Chromalox 1020, 1030 Installation & Operation Manual
Installation & Operation Manual
1020 & 1030
Temperature Controllers
PK552
0037-75578
August 2018
i
Safety and Warranty Information
Products covered in this issue of the manual: 1020 &
1030 Process and Over-Temperature Controllers.
This manual supplements the Quick Start Product
manual supplied with each instrument at the time of
shipment. Information in this installation, wiring and
operation manual is subject to change without notice.
Copyright © August 2015, Chromalox Corporation, all
rights reserved. No part of this publication may be reproduced, transmitted, transcribed or stored in a retrieval system, or translated into any language in any
form by any means without the written permission of
Chromalox.
Copies of this manual are available in electronic format
on the Chromalox web site (www.chromalox.com) .
THE INTERNATIONAL HAZARD SYMBOL IS INSCRIBED ADJACENT TO THE REAR CONNECTION TERMINALS
IT IS IMPORTANT TO READ THIS MANUAL BEFORE INSTALLING OR COMMISSIONING THE
UNIT.
WARNING: PRODUCTS COVERED BY THIS MANUAL ARE SUITABLE FOR INDOOR USE, INSTALLATION CATEGORY II, POLLUTION CATEGORY
2 ENVIRONMENTS
THIS SYMBOL MEANS THE EQUIPMENT IS PROTECTED THROUGHOUT
BY DOUBLE INSULATION.
Warranty and Returns Statement
These products are sold by Chromalox under the warranties set forth in the following paragraphs. Such warranties are extended only with respect to a purchase
of these products, as new merchandise, directly from
Chromalox or from a Chromalox distributor, representative, or reseller and are extended only to the first
buyer thereof who purchases them other than for the
purpose of resale.
Warranty
These products are warranted to be free from functional defects in material and workmanship at the time the
products leave Chromalox factory and to conform at
that time to the specifications set forth in the relevant
Chromalox instruction manuals sheet or sheets, for
such products for a period of three years.
THERE ARE NO EXPRESSED OR IMPLIED WARRANTIES, WHICH EXTEND BEYOND THE WARRANTIES HEREIN AND ABOVE SET FORTH. CHROMALOX MAKES NO WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE WITH
RESPECT TO THE PRODUCTS.
Limitations
Chromalox shall not be liable for any incidental damages, consequential damages, special damages, or any
other damages, costs or expenses excepting only the
cost or expense of repair or replacement as described
above. Products must be installed and maintained in
accordance with Chromalox instructions. There is no
warranty against damage to the product resulting from
corrosion. Users are responsible for the suitability of
the products to their application. For a valid warranty
claim, the product must be returned carriage paid to
the supplier within the warranty period. The product
must be properly packaged to avoid damage from
Electrostatic Discharge or other forms of harm during
transit.
iii
Table of Contents
Contents Page Number
Safety & Warranty .................................................................................................................................................. iii
Chapter 1 Installation ............................................................................................................................................. 1
1.1 Unpacking .................................................................................................................................................... 1
1.2 Cleaning ....................................................................................................................................................... 1
1.3 Installation .................................................................................................................................................... 1
Chapter 2 Electrical Installation ............................................................................................................................ 2
2.1 Installation Considerations .......................................................................................................................... 2
2.2 AC Power Wiring .......................................................................................................................................... 2
2.3 Wire Installation ............................................................................................................................................ 2
2.4 Use of Shielded Cable ................................................................................................................................. 2
2.5 Noise Suppression at Source ...................................................................................................................... 2
2.6 Sensor Placement ........................................................................................................................................ 3
2.7 Panel Wiring ................................................................................................................................................. 3
2.8 Terminal Wiring ............................................................................................................................................ 4
2.9 Power Connection ....................................................................................................................................... 4
Chapter 3 Powering Up .......................................................................................................................................... 7
3.1 Powering Up Procedure ............................................................................................................................... 7
3.2 First Power Up or Factory Default ............................................................................................................... 7
3.3 Auto-Tune .................................................................................................................................................... 7
3.4 Front Panel ................................................................................................................................................... 7
3.5 General Navigation & Editing ....................................................................................................................... 8
3.6 Mode (or Menu) Structure ............................................................................................................................ 8
3.7 Returning to Perator Mode .......................................................................................................................... 8
3.8 Mode and Access and Lock Codes ............................................................................................................. 8
3.9 Use of the Controller for Non-Temperature Applications.............................................................................8
3.10 Controller Transmitter Function ................................................................................................................. 8
3.11 User Mode & Screens on Standard & Extruction models .......................................................................... 9
3.12 Warnings & Messages ............................................................................................................................ 10
Chapter 4 Initial Default Settings ........................................................................................................................ 12
4.1 Factory Reset Procedure ........................................................................................................................... 12
Chapter 5 Setup Mode ......................................................................................................................................... 13
5.1 Navigating the Setup Screens ................................................................................................................... 13
Chapter 6 Advanced Configuration Mode ......................................................................................................... 15
Chapter 7 User Mode ........................................................................................................................................... 16
7.1 User Menu ................................................................................................................................................. 16
7.2 Input Menu ................................................................................................................................................. 17
7.3 User Calibration Menu ............................................................................................................................... 18
7.4 Outputs Menu ............................................................................................................................................ 18
7.5 Control Menu (Standard Model) ................................................................................................................. 19
7.6 Control Menu (Extrusion Model) ................................................................................................................ 20
7.7 Setpoint Menu (Standard Model) ............................................................................................................... 21
7.8 Setpoint Menu (Extrusion Model) .............................................................................................................. 21
7.9 Alarm Menu ................................................................................................................................................ 22
7.10 Communications Menu ............................................................................................................................ 22
7.11 Display Menu ........................................................................................................................................... 23
7.12 Operator Screens Menu ........................................................................................................................... 23
7.13 Information Menu ..................................................................................................................................... 23
7.14 Exiting the Advanced Configuration Mode .............................................................................................. 23
iviv
Contents Page Number
Chapter 8 Calibration Mode ................................................................................................................................ 24
8.1 Single Point Calibration (PV Offset) ........................................................................................................... 24
8.2 Two Point Calibration ................................................................................................................................. 24
8.3 Base Input Calibration ............................................................................................................................... 25
8.4 Calibration Check ...................................................................................................................................... 25
8.5 Base Calibration Procedure ....................................................................................................................... 26
8.6 Calibrating the mV Input ............................................................................................................................ 25
8.7 Calibrating Other Input Types .................................................................................................................... 26
8.8 Calibration Input States ............................................................................................................................. 26
8.9 Calibration Progress .................................................................................................................................. 26
8.10 Calibration Modbus Addresses ............................................................................................................... 26
Chapter 9 Automatic Tuning ................................................................................................................................ 27
9.1 Running the Pre-Tune ................................................................................................................................ 27
9.2 Running Tune at SP ................................................................................................................................... 27
9.3 Tuning at SP Troubleshooting .................................................................................................................... 27
9.4 Tuning at SP for Heat and Cool ................................................................................................................. 28
Chapter 10 Digital Input Operation ..................................................................................................................... 29
Chapter 11 Timer Feature .................................................................................................................................... 31
11.1 Timer Feature ........................................................................................................................................... 31
11.2 Delay, Ramp & Timer Diagram ................................................................................................................. 31
Chapter 12 Extrusion Model Only Features ....................................................................................................... 32
12.1 Non-Linear Cooling Function ................................................................................................................... 32
12.2 Method ..................................................................................................................................................... 32
12.3 Parameter Adjustment ............................................................................................................................. 34
12.4 Soft Start Function ................................................................................................................................... 34
12.5 Extrusion Only Parameters in the Control Menu...................................................................................... 35
Chapter 13 Limiter Models .................................................................................................................................. 36
13.1 Introduction to the Limiter Model ............................................................................................................ 36
13.2 Limiter Modbus Communications ............................................................................................................ 36
13.3 Limiter Digital Input .................................................................................................................................. 36
13.4 Limiter Operator Mode & Screens ........................................................................................................... 37
13.5 Limiter Output Latching ........................................................................................................................... 37
13.6 Limiter Setup Mode Parameters .............................................................................................................. 37
13.7 Limiter Advanced Configuration Parameters ........................................................................................... 40
13.8 Limiter Input Menu ................................................................................................................................... 40
13.9 Limiter User Calibration Menu ................................................................................................................. 40
13.10 Limiter Outputs Menu ............................................................................................................................ 41
13.11 Limiter Communications Menu .............................................................................................................. 43
13.12 Limiter Display Menu ............................................................................................................................. 43
13.13 Limiter Information Menu ....................................................................................................................... 43
13.14 Limiter Exiting from Advanced Configuration Mode .............................................................................. 43
Chapter 14 Configuration Software .................................................................................................................... 44
14.1 Introduction .............................................................................................................................................. 44
14.2 Connectivity Requirements ...................................................................................................................... 44
14.3 Installing & Accessing the Configuration Program .................................................................................. 45
14.4 Getting Started ........................................................................................................................................ 45
14.5 Troubleshooting the Series 20 Configurator ............................................................................................ 46
14.6 Getting Started (continued) ...................................................................................................................... 47
14.7 Navigating the Configurator ..................................................................................................................... 48
vv
Contents Page Number
Chapter 15 Serial Communications .................................................................................................................... 51
15.1 Supported Protocol ................................................................................................................................. 51
15.2 RS485 Configuration ................................................................................................................................ 51
15.3 RS485 Device Addressing ....................................................................................................................... 51
15.4 Link Layer ................................................................................................................................................. 51
15.5 Supported Modbus Functions ................................................................................................................. 52
15.6 Function Descriptions .............................................................................................................................. 52
15.7 Function 03/04 Read Holding/Input Registers ........................................................................................ 52
Chapter 16 Modbus Addresses ........................................................................................................................... 54
16.1 Input Parameters ..................................................................................................................................... 54
16.2 Standard Extrusion Modbus Addresses .................................................................................................. 55
16.3 Limiter Modbus Addresses ...................................................................................................................... 63
Chapter 17 Specifications ................................................................................................................................... 68
Chapter 18 Glossary ............................................................................................................................................. 70
Chapter 19 Order Tables ...................................................................................................................................... 78
vi
1 Installation
)
4.76”
1.1 Unpacking
Carefully remove the product from its packing. Please
retain the packing for future use.
A single sheet concise manual is also supplied in one
or more languages. Examine the delivered items for
damage or defects. If any are found, contact your supplier immediately.
1.2 Cleaning
Clean the front panel by wiping down with a dry cloth.
Never allow water or any other substances to ingress
into the instrument.
1.3 Installation
Installation should only be performed by technically competent personnel. It is the responsibility of the installing engineer to ensure that
the configuration is safe. Local regulations
regarding electrical installation & safety must
be observed (e.g. US National Electrical Code
(NEC) or Canadian Electrical Code.
This instrument is designed for indoor back of panel
use.
(121 mm)
3.90”
(99 mm)
4.84”
(123 mm)
This equipment is protected throughout by
double insulation, when installed properly.
This type of installation does not need an earth
connection, but it is vital for safety reasons,
that the instrument is replaced if the instrument housing is broken.
The optional bus connection should be slid onto the
DIN Rail before fitting the 1020/1030 Rail.
The connectors must be pushed together to share the
bus.
0.89”
(22.5 mm)
4.21”
(107 mm
This bus connection links up the optional RS485 communications connections without extra wiring but does
not supply power.
Ensure there is adequate air flow inside the
panel to prevent overheating.
11
2 Electrical Installation
The installation should be only performed by
technically competent personnel.
It is the responsibility of the installing engineer
to ensure that the configuration is safe.
Local Regulations regarding electrical installation & safety must be observed (e.g. US National Electrical Code (NEC) or Canadian Electrical
Code).
2.1 Installation Considerations
Ignition transformers, arc welders, motor drives, mechanical contact relays and solenoids are examples of
devices that generate electrical noise in typical industrial environments.
The following guidelines MUST be followed to minimise their effects.
If the instrument is being installed in existing equipment, the wiring in the area should be checked to ensure that good wiring practices have been followed.
Noise-generating devices such as those listed above
should be mounted in a separate enclosure.
If this is not possible, separate them from the instrument, by the largest distance possible.
If possible, eliminate mechanical contact relays and
replace with solid-state relays. If a mechanical relay
cannot be replaced, a solid-state relay can be used to
isolate the instrument.
A separate isolation transformer to feed only the instrumentation should be considered. The transformer
can isolate the instrument from noise found on the AC
power input.
2.2 AC Power Wiring - Neutral (for
100 to 240V AC versions)
It is good practice to ensure that the AC neutral is at or
near ground (earth) potential. A proper neutral will help
ensure maximum performance from the instrument.
2.3 Wire Isolation
Four voltage levels of input and output wiring may be
used with the unit:
• Analogue input (for example thermocouple, RTD,
VDC, mVDC or mADC)
• Relays outputs
• SSR Driver outputs
• AC power
The only wires that should run together are
those of the same category.
If any wires need to run parallel with any other lines,
maintain a minimum space of 6” between them. If wires
MUST cross each other, ensure they do so at 90 degrees to minimize interference.
2.4 Use of Shielded Cable
All analog signals must use shielded cable. This will
help eliminate electrical noise induction on the wires.
Connection lead length must be kept as short as possible keeping the wires protected by the shielding. The
shield should be grounded at one end only. The preferred grounding location is at the sensor, transmitter
or transducer.
2.5 Noise Suppression at Source
Usually when good wiring practices are followed, no
further noise protection is necessary. Sometimes in
severe electrical environments, the amount of noise is
so great that it must be suppressed at source. Many
manufacturers of relays, contactors, etc. will supply
‘surge suppressors’ which mount on the noise source.
For those devices that do not have surge suppressors
supplied, Resistance-Capacitance (RC) networks and/
or Metal Oxide Varistors (MOV) may be added.
2
Inductive coils: - MOVs are recommended for transient suppression in inductive coils, connected in parallel and as close as possible to the coil. Additional
protection may be provided by adding an RC network
across the MOV.
Figure 5. Contacts: - Arcing may occur across contacts when they open and close. This results in electrical noise as well as damage to the contacts. Connecting a properly sized RC network can eliminate this arc.
For circuits up to 3 amps, a combination of a 47 ohm
resistor and 0.1 microfarad capacitor (1000 volts) is
recommended. For circuits from 3 to 5 amps, connect
two of these in parallel.
2.6 Sensor Placement (Thermocouple or
RTD)
If the temperature probe is to be subjected to corrosive
or abrasive conditions, it must be protected by an appropriate thermowell. The probe must be positioned to
reflect true process temperature: In a liquid media, the
most agitated area. In air, the best circulated area.
The placement of probes into pipe work some
distance from the heating vessel leads to transport delay, which results in poor control.
For a two wire RTD a wire link should be used in place
of the third wire. Two wire RTDs must only be used with
lead lengths less than 3 meters (10 ft.). Use of three
wire RTDs is strongly recommended.
2.7 Panel Wiring
In general, all wiring connections are made to the instrument after it is installed. Copper wires must be
used for all connections (except thermocouple signal
wires).
To avoid electrical shock, AC power wiring
must not be connected to the source distribution panel until all wiring procedures are completed.
Check the information label on the case to determine the correct voltage before connecting
to a live supply.
3
2.8 Terminal Wiring
The diagram shows all possible option combinations.
Please check the product configuration before wiring.
Dedicated Configuration Socket (on bottom of the instrument)
The wiring label shows the power requirements, connector positions and terminal number.
This example is:
TOP
1 & 2 Rear = RS485 Comms
3 & 3 Rear = Linear Out 3
5 & 6 Front = SSR Driver Out 2
7 & 8 Front = 100-240VAC power.
BOTTOM
9 & 10 Rear = Digital Input
11, 12 Rear & 16 Front = Relay Out 1
13, 14 & 15 Front = Process Input
2.9 Power Connection
To avoid damaging your instrument it is critical the
power connection is made to the correct terminals
Power is connected to pins 7 & 8.
Top, rear connector on the right-hand side.
(front connector omitted from picture for clarity)
The green LED shows when power is correctly connected.
NEVER DIRECTLY CONNECT THIS SOCKET TO
A USB PORT.
A configuration socket to USB adaptor can be obtained
from your supplier.
4
1020/1030 Rail Isolation Chart
Universal
PSU
PSU
Input Relay SSR Linear
RS485
Comms
Non-
Isolated
Digital
Input
Isolated
Digital
Input
Configuration
Port
Universal
Input
Relay
SSR
Linear
RS485 Comms
Non-Isolated
Digital Input
Isolated
Digital Input
Configuration
Port
Not Applicable
No Isolation
Reinforced Isolation
5
1020/1030 Input & Output Map
Relay COM / Linear +
Relay COM / Linear +
Relay NO / Linear -
-
+
Relay COM / Linear +
Relay NO / Linear -
Relay COM / SSR -
Relay NO / SSR+
L +
N -
Relay COM / Linear +
Relay NO / Linear -
Relay COM / SSR -
Relay NO / SSR+
L +
N -
Relay COM / Linear +
Relay NO / Linear -
+
-
Volt-free or TTL
compatible
Relay COM / SSR -
Relay NO / SSR+
Relay NC
L +
N -
Relay COM / Linear +
Relay NO / Linear -
+
-
Volt-free or TTL
compatible
Relay COM / SSR -
Relay NO / SSR+
Relay COM / SSR -
Relay NO / SSR+
Relay NC
Use cables with 80°C minimum temperature rating, conductor sizes 30-12 AWG
1
2
3
4
5
6
7
8
9
10
16
11
12
RS485 A (Rx/Tx+)
RS485 B (Rx/Tx-)
Relay NO / Linear -
Relay COM / SSR
Relay NO / SSR+
+
Volt-free or TTL
compatible
-
Relay COM / SSR -
Relay NO / SSR+
Output 3 – Standard & Extrusion
models
Output 2 – Standard & Extrusion
models
L
Power – low power or mains (hardware dependent)
N -
Output 1 – Standard and
Extrusion models
Communications
Output 3 (Alarm 2 or Retx PV) –
Limiter model
Alarm 1 output – Limiter model
Digital Input
Limit output – Limiter model
(Relay only)
13
14
15
RTD
TC / RTD / Linear
TC / RTD / Linear
Input – thermocouple, RTD or linear
6
3 Powering Up
ENSURE SAFE WIRING PRACTICES HAVE BEEN
FOLLOWED. WHEN POWERING UP FOR THE
FIRST TIME, DISCONNECT THE OUTPUT CONNECTIONS.
3.2 First Power Up or Factory De-
fault
When the unit is initially powered up or the user restores
the factory defaults to the device, it immediately enters
the Setup menu without requiring an unlock code. The
user must then cycle through every parameter, to either
view or adjust the value, and then exit the menu.
Check carefully the supply voltage and connections before applying power.
The instrument must be powered from a supply according to the wiring label on the side of the unit. (100vac
to 240Vac, or 24 Vac/dc depending upon the model
purchased.)
3.1 Powering Up Procedure
At power-up, a self-test procedure is run, during which
a product logo screen is displayed.
When powering up for the first time the instrument
starts up in the Setup Mode after the product logo
screen is displayed.
You must complete the Setup by
cycling through all of the parameters
before using the device for the first
time.
1. Use or to review every parameter.
2. Change value if necessary using , then
use or to adjust the value, then to save.
3. Exit Setup by pressing & together.
If the above steps are not followed the Setup has not
been completed so the device will go into Setup, again,
on every subsequent power up.
3.3 Auto-Tune
The controller can be auto-tuned from the Setup Mode.
1. Pre-tune
2. Auto-tune at setpoint
Auto-Tuning will not engage if:
• Controller is set to On/Off Control
• Setpoint is ramping
• PV is within 5% of the input range
from setpoint
3.4 Front Panel
Display shows PV (process variable), units, SP (setpoint), alarm/latch statuses,
error & warning messages.
By default, the display turns off after 5 minutes without any key presses.
3 navigation keys:
Ok/Select
Up
Down
This is configurable in the Advanced Configuration, in the Display submenu, parameter Screen Timeout. Any key press turns the display back on.
Standard:
3 Output Status LEDs
1 2 3
Extrusion:
3 Status LEDs for:
Heat Cool Alarm
7
Limiter:
3 Status LEDs for
LM EX AL
3.5 General Navigation & Editing
• Press or keys to navigate between parameters or menu items.
• Press to highlight a parameter value, ready for
editing.
• Press or to change the parameter value, then press within 60 seconds to confirm
change.
3.6 Mode (or Menu) Structure
There are 3 main modes (or menus) on the device –
Setup and Advanced Configuration Mode.
• User Mode - the live screen used for normal operation. The process variable can always be seen in
this mode
• Setup Mode – allows access to the most important
parameters
• Advanced Configuration Mode - access all parameters via sub-menus
Setup Mode - press & .
Advanced Configuration - press & .
Never connect the instrument’s configuration
socket directly to a USB port as it will damage
the controller.
3.7 Returning to Operator Mode
3.9 Use of the Controller for NonTemperature Applications
In the majority of applications this controller will be
used for temperature sensing, either via a sensor or a
linear DC input, which use heat and cool. However this
controller can be used for other types of processes.
If your process is not a temperature then the parameters labelled as “HEAT”refer to reverse acting outputs
used to increase the process value and “COOL” to decrease the process value.
As an example you may have a system that reads and
controls humidity. The “HEAT” output drives the humidifier and the “COOL” output drives the de-humidifier. Use the “HEAT” parameters to control the humidifier
and the “COOL” parameters to control the de-humidifier.
Often the “HEAT” and “COOL” is referred to as “Primary” and “Secondary” on other controllers.
3.10 Controller Transmitter Function
The Standard 1020 & 1030 model can be used as a
“transmitter” to retransmit the process value or controller setpoint via Output 3, if the linear option is fitted.
The parameter Usage in the Linear Output sub-menu
can be set to PV Retransmit or SP Retransmit.
In the Display menu, the parameter Transmitter can be
used to enable Transmitter view. This hides the Setpoint from view.
Control functions will remain active if
they have been configured.
Press & to move back one level
From a sub-menu you will need to do this twice; once
to return to Advanced Configuration Mode then again
to exit. After 120 seconds without key presses the unit
returns automatically to the first Operator mode screen.
3.8 Mode Access and Lock Codes
Separate lock codes can be set for the Setup mode
and for the Advanced Configuration mode.
• Setup mode lock code – default 10.
• Advanced Configuration mode lock code – default
20.
Hold the button while powering up for a read-only
view of lock codes.
8
3.11 User Mode & Screens on Standard & Extrusion models
User Screen Temperature Unit.
PV – process variable (e.g. process temperature)
SP - Setpoint
Manual control
Transmitter screen is present on Standard model only.
Important: The following parameters are only displayed if set to “Show” in the User sub-menu.
Alarm State
Latch State
PV – process variable (e.g. process temperature)
Manual Power is shown as P%.
Transmitter parameter = Enable, SP is hidden.
The device still functions as a controller
To act as a PV transmitter the parameter Usage in the
Linear Output sub-menu needs to be set to PV Retransmit.
Alarm triggered
Alarm configured, but not triggered
– Alarm not set
Output Latched
Latch configured, but
output not Latched
using the local Setpoint.
To clear press
to select Yes.
Press to accept.
then
– Latch not set
Maximum PV
Minimum PV
Screens show the Maximum & Minimum PV reached.
Control Enable OFF - Control output(s) disabled. (Ignored when in manual mode).
ON - Control output(s) enabled.
Manual Control Enable OFF - Automatic control, PID or On-Off control available.
ON - Manual control, Manual Power shown as P% xxx
Time On Remaining On Timer Visible when On Timer is active.
See Ramp & Timers diagram.
Delay Time Remaining Delay Timer Visible when Delay Timer is active.
See Ramp & Timers diagram.
9
To clear press then
to select Yes.
Press
to accept.
3.12 Warnings & Messages
Pop-Up Alerts
Pop-up alerts appear in front of the current screen.
They must be acknowledged before you can access
other screens.
Pop-Up Alert List
Message Description
Press
& together to clear the pop-up alert.
Alarm 1
Alarm 2
Alarm 1 & 2
Control Enabled
Calibration Pass
Calibration Fail
Tuning in Progress
Setup not completed
Offset in use
Limit Exceeded
Tune Error
PV within 5% of SP
Tune Error
Setpoint is ramping
Tune Error
Control is ON/OFF
Tune Error
Control is manual
Tune Error
Tune at Setpoint not able to run
Tune Error
Sensor Break
Tune Error
Timer Running
Alarm 1 is active.
Alarm 2 is active.
Alarm 1 and 2 are active.
Alerts user that the control is re-enabled. (not Limiter.)
Factory calibration (Full Input Calibration has passed.)
Factory calibration (Full Input Calibration has failed.)
Tune at Setpoint or Pre-Tune is running. (Not Limiter.)
Please refer to First Power Up or Factory Default section.
SP offset is being used in Setpoint sub-menu.
Limiter only, indicates when the limit value has been exceeded.
PV within 5% of the scale range input from SP (for Pre-Tune). Try a different
setpoint or narrow the scale range input.
Setpoint is ramping. Turn off ramping and try again.
Control is not set to PID, i.e. the proportional band = 0. Set the proportional
band to any other value and try again.
Manual control enabled. Set Manual Control Enable to OFF and try again.
Tune at setpoint has timed out or cannot run.
Check your sensor.
Timer Running. Set the Enable Timer parameter to Disabled.
10
Message List
Message Description
ALARM
LATCH
LIMIT
HIGH
LOW
OPEN
ERROR
TUNE
P%
Ramp
Alternates with PV and shows one, or both, Alarms are active.
Alternates with PV, one or more outputs are latched on & no alarm is active.
On Limiter model, alternates with PV to show Limit is active.
Process variable input >5% over-range.
Check for possible issues with sensor or connections.
Also, check that Scale Range Maximum is high enough for your application.
Process variable input >5% under-range.
Check for possible issues with sensor or connections.
Also, check that Scale Range Minimum is low enough for your application.
Break detected in process variable input sensor, wiring or wrong input type selected.
Shows OPEN until resolved, Control is disabled on Standard or Extrusion models), or
Limit state set until resolved on Limiter model.
Selected input range is not calibrated.
Shows ERROR until resolved. Control is disabled on Standard or Extrusion models),
or Limit state set until resolved on Limiter model.
Alternating with SP shows Auto-tuning is in progress.
Manual power value replaces setpoint, shows P% xxx of power.
Setpoint ramp is active (alternates with actual setpoint).
Control is disabled. Control output(s) are off.
OFF
Enable control by setting Control Enable to ON or check state of the Digital Input if
Digital I/P Action is set to Ctrl Enable/Disable.
DELAY
Shows when Delay Timer is active, control is off until the timer finishes.
The Automatic Tuning parameter must be changed to Off to clear any tuning message.
Display alternates between the tuning code & setpoint
tErr1
tErr2
tErr3
tErr4
tErr5
tErr6
tErr7
tErr8
PV within 5% of the scale range input from SP (for Pre-Tune).
Try a different setpoint or narrow the scale range input.
Setpoint is ramping.
Control is ON/OFF. Control is not set to PID, i.e. the proportional band = 0.
Control is manual. Set Manual Control Enable to OFF.
Tune at Setpoint not able to run.
Sensor Break.
Timer Running. Set the Enable Timer parameter to Disabled before attempting to run
tuning again.
Control is disabled. Please check it is safe to enable control and then go to the User
menu to change Control Enable to ON.
11
4 Initial Default Settings
Your 1020 & 1030 Process and Over-temperature Controller will arrive with specific factory settings. If at any
point the factory default process is performed, all the
parameters will be returned to the values shown below.
4.1 Factory Reset Procedure
Press to highlight NO.
Press to move highlight to YES.
Press to accept.
A confirmation screen appears.
If you are sure press to show YES (leave as NO to cancel).
Press to confirm your choice.
The instrument shows the default for the Input Type and its
default value.
The Reset to Defaults can be found in
the sub-menu Display in the Advanced
Configuration on all models.
The user must review all parameters in the Set-up menu before
exiting.
12
5 Setup Mode
5.1 Navigating the Setup Screens
To access the Setup Mode from User Mode, press
& together. Enter code for Setup Lock (default = 10)
using & , then press .
Lock Code 10 Lock code to enter Setup Mode. Default is 10
Parameter Name Description Meaning & Visibility
Input Type
-200 to 1200ºC
-328 to 2192ºF
-240 to 1373ºC
-400 to 2503ºF
-199 to 800ºC
-328 to 1472ºF
100 to 1824ºC 211 to 3315ºF B Thermocouple
0 to 2320ºC 32 to 4208ºF C Thermocouple
0 to 762ºC
32 to 1403ºF
0 to 1399ºC 32 to 2551ºF N Thermocouple
0 to 1795ºC 32 to 3198ºF R Thermocouple
0 to 1762ºC 32 to 3204ºF S Thermocouple
-240 to 400ºC
-400 to 752ºF
0 – 50mV** 0 – 50mV**
10 – 50mV 10 – 50mV
-128.8 to 537.7ºC
-199.9 to 999.9ºF
-128.8 to 537.7ºC
-199.9 to 999.9ºF
-128.8 to 537.7ºC
-199.9 to 999.9ºF
0.0 to 537.7ºC
32.0 to 999.9ºF
-128.8 to 400.0ºC
-199.9 to 752.0ºF
0 – 20mA 0 – 20mA
4 – 20mA 4 – 20mA
0 – 5V 0 – 5V
1 – 5V 1 – 5V
0 – 10V 0 – 10V
2 – 10V 2 – 10V
J Thermocouple
K Thermocouple
PT100
L Thermocouple
T Thermocouple
** 0 – 50mV is only linear dc input available on Extrusion models.
Input Units ˚C ˚F Select °C or °F temperature units – Default is °C
Units parameter hidden when linear input is used and units are not shown on the display
Input Decimal
Place
0000 00.00 Number of decimal resolution. (2 or 3 decimal
000.0 0.000
places only available.
13
Parameter Name Description Meaning & Visibility
Scale Range Upper Limit
1000 Upper limit of scaled input range. (Only visible in
Setup Mode when a DC linear type is selected).
Default is input max.
Scale Range
Lower Limit
0 Lower limit of scaled input range. (Only visible in
Setup Mode when a DC linear type is selected).
Default is input min.
Input Digital I/P
Action
None None, Alarm Reset (clears latched alarms), Ctrl
Enable/Disable (disables control), Ctrl Auto/
Manual, Pre-Tune Start/Stop, Tune at SP Start/
Stop
Output 1 Usage Heat Heat, Cool, Non Linear Cooling (on Extrusion
model only), Alarm 1, Alarm 2, Alm. 1 or 2 (logical ‘OR’ of Alarm 1 & 2), Loop Alarm
Output 2 Usage Alarm 1 Same options as Output 1 Usage
Output 3 Usage Alarm 2 Same options as Output 1 Usage
If a Relay or SSR drive is fitted in Output 3 you will see >Output 3.
If the Linear option is fitted in Output 3 you will see the >Linear Output menus instead.
Linear Output
PV Retx Heat, Cool, PV Retx, SP Retx
Usage
Linear Output Type 0-10V 0-10V, 2-10V, 0-20mA, 4-20mA, 0-5V, 1-5V
Linear Output
Scale Range Max.
>Linear Output
Scale Range Min.
1373 Maximum PV or SP value corresponding to
maximum linear output for retransmission.
-240 Minimum PV or SP value corresponding to minimum linear output for retransmission.
Alarm 1 Adjust 1373 Sets the Alarm 1 value. (Range minimum to
range maximum) OFF disables the alarm. (Default alarm type is high alarm)
Alarm 2 Adjust -240 Sets the Alarm 1 value. (Range minimum to
range maximum) OFF disables the alarm. (Default alarm type is low alarm)
Setpoint Adjust 0 Target setpoint. Adjustable between setpoint
upper and lower limits Default is 0
Coms Unit
1 Modbus address from 1 to 255
Address
Coms Baud Rate 9600 1200, 2400, 4800, 9600, 19200 & 38400 bps
1. The Start Tune at SP function is not available for
Heat & Cool processes.
2. If the Input Type is changed, input scaling and
alarm values are set to new values based on the
maximum and minimum of the new input type. If
necessary, review these settings.
3. If necessary, press
& to clear the “Control is
Enabled” Pop Up Alert then press & to exit
the Setup mode.
14
6 Advanced Configuration Mode
The Advanced Configuration mode gives access to all
the parameters accessible from the front panel; however, the device hides parameters that are not relevant
to your exact model code specification & configuration.
It may be faster to access some
parameters from the Setup Mode.
Lock Code 20
Menu Name Meaning & Visibility
User
Input Set up input sensor and range.
Calibration For entering calibration points.
Outputs Set functions for up to 3 outputs.
Control Control settings for PID, or ON/OFF control, and Auto-tune.
Provides access to User parameters including Control Enabled and Manual Control
Enabled parameters.
Press
Operator screen.
Enter Advanced Lock-code using & , then
press .
& to enter Advanced Configuration from
Lock code to enter Advanced Configuration
Mode. Default is 20.
Setpoint Setpoint and timer settings.
Alarm All alarm settings including sensor break alarm.
Comms Modbus address, baud rate and parity - only shown if RS485 option is fitted.
Display Lock code set up and Basic Setpoint Control enable/disable.
Operator Visibility setting for parameters that can be made visible in the User Mode.
Info
Revision level, Firmware version, Serial number and Manufactured date.
15
7 User Mode
The normal, live screen showing the PV (process variable) or temperature is called the User Mode.
7.1 User Menu (Applicable to Standard and Extrusion Models)
Parameter Description Default Value
Alarm State
Alarm triggered
Alarm configured, but not
triggered
– Alarm not set
N/A
Latch State
To clear any latched outputs, press
Maximum PV
Minimum PV
Control Enable OFF - Control output(s) disabled. (Ignored when in man-
Manual Control Enable OFF - Automatic control, PID or On-Off control available.
To clear the stored value, press
Yes.
Press to accept.
ual mode).
ON - Control output(s) enabled.
ON - Manual control, Manual Power shown as P% xxx
then to select Yes. Press to accept.
Output Latched
Latch configured, but output
not Latched
– Latch not set
then to select
N/A
Screens show the
Maximum & Minimum PV
reached.
ON
OFF
16
7.2 Input Menu (Applicable to Standard and Extrusion Models)
Parameter Description Default Value
Input Type Refer to Input types in the table in the Setup menu sec-
tion for a full list of inputs available.
Units Display Units either °C or °F.
This parameter is hidden when input is a linear type and
°C or °F are hidden from the display.
Units hidden when linear input is used and no unit is shown on the display
Decimal Place 0000
000.0
00.00 (not for temperature)
0.000 (not for temperature)
For temperature inputs, enter the maximum working
Scale Range Maximum
Scale Range Minimum
Filter Time
CJC Enable Enable Enables the internal thermocouple CJC (Cold Junc-
Digital I/P Action None
range. For linear inputs, enter the display value for the
maximum input level
For temperature inputs, enter the minimum working range.
For linear inputs, enter the display value for the minimum
input level.
Input filter time value to reduce noise. OFF or 0.5 to 100.0
seconds in 0.5 increments
tion Compensation). Disable Disables the internal CJC. If
disabled, external compensation must be provided.
Alarm Reset (clears latched alarms)
Ctrl Enable/Disable (disables control)
Ctrl Auto/Manual
Pre-Tune Start/Stop
Tune at SP Start/Stop
K thermocouple
°C
0000
Maximum allowed for
Input Type
Minimum allowed for
Input Type
2.0
Enable
None
The input scale range, consisting of
Scale Range Maximum & Scale Range
Minimum above, is used to narrow the
working range of the controller.
If the measured value is more than 5%
above or below the scaled range PV
display is replaced by HIGH (over-range)
or LOW (under-range).
The scale range also affects if Pre-Tune
will run. If the PV is <5% of the scaled
range from setpoint Pre-Tune cannot be
used.
17
7.3 User Calibration Menu (Applicable to Standard and Extrusion Models)
Parameter Description Default Value
Offset Shifts the input value up or down by this offset value,
across the entire range.
Low Point Enter value at which the low point error was measured. Lower Limit
Low Offset Enter equal, but opposite offset value to the observed
low point error.
High Point Enter value at which the high point error was measured. Upper Limit
High Offset
Enter an equal, but opposite offset value to the observed
high point error.
0
0
0
7.4 Outputs Menu (Applicable to Standard and Extrusion Models)
Parameter Description Default Value
Output 1 Sub-menu
Heat (Reverse acting control)
Cool (Direct acting control)
Non Linear Cooling (Extrusion model only)
Usage
Alarm Action
Latching
LED Indicator Direct - LED Indicator lit when output is active
Output 2 Sub-menu
Usage Same options as Output 1 - Usage Alarm 1
Alarm Action Same options as Output 1 - Alarm Action Direct
Latching Same options as Output 1 - Alarm Latching Off
LED Indicator Same options as Output 1 - LED Indicator Direct
Output 3 Sub-menu
If a Relay or SSR drive is fitted in Output 3, this sub-menu is visible.
Usage Same options as Output 1 Usage Alarm 2
Alarm Action Same options as Output 1 - Alarm Action Direct
Alarm Latching Same options as Output 1 - Alarm Latching Off
LED Indicator Same options as Output 1 - LED Indicator Direct
Alarm 1
Alarm 2
Alarm 1 or 2
(i.e. logical ‘OR’ of Alarm 1 & 2)
Loop Alarm
Direct - Output active when alarm triggers
Reverse - Output active when alarm is not triggered
Off - Alarm doesn’t latch
On – Alarm latches (remains in active state until cleared)
Reverse - LED Indicator lit when output is inactive
Heat
Direct
Off
Direct
18
Parameter Description Default Value
Linear Output Sub-menu
If the Linear option is fitted in Output 3, this sub-menu is visible.
Heat (Reverse acting control)
Usage
Type
Scale Range Maximum
Scale Range Minimum
Retransmission of PV or SP: PV Retx, SP Retx
Display value at which retransmission output is at its
maximum value ( -1999 to 9999)
Display value at which retransmission output is at its
minimum value ( -1999 to 9999)
Cool (Direct acting control)
0-10V
2-10V
0-20mA
7.5 Control Menu (For Standard Model only)
Parameter Description Default Value
4-20mA
0-5V
1-5V
PV Retx
0-10V
1000
0
Proportion Heat Band The Proportional Bands for heating and cooling control,
Proportion Cool Band
Auto Reset (Integral) 0.01 to 99.59. and OFF (0.00) (minutes & seconds). 5.00
Overlap/Deadband In display units, range -20 to +20% of Heat & Cool Pro-
Differential (On/Off) Visible when using On-Off control.
Loop Alarm Time Visible when On/Off control & Loop Alarm assigned to an
Manual Reset (Bias) Manual Reset. Biasing of the control working point, 0 to
Heat Cycle Time 0.1 to 512.0 seconds
Cool Cycle Time 32.0
Output Interlock Prevents simultaneous activation of both heat & cool
Heat Power Limit % heating and cooling power upper limits
Cool Power Limit 100%
Power Up Action
Automatic Tuning
in display units. Set to ON/OFF (0) or PID control:
1 to 9999 - 0 decimal places
0.1 to 999.9 - 1 decimal place
0.01 to 99.99 - 2 decimal places
0.001 to 9.999 - 3 decimal places
Possible values/resolution depends on values display
resolution.
portional Band
In display units centred about the setpoint.
Range: 0.1% to 10.0% of input span
output.
Sets time before the loop alarm triggers.
(minutes & seconds)
100%. (-100% to 100% if heat/cool control)
Relay/SSR control output cycle times
outputs. Choose from On or Off.
Do not use if PB ‘overlap’ has been set
0 to 100%
Last - Powers up with control enable/disable in the same
state as on power off or power failure.
On - Always powers up with control enabled.
Off
Start Pre-Tune
Start Tune at SP
(Not available for Heat & Cool processes.)
161
161
0
8
99.59
25%
32.0
Off
100%
Last
Off
19
7.6 Control Menu (For Extrusion Model only)
Parameter Description Default Value
Proportion Heat Band The Proportional Bands for heating and cooling control,
Proportion Cool Band
Auto Reset (Integral) 0.01 to 99.59. (minutes & seconds) and OFF (0.00). 5.00
Overlap/Deadband In display units, range -20 to +20% of Heat & Cool
Differential (On/Off) Visible when using On-Off control.
Loop Alarm Time Visible with On-Off control & Loop Alarm assigned to an
Manual Reset (Bias) Manual Reset. Biasing of the control working point, 0 to
Soft Start Time 0:01 to 60:00 or OFF (0:00) (hours & minutes) OFF
Soft Start Setpoint The setpoint used by the Soft Start.
Heat Cycle Time
Cool Cycle Time 32.0
Output Interlock
Heat Power Limit
Cool Power Limit 100%
Minimum Cooling
Impulse Length
Minimum Off Time
Non Linear Adjust
Power Up Action
Automatic Tuning
in display units. Set to ON/OFF (0) or PID control:
1 to 9999 - 0 decimal places
0.1 to 999.9 - 1 decimal place
0.01 to 99.99 - 2 decimal places
0.001 to 9.999 - 3 decimal places
Possible values/resolution depends on values display
resolution.
Proportional Band. -ve values=Deadband.
In display units centred about the setpoint.
Range: 0.1% to 10.0% of input span
output. Sets time before the loop alarm triggers.
(minutes & seconds)
100%. (-100% to 100% if heat/cool control)
See Soft Start function section.
0.1 to 512.0 seconds
Relay/SSR control output cycle times
Prevents simultaneous activation of both heat & cool
outputs. Choose from On or Off.
Do not use if PB ‘overlap’ has been set
% heating and cooling power upper limits, adjustable
from 0 to 100%
Sets the minimum temperature at which water cooling
will activate.
Non-linear cooling pulse time.
0.01 to 99.99 (seconds)
Minimum non-linear cooling pulse time.
0.01 to 99.99 (seconds)
Attenuates effective cooling vs PID cooling power.
From 1 to 999.9
Last - Powers up with control enable/disable in the same
state as at power off.
On - Always powers up with control enabled.
Off
Start Pre-Tune
Start Tune at SP (Not available for dual Heat & Cool)
161
161
0
8
99.59
25%
-240
32.0
Off
100%
120
10
20
5
Last
Off
20
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