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

8 Chromalox 1603 User's Manual

P1 - Input Type and Standard Range

0 = TC type L range 0 / +800 °C
1 = TC type J range 0 / +800 °C
2 = TC type K range 0 / +999 °C
3 = TC type N range 0 / +999 °C
4 = RTD type P t 100 range -199 / +500 °C
5 = RTD type P t 100 range -19.9 / +99.9 °C
6 = TC type T range 0 / +400 °C
8 = TC type L range 0 / +999 °F
9 = TC type J range 0 / +999 °F
1 0 = TC type K range 0 / +999 °F
1 1 = TC type N range 0 / +999 °F
1 2 = RTD type Pt 100 range -199 / +999 °F
1 3 = TC type T range 0/+752 °F

Note: To set the display for °C engineering units, place
the °C sticker label on the controller faceplate. The label
is located in the shipping box.

P2 = Initial Scale Value

Not present when P1 = 5
Enter the initial and full scale values which are going to
be used by the PID algorithm to calculate the input span.

When this parameter is modified, rL (setpoint lower
limit) is automatically modified to the same value.

P3 = Full Scale Value

Not present when P1 = 5
When this parameter is modified, rH (setpoint upper
limit) is automatically modified to the same value. The
initial and full scale values determine the input span
which is used by the PID algorithm, the SMART and the
alarm functions.

Note: The minimum input span (P3 - P2) is 600°F
(300°C) for TC input and 200°F (100°C) for RTD input.

P4 = Main Output Action

The 1603 skips this parameter when P5 = 5 (cooling)
r = reverse action (heating)
d = direct action (cooling)

P5 = Output 2 Functions

0 = None
1 = Process alarm (absolute)
2 = Band alarm (+ and - deviation)
3 = Deviation alarm (+ or - deviation)
4 = Controller failure indicator (under- or over-range,

CJC or A-D converter failure)

5 = Cooling output
Note: When P5 = 5, the P4 parameter is forced to “r”.

Chromalox 1603 User's Manual 9

P6 = Output 2 Operative Mode

P6 is available only when P5 is different from 0.
When P5 = 1, 2, or 3:
H.A. = high alarm (outside boand) with automatic reset
L.A. = low alarm (inside band) with automatic reset
H.L. = high alarm (outside band) with manual reset
L.L = low alarm (inside band) with manual reset
When p5 = 4, the selections H.A. and L.A. are controller
failure indicator alarms with automatic reset. The H.L.
and L.L. selections are controller failure indicator alarms
with manual reset.
When P5 = 5, this parameter selects the cooling medium:

AIr= Air
OIL = Oil
H

2

0 = Water
Note: Different set of cooling medium produces the
automatic modification of the relative cooling gain and of
the cooling cycle time.

P7 = Alarm Action

Present only when P5 is different from 0 or 5.

r = reverse (relay de-energized in alarm condition)
d = direct (relay energized in alarm condition)

P8 = Alarm Inhibit

Present only when P5 is different from 0,4 or 5.

OFF = Inhibit disabled
ON = Inhibit enabled

Note: If the alarm is programmed as band or deviation
alarm, this function disables the alarm condition after a
setpoint change or at the controller startup until the
process variable passes the alarm setpoint plus or minus
hysteresis. If the alarm is programmed as a process alarm,
this function disables the alarm condition at controller
startup until the process variable passes the alarm setpoint
plus hysteresis.

P9 = OFFSET Applied to the Measured Temperature

This OFFSET is applied along the whole range.
When P1 = 5 P9 is programmable from -19.9 to

19.9 °C.

When P1 ≠ 5 P9 is programmable from -199 to

199 °C or °F.

P10 = Threshold of the “Soft Start” Function

Enter the Threshold value, in °C or °F, for the automatic
start of the “Soft Start” function (limiting output power).
If the unit powers up below the Threshold value, the
“Soft Start” function is enabled and limits the power
output to “OLH” for “tOL” minutes. “OLH” and “tOL”
are set in the Operator Mode.

P6 C (cycle time) rC (cool gain)

Air 10(s) 1
Oil 4(s) 0.8

H

2

O 2(s) 0.4

10 Chromalox 1603 User's Manual

P11 = User Defined Security Code

0 = Security lock disabled. All Operator Mode

parameters can be modified.

1 = Security lock enabled. No parameters can be

modified except the setpoint.

2 to 499 = Select the security code (to be stored).

During the “Operator Mode” the security code
setting will display:

a. The controller is “Unlocked”

and all parameters can be
modified. To make the device
Locked,” insert a number
different from the security code.
Now none of the parameters can
be modified except the SP.

b. The controller is “locked” and

none of the parameters can be
modified except the SP.
To “Unlock” the device, insert
the security code.

500 to 999 = Selecting a security code between these two
numbers, everything will occur as explained above except
that when the device is “Locked” the only parameters
that can be modified are the setpoint and the alarm
setpoint.

P12 = Control Output Maximum Rate of Rise

Programmable from 1% to 10% of the output per second.
The ramp is applied when the controller changes the
percent of output desired. Above 10%, the display will
show “InF”, meaning that no ramp is imposed and the
output immediately changes to the PID calculated value.
P12 not used if ON/OFF control selected.

Advanced Configuration

When the standard configuration procedure is completed,
the controller shows “-,-,-,-,” on both displays. When it is
desired to end the configuration procedure, push the
FUNC pushbutton. The display will show “COnF”.

To access the advanced configuration parameter, procede
as follows:

1. using ▲ and ▼ pushbuttons, set the 219 code.

2. push the FUNC pushbutton.

Chromalox 1603 User's Manual 11

P14 = Display of the Operator Parameters

This parameter is available only if P11 is different from 0.
This parameter allows you to enable/disable the display of
the operator parameters.
OFF = parameter cannot be displayed
ON = parameter can be displayed, but not changed

P15 = SMART Function Enabling/Disabling

0 = The SMART function is disabled
1 = The SMART function enabling/disabling is NOT

protected by the Security Code (P11).

2 = The SMART function enabling/disabling is

protected by the Security Code (P11).

P16 = Maximum Value of the Proportional Band by

the SMART Function

This parameter may be programmed from P17 or P18
value to 99.9.

P17 = Minimum Value of the Proportional Band Set

by the SMART Function in Heating Control
Only

This parameter is present only if P5 is different from 5.
It may be programmed from 1.0% to P16 value.

P18 = Minimum Value of the Proportional Band Set

by the SMART Function in Heating/Cooling
Control Only

This parameter is present only when P5 is equal to 5.
This parameter may be programmed from 1.5% to P17.

P19 = Automatic Modification of Relative Cooling

Gain

This parameter is present only when P5 is equal to 5.
OFF = The SMART function does not modify the

“relative cooling gain” parameter.

ON = The SMART function modifies the “relative

cooling gain” parameter (rC).

P20 = Minimum Value of Integral Time Set by

SMART Function

P20 is programmable from 00.1 (10 seconds) to 02.0
(2 minutes).

P21 = Extension of the Anti-Reset-Windup

Range: from -30 to +30% of the proportional band
Note: A positive value increases the high limit of the
anti-reset-windup (over setpoint), while a negative value
decreases the low limit of the anti-reset-windup (under
setpoint).

End of Advanced Configuration

When the advanced configuration procedure is
completed, the controller displays “CnF”.

To restart Configuration

Push FUNC to begin the Configuration Mode.

12 Chromalox 1603 User's Manual

+

+

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

Operator Mode

1. Remove the controller from its case.

2. Set the internal switch V2 in closed condition.

3. Reinsert the controller in its case.

4. If, during the configuration procedure, a display in °C

has been selected, it is necessary to put the °C sticker
label on the front of the controller. The additional
label is located in the shipping box.

5. The 1603 displays the measured temperature on the
upper display and the programmed set point on the
lower display. This display is known as the “normal
display mode.” If error 400 message is displayed, press

the ▲ or ▼ simultaneously until normal display mode
appears.

V2

°C

Closed Position

Indicators

SMART= Flashes when the first part of the SMART

algorithm is active. Lit when the second
part of the SMART algorithm is active.

OUT = Lit when OUT 1 is in ON condition.
ALM = Lit when Alarm 1 is in alarm condition or

when this output is used as a time
proportioning cooling control output.

Figure 10

Chromalox 1603 User's Manual 13

Pushbutton Functions

FUNC = Must be pressed to store the new value of a

selected parameter and increments to the
next parameter. Parameter values are
displayed on the upper display; parameter
name is displayed on the lower display.

SMART= Enables or Disables the SMART function,

when held for 1.5 seconds.
Scrolls operator parameters back
(in reverse order).

▲ = Increases the value of the selected parameter.
▼ = Decreases the value of the selected parameter.
▼ + FUNC = Press together to perform an LED/

indicator test. Press both again to turn
LED/ indicator test “off”.

Note: A 10 second time out occurs during parameter
modification. If, during parameter modification, no
pushbutton is pressed for more than 10 seconds, the
controller automatically reverts to the “normal display
mode”. The new setting of the last parameter modified is
stored, prior to the time out, only if the FUNC
pushbutton was depressed.

Manual Reset of Alarms

If the alarm has been configured as a latching alarm, the
alarm status persists after the alarm condition disappears
until the alarm is reset.
To reset the alarm, press the FUNC pushbutton to select
the “n.rS” parameter. The displays will show “n.rS” and
“OFF”. Using ▲ and ▼, select “ON” and push the FUNC
pushbutton again.
The alarm reset action will only occur if the alarm
condition no longer exists.

14 Chromalox 1603 User's Manual

SMART Function

The SMART function automatically calculates the
optimum PID control parameters. To enable the SMART
function, push and hold the SMART pushbutton for more
than 1.5 seconds, when the controller is in normal display
mode. The SMART LED will light or flash according to
the algorithm automatically selected. When the SMART
function is enabled, it is possible to display but not to
modify the control parameters (PB, TI, TD and rC).
When the traditional control (PID) is desired, push and
hold the SMART pushbutton for more than 1.5 seconds
again to turn the “SMART” OFF. The controller
maintains the last set of SMART calculated control
parameters and allows parameters to be adjusted.

Notes:

1. During the SMART function operation, the relative
cooling gain (if present and controlled by SMART) is
limited within the following ranges:

Cooling Medium Range

Air 0.85 to 1.00
Oil 0.80 to 0.90
H2O 0.30 to 0.60

2. The SMART function uses a derivative time equal to
1/4 of the integral time.

3. The limits of the proportional band set by the SMART
function are programmed by P16, P17, and P18
parameters.

4. The lower limit of the integral time set by SMART
function is programmed by P20 parameter.

5. When ON/OFF control is programmed (PB = 0), the
SMART function is disabled.

6. The SMART enabling/disabling can be protected by
the safety lock (see P15 parameter).

Chromalox 1603 User's Manual 15

Direct Access to Setpoint Modification

When direct access to setpoint modification is required,
proceed as follow:

1. Push, for more than 3 seconds, the ▲ or ▼ pushbutton;
the set point value, shown on the lower display, will
start to change.

2. Using the ▲ and ▼ pushbuttons, set the desired value.

3. When the desired value is reached, do not push any
pushbutton for more than 3 seconds. The new setpoint
will become operative 3 seconds after the pushbutton is
released.

If, during this procedure, there is no interest in
memorizing the new value, push the FUNC pushbutton;
the controller returns automatically to the normal display
mode without having memorized the new setpoint.

Output Power OFF

To turn the output signal OFF, press and hold the ▲
pushbutton then push FUNC.

Pressing both pushbuttons for more than 3 seconds, will
cause the controller will show “OFF” instead of the set
point value.

In the output power OFF condition, the parameters can
always be viewed and modified. When control is disabled
(output power off), the alarms are not in an alarm
condition. The alarm output status depends on the type of
alarm action.

When the output is OFF, all parameters can be reviewed
and modified. The SMART function will be disabled
during the OFF condition. If power is lost, the unit will
power-up in the OFF condition.

To return to normal control, press and hold the ▲ and
then push FUNC for more than 3 seconds. The controller
then automatically goes to the NORMAL DISPLAY
MODE.

The alarm inhibit function, if configured, will be
activated as if it were a powerup.

Lamp Test

To verify operation of the display LED, push ▼ and
FUNC together. The instrument LEDs will flash until the
Lamp Test is turned off.

To turn off the Lamp Test, press ▼ and FUNC together.
No pushbutton functions are operable during the Lamp

Test.

16 Chromalox 1603 User's Manual

1603 Operator Parameters

Push the FUNC pushbutton. The lower display will show
the cue while the upper display will show the value of the
selected parameter. Not all parameters will be displayed
due to specific unit configuration.

Cue Description
SP Setpoint—range set at P1-Sensor Selection. May

be limited by setting low and high limits at P2
and P3 (see configuration parameters).

n.rS Manual reset of latching alarms. Press ▲ to set

ON, then press FUNC to reset the alarm.

nnn Security code for parameter protection.

ON=the controller is in LOCK condition
OFF=the controller is in UNLOCK condition
When it is desired to switch from LOCK to
UNLOCK condition, set a value equal to P11
parameter.
When it is desired to switch from UNLOCK to
LOCK condition, set a value different from P11
parameter.

Cue Description
AL Alarm setpoint—range for a process alarm set

at P1-Sensor Selection and may be limited by
setting low and high limits at P2 and P3
(see Configuration Parameters). Range for a
band alarm 0-500, range for a deviation alarm

-199 to 500.
HSA Alarm hysteresis—deadband range from 0.1 to10.0 %.
Pb Proportional band—range from 1.0 to 99.9 % of

span (P3-P2) for heat or cool control and 1.5 to

99.9% of span (P3-P2) for heat/cool control. When

Pb = 0 the controller performs as an ON/OFF
control and ti, td, C, C2, rC, OLP, OLh and tOL
parameters are skipped.

HS Hysteresis (deadband for ON/OFF control action

(Pb = 0)—range from 0.1 to 10 % of input span
(P3-P2).

ti Integral time—range from 0 minutes and 10

seconds to 20 minutes and 0 seconds (minutes.
seconds); above the upper limit the display
blanks out and the integral action is excluded.

td Derivative time—range from 0.00 to 9.59

Chromalox 1603 User's Manual 17

1603 Operator Parameters (continued)

(minutes. seconds). td = 0, turns off derivative

action.
Cue Description
IP Integral PreLoad—range 0 to 100% for one

control output, -100 to 100% for two control

outputs (P5 =5). This parameter does not

appear when Pb (Proportional Band) = 0.
C Heating cycle time—range from 1 to 200 seconds (30

seconds or greater recommended for relay outputs).
C2 Cooling cycle time—range from 1 to 200

seconds (30 seconds or greater recommended

for relay outputs). Available if P5 = 5.
rC Relative cooling gain—range from 0.20 to 1.00.

This parameter does not appear if P5 ≠ 5 or

PB = 0.
OLP Dead zone/Overlap—range from -20% to + 50%

of the proportional band. A negative value is a

dead zone and a positive value creates an

overlap. Available if P5 = 5 and PB ≠ 0.
rL SP low limit—range from the initial scale value

(P2) to rH value.

Cue Description
rH SP high limit—range from the rL value to the full

scale value (P3).

OLH Output power maximum value—range 0 to 100%

heating, -100 to 100% heat/cool, limits power
continuously (tOL = Inf) or on start up per tOL
setting. PB ≠ 0.

tOL Time interval for OLH power output limit, range

1 to 100 minutes or if “Inf” infinite. The timer
starts on power up if the actual temperature is
less than P10 (threshold value). A new TOL
value will not become active until the unit is
powered up. If PB = 0, this parameter will not
be displayed.

18 Chromalox 1603 User's Manual

Error Messages

OVERRANGE, UNDERRANGE, and BURN-OUT
INDICATIONS

The controller shows the OVERRANGE and
UNDERRANGE conditions with the following

UnderrangeOverrange

indications:
The sensor leads break can be signalled as:

• for TC input: OVERRANGE

• for RTD input: OVERRANGE

Sensor leads short circuit detection:
On RTD input, a special test is provided to signal
OVERRANGE when input resistance is less than 15 ohm
(short circuit sensor detection).

Note;

• When the controller is set for one output only, and an
OVERRANGE is detected, the OUT 1 turns OFF (if
reverse action) or ON (if direct action).

• When the controller is set for heating/cooling action,
an and OVERRANGE is detected, OUT 1 turns OFF
and OUT 2 turns ON.

• When the controller is set for one output only, and an
UNDERRANGE is detected, the OUT 1 turns ON (if
reverse action) or OFF ( if direct action).

• When the controller is set for heating/cooling action,
and an UNDERRANGE is detected, OUT 1 turns ON
and OUT 2 turns OFF.

• When an OVERRANGE or UNDERRANGE is
detected, the alarms operate as in the presence of the
maximum or the minimum measurable value
respectively.

To eliminate the OUT OF RANGE condition, proceed as
follows:

1. Check the input signal source and the connecting line.

2. Make sure that the input signal is in accordance with
controller configuration; otherwise, modify the input
configuration. See P1.

Chromalox 1603 User's Manual 19

ERRORS

Diagnostics are made at controller power-up and during
normal mode of operation. If a fault condition (error) is
detected, the lower display will show the message “Err”
while the upper display shows the error code.

10 0 EEPROM memory writing error.

After 2 seconds the controller restarts
automatically. If this error persists, send the
controller back to your supplier.

1 50 General hardware error on the CPU card.

If this error persists, send the controller
back to your supplier.

20 0 Protect register memory error.

The controller remakes this check every 2
seconds.
Set the switch V2 in open condition. Switch
on the controller. Set the switch V2 in
closed condition, and power the controller.
If this error persists, send the controller
back to your supplier.

201-219 Wrong configuration parameter value (2xx,

where xx is the Configuration Code).
The two least significant digits show the
number of the wrong configuration
parameter. Return to the configuration
procedure and check the values.

30 1 RTD calibration error.

Go to calibration procedure and check the
P1 and PH calibrations. See RTD calibration
check.

30 5 Thermocouple input calibration error.

Go to calibration procedure and check the tl
and tH calibrations. See Thermocouple
Calibration Check.

30 7 Reference junction calibration error.

Go to calibration procedure and check the
tJ calibration. See Cold Junction Calibration
specs.

ERROR Descriptions

ERROR Descriptions

20 Chromalox 1603 User's Manual

4 00 One or more control parameters are out of

range with respect to the allowed values.
It may appear at controller power-up after
configuration changes.
Push and hold ▲ and ▼ pushbuttons
simultaneously and load all the default
parameters.

500 Autozero error.

The controller measures an internal
autozero value too negative or too positive.
The controller checks this condition every
30 seconds.
If this error persists, send the controller
back to your supplier.

50 2 Cold junction measurement errors.

The controller cannot perform cold junction
compensation.
Check the ambient temperature and, if
necessary, re-calibrate the cold junction.
If this error persists, send the controller
back to your supplier.

ERROR Descriptions ERROR Descriptions

51 0 Incorrect measured value during calibration

procedure.
Check the input value and, if necessary,
calibrate the controller.
If this error persists, send the controller
back to your supplier.

Figure 11

Dip Switch Location: To start calibration, V2 must be
OPEN.

+

+

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

V2

Open Position

Calibration

Chromalox 1603 User's Manual 21

Note:
All 1603s are calibrated at the manufacturing
plant. It is not necessary to calibrate the 1603 on
receipt.

For a good calibration, it is necessary to proceed as
follows:

1. The controller under calibration should be mounted in
its case in order to keep the internal temperature
constant.

2. The ambient temperature should be stable. Avoid any
draft due to air conditioning, etc.

3. The relative humidity should not exceed 70%.

4. Minimum warm-up time must be 20 minutes.

5. If possible, operate in a noise free environment.

6. During calibration, connect one input at a time to the
rear terminal block.

WARNING:
Do not attempt calibration without the
recommended simulators or calibrators.

General Guide Lines for Calibration

Calibration Procedure

Calibration parameters are logically divided in groups of
two parameters each (initial and final scale value). After
each group, the calibration check is provided but it is also
possible to do the check without calibrating.

Note:

Pushing the SMART pushbutton goes back to the
previous parameter without modifying the calibration.

For this calibration procedure it is necessary to use
calibrators with the following accuracy and resolution:

Accuracy

1. For TC input: +0.005% output +0.001% range
+ 5 µV

2. For RTD Input: ±0.02% ±0.0025 Ω/decade.

3. For cold junction compensation: better than 0.1°C.

Resolution

1. For TC input: 1 µV.

2. For RTD input: 10 mΩ

3. For cold junction compensation: better than 0.1°C.

22 Chromalox 1603 User's Manual

Calibration Procedure (continued)

All the controllers are originally calibrated at the factory
by means of calibrators with high accuracy and resolution.
The following is a complete list of calibration symbols:

Code Parameter

tL TC input initial scale value (0 mV)
tH TC input full scale value (50 mV)
t. TC input check
rJ Cold junction compensation
rJ. Cold junction compensation check
PL RTD input initial scale value (0 Ω)
PH RTD input full scale value (300.00Ω)
P. RTD input check

How to Proceed

1.To start calibration, V2 must be OPEN (see Figure 11).

2.Switch on the controller. The display will show CnF.

3.Push ▲ pushbutton. The display will show CAL.

4.Push the FUNC pushbutton to display the first
calibration code.

5.Depress FUNC pushbutton in sequence until the
desired calibration code is reached.

TC Input Initial Scale Value

1.Provide connections between calibrator and controller
under test as shown in Figure 12.

2.“OFF” will show on the upper display, while “tL” will
appear on the lower display.

3.Set calibrator to 0.000 mV. Push ▲ pushbutton. The
upper display will change to “ON”.

4.After 30 seconds, start calibration by pushing FUNC
pushbutton. Only the decimal point of the last
significant digit will light to indicate that the
controller is performing the calibration routine. At the
end of this calibration routine, the controller will go to
the next parameter.

Figure 12

3

2

+

-

RTD Calibration only:

If only calibrating RTDs, press FUNC until the “PL”
parameter is displayed and proceed to page 24 (PL) for
further instructions.

Chromalox 1603 User's Manual 23

tH-TC Input—Full Scale Value

1. After “tL” is calibrated, the 1603 will display “tH” for
the full scale value.

2. Set the calibrator to 50.000 mV (full scale value).

3. Push ▲ pushbutton. The upper display will show “ON”.

4. After 30 seconds, start calibration by pushing the
FUNC pushbutton. Only the decimal point of the last
significant digit will light to indicate that the
controller is performing the calibration routine. At the
end of this calibration routine, the controller will go
the next step.

TC Input Check

000
t. 3 0

1. Check the zero calibration by setting the calibrator to

0.000 mV. The readout must be t.00 000 ± 10 counts.

2. Check linearity at half scale by setting 25.000 mV on
the calibrator. The readout must be “t 15 000” ± 10
counts.

3. If linearity is incorrect, repeat thermocouple
calibration.

4. Push the FUNC pushbutton. “OFF” and “rJ” will appear
on the display.

RJ—Cold Junction Compensation
Note:

Make sure that tL and tH parameters are correctly
calibrated before rJ calibration.

1. Measure the temperature close to terminals 1 and 3
using an instrument with accuracy better than 0.1°C
(see Figure 13).

2. Wait a few minutes to allow the temperature to
stabilize over the entire system.

3. “rJ” and “OFF” are being displayed. Using ▲ and ▼
pushbuttons, set a value equal to the temperature
measured by the measuring device in a tenth of °C.

The display will show “t” followed by a number showing
the measured value in counts.

With the calibrator set to 50.000 mV, the calibration is
correct if the indication is “t.30 000” ± 10 counts.

24 Chromalox 1603 User's Manual

RJ—Cold Junction Compensation (continued)

4.Start calibration by pushing the FUNC pushbutton.
Only the decimal point of the last significant digit will
light to indicate that the controller is performing the
calibration routine. At the end of this calibration
routine, the controller will go to the next calibration
step.

Figure 13

1

3

+

Measuring

Device

Cold Junction Compensation Check

The display will show “rJ.” and the temperature, in tenths
of °C, measured by the CJ compensator.
Make sure that the display readout is equal to the value
read on the measuring device.
Push the FUNC pushbutton. The controller will go to the
next parameter.

PL—RTD Input Initial Scale Value

1.Connect a resistor box as shown in Figure 14.

2.Set 0.00 Ω on the resistor box.

3.Push ▲ pushbutton. The upper display will show “ON”.

4.After 30 seconds, start calibration by pushing FUNC
pushbutton. Only the decimal point of the last
significant digit will light to indicate that the
controller is performing the calibration routine. At the
end of this calibration routine, the controller will go to
the next parameter.

Figure 14

1

2

3

TC Calibration only:

Thermocouple calibration is now complete, if RTD
calibration is not needed. Press FUNC until “CAL” is
displayed. See Step 5 on page 25.

Chromalox 1603 User's Manual 25

PH—RTD Input Full Scale Value

1. Set the resistance box to 300.00 Ω.

2. Push ▲ pushbutton. The upper display will show “ON”.

3. Wait 30 seconds then push the FUNC pushbutton.
Only the decimal point of the last significant digit will
light to indicate that the controller is performing the
calibration routine. At the end of this calibration
routine. The controller will go to the next parameter.

P.—RTD Input Check

1. The display will show “P.” followed by a number
showing the measured value in counts.

000
P. 3 0

Set the resistance box to 300.00 Ω. The calibration is
correct if the indication is “P. 30 000” ± 10 counts.

2. Check the zero calibration by setting 0.00 Ω on the
resistance box. The readout should be “P. 00 000” ± 10
counts.

3. Check linearity using the table below.
The relationship between input signal and counts for

RTD input is not linear.
The correct relationship is shown in the following table:

4. If linearity is incorrect, repeat RTD calibration.

5. Push the FUNC pushbutton.
The calibration procedure is terminated and the display

will show “CAL”. When it is desired to go to the
configuration procedure, depress the ▲ pushbutton and
the display will show “CnF” and the controller is in
configuration mode.
If the previous configuration is correct, switch the
controller OFF and set the switch V2.

Resistor Box Display

Ω Counts

00 ± 10 counts
100 10 153 ± 10 counts
200 20 151 ± 10 counts
300 30 000 ± 10 counts

26 Chromalox 1603 User's Manual

Warranty And Limitation Of Remedy
And Reliability

Chromalox warrants only that the Products and parts
manufactured by Chromalox, when shipped, and the work
performed by Chromalox when performed, will meet all
applicable specification and other specific product and
work requirements (including those of performance), if
any, and will be free from defects in material and
workmanship under normal conditions of use. All claims
for defective or nonconforming (both hereinafter called
defective) Products, parts or work under this warranty
must be made in writing immediately upon discovery, and
in any event, within three (3) years from delivery,
however all claims for defective Products and parts must
be made in writing no later than three (3) years after
shipment by Chromalox. Defective and nonconforming
items must be held by Chromalox’s inspections and
returned to the original f.o.b. point upon request. THE
FOREGOING IS EXPRESSLY IN LIEU OF ALL
OTHER WARRANTIES WHATSOEVER, EXPRESS,
IMPLIED AND STATUTORY, INCLUDING,
WITHOUT LIMITATION, THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE.

Notwithstanding the provisions of this WARRANTY
AND LIMITATIONS Clause, it is specifically understood
that Products and parts not manufactured and work not
performed by Chromalox are warranted only to the extent
and in the manner that the same are warranted to
Chromalox by Chromalox’s vendors, and then only to the
extent that Chromalox is reasonably able to enforce such
a warranty, it being understood Chromalox shall have no
obligation to initiate litigation unless buyer undertakes to
pay all cost and expenses therefore including but not
limited to attorney’s fees, and indemnifies Chromalox
against any liability to Chromalox’s vendors arising out of
such litigation.

Upon buyer’s submission of a claim as provided above and
in its substantiation, Chromalox shall at its option either
(i) repair or replace its Products, parts or work at the
original f.o.b. point of delivery or (ii) refund an equitable
portion of the purchase price.

The foregoing is Chromalox’s only obligation and buyer’s
exclusive remedy for breach of warranty, and is buyer’s
exclusive remedy against Chromalox for all claims arising
hereunder or relating hereto whether such claims are
based on breach of contract, tort (including negligence
and strict liability) or other theories, buyer’s failure to

Chromalox 1603 User's Manual 27

submit a claim as provided above shall specifically waive
all claims for damages or other relief, including but not
limited to claims based on latent defects. In no event
shall buyer be entitled to incidental or consequential
damages and buyer should hold Chromalox harmless
therefrom. Any action by buyer arising hereunder or
relating hereto, whether based on breach of contract, tort
(including negligence and strict liability) or other
theories, must be commenced within three (3) years after
the date of shipment or it shall be barred.

Returns

Items returned to Chromalox Instruments and Controls
must be accompanied by a Return Authorization Number.
This number may be obtained from Chromalox
Instruments and Controls, Customer Service Department,
Telephone Number [phone]. It should appear on
the exterior of the shipping carton and on the shipping
documents. Defective items will be repaired or replaced at
our option, at no charge.

Return the defective part or product, freight prepaid, to:

Chromalox Instruments and Controls
1382 Heil-Quaker Blvd.
LaVergne, TN 37086-3536

28 Chromalox 1603 User's Manual

Chromalox

®

INSTRUMENTS AND CONTROLS

1382 HE IL QUAKER BOULEVARD

LAVERGNE, TN 37086-3536

PHO NE [phone]

FAX [phone]

WIEG AN D IN DU STRIAL D IVIS IO N

EM ERSON E LECTR I C CO.

®