PA

PB
PC
PD

= 4–20mA
= 0–5V
= 0–10V

INPUT SENSOR SELECTION
Temperature sensors

Thermocouples Description Sensor range Linearity

tC b Pt-30%Rh/Pt-6%Rh 0 to 1800 °C 2.0 *
tC E Chromel/Con 0 to 600 °C 0.5
tC J Iron/Constantan 0 to 800 °C 0.5
tC K Chromel/Alumel -50 to 1200 °C 0.25*
tC L Fe/Konst 0 to 800 °C 0.5
tC n NiCrosil/NiSil -50 to 1200 °C 0.25*
tC r Pt-13%Rh/Pt 0 to 1600 °C 2.0*
tC s Pt-10%Rh/Pt 0 to 1600 °C 2.0*
tC t Copper/Con -200 / 250 °C 0.25*

Resistance
thermometer

rtd 2/3 wire Pt100/RTD-2/3 -200 / 400 °C 0.25*

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

Linear input (specification)

Maximum recommended display resolution: 1mV / 500°

Linear Input Typical accuracy Range

0–50mV +/- 0.1% -199 to 9999

4–20mA +/- 0.1% -199 to 9999

0–5 +/- 0.1% -199 to 9999

0–10V +/- 0.1% -199 to 9999

SPECIFICATION

Thermocouple

9 types
Standards: IEC 584-1-1:EN60584-1
CJC rejection: 20:1 (0.05°/°C) typical
External resistance: 100Ω maximum

Resistance thermometer

RTD-2/Pt100 2 wire
Standards: IEC 751:EN60751

(100Ω 0°C/138.5Ω 100°C Pt)

Bulb current: 0.2mA maximum

Linear process inputs

see Linear input (specification)

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: 50ppm/°C SM typical
Reference conditions: 22°C ±2°C, rated voltage after 15 minutes

settling time.

Output devices

check configuration

SSd1 and SSd2: solid state relay driver: To switch a remote SSR

6Vdc (nominal) 20mA non-isolated
Miniature power relay: form A/SPST contacts (AgCdO)
rLY, rLY1 and rLY3: 2A/250ac resistive load
Analogue output: 4–20mA 500Ω max +/- 0.1% fs typical

0–5Vdc 10mA (500Ω min) +/- 0.1% fs typical
0–10Vdc 10mA (1KΩ min) +/- 0.1% fs typical

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 - flashing

SP1 square, green; SP2/SP3 round, red

Keypad: 3 elastomeric buttons

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)

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English

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 Page 19

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/SP3 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 warranty 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.

Copyright CAL Controls Ltd. 2000

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 development, CAL Controls Ltd reserves
the right to make changes without prior notice.

CUSTOMER FEEDBACK

It is CAL Controls aim to provide the best possible service to our customers. Feedback
from our customers is therefore very important to ensure that we can make continual
improvements to our products and services. Should you wish to register any issues with
CAL please e-mail us at [e-mail] or via the ‘contact us’ section of our
web site at www.cal-controls.co.uk. Title your e-mail comments as ‘Registered customer
feedback’ or ‘Registered customer complaint’.

Alternatively you can contact us on tel: [phone] or fax: [phone]

23

English

CAL Controls

CAL Controls Ltd

Bury Mead Road, Hitchin, Herts, SG5 1RT. UK

Tel: + 44 (0)1462-436161 Fax: + 44 (0)1462-451801

email: [e-mail]

http://www.cal-controls.com

CAL Controls Inc

1117 S.Milwaukee Avenue, Libertyville, IL 60048. USA

Tel: [phone] Fax: [phone]

email: [e-mail]

http://www.cal-controls.com

33022/02/0901/000M18/1