Chromalox 1604 User Manual

1604

Temperature Controller

Issue date r USER'S MANUAL
May 2000

Chromalox

1604

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CONTENTS

MOUNTING REQUIREMENTS ........................... 1

OUTLINE AND CUT OUT DIMENSIONS ........... 2

CONNECTION DIAGRAMS ................................ 3

PRELIMINARY HARDWARE SETTINGS ........... 9

CONFIGURATION PROCEDURE .................... 10

OPERATIVE MODE .......................................... 18

Display function .......................................... 18

Indicators ................................................... 18

Pushbutton function during

operating mode .......................................... 19

Enable/disable the control output ............... 20

SP/SP2 selection ....................................... 20

OUT 1 failure detection function ................. 20

Direct access to the set point ..................... 20

Manual function .......................................... 21

Serial link ................................................... 21

Lamp test ................................................... 22

SMART function ......................................... 22

OPERATIVE PARAMETERS ............................ 23

ERROR MESSAGES ........................................ 26

GENERAL INFORMATIONS ............................ 28

MAINTENANCE ................................................ 32

DEFAULT PARAMETERS ...............................A.1

II

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III

Model identification

Model

1604 1/16 DIN Temperature Controller

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 - Alarm

1 Relay, 2 Amp at 250 VAC (Resistive load)

Code

0 None

1 Out #3, 2 Amps at 250 V AC (Resistive load)

2 Heater Break Down input, Out #3

3 RS 485 Digital communications, Out #3

4 RS 485 Digital comm., Heater Break Down input, Out #3

Code Instrument Power

3 100 - 240 Vac

5 24 Vac/dc

Code

0 Add to complete model number

1601 6 1 0 3 0 Typical Model Number

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1

MOUNTING REQUIREMENTS

Select a location, for instrument mounting, where
minimum vibrations are present and the ambient
temperature is within 0 and 50 °C (32 and 122°F).
The instrument can be mounted on a panel up to
15 mm thick with a square cutout of 45 x 45 mm.
For outline and cutout dimensions refer to Fig. 2.
The surface texture of the panel must be better
than 6,3 mm.
The instrument is shipped with rubber panel
gasket (50 to 60 Sh).
To assure the IP65 and NEMA 4 protection, insert
the panel gasket between the instrument and the
panel as show in fig. 1.
While holding the instrument against the panel
proceed as follows:

1) insert the gasket in the instrument case;

2) insert the instrument in the panel cutout;

3) pushing the instrument against the panel,

insert the mounting bracket;

4) with a screwdriver, turn the screws with a

torque between 0.3 and 0.4 Nm.

Panel

bracket

Screw

Gasket

Fig. 1

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2

OUTLINE AND CUT OUT
DIMENSIONS

Fig. 2 OUTLINE AND CUT-OUT DIMENSIONS

1.9
(48)

2.2

(56)

4.8

(122)

3.0

(75)

2.4
(60)

1.77
(45)

1.77
(45)

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3

CONNECTION DIAGRAMS

Connections are to be made with the instrument
housing installed in its proper location.

Fig. 3

REAR TERMINAL BLOCK

NO

1

3

4

5

6

7

8

9

10

2

11

13

14

15

12

RS 485

NO

OUT3

SSR

OUT1

OUT2/3

LINEAR

NO

C

CPWR LINE

100/240VAC

A/A’B/B’

OUT2

IN

CT/SP-SP2

C

+

-

T/C

RTD

+

-

A) MEASURING INPUTS
NOTE: Any external component (like zener

barriers 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

Fig. 4 THERMOCOUPLE INPUT WIRING

NOTE:

1) Don’t run input wires together with power ca­bles.

2) For TC wiring use proper compensating cable
preferable shielded.

3) When a shielded cable is used, it should be
connected at one point only.

9

+

_

Shield

9

+

_

Shield

10

10

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4

LINEAR INPUT

Fig. 6 mA, mV AND V INPUTS WIRING

NOTE:

1) Don’t run input wires together with power

cables.

2) Pay attention to the line resistance; a high line

resistance may cause measurement errors.

3) When shielded cable is used, it should be

grounded at one side only to avoid ground loop
currents.

4) The input impedance is equal to:

< 5 W for 20 mA input
> 1 MW for 60 mV input
> 200 kW for 5 V input
> 400 kW for 10 V input

RTD INPUT

Fig. 5 RTD INPUT WIRING

NOTE:

1) Don’t run input wires together with power
cables.

2) Pay attention to the line resistance; a high line
resistance may cause measurement errors.

3) When shielded cable is used, it should be
grounded at one side only to avoid ground loop
currents.

4) The resistance of the 3 wires must be the
same.

8

RTD

10

9 8

RTD

10

9

Shield

_

+

mA,

mV

or
V

9

+

_

G

mA
mV

or

V

10

9

10

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5

B.1) LOGIC INPUT

This instrument can use the input "IN CT/SP­SP2" (connections 14 and 15) as current
transformer input or logic input.

Safety note:

1) Do not run logic input wiring together with
power cables.

2) Use an external dry contact capable of
switching 0.5 mA, 5 V DC.

3) The instrument needs 100 ms to recognize a
contact status variation.

4) The logic inputs are NOT isolated by the
measuring input.

5) This feature excludes the current transformer
input.

Fig. 7 - LOGIC INPUT WIRING

When the logic input is selected, it is used to
switch, by an external contact, from main set
point to second set point and viceversa.

logic input op. set point

open SP
close SP2

14

IN CT/SP-SP2

15

B.2) CURRENT TRANSFORMER INPUT

This instrument can use the input "IN CT/SP­SP2" (connections 14 and 15) as current
transformer input or logic input.

Safety note:

1) Do not run current transformer input wiring
together with AC power cables.

2) The minimum active period to perform this
measurement is equal to 400 ms.

3) This feature excludes the logic input function.

4) The input impedance is equal to 10 W.

Fig. 8 - CURRENT TRANSFORMER INPUT

WIRING

This input allows to measure and display the
current running in the load driven by the
OUTPUT1 during the ON and OFF period of the
OUT 1 cycle time. By this feature it is also
available the "OUT 1 failure detection" function
(see page 20).

14

15

Load

Current

transformer

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6

INDUCTIVE LOADS

High voltage transients may occur switching
inductive loads.
Through the internal contacts these transients
may introduce disturbances which can affect the
performance of the instrument.
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 Fig. 10.

Fig. 10 EXTERNAL SWITCH IN SERIES WITH

THE INTERNAL CONTACT

In this case it is recommended to install an
additional RC network across the external contact
as show in Fig. 10
The value of capacitor (C) and resistor (R) are
shown in the following table.

The cable involved in relay output wiring must be
as far away as possible from input or communica­tion cables.

C) RELAY OUTPUTS

Fig. 9 RELAY OUTPUTS WIRING

The contact rating of the OUT 1 is 3A/250V AC
on resistive load.
The contact rating of the OUT 2 and 3 is 2A/250V
on AC resistive load.
The number of operations is 1 x 105 at specified
rating.
NOTES 1) To avoid electrical 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) Don’t run input wires together with
power cables.

All relay contacts are protected by varistor against
inductive load with inductive component up to 0.5 A.

The following recommendations avoid serious
problems which may occur, when using relay
output for driving inductive loads.

OUT 1

(heating or

cooling)

OUT 2

(cooling /AL1)

OUT 3
(AL 2)

6

7

C

NO

1

2

3

NO - OUT 2

C - OUT 2/3

NO - OUT 3

LOAD

R

C

POWER

LINE

LOAD

(mA)

<40 mA
<150 mA
<0.5 A

C

(mF)

0.047

0.1

0.33

R

(W)

100

22
47

P.

(W)

1/2

2
2

OPERATING

VOLTAGE

260 V AC
260 V AC
260 V AC

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7

VOLTAGE OUTPUTS FOR SSR DRIVE

Fig. 11 SSR DRIVE OUTPUT WIRING
It is a time proportioning output.

Logic level 0: Vout < 0.5 V DC.
Logic level 1:

- 14 V

+ 20 % @ 20 mA

- 24 V

+ 20 % @ 1 mA.

Maximum current = 20 mA.

NOTE: This output is not isolated. A double or
reinforced isolation between instrument output
and power supply must be assured by the
external solid state relay.

SERIAL INTERFACE

RS-485 interface allows to connect up to 30
devices with one remote master unit.

Fig. 12 - RS-485 WIRING
The cable length must not exceed 1.5 km at 9600
BAUD.
NOTE: 1) This is an RS485 isolated interface.

2)The following report describes the
signal sense of the voltage appearing
across the interconnection cable as
defined by EIA for RS-485.
a) The ” A ” terminal of the generator shall
be negative with respect to the ” B ”
terminal for a binary 1 (MARK or OFF)
state.
b) The ” A ” terminal of the generator shall
be positive with respect to the ” B ”
terminal for a binary 0 (SPACE or ON)

12

13

COMMON

11

B'/B

B/B'

A/A'

A'/A

M

A
S
T
E
R

I
N
S
T
R
U
M
E
N
T

+

_

_

+

6

7

OUT 1

SOLID STATE

RELAY

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8

and within easy reach of the operator;

- it shall be marked as the disconnecting
device for the equipment.
NOTE: a single switch or circuit-breaker can drive
more than one instrument.

9) When a neutral line is present, connect it to
terminal 4

5

4

POWER LINE 100 V to 240 V A.C

(50/60Hz)

or 24 V AC/DC

D) POWER LINE WIRING

Fig. 13 POWER LINE WIRING

NOTES:

1) Before connecting the instrument to the power
line, make sure that line voltage corresponds to
the descrtiption on the identification label.

2) To avoid electrical shock, connect power line at
the end of the wiring procedure.

3) For supply connections use No 16 AWG or larger
wires rated for at last 75 °C.

4) Use copper conductors only.

5) Don’t run input wires together with power cables.

6) For 24 V DC the polarity is a do not care condition.

7) The power supply input is NOT fuse protected.
Please, provide it externally.

Power supply Type Current Voltage

24 V AC/DC T 500 mA 250 V

100/240 V AC T 125 mA 250 V
When fuse is damaged, it is advisable to verify
the power supply circuit, so that it is necessary to
send back the instrument to your supplier.

8) The safety requirements for Permanently
Connected Equipment say:

- a switch or circuit-breaker shall be included in
the building installation;

- It shall be in close proximity to the equipment

N (L2)

P (L1)

N (L2)

P (L1)

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9

OPEN INPUT CIRCUIT

This instrument is able to identify the open circuit
for TC and RTD inputs.
The open input circuit condition for RTD input is
shown by an "overrange" indication.
For TC input, it is possible to select overrange
indication (standard) or underrange indication set­ting the CH101 and SH101 according to the follow­ing table:

Overrange (STD) CH101 = close SH101 = open
Underrange CH101 = open SH101 = close

Both pads are located on the soldering side of the
CPU card

Fig. 15

PRELIMINARY HARDWARE
SETTINGS

1) Remove the instrument from its case.

2) It is necessary to set J106 according to the

desired input type as shown in the following figure.

INPUT J106

TYPE 1-2 3-4 5-6 7-8 9-10

TC-RTD open close open open open

60 mV open close open open open

5 V close open close open open

10 V open open close open open

20 mA open open open close close

NOTE : the not used jumper can be positioned on
pin 7-9

CH101

SH101

1 3 5 7 9

2 4 6 8 10

J106

V101

J102

Fig. 14

3) Select the output 1 contact : NO (standard) or

NC by setting J102 according to the following

table:
Contact NO (standard) NC
J102 1 - 2 2 - 3

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