CAL Controls CALogix Installation Instructions Manual
CALogix installation sheet Page 1 of 6
System Overview
CALogix is a modular multi-loop PID controller with logic function capability. The controller consists of a
DIN-rail mount base-unit that incorporates power supply, RS485 communications ports and slots for up
to 4 control modules. The control modules are available as PID or Logic I/O and can be selected then
mounted into the base-unit as required for the application. Variations in PID control modules include
temperature sensor and linear (0-50mV, 4-20mA, 0-5V & 0-10V) inputs with options for relay, ssd or
analog (4-20mA, 0-5V & 0-10V) outputs. Logic I/O modules have user defined 0-5, 0-10, 0-24Vdc inputs
with relay or ssd outputs. All wiring connectors to the base uni t and control modules are plug-in to
reduce installation and maintenance times.
CALogix is configured using the Windows based CALogix-sw configuration tool which is provided with
each base-unit. PID setup, input & output parameter settings, profile creation and writing logic function
block diagrams can all be performed within the software utility. These settings can be read, modified and
written to and from the controller and also saved on the PC as a file to be recalled at a later date when
required. The program also provides information on current process value, set-points and output status
which can be useful when commissioning the system.
Mechanical Installation
The controller is designed as two main components
BASE-UNIT
DIN rail mount device containing main CPU and connections for up to 4 control modules.
CONTROL MODULE
PID or Logic control modules can be mixed as required for the application and plugged in to base-unit.
1 base-unit and 1-4 control modules must be used for operation of product. A CALogix system can
only be configured using CALogix-sw pc -based software.
MOUNTING
To mount a base unit with control modules proceed as follows:
1. Affix 35mm type DIN rail securely to mounting surface, minimum length 140mm. The unit
should be mounted vertically as shown.
2. Attach carrier unit to DIN rail ensuring the spring release is at the bottom, facing downward.
3. Ensuring the input terminals are facing downwards, add the control modules to base unit.
Press the top and bottom tabs on the module lightly and ensuring module is kept straight,
push to locate in base unit (see diagram below).
4. Pre-wire connectors and plug into the appropriate modules (we suggest wire ma rkers for
identification)
REMOVING A MODULE
1. Isolate supply to CALogix and all module input and output connectors.
2. Unplug connectors to module requiring removal.
3. Press tabs as shown above to release module.
4. Carefully pull the module away from base-unit ensuring tabs are free to remove.
Press
CALogix Installation Instructions
DM0000M20
CALogix installation sheet Page 2 of 6
REMOVING BASE-UNIT FROM DIN-RAIL
1. Isolate supply to CALogix and all module input and output connectors.
2. Unplug connectors to base-unit and all modules.
3. Insert screwdriver into DIN-rail release block and apply pressure away from the controller, the
base-unit can then be removed.
REPLACING A CONTROL MODULE
When replacing a control module follow the instructions above for removing and installing control
modules. If a control module is being replaced with another that has the same part number, all
parameter settings will be automatically transferred from the base unit to the new module on repowering the system, no reconfiguration will be required.
If a module is being replaced with a module that has a different part number, ensure
that the system is re-wired accordingly and the module settings are modified to reflect the
changes made, before running your system. Failure to do so may result in dangerous operation
or damage to the system.
If you are replacing logic modules with PID modules, it is important to turn off or delete any
associated logic.
CLEANING
Wipe down with damp cloth (water only).
DIMENSIONS
Electrical Installation
The system is designed to be installed in an enclosure which provides adequate protection against
electrical shock. The enclosure should also be of a sufficient IP (NEMA) rating for protection against
water and dust.
OUTPUT DEVICES
Three types of output are available on a module: relay, solid state relay drive (ssd) and analog. Output
1 may be any one of the three options, output 2 can be relay or ssd and output 3 is always relay. Any
of these outputs can be assigned as SP1, SP2 and SP3 using the CALogix-sw software. Check the
model number and output configuration before wiring the instrument and applying power. See section
on output options for more details.
1. Solid state relay drive
12Vdc +10/-15% (nominal), 20mA
To switch remote SSR
2. Miniature power relay
2A/250Vac resistive, Form A/SPST contacts
3. Analog Output (Isolated) - NOT AVAILABLE WITH LOGIC I/O MODULE
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
18-30Vdc, 8 watts ±10% fluctuation permitted
WIRING THE CONNEC TOR
Prepare the cable carefully, remove between 6 and 8mm insulation and ideally tin or terminate to avoid
bridging. Prevent excessive cable strain. Maximum recommended wire size 32/0.2mm 1.0mm² (18
AWG)
REPLACING MODULES
Hot-plugging of modules should not be carried out. To change a module always de-power the baseunit. Once power is re-applied the carrier will reload the settings for that module and continue with the
original module settings. Hot-plugging can cause the carrier to fail and is potentially dangerous.
INDUCTIVE LOADS
To prolong relay contact life and suppress interference, it is recommended engineering practice to fit a
snubber (0.1µF/100Ω) between relay output terminals.
EN61010 - 1 / UL61010C-1/ CSA22.2 No 1010
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 suitable for measurement category II or III
− To avoid possible hazards, accessible co nductive parts of the installation shou ld be protectively
earthed in accordance with EN61010 for Class 1 equipment.
CAUTION
Snubber leakage current can cause some electro-mechanical devices to be held ON. Check
with manufacturers specification.
Note : Ensure adequate clearance for connectors and wiring
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