Chromalox 1603 User Manual
1603
Issue Date
June 1999
USER’S MANUAL
0037-75214
Temperature Controller
❑
Chromalox 1603 User's Manual i
Model Identification..................................Page ii
Dimensions and Panel Cut Out ........................ 1
Wiring.........................................................................2
Thermocouple Inputs.................................... 2
RTD Inputs........................................................ 3
Relay Outputs .................................................. 3
Voltage Outpus ............................................... 5
Power Line and Grounding ........................ 6
Configuration Procedure.....................................7
Advanced Configuration ...................................10
Operator Mode .....................................................12
Pushbutton Functions ........................................13
Manual Reset of Alarms ...................................13
SMART Function..................................................14
Direct Access to Setpoint Modification ......15
Output Power OFF...............................................15
Lamp Test ...............................................................15
1603 Operator Parameters ...............................16
Error Messages ....................................................18
Error Descriptions................................................19
Calibration Procedure ........................................21
Warranty and Return..........................................26
Contents
ii Chromalox 1603 User's Manual
Model Identification
Model
1603 1/16 DIN Temperature Controller, Dual Display
Code Output 1 - Heat or Cool
1 Relay, 3 Amps at 250 Vac (Resistive)
6 SSR Drive, 14 Vdc at 20 mA
Code Output 2 - Cool or Alarm
1 Relay, 1 Amp at 250 Vac (Resistive Load)
Code
0 Add to complete model number
Code Instrument Power
3 100-240 Vac
5 24 Vac/dc
Code
0 Add to complete model number
1603 - 61030Typical Model Number
Chromalox 1603 User's Manual 1
1600
SMART
SMART
FUNC
ALM
OUT
˚F
Figure 1
Dimensions and P anel Cut Out
3.0
(75)
2.4
(60)
1.9
(48)
1.77
(45)
1.9
(48)
3.9
(100)
Dimensions in inches (mm in parenthesis)
1.77
(45)
2 Chromalox 1603 User's Manual
Figure 2
Wiring
6
7
8
8
9
10
8
1
2
3
4
5
INST . PWR.
T/C
RTD
+
-
OUT 2
+
-
SSR (Output Code 6 only)
MAIN RELA Y (Output Code 1 only)
NO C NC
"C" "NO"
Sensor Inputs
Note:
Any external components (like Zener diodes, etc.)
connected between sensor and input terminals may cause
errors in measurement due to excessive and/or not
balanced line resistance or possible leakage currents.
TC Input
Figure 3
Thermocouple Input W iring
Wiring Guidelines
3
2
+
-
3
2
+
-
Chromalox 1603 User's Manual 3
Notes:
1.Do not run input wires with power cables.
2.For TC wiring use proper compensating cable (use
type J TC extension wire with type J TC
connections), preferably shielded.
3.Shielded cable should be grounded at one end only.
RTD Input
Figure 4
RTD Input Wiring
Notes:
1.Do not run input wires together with power cables.
2.Observe the line resistance; a high line resistance
may cause measurement errors.
3.When shielded cable is used, it should be grounded
at one end only to avoid ground loop currents.
4.The resistance of the 3 wires must be the same.
TC Inputs (continued)
Relay Outputs
Figure 5
Relay Outputs
123 123
RTD RTD
OUT 1
6
7
8
5
4
OUT 2
NC
C
NO
C
NO
4 Chromalox 1603 User's Manual
Relay Outputs (continued)
The OUT 1 NO contact and the OUT 2 contact are
protected by varistor against inductive loads with
inductive components up to 0.5 A.
OUT 1 contact rating is 3A/250Vac resistive load.
OUT 2 contact rating is 1A/250Vac resistive load.
The number of operations is 1 x 10
5
at specified rating.
Notes:
1.To avoid electric shock, connect power line at the
end of the wiring procedure.
2.For power connections use No 16 AWG or larger
wires rated for at last 75 °C.
3.Use copper conductors only.
4.Do not run input wires together with power cables.
Inductive Loads
Employing the following recommendations will help
avoid serious problems that may occur when relay outputs
are used with inductive loads.
High voltage transients may occur when switching
inductive loads. Through the internal contacts these
transients may introduce disturbances that can affect the
performance of the controller.
For all the outputs, the internal protection (varistor)
assures a correct protection up to 0.5 A of inductive
component.
The same problem may occur when a switch is used in
series with the internal contacts as shown in Figure 8.
Figure 6
External Switch in Series with the Internal Contact
C
R
Load
Power
Line
Chromalox 1603 User's Manual 5
The SSR Drive Output is a time proportioning output.
Logic Level 0:Vout < 0-5 Vdc
Logic Level 1:14V ± 20% @ 17mA
+24V ± 20% @ 1mA
Maximum = 17mA
Notes:
1.This output is not isolated. An external solid state
relay with 2600V isolation must be used to isolate
the controller output and power supply for CE
compliance. The Chromalox Series 4115, 7710,
4001, and 4003 meet these isolation requirements.
2.To determine Output #1 output type, check the tag
on your controller and compare it to the model
identification table on page ii.
Inductive Loads (continued)
Warnings:
When a relay output is used to drive an inductive
load, it is suggested that you connect an external
snubber network (RC) across the terminals using
Chromalox P/N 0149-01305.
Voltage Outputs for SSR Drive
Figure 7
SSR Drive Output Wiring
8
7
+
-
+
-
˜
6 Chromalox 1603 User's Manual
Power Line and Grounding
Figure 8
Power Supply
10
9
N
Power Supply
100 to 240 Vac
or 24 Vac/Vdc
Notes:
1. Before connecting the power line, check that the
voltage is correct (see Model Identification, pg. ii).
2. For supply connections use 16 AWG or larger wires
rated for at least 75 °C.
3. Use copper conductors only.
4. Do not run input wires with power cables.
5. Polarity does not matter for 24 Vdc wiring.
6. The power supply input is NOT fuse protected.
Please provide external fusing.
When the fuse is damaged, it is advisable to verify the
power supply circuit. Return the controller to Chromalox
for test and verification.
7. Safety requirements for permanently connected
equipment:
• Include a switch or circuit-breaker in the
installation.
• Place the switch in close proximity to the
equipment and within easy reach of the
operator.
• Mark the switch as the disconnecting device for
the equipment.
Note:
A single switch or circuit-breaker can drive more
than one controller.
8. When the NEUTRAL line is present, connect it to
terminal 10.
9. To avoid shock and possible controller damage,
connect power last.
Power supply Type Current Voltage
24 V AC/DC T 500 mA 250 V
100/240 V AC T 125 mA 250 V
Chromalox 1603 User's Manual 7
General Operation
There are two setup modes for the 1603:
• Configuration Mode
• Operator Mode
In general, the Configuration Mode is the initial setup of
the controller when first installed. Input type and alarm
setup are examples of Configuration Mode settings. The
Operator Mode includes settings that might be adjusted
frequently with daily control operations such as setpoints
and PID parameters.
Pushbutton Functionality
During Configuration Procedure
FUNC = Must be pressed to store the new value of a
selected parameter and increments to the
next parameter.
SMART= In configuration Mode, scrolls parameters
back (in reverse order) without storing the
new parameter value.
▲ = Increases the value of the selected parameter .
▼ = Decreases the value of the selected parameter.
Configuration Procedure
1. Remove the controller from its case.
2. Set the internal switch V2 (see Fig. 9) in open
condition.
3. Reinsert the controller in the case.
4. Switch the controller “ON”.
Note: If “CAL” indication is immediately displayed,
press the ▲ pushbutton to return to the configuration
mode “CnF.”
5. Push the FUNC pushbutton. The lower display will
show the parameter alphanumeric and the upper
display will show the parameter value.
+
+
1
3
4
2
PZ3
PZ4
PZ5
V2
B
L4
C6
C10
C5
C8
L3
L2
C7
R7
R8
J6
J5
2
C14
C2
R4
R5
R11
Q2
R3
PZ2
PZ1
C15
K2
C9
Figure 9
V2
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