GS Chromalox 4081, Chromalox 4082 Installation & Operation Manual

Installation & Operation Manual

4081/4082 Graphical Proﬁle

Controller & Recorder

PK532-1 0037-75562 March 2016

This manual supplements the Concise Product manual(s) supplied with each instrument at the time of shipment. Information in this installation, wiring and operation manual is subject to change without notice.

Copyright © February 2016, Chromalox, 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) Printed versions are available from Chromalox or its representatives.

Note: It is strongly recommended that applications incorporate a high or low limit protective device, which will shut down the equipment at a preset process condition in order to prevent possible damage to property or products.

The Safety Alert Symbol: is found throughout these installation instructions to identify potential hazards that can result in personal injury. The seriousness of the potential risk is identiﬁed by one of these three words:

DANGER – will result in serious injury or death.

WARNING – could result in serious injury or death.

CAUTION – may result in minor or moderate injury.

Note: It is strongly recommended that applications incorporate a high or low limit protective device, which will shut down the equipment at a pre-set process condition in order to prevent possible damage to property or products.

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 C 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.

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.

THIS SYMBOL MEANS THE EQUIPMENT IS PROTECTED THROUGHOUT BY DOUBLE INSULATION.

WARNING: PRODUCTS COVERED BY THIS MANUAL ARE SUITABLE FOR INDOOR USE, INSTALLATION CATEGORY II, POLLUTION CATEGORY 2 ENVIRONMENTS.

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.

This user guide covers all versions of the Chromalox 4081/4082 Controller & Recorder.

Table of Contents

Contents Page Number

Warranty and Returns Statement ......................................................................................................................... i

1 Introduction ..................................................................................................................................................... 1

2 Installation ....................................................................................................................................................... 1

Unpacking ......................................................................................................................................................... 1

Installation ......................................................................................................................................................... 2

Panel-Mounting ................................................................................................................................................ 2

Cleaning ............................................................................................................................................................ 2

3 Field Upgrade Options .................................................................................................................................... 3

Plug-Modules and Upgradeable Functions ...................................................................................................... 3

Preparing to Install or Remove Plug-in Modules .............................................................................................. 4

Removing/Replacing Option Modules .............................................................................................................. 4

Replacing the Instrument in its Housing ........................................................................................................... 5

Auto Detection of Plug-in Modules ................................................................................................................... 5

Data Recorder Board ........................................................................................................................................ 5

Proﬁler Enabling ................................................................................................................................................ 5

4 Electrical Installation ...................................................................................................................................... 6

Avoiding EMC Problems ................................................................................................................................... 6

Cable Isolation & Protection ........................................................................................................................ 6

Noise Suppression at Source ...................................................................................................................... 6

Sensor Placement (Thermocouple or RTD) ...................................................................................................... 7

Thermocouple Wire Identiﬁcation ..................................................................................................................... 7

Thermocouple Wire Color CHART ............................................................................................................... 7

Pre-wiring – Cautions, Warnings & Information ............................................................................................... 8

Connections and Wiring ................................................................................................................................... 9

Central Terminal Connections ...................................................................................................................... 9

Outer Terminal Connections ...................................................................................................................... 10

Power Connections ................................................................................................................................... 10

Universal Input 1 Connections ................................................................................................................... 11

Universal / Auxiliary Input 2 Connections .................................................................................................. 12

Base Option 1 ............................................................................................................................................ 13

Base Option 2 ............................................................................................................................................ 13

Plug-in Module Slot 1 Connections ........................................................................................................... 13

Plug-in module slot 2 Connections............................................................................................................ 14

Plug-in Slot 3 Connections ........................................................................................................................ 15

Plug-in Slot A Connections ........................................................................................................................ 16

Option C Connections ............................................................................................................................... 17

5 Powering Up .................................................................................................................................................. 18

Powering Up Procedure .................................................................................................................................. 18

Front Panel Overview ...................................................................................................................................... 18

Display ............................................................................................................................................................ 18

LED Functions ................................................................................................................................................. 19

Keypad Functions & Navigation ...................................................................................................................... 19

Contents Page Number

6 Messages & Error Indications ...................................................................................................................... 20

Plug-in Module Problems ............................................................................................................................... 20

Sensor Break Detection ................................................................................................................................. 20

Un-Calibrated Input Detection ........................................................................................................................ 20

PV Over-range or Under-range Indication ...................................................................................................... 20

Auxiliary Input Over-range or Under-range Indication ................................................................................... 20

Cascade-Open ................................................................................................................................................ 20

Proﬁle Not Valid .............................................................................................................................................. 20

USB Data Transfer Failure message ............................................................................................................... 20

Getting Help .................................................................................................................................................... 20

7 Application Setup .......................................................................................................................................... 21

Pre-Commissioning Considerations ............................................................................................................... 21

8 Operation and Conﬁguration Menus ........................................................................................................... 23

Operation Mode .............................................................................................................................................. 23

Navigating and Adjusting Values in Operator Mode .................................................................................. 23

OPERATION MODE SCREEN SEQUENCE ............................................................................................... 24

Main Menu ...................................................................................................................................................... 29

Entry into the Main Menu ........................................................................................................................... 29

Unlock Codes ........................................................................................................................................... 29

Main Menu Options ............................................................................................................................. 29

Setup Wizard .................................................................................................................................................. 30

Manual entry to the Setup Wizard ............................................................................................................. 30

Setup Wizard Screens .......................................................................................................................... 30

Supervisor Mode ............................................................................................................................................. 30

Entry into Supervisor Mode ...................................................................................................................... 30

Supervisor Mode Screens ................................................................................................................... 31

Conﬁguration Menu ........................................................................................................................................ 31

Entry into the Conﬁguration Menu .................................................................................................................. 31

Conﬁguration Menu Screens: ................................................................................................................... 31

Input Conﬁguration Sub-Menu Screens .................................................................................................... 35

Control Conﬁguration Sub-Menu Screens ................................................................................................ 36

Outputs Conﬁguration Sub-Menu Screens ............................................................................................... 42

Alarm Conﬁguration Sub-Menu Screens ................................................................................................... 43

Communications Conﬁguration Sub-Menu Screens ................................................................................. 44

Data Recorder Conﬁguration Sub-Menu Screens ..................................................................................... 44

Clock Conﬁguration Sub-Menu Screens ................................................................................................... 46

Display Conﬁguration Sub-Menu Screens ................................................................................................ 46

Lock Code Conﬁguration Sub-Menu Screen............................................................................................. 47

Reset To Defaults Sub-Menu Screen ......................................................................................................... 47

The USB Menu ............................................................................................................................................... 47

Entry into the USB Menu ........................................................................................................................... 47

USB Menu Screens .............................................................................................................................. 48

Recorder Control Menu ................................................................................................................................. 49

Entry into the Recorder Control Menu ....................................................................................................... 49

Recorder Menu Screens ...................................................................................................................... 49

Proﬁler Setup Menu ....................................................................................................................................... 50

Entry into the Proﬁler Setup Menu ............................................................................................................ 50

Proﬁler Setup Menu Screens .......................................................................................................... 50

Proﬁler Control Menu ...................................................................................................................................... 51

Proﬁler Control Menu Screens ................................................................................................................... 53

iii

Contents Page Number

Service & Product Information Mode .............................................................................................................. 54

Entry into Service & Product Information Mode ....................................................................................... 54

Service & Product Information Screens: ............................................................................................. 54

Automatic Tuning Menu .................................................................................................................................. 55

Entry into the Automatic Tuning Menu ...................................................................................................... 55

Automatic Tuning Menu Screens ......................................................................................................... 55

Lost Lock Codes ............................................................................................................................................. 56

9 Input Calibration & Multi-point Scaling ....................................................................................................... 57

User Calibration .............................................................................................................................................. 57

Calibration Reminder ................................................................................................................................ 57

Single Point Calibration ............................................................................................................................. 57

Two Point Calibration ................................................................................................................................ 58

Multi-point Scaling ..................................................................................................................................... 58

Base Calibration Adjustment .......................................................................................................................... 58

Required Equipment ................................................................................................................................. 59

Performing a Calibration Check ................................................................................................................ 59

Recalibration Procedure ........................................................................................................................... 59

Input Calibration Phases ..................................................................................................................... 59

10 Digital Inputs ................................................................................................................................................ 60

Digital Signal Type ........................................................................................................................................... 60

Inverting Digital Inputs .............................................................................................................................. 60

Soft Digital Inputs ........................................................................................................................................... 60

Digital Input Functions .................................................................................................................................... 60

11 Cascade Control ........................................................................................................................................... 62

Normal Cascade Operation ........................................................................................................................... 62

Cascade-Open ................................................................................................................................................ 62

Manual Mode ................................................................................................................................................. 62

Cascade Tuning .............................................................................................................................................. 63

12 Ratio Control ................................................................................................................................................ 64

13 Redundant Input ........................................................................................................................................... 64

14 Valve Motor Drive / 3-Point Stepping Control ........................................................................................... 66

Pro-EC44 2-Loop Graphical Proﬁle Controller & Recorder ............................................................................ 66

Special Wiring Considerations for Valve Motor Control ................................................................................. 66

Position Feedback .......................................................................................................................................... 66

Valve Limiting ............................................................................................................................................. 66

15 Setpoint Sources ........................................................................................................................................... 67

Loop 1 Setpoint Sources ............................................................................................................................... 67

Loop 1 Proﬁle Setpoint ............................................................................................................................. 67

Loop 2 Setpoint Sources ................................................................................................................................ 67

Loop 2 Proﬁle Setpoint ............................................................................................................................. 67

16 Proﬁler ............................................................................................................................................................ 68

Proﬁle Components ....................................................................................................................................... 68

Proﬁle Header & Segment Information ...................................................................................................... 68

Proﬁle Starting & Standard Segments ....................................................................................................... 68

Two Loop Proﬁles ..................................................................................................................................... 69

Contents Page Number

Loop-back Segments ............................................................................................................................... 70

Proﬁle Running / Holding vs. Hold Segments ................................................................................................ 70

The Auto-Hold Feature ................................................................................................................................... 70

Auto Hold Examples ................................................................................................................................. 70

Proﬁle Cycles & Repeat Sequences .............................................................................................................. 71

Power/Signal Lost Recovery Actions.............................................................................................................. 72

Proﬁle End Actions .......................................................................................................................................... 73

Proﬁle Abort Actions ...................................................................................................................................... 73

17 USB Interface ................................................................................................................................................ 74

Using the USB Port ........................................................................................................................................ 74

USB Memory Stick Folders & Files ........................................................................................................... 74

18 Data Recorder ............................................................................................................................................... 75

Recordable Values ......................................................................................................................................... 75

Recorder Control and Status ..................................................................................................................... 75

Uploading Data .......................................................................................................................................... 75

Additional Features & Beneﬁts from the Recorder ......................................................................................... 75

19 Controller Tuning ........................................................................................................................................... 76

PID Sets & Gain Scheduling ........................................................................................................................... 76

Automatic Tuning ............................................................................................................................................ 76

Manually Tuning .............................................................................................................................................. 78

Tuning Control Loops - PID with Primary Output only ............................................................................... 78

Tuning Control Loops - PID with Primary & Secondary Outputs ............................................................... 78

Valve, Damper & Speed Controller Tuning ................................................................................................. 79

Fine Tuning ................................................................................................................................................ 81

20 Serial Communications ................................................................................................................................ 83

Supported Protocols ....................................................................................................................................... 83

RS485 Conﬁguration.................................................................................................................................. 83

Ethernet Conﬁguration ............................................................................................................................... 83

Supported Modbus Functions ........................................................................................................................ 84

Function Descriptions ................................................................................................................................ 84

Exception Responses ................................................................................................................................ 86

Modbus Parameters ....................................................................................................................................... 86

Data Formats ............................................................................................................................................. 86

Parameter Register Address Listings ............................................................................................................. 87

Calibration Reminder Parameters .............................................................................................................. 87

Universal Process Input 1 Parameters....................................................................................................... 88

Universal Process Input 2 Parameters....................................................................................................... 92

Digital Input Setup Parameters .................................................................................................................. 97

Plug-in Module Slot A Parameters .......................................................................................................... 112

Plug-in Module Slot 1 Parameters ........................................................................................................... 114

Plug-in Module Slot 2 Parameters .......................................................................................................... 116

Plug-in Module Slot 3 Parameters .......................................................................................................... 119

Output 4 Parameters ............................................................................................................................... 122

Output 5 Parameters ............................................................................................................................... 124

Linear Output 6 Parameters ..................................................................................................................... 126

Linear Output 7 Parameters ..................................................................................................................... 127

Loop 1 Setpoint Parameters ................................................................................................................... 128

Loop 2 Setpoint Parameters .................................................................................................................... 129

Aux A Input Parameters ........................................................................................................................... 130

Contents Page Number

Loop 1 Control Parameters...................................................................................................................... 131

Loop 2 Control Parameters...................................................................................................................... 137

Alarm Parameters .................................................................................................................................... 143

Recorder & Clock Parameters ................................................................................................................. 151

Display & Security .................................................................................................................................... 157

Instrument Data Parameters .................................................................................................................... 164

Proﬁler Control & Status Parameters ....................................................................................................... 166

Proﬁle Setup via Modbus ......................................................................................................................... 169

21 Glossary ....................................................................................................................................................... 186

22 PC Software ................................................................................................................................................. 208

Using the PC Software ................................................................................................................................ 208

Instrument Simulation ................................................................................................................................... 209

Conﬁguring the Connection .......................................................................................................................... 210

Instrument Conﬁguration .............................................................................................................................. 212

Main Parameter Adjustment .................................................................................................................... 212

Extending Functionality via Software ....................................................................................................... 213

Proﬁle Creation and Editing .......................................................................................................................... 214

Data Recorder Trend Upload & Analysis ....................................................................................................... 216

23 Speciﬁcations ............................................................................................................................................. 217

Universal Process Inputs .............................................................................................................................. 217

General Input 1 and 2 Speciﬁcations ....................................................................................................... 217

Thermocouple Input ................................................................................................................................. 217

Resistance Temperature Detector (RTD) Input ........................................................................................ 218

DC Linear Input ........................................................................................................................................ 218

Input Functions ........................................................................................................................................ 219

Auxiliary Input ............................................................................................................................................... 219

Digital Inputs ................................................................................................................................................. 220

Output Speciﬁcations .................................................................................................................................. 221

Communications .......................................................................................................................................... 223

Control Loop(s) ............................................................................................................................................. 224

Alarms ........................................................................................................................................................... 225

Proﬁler Option ............................................................................................................................................... 225

Data Recorder Option ................................................................................................................................... 226

Display .......................................................................................................................................................... 226

Operating Conditions ................................................................................................................................... 226

Conformance Norms .................................................................................................................................... 226

Dimensions ................................................................................................................................................... 226

24 Chromalox 4801/4082 Product Coding ..................................................................................................... 227

1 Introduction

This product is a 1/4 DIN size (96 x 96mm front) microprocessor based graphical process controller, featuring a 160 x 80 pixel, monochrome LCD with dual color (red/ green) backlight. It operates from 100-240V at 50/60 Hz or 24V-48V AC/DC, depending on the model purchased. It can measure and control up to two process variables from a variety of sources such as temperature, pressure, ﬂow and level. Primary and secondary control outputs are possible for each loop.

Optional features include a second process input, USB interface, remote setpoint inputs RS485 or Ethernet communications, proﬁle control and data recording. Control options include cascade, ratio and 3-point stepping valve control. Automatic tuning or 5 stage gain-scheduling are also available.

The USB Interface option allows uploading or downloading instrument conﬁguration settings to/from a USB memory stick, for easy conﬁguration of multiple instruments or transfer to/from the PC conﬁguration software. If the data recorder or proﬁler options are ﬁtted, recordings and proﬁle information can be transferred via the memory stick.

The data recorder option allows the user to make recordings of the processes over time. Recordings can be transferred to a memory stick using the USB interface or downloaded via one of the communications options.

The Proﬁler option allows the user to predeﬁne up 255 segments, shared amongst up to 64 Setpoint Proﬁles. These control the setpoint levels for the control loop(s)

over time, increasing, decreasing or holding their values as required. When combined with the real-time clock (part of the Data Recorder option) the proﬁling capabilities are expanded to allow automatic program start at a deﬁned time and day.

Inputs are user conﬁgurable for thermocouple and RTD probes, as well as linear process signal types such as mVDC, VDC or mADC. Two-point calibration or multipoint scaling can compensate for errors or non-linear signals. Output options include single or dual relays, single or dual SSR drivers, triacs or linear mA/V DC. These can be used for process control, alarms/events or retransmission of the process variable or setpoint to external devices. Transmitter power supply options can provide an unregulated 24V DC (22mA) auxiliary output voltage, or a 0 to 10VDC stabilized excitation for external signal transmitters.

Up to 7 alarms can be deﬁned as process high or low, deviation (active above or below controller setpoint), band (active both above and below setpoint), rate of input change, control loop, PID power or signal break types. Alarm status can be indicated by lighting an LED, changing the display backlight color or viewing the active alarm status screen. These alarms can be linked to any suitable output.

Conﬁguration for basic applications is possible using the easy Setup Wizard run automatically at ﬁrst powerup or manually later. Access to the full range of parameters is via a simple menu driven front panel interface, or the PC based conﬁguration software.

2 Installation

ELECTRIC SHOCK/FIRE HAZARD. Read and understand all instructions before ine installation, servicing or operating controller. Failure to do so could result in personal injury or death and/or equipment or property damage.

Unpacking

1. Remove the product from its packing. Retain the

packing for future use, in case it is necessary to transport the instrument to a different site or to return it to the supplier for servicing.

2. The instrument is supplied with a panel gasket and

push-ﬁt mounting clamp. A multi-page concise manual is supplied with the instrument, in one or more languages. Examine the delivered items for damage or defects. If any are found, contact your supplier immediately.

Installation

ELECTRIC SHOCK/FIRE HAZARD. 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). Failute to follow these instructions could result in personal injury or death or equipment/property damage.

Figure 1. Main Dimensions

Gasket

Mounting Panel

Panel-Mounting

The mounting panel must be rigid and may be up to

6.0mm (0.25 inches) thick. The cut-out size is:

92mm x 92mm (+0.5mm / -0.0mm).

Instruments may be mounted side-by-side in a multiple installation, but instrument to panel moisture and dust sealing will be compromised. Allow a 20mm gap above, below and behind the instrument for ventilation. The cut-out width (for n instruments) is:

(96n - 4) mm or (3.78n - 0.16) inches

If panel sealing must be maintained, mount each instrument into an individual cut-out with 10mm or more clearance between the edges of the holes.

Note: The mounting clamp tongues may engage the ratchets either on the sides or the top/bottom faces of the Instrument housing. When installing several Instruments side-by-side in one cut-out, use the ratchets on the top/bottom faces.

Ensure the inside of the panel remains within the instrument operating temperature and that there is adequate airﬂow to prevent overheating.

Note: For an effective IP66 seal against dust and moisture, ensure gasket is well compressed against the panel, with the 4 tongues located in the same ratchet slot.

Do not remove the panel gasket, as this may result in inadequate clamping and sealing of the instrument to the panel.

Once the instrument is installed in its mounting panel, it may be subsequently removed from its housing if necessary, as described in the Fitting and Removing Plugin Modules section.

Cleaning

Clean the front panel by washing with warm soapy water and dry immediately. If the USB option is ﬁtted, close the USB port cover before cleaning.

Clamp

Ratchets

Instrument

Housing

Figure 2. Panel-Mounting

1. Insert instrument into the panel cut-out.

2. Hold front bezel firmly

(without pressing on the display area), and re-fit mounting clamp. Push the clamp forward, using a tool if necessary, until gasket compresses and instrument is held firmly

in position.

3 Field Upgrade Options

Plug-Modules and Upgradeable Functions

Plug-Modules can be either pre-installed at the time of manufacture, or retroﬁtted in the ﬁeld to expand the capabilities of the controller. Contact your supplier to purchase these items. Part numbers and circuit board identiﬁcation numbers for the plug-in modules and accessories are shown in below:

Table 1. Options and Accessories

Plastic pegs prevent ﬁtting of older non-reinforced single relay modules (Board Identiﬁcation Numbers 637/01 and 638/01). Fitting the older relay modules reduces the isolation rating to Basic 240V Isolation and is therefore not recommended. Remove this peg when ﬁtting Dual Relay Modules.

PAR T

NUMBER DESCRIPTION

OPTION SLOT (OUTPUT) 1

0149-50043

0149-50044

0149-50077

0149-50047

OPTION SLOT (OUTPUT) 2 OR 3

0149-50050

0149-50049

0149-50051

0149-50052

0149-50070

0149-50053

OPTION SLOT A

0149-50056

0149-50057

0149-50055

0149-50058

ACCESSORIES

0149-50063

0149-50092

0149-50086

0149-50088

Single Relay Output for option slot (Output) 1 716/01

Single SSR Driver Output for option slot (Output) 1 716/02

Triac Output for option slot (Output) 1

Linear mA / Voltage Output module for option slot (Output) 1

Single Relay Output for option slot (Output) 2 or 3

Dual Relay Output for option slot (Output) 2 or 3

Single SSR Driver Output for option slot (Output) 2 or 3

Dual SSR Driver Output for option slot (Output) 2 or 3

Triac module Output for slot (Output) 2 or 3

24VDC Transmitter Power Supply for option slot (Output) 2 or 3

Digital Input for plug-in module slot A

Basic Auxiliary Input for plug-in module slot A

RS485 Serial Communications for plug-in module slot A

Ethernet Communications for plug-in module slot A

Proﬁler Enable Key-code

ChromaloxPro Conﬁguration Software Only (60 & 80 Series)

Univ S/W Converter & PC Cable 20/40/50/60/80 Series

Cable Only – 40/50/80 Series to Universal Adaptor

BOARD IDENTIFICATION

NUMBER

716/01

716/02

716/03

639/01

717/01

644/01

717/02

644/02

647/01

642/01

641/02

653/01

680/01

707/01

Board Positions

Board Mounting

l Latch (x1)

Board

100

Main Board Connectors

Note: All dual relay modules have reinforced isolation.

Struts (x4)

Front Panel Remova

Plug-in Module A

Plug-in Module 3

Power Supply

2nd Universal Input & Base Option 2 Board

1st Universal Input & Base Option 1 Board

Plug-in Module 1

Plug-in Module 2

USB/Digital Input C Option Board

Figure 3. Rear View (uncased) & Board Positions

Preparing to Install or Remove Options

Modules

POWER SUPPLY

BOARD

Transformer

Color Code

-240V (Yellow)

24-48V(Blue)

Display Board

Connections

1st UNIVERSAL

INPUT / BASE

OPTION 1

BOARD

Module Slot 3

Connector PL4B

Module Slot A Connectors PL5, & PL6

Module Slot 1 Connectors PL7 & PL8

PC Configurator

Socket SK1

Module Slot 2 Connector PL4A

Figure 4. Main Board Connectors

This product is designed to allow the user to reconﬁgure some hardware options in the ﬁeld by changing the plug-in modules in slots 1, 2, 3, & A located on the power supply and 1st universal input boards. The main boards (display/CPU, power supply, inputs 1 & 2 and digital input/USB) are factory ﬁtted, but may be removed while reconﬁguring the plug-in modules. Take care when re-ﬁtting these boards. Observe the power supply board transformer color, and case labelling to check the supply voltage, otherwise irreparable damage may occur.

ELECTRIC SHOCK HAZARD. Disconnect all power before installing or servicing controller. Failure to do so could result in personal injury or property damage.

1. Grip the edges of the front panel (there is a ﬁnger grip on each edge) and pull it forwards approximately 10mm, until the Front Panel Removal Latch prevents further movement. The purpose of the latch is to prevent removal of the instrument without the use of a tool.

2. The Front Panel Removal Latch must be pushed down to allow removal of the instrument. Using a tool (e.g. screwdriver or pen tip), press down it down through the front central ventilation hole. This will release the instrument from the case.

3. The internal boards can now be accessed. Take note of the orientation of the instrument and boards for subsequent replacement into the housing. The positions of the boards, their mountings and the Front Panel Removal Latch are shown above.

Replacement of boards must be carried out by a technically competent technician. If the Power Supply board does not match the labelling, users may apply incorrect voltage resulting in irreparable damage.

Removing/Replacing Option Modules

1. To remove or replace Plug-in Modules 1, 2, 3 or A it

is necessary to detach the power supply and input boards from the front panel by lifting ﬁrst the upper and then lower mounting struts.

2. Remove or ﬁt the modules to the connectors on the power supply and input boards. The location of the connectors is shown below. Plastic pegs prevent ﬁtting of older nonreinforced single relay modules – Remove the peg to ﬁt dual relay modules

3. Assemble the Power Supply and Input boards together. Tongues on each option module locate into slots cut into the main boards, opposite each of the connectors. Hold the Power and Input boards together and relocate them back on their mounting struts.

4. Push the boards forward to ensure correct connection to the front Display/CPU board and re-check the installation of the Option C and/or 2nd Input / Base Option 2 boards if present.

Check for correct orientation of the modules and that all pins are located correctly.

Replacing the Instrument in its Housing

Data Recorder Board

If installed, the Data Recorder memory and Real Time Clock (RTC) components are located on a plug-in daughter board attached to the front Display/CPU board.

Servicing of the Data Recorder/RTC circuit and replacement of the lithium battery should only be carried out by a technically competent technician.

ELECTRIC SHOCK HAZARD. Disconnect all power before installing or servicing controller. Failure to do so could result in personal injury or property damage.

With the required option modules correctly located into their respective positions the instrument can be replaced into its housing as follows:

1. Hold the Power Supply and Input boards together.

2. Align the boards with the guides in the housing.

3. Slowly and ﬁrmly, push the instrument into position

in its case.

Ensure that the instrument is correctly orientated. A mechanical stop will operate if an attempt is made to insert the instrument in the wrong orientation, this stop MUST NOT be over-ridden.

Auto Detection of Plug-in Modules

The instrument automatically detects which plug-in modules have been ﬁtted into each slot. The menus and screens change to reﬂect the options compatible with the hardware. The modules ﬁtted can be viewed in the product information menu, as detailed in the Product & Service Information Mode section of this manual.

Proﬁler Enabling

If you purchased a controller with the Proﬁler option installed, these features will be enabled during manufacture.

Controllers supplied without the Proﬁler option installed can be upgraded in the ﬁeld by purchasing a licence code number from your supplier. A unique code must be purchased to enable proﬁling on each controller that requires it.

Entering the Proﬁler Enable Code

Hold down the and keys during the power-up “splash screen”.

Using the or keys, enter the 16-character licence code in the displayed screen.

Press to move on to the next character. Press to move back to the previous character.

Press after entering the ﬁnal character.

To conﬁrm if proﬁling is installed in your instrument, check the Controller Feature Information in Product & Service Information Mode.

4 Electrical Installation

ELECTRIC SHOCK/FIRE HAZARD. 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). Failure to follow these instructions could result in personal injury or

death and/or equipment / property damage.

Avoiding EMC Problems

This controller has passed EMC compliance tests to EN61326. There should be no difﬁculty achieving this level of compliance in use, but it should be borne in mind that the wiring of the installation can signiﬁcantly reduce the efﬁciency of instrumentation immunity due to the ease with which high frequency RF can enter via unprotected cables.

The following general recommendations can reduce the possibility of EMC problems.

1. If the instrument is being installed in existing equipment, wiring in the area should be checked to ensure that good wiring practices have been followed.

2. The controller should be mounted in a properly earthed metal cabinet. All round metal shielding is important, so the cabinet door may require a conductive sealing strip.

3. 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.

4. Consider using a separate isolation transformer to feed only the instrumentation. A transformer can protect instruments from noise found on the AC power supply.

tween them. If wires MUST cross each other, ensure they do so at 90 degrees to minimize interference.

Keep signal cables as short as possible. If an earthed thermocouple is used or if the sensor has a screened cable, it should be earthed at one point only, preferably at the sensor location or cabinet entry point, by means of a metal gland. Ideally all analogue and digital signals should be shielded like this, but for unscreened cables, large diameter ferrite sleeves at the cabinet entry point are an effective method of reducing RF interference. Looping cables through the ferrite sleeves a number of times improves the efﬁciency of the ﬁltering. For mains input cables the ﬁtting a suitable mains ﬁlter can provide good results.

Noise Suppression at Source

If possible, eliminate mechanical contact relays and replace with solid-state relays. Noise-generating devices such as Ignition transformers, arc welders, motor drives, relays and solenoids should be mounted in a separate enclosure. If this is not possible, separate them from the instrumentation, by the largest distance possible.

Many manufacturers of relays, contactors etc supply ‘surge suppressors’ to reduce noise at its source. For those devices that do not have surge suppressors supplied, Resistance-Capacitance (RC) networks and/or Metal Oxide Varistors (MOV) may be added.

Inductive coils: MOVs are recommended for transient suppression in inductive coils. Connect as close as possible, in parallel to the coil. Additional protection may be provided by adding an RC network across the MOV.

Cable Isolation & Protection

Four voltage levels of input and output wiring may be used with the unit:

1. Analog inputs or outputs (for example thermocouple, RTD, VDC, mVDC or mADC)

2. Relays & Triac outputs

3. Digital Inputs & SSR Driver outputs

4. AC power

The only wires that should run together are those of the same category.

If any wires need to run parallel with any from another category, maintain a minimum space of 150mm be-

Figure 5. Transient Suppression

with Inductive Coils

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.

Figure 6. Contact Noise Suppression

Sensor Placement (Thermocouple or RTD)

If a temperature probe is to be subjected to corrosive or abrasive conditions, it must be protected by an appropriate thermowell.

Probes must be positioned to reﬂect the true process temperature:

1. In a liquid media - the most agitated area

2. 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 (see the wiring section for details). Two wire RTDs should only be used with lead lengths less than 3 metres.

Use of three wire RTDs is strongly recommended to reduce errors do to lead resistance.

Thermocouple Wire Identiﬁcation

The different thermocouple types are identiﬁed by their wires color, and where possible, the outer insulation as well. There are several standards in use throughout the world, but most regions now use the International IEC584-3 standard.

The table below shows the wire and sheath colors used for most common thermocouple types. The format used in this table is:

+ Wire

Sheath

- Wire

Type

J +*

T +

K +

N +

B +

R & S +

Table 2. Thermocouple Extension Wire Colors

International

IEC584-3

Black

White Red Blue Black Blue

Brown

White Red Blue Blue Brown

Green

White Red Blue Purple Green

Pink

White Red Blue

Grey

White Red Grey

Orange

White Red Blue Green White

Black

Brown

Green

Pink

Grey

Orange

USA ANSI

MC 96.1

White

Black

Blue

Yellow

Orange

Grey

Black

Green

British

BS1843

Yellow

Black

White

Blue

Brown

Red

Orange

White

Green

French

NFC 42-324

Yellow

Black

Yellow

Blue

Yellow

Green

German

DIN 43710

Red

Blue

Red

Brown

Red

Green

Red

Grey

Red

White

C (W5)

*Wire is magnetic. a magnet can be used to assist with correctly identifying the type and polarity of the conductors

White

Red

Pre-Wiring: Cautions, Warnings & Information

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).

ELECTRIC SHOCK/FIRE HAZARD. THIS EQUIPMENT IS DESIGNED FOR INSTALLATION IN AN ENCLOSURE THAT PROVIDES ADEQUATE PROTECTION AGAINST ELECTRIC SHOCK. THE ISOLATION SWITCH SHOULD BE LOCATED IN CLOSE PROXIMITY TO THE UNIT, IN EASY REACH OF THE OPERATOR AND APPROPRIATELY MARKED. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PERSONAL INJURY OR DEATH AND/OR EQUIPMENT / PROPERTY DAMAGE.

This symbol means the equipment is protected throughout by double insulation. All external circuits connected must provide double insulation. Failure to comply with the installation instructions may impact the protection provided by the unit.

ELECTRIC SHOCK/FIRE HAZARD. 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. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PERSONAL INJURY OR DEATH AND/OR EQUIPMENT / PROPERTY DAMAGE.

OPTION

Connections and Wiring

Central Terminal Connections

Note: The wiring diagram below shows all possible combinations to the main connections (numbered 1 to 24) in the centre of the case rear. The actual connections required depends upon the features and modules ﬁtted.

ELECTRIC SHOCK/FIRE HAZARD. CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PERSONAL INJURY OR DEATH AND/OR EQUIPMENT / PROPERTY DAMAGE.

OPTION

Figure 7. Central Terminals 1 to 24

OPTION

Outer Terminal Connections

Note: The wiring diagram below shows the Central Terminals (numbered 25 to 42) at the sides of the case rear. Connections for the 2nd Input, Base Option 2 and Digital Input C are shown. The actual connections required depends upon the features and modules ﬁtted.

Figure 8. Outer Terminals 25 to 42

Power Connections

Power Connections - Mains Powered Instruments

Mains powered instruments operate from a 100 to 240V (±10%) 50/60Hz supply. Power consumption is 20VA. Connect the line and neutral as illustrated via a UL listed fuse type: 250V AC 1Amp anti-surge and a two-pole IEC60947-1 & IEC60947-3 compliant isolation switch / circuit breaker located within easy reach of the operator and appropriately marked. If relays switch mains voltage this should be separate from the instruments mains supply.

Figure 9. Mains Power Connections

Power Connections - 24/48V AC/DC Powered Instruments

24/48V AD/DC powered instruments will operate from a 20 to 48V AC or 22 to 55V DC supply. AC power consumption is 15VA max, DC power consumption is 12 watts max. Connection should be via a UL listed fuse type: 65v dc 350mAamp anti-surge and a two-pole IEC60947-1 & IEC60947-3 compliant isolation switch / circuit breaker located within easy reach of the operator and appropriately marked.

Figure 10. 24/48V AC/DC Power

Connections

Universal Input 1 Connections – PT100 / NI120 (RTD) input

The inputs supports two types of RTD. PT100 (platinum sensor, 100Ω at 0°C). For three wire RTDs, connect the resistive leg and the common legs of the RTD as illustrated. For a two wire RTD a wire link should be ﬁtted across terminals 2 & 3 (in place of the third wire). Two wire RTDs should only be used when the leads are less than 3 metres long. Avoid cable joints.

Universal Input 1 Connections

Universal Input 1 is present on all models. This input is normally used for the measured variable signal from a process to be controlled. It can be connected to thermocouples; resistance temperature detectors; analogue mA; mV or V DC signals. The input settings are in the Input 1 Conﬁguration sub-menu. Connections for the various types are shown below. Ensure that the signal is correctly connected, paying particular attention to the polarity.

Universal Input 1 Connections Thermocouple (T/C)

Supported thermocouple types & ranges are listed in the input speciﬁcations section on page 245. Only use the correct thermocouple wire or compensating cable from the sensor to the instrument terminals avoiding joints in the cable if possible. Where joints are made, special thermocouple connectors must be used. Failure to use the correct wire type and connectors will lead to inaccurate readings. Ensure correct polarity of the wires by cross-referencing the colors with the thermocouple reference table.

Figure 12. Input 1 - RTD Connections

Four wire RTDs can be used, provided that the fourth wire is left unconnected. This wire should be cut short or tied back so that it cannot contact any of the terminals on the rear of the instrument.

Universal Input 1 Connections - Linear Volt, mV or mA input

The input supports the following linear/analogue signals: 0 to 50mV; 10 to 50mV; 0 to 5V; 1 to 5V; 0 to 10V; 2 to 10V; 0 to 20mV; 4 to 20mA from any suitable source. Voltage & millivolt signals are connected to terminals 2 & 3, milliamp signals are connected to 1 & 3. Carefully observe the position & polarity of the connections.

Figure 11.

Input 1 - Thermocouple Connections

Figure 13. Input 1 - DC Volt, mV & mA Connections

Universal / Auxiliary Input 2 Connections

An Auxiliary Input 2 option is ﬁtted to some models. This can connect to a potentiometer; analogue mA; mV or V DC signal for a remote setpoint input signal, or for ﬂow/valve position feedback information. Alternatively, a second Universal Input 2 option may be ﬁtted. In addition to the remote setpoint input signal or feedback information possible with the auxiliary input, the 2nd Universal Input can be used as a second process control loop for two control loops, or used in conjunction with input one in more complex single control loops. Universal Input 2 can be connected to thermocouples; resistance temperature detectors; potentiometers; analogue mA; mV or V DC signals.

The settings are in the Input 2 Conﬁguration sub-menu. Connections for the various types are shown below. Ensure that the signal is correctly connected, paying particular attention to the polarity.

Universal Input 2 Connections Thermocouple (T/C)

The optional 2nd universal input, supports various thermocouple types. Supported types & ranges are listed in the input speciﬁcations section on page 245. Only use the correct thermocouple wire or compensating cable from the sensor to the instrument terminals avoiding joints in the cable if possible. Where joints are made, special thermocouple connectors must be used. Failure to use the correct wire type and connectors will lead to inaccurate readings. Ensure correct polarity of the wires by cross-referencing the colors with a thermocouple reference table.

Figure 15. Input 2 - RTD Connections

Four wire RTDs can be used, provided that the fourth wire is left unconnected. This wire should be cut short or tied back so that it cannot contact any of the terminals on the rear of the instrument.

Universal / Auxiliary Input 2 Connections Linear Volt, mV or mA input

The optional auxiliary or 2nd universal input supports the following linear/analogue signals: 0 to 50mV; 10 to 50mV; 0 to 5V; 1 to 5V; 0 to 10V; 2 to 10V; 0 to 20mV; 4 to 20mA from any suitable source. Voltage & millivolt signals are connected to terminals 2 & 3, milliamp signals are connected to 1 & 3. Carefully observe the polarity of the connections.

Figure 14. Input 2 - Thermocouple Connections

Universal Input 2 Connections – PT100 / NI120 (RTD) Input

The optional 2nd universal input, supports two types of RTD. PT100 (platinum sensor, 100Ω at 0°C). For three wire RTDs, connect the resistive leg and the common legs of the RTD as illustrated. For a two wire RTD a wire link should be ﬁtted across terminals 35 & 36 (in place of the third wire). Two wire RTDs should only be used when the leads are less than 3 metres long. If possible, avoid cable joints.

Figure 16. Input 2 - DC Volt, mV & mA Connections

Universal / Auxiliary Input 2 Connections – Potentiometer

The optional auxiliary or 2nd universal input, the terminals detailed below can be used to connect a feedback potentiometer. Minimum potentiometer resistance is ≥100Ω.

Figure 17. Input 2 - Potentiometer Connections

Base Option 1

Base Option 1 provides one or two factory ﬁtted outputs. A relay designated as Output 4 is ﬁtted on all models, and an optional linear mA/V DC designated as Output 6. Base options cannot be added after manufacture. The functions of outputs 4 & 6 are set in the Output Conﬁguration sub-menu. Connect as illustrated below.

Base Option 1 Relay Output 4

Present on all instruments, Output 4 is a SPST relay, rated at 2 amps at 240 VAC resistive. If it is used to switch mains voltages, the supply should be separate from the instrument supply and should be correctly

switched and fused.

Figure 20. Relay Output 5 Connections

Base Option 2 Linear Output 7

Part of base option 2, Output 7 is an optional linear mV/V DC analogue output. The type & range are selectable from 0 to 5, 0 to 10, 2 to 10V & 0 to 20 or 4 to 20mA.

Figure 21. Linear Output 7 Connections

Figure 18. Relay Output 4 Connections

Base Option 1 Linear Output 6

Part of base option 1, Output 6 is an optional linear mV/V DC analogue output. The type & range are selectable from 0 to 5, 0 to 10, 2 to 10V & 0 to 20 or 4 to

20mA.

Figure 19. Linear Output 6 Connections

Base Option 2

Base Option 2 provides one or two factory ﬁtted outputs. An optional relay designated as Output 5, and an optional linear mA/V DC designated as Output 7. Base options cannot be added after manufacture. The functions of outputs 5 & 7 are set in the Output Conﬁguration sub-menu. Connect as illustrated below.

Plug-in Module Slot 1 Connections

A selection of plug-in modules are available for Module Slot 1. They can be ﬁtted during manufacture, or purchased and ﬁtted later by the user. Modules in slot 1 are designated Output 1. They are not interchangeable with those in slot 2 or 3. Their function is set in the Output Conﬁguration sub-menu. Connect as illustrated below.

Plug-in Module Slot 1 – Single Relay Output Module

If ﬁtted with a single relay output module, connect as shown. The relay contacts are SPDT and rated at 2 amps resistive, 240 VAC. If it is used to switch mains voltages, the supply should be separate from the instrument supply and should be correctly switched and fused.

Base Option 2 Relay Output 5

Part of base option 2, Output 5 is a SPST relay, rated at 2 amps at 240 VAC resistive. If it is used to switch mains voltages, the supply should be separate from the instrument supply and should be correctly switched and fused.

Figure 22.

Plug-in Module Slot 1 – Single Relay Module

Plug-in Module Slot 1 – Single SSR Driver Output Module

If ﬁtted with a single SSR Driver output module, connect as shown. The 10V DC pulse signal (load resistance ≥500 ohms) is isolated from all inputs/outputs except other SSR drivers.

Figure 23.

Plug-in Module Slot 1 – Single SSR Driver Module

Plug-in Module Slot 1 - Triac Output Module

If ﬁtted with a triac output module, connect as shown. This output is rated at 0.01 to 1 amp @ 280V AC 50/60Hz. Isolated from all other inputs and outputs. A snubber should be ﬁtted across inductive loads to ensure reliable switch off of the Triac.

Figure 24. Plug-in Module Slot 1 - Triac Module

Plug-in Module Slot 1 - Linear Voltage or mADC Output module

If ﬁtted with a DC linear output module, connect as shown. Output type & range are selectable from 0 to 5, 0 to 10, 2 to 10V & 0 to 20 or 4 to 20mA. Isolated from all other inputs and outputs.

Plug-in Module Slot 2 – Single Relay Output Module

Figure 26.

Plug-in Module Slot 2 – Single Relay Module

Plug-in Module Slot 2 - Dual Relay Output Module

If ﬁtted with a dual relay output module, connect as shown. This module has two independent SPST relays for outputs 2A and 2B, with a shared common terminal. The contacts are rated at 2 amp resistive 240 VAC. If used to switch mains voltages, the supply should be separate from the instruments mains supply and the contacts should be correctly switched and fused.

Figure 25. Plug-in Module Slot

1 - Linear Voltage & mADC Module

Plug-In Module Slot 2 Connections

A selection of plug-in modules are available for Module Slot 2. They are interchangeable with slot 3, but not slot 1.They can be ﬁtted during manufacture, or purchased and ﬁtted later by the user. Modules in slot 2 are designated Output 2, and for dual modules Output 2A and 2B. Their functions are set in the Output Conﬁguration sub-menu. Connect as illustrated below.

Figure 27.

Plug-in Module Slot 2 - Dual Relay Module

Plug-in Module Slot 2 – Single SSR Driver Output Module

If ﬁtted with a single SSR Driver output module, connect as shown. The 10V DC pulse signal (load resistance ≥500 ohms) is isolated from all inputs/outputs except other SSR drivers.

Figure 28.

Plug-in Module Slot 2 – Single SSR Driver Module

Figure 31. Plug-in Module Slot 2 -

Transmitter Power Supply Module

Plug-in Module Slot 2 – Dual SSR Driver Output Module

If ﬁtted with a dual SSR Driver output module, the two solid-state relay driver outputs are designated as Output 2A and 2B. The outputs are 10V DC pulse signals, (load resistance ≥500 ohms). They are isolated from all inputs/output except other SSR driver outputs. Connect as shown making note of the shared positive common terminal.

Figure 29.

Plug-in Module Slot 2 – Dual SSR Driver Module

Plug-in Module Slot 2 Triac Output Module

If ﬁtted with a Triac output module, connect as shown. This output is rated at 0.01 to 1 amp @ 280V AC 50/60Hz. Isolated from all other inputs and outputs. A snubber should be ﬁtted across inductive loads to ensure reliable switch off of the Triac.

Figure 30. Plug-in Module Slot 2 - Triac Module

Plug-in Slot 3 Connections

A selection of plug-in modules are available for Module Slot 3. They are interchangeable with slot 2, but not slot 1.They can be ﬁtted during manufacture, or purchased and ﬁtted later by the user. Modules in slot 3 are designated Output 3, and for dual modules Output 3A and 3B. Their functions are set in the Output Conﬁguration sub-menu. Connect as illustrated below.

Plug-in Module Slot 3 – Single Relay Output Module

Figure 32.

Plug-in Module Slot 3 – Single Relay Module

Plug-in Module Slot 3 - Dual Relay Output Module

If ﬁtted with a dual relay output module, connect as shown. This module has two independent SPST relays for outputs 3A and 3B, with a shared common terminal. The contacts are rated at 2 amp resistive 240 VAC. If used to switch mains voltages, the supply should be separate from the instruments mains supply and the contacts should be correctly switched and fused.

Plug-in Module Slot 2 Transmitter Power Supply Module

If ﬁtted with a transmitter power supply module (TxPSU), connect as shown. The output is a 24V nominal (unregulated, 19 to 28V DC), supply at 22mA max. Only one TxPSU is supported, do not ﬁt in slot 2 if one is already ﬁtted in slot 3.

Figure 33

Plug-in Module Slot 3 - Dual Relay Module

Plug-in Module Slot 3 – Single SSR Driver Output Module

If ﬁtted with a single SSR Driver output module, connect as shown. The 10V DC pulse signal (load resistance ≥500 ohms) is isolated from all inputs/outputs except other SSR drivers.

Figure 34

Plug-in Module Slot 3 – Single SSR Driver Module

Plug-in Module Slot 3 – Dual SSR Driver Output Module

If ﬁtted with a dual SSR Driver output module, the two solid-state relay driver outputs are designated as Output 3A and 3B. The outputs are 10V DC pulse signals, (load resistance ≥500 ohms). They are isolated from all inputs/output except other SSR driver outputs. Connect as shown making note of the shared positive common terminal.

Plug-in Module Slot 3 - Transmitter Power Supply Module

Figure 37. Plug-in Module Slot 3 -

Transmitter Power Supply Module

Plug-in Slot A Connections

A selection of plug-in modules are available for Module Slot A. They can be ﬁtted during manufacture, or purchased and ﬁtted later by the user. Depending on their functions, they are setup Input or Communications conﬁguration sub-menus. Connect as illustrated below.

Figure 35.

Plug-in Module Slot 3 – Dual SSR Driver Module

Plug-in Module Slot 3 Triac Output Module

Figure 36. Plug-in Module Slot 3 - Triac Module

Plug-in Module Slot A – Basic Auxiliary Input Module

If ﬁtted with a basic auxiliary mA/V DC analogue input module, connect as shown. Isolated from all inputs/ outputs. Consider using the 2nd auxiliary input (if available) instead, as this has additional features and leaves plug-in module slot A free for other modules.

Figure 38. Plug-in Module Slot A –

Basic Auxiliary Input Module

Plug-in Module Slot A Ethernet Communications Module

If ﬁtted with the Ethernet communication module, the communications protocol available is Modbus TCP. Isolated from all inputs/outputs. If necessary, cut out the removable panel to access the RJ45 connector through the top of the case. No rear connections are required.

Plug-in Module Slot A RS485 Serial Communications Module

If ﬁtted with the RS485 serial communication module, the protocol used is Modbus RTU. Isolated from all inputs/outputs. Carefully observe the polarity of the A (Rx/Tx +ve) and B (Rx/Tx -ve) connections.

Figure 39. Plug-in Module Slot A –

RS485 Serial Communications Module

External computing devices connected to the communications port should comply with the standard, UL 60950.

Plug-in Module Slot A – Single Digital Input Module

If a digital input module is ﬁtted, it provides a fully isolated input that is held high via a pull-up resistor. The input can be connected to either to voltage free contacts (e.g. from a switch), or a TTL compatible signal. Logic High = Open contacts (>5000Ω) or 2 to 24VDC signal. Logic Low = Closed contacts (<50Ω) or -0.6 to +0.8VDC signal.. Connect as shown.

Option C Connections – Multiple Digital Input Module

If the Multiple Digital Input option is ﬁtted, the connections are as illustrated. The 8 opto-isolated inputs each have a positive input terminal and share a common negative terminal. The inputs are held high with internal pull-up resistors, so may be connected to either voltage free contacts (e.g. from a switch), or TTL compatible signals: Logic High = Open contacts (>5000Ω) or 2 to 24VDC signal. Logic Low = Closed contacts (<50Ω) or -0.6 to +0.8VDC signal.

Figure 40. Plug-in Module Slot A –

Digital Input A Module

Option C Connections

Option C offers a factory ﬁtted multiple digital input option. The board also accommodates the USB port if that is option is ﬁtted. The USB port does not have connections on the rear terminal, it is accessed via the front panel.

Figure 14. Input 2 - Thermocouple Connections

Special Wiring Considerations for Valve Motor Control

Valve Motor Drive (VMD) controllers require two identical outputs to be assigned to position the valve. One to open and one to close the valve. These outputs can be two single relays, two triacs, two SSR drivers or one dual relay, but it is recommended to use two single relays (SPDT change-over contacts), and to interlock the relay wiring as shown. This prevents both motor windings from being driven at the same time, even under fault conditions.

Switching actuators directly connected to the valve motor must only be used up to half of their rated voltage (see CAUTION below). The internal relay and triac outputs are rated at 240VAC, so the maximum motor voltage when using them in this way is therefore 120V unless interposing relays are used. Interposing relays or other devices used to control the valve must themselves be rated for twice the motor supply voltage.

Open Valve

“OPEN” RELAY

N/O

N/C

“CLOSE” RELAY

2 x 120V = 240V

120V

N/C C N/O

120VAC SUPPLY

Winding

Valve Common

Close Valv Winding

Figure 42. Interlocking of Valve Motor Drive Relays

5 Powering Up

Ensure safe wiring practices have been followed. When powering up for the ﬁrst time, disconnect the output connections. The instrument must be powered from a supply according to the wiring label on the side of the unit. The supply will be either 100 to 240V AC, or 24/48V AC/DC powered. Check carefully the supply voltage and connections before applying power

ELECTRIC SHOCK/FIRE HAZARD. The windings of a valve motor effectively form an autotransformer. This has a voltage doubling effect when power is applied to either the Open or Close terminal, causing twice the supplied voltage at the other terminal. For this reason, switching devices directly connected to the valve motor must only be used up to half of their rated voltage. The maximum motor voltage when using the internal relays/triacs is therefore 120V unless interposing relays are used. Interposing relays or other devices used to control the valve must themselves be rated for twice the motor supply voltage. Failure to follow these instructions could result in personal injury or equipment damage.

Powering Up Procedure

At power up, a self-test procedure is automatically started, during which a splash screen is displayed and the LED indicators are lit. At the ﬁrst power up from new, a Setup Wizard runs to assist conﬁguration of basic applications (refer to the Setup Wizard section on page 43). At all other times, the instrument returns to the normal operation mode once the self-test procedure is complete.

Front Panel Overview

The illustration below shows an instrument ﬁtted with the optional USB socket located to the right of the four keypad buttons. Clean the front panel by washing with warm soapy water and dry immediately. If the USB option is ﬁtted, close the port cover before cleaning.

Display

The instrument has a 160 x 80 pixel monochrome graphical display with dual color (red/green) backlight. The main display typically shows the process variables, setpoints, power / deviation bar graphs or graphical trends during normal operation. There are recorder and proﬁle status screen. The top line of the display has labels for the 4 LED indicators. If desired, the backlight color can be changed to indicate the presence of an active alarm or latched output. Refer to the Display Conﬁguration section.

Figure 43. A Typical Front Panel

LED Functions

There are four red LEDs that by default indicate the status of the primary & secondary outputs, automatic tuning and alarm status. The top line of the graphical display has four labels for LED indicators. The function of these LEDs and their display labels can be changed using the PC conﬁguration software. The information in this manual assumes standard functions for these

LEDs.

Button Function

Moves backward to the previous parameter or screen in the current mode. Holding this key down for more than 1 second skips immediately to the previous screen accepting ALL values as shown.

CAUTION: If editing a parameter, ensure that the current (highlighted) parameter value is correct before pressing the key as this action will update the instrument to the value displayed.

In menus and conﬁguration choice screens, this key moves to the next item on the list.

Editable values can be decreased by pressing this key. Holding the key down speeds up the change.

In Trend views this key moves the Cursor Line back through the stored data points

In menus and conﬁguration choice screens, this key moves to the previous item on the list.

Editable values can be increased by pressing this key. Holding the key down speeds up the change.

In Trend views this key moves the Cursor Line forward through the stored data points

Moves forward to the next parameter or screen in the current mode. Holding this key down for more than 1 second skips immediately to the next screen accepting ALL values as shown.

CAUTION: If editing a parameter, ensure that the current (highlighted) parameter value is correct before pressing the key as this action will update the instrument to the value displayed.

Keypad Functions & Navigation

Each instrument has four keypad switches, which are used to navigate through the user menus and adjust the parameter values. In conﬁguration screens, a context sensitive scrolling help text is displayed that guides the user about the function of the keys.

Pressing the key while holding down the key causes the instrument to move up one menu level. From Operation Mode and in most menus, this will result in entry to the Main Menu.

From sub-menus, it is necessary to carry out this sequence more than once to reach the main menu.

CAUTION: If editing a parameter, ensure that the current (highlighted) parameter value is correct before pressing the key as this action will update the instrument to the value displayed.

6 Messages and Error Indicators

Plug-in Module Problems

If an invalid or unknown module is detected in one of the plug-in module slots during the power-up self-test, the message “Fault Found, Press , for details” is shown. This is followed by “Replace faulty module in Module Slot n, Press ,” (where n is the faulty slot location). The Service Contact information is displayed next showing details of who to contact if a fault persists

Replace the module in slot “n”. If this does not solve the problem, return the instrument for investigation.

Do not continue using the product until the the error is resolved.

Sensor Break Detection

Whenever a problem is detected with a process variable or auxiliary input connection, the displayed value for that input is replaced with the word “OPEN”; except in Ratio control where an open input 1 or 2 is shown as “x1-Open” or “x2-Open”. See Redundant Input to protect critical processes from sensor faults.

This may be the result of a failed sensor, a broken connection or an input circuit fault.

In this condition, the control outputs go to the pre-set power value (see Control Conﬁguration.)

Correct the signal/wiring problem to continue normal operation.

Un-Calibrated Input Detection

The instrument is fully calibrated during manufacture. If a fault occurs and calibration data is lost, the process input displays are replaced with the word “ERROR” and error is shown instead of “Calibrated” for effected inputs in Service & Product Information mode.

In this condition, the control outputs go to the pre-set power value (see Control Conﬁguration).

Perform a full base calibration of the input before continuing normal operation. If the problem persists, return the instrument for servicing.

PV Over-Range or Under-Range Indication

If a measured process input value is more than 5% above than the Scaled Input Upper Limit, its value is replace by the word “HIGH” to indicate that it is out of range.

If a measured process input value is more than 5% below than the Scaled Input Lower Limit, its value is replaced by the word “LOW” to indicate that it is out of range.

Auxiliary Input Over-range or Under-range Indication

If the auxiliary Remote Setpoint input is more than 5% above than the Auxiliary Input Upper Limit, its value is replaced by the word “HIGH” to indicate that it is out of range.

If the auxiliary Remote Setpoint input is more than 5% below than the Auxiliary Input Lower Limit, its value is replace by the word “LOW” to indicate that it is out of range.

Cascade-Open

“Cascade Open” is shown on the main screen if the internal link has be severed between cascaded master and slave control loops. This mode should only be used for diagnostics and slave tuning. Close the cascade for proper operation. Refer to the Cascade Control section for more information.

Proﬁle Not Valid

If the user attempts to run a proﬁle that would take the setpoint beyond the current setpoint limits, the proﬁle will not run and the message “Proﬁle Not Valid” is displayed at the bottom of the proﬁle status screen.

USB Data Transfer Failure message

If the instrument cannot successfully write to the USB memory stick, the message “Data Transfer Failure” will be displayed. Check that there is adequate disk space on the memory stick, then retry.

If the instrument cannot successfully read data from the USB memory stick, the message “Data Transfer Failure” will also appear. Check that this operation would not cause the maximum number of proﬁles and/ or segments to be exceeded then retry.

Getting Help

First Level Support

If the errors persist or other problems are encountered, refer your supplier for ﬁrst level support. This includes help with conﬁguration, tuning, servicing and replacement modules.

Second Level Support

If your supplier is unable to assist or cannot be contacted, check the Service & Product Information screen on the main menu for details of who to contact.

Third Level Support

If further assistance is required, contact the nearest company from those listed on the back page of this manual.

Servicing

If you need to return your instrument for servicing, contact your supplier or check the Service & Product Information screen on the main menu for instructions for its return.

7 Application Setup

Before beginning conﬁguration, consider how the controller will be used in your application. For instance, how many control loops are needed, is cascade or ratio control required, will the unit control a valve motor, do you need setpoint proﬁling etc. Consideration should also be given to the output types, alarms and tuning method.

This section is intended to help with this process, guiding you through the major conﬁguration settings. Additional information can be found in the relevant sections of this manual, including the glossary, conﬁguration menus, and dedicated sections for major features. These are listed in the table of contents.

Pre-Commissioning Considerations

An easy Setup Wizard is available for basic applications where the most commonly required parameters are present for adjustment in turn. The wizard has a sub-set of the full conﬁguration menu options. For

Loop 1 / Master

Process Type*

(only if 2nd

input ﬁtted)

One Loop*

Input 2 Conﬁguration | Input 2 Usage = Not Used

Two Loops*

Input 2 Conﬁguration | Input 2 Usage = Standard

+Feedback*

Input 2 Conﬁguration | Input 2 Usage = Feedback

Redundant*

Input 2 Conﬁguration | Input 2 Usage = Feedback

Standard PID Control Select = Control Standard

Valve Motor Drive Control Select = VMD (TPSC) Control

Standard PID Control Select = Control Standard

Valve Motor Drive Control Select = VMD (TPSC) Control

Standard PID Control Select = Control Standard

Valve Motor Drive Control Select = VMD (TPSC) Control

Control Conﬁguration: Control Select

Control

Conﬁguration:

Control Type

Primary Only Control Type = Single

Primary/Secondary Control Type = Dual

Primary Only Control Type = Single

Primary/Secondary Control Type = Dual

Primary Only Control Type = Single

Primary / Secondary Control Type = Dual

more complex applications where the wizard is not sufﬁcient, consideration must be given to the following fundamental questions:

If ﬁtted, how will the 2nd input be used?

• One loop only (if the 2nd input not ﬁtted or not used in this application)

• Two independent control loops

• Valve feedback for loop 1

• A “redundant” backup for the 1st input

• Cascaded with the ﬁrst control loop

• A reference input for ratio control

How will the instrument physically control the process?

• Primary only or primary & secondary control outputs

• Direct valve motor drive outputs

The table below shows the main input and control conﬁguration settings for these application types (see conﬁguration menus).

Loop 2 / Slave

Control Conﬁguration: Control Select

Standard PID Control Select = Control Standard

Valve Motor Drive Control Select = VMD (TPSC) Control

Primary Only Control Type = Single

Primary / Secondary Control Type = Dual

Control

Conﬁguration:

Control Type

Loop 1 / Master

Loop 2 / Slave

Process Type*

(only if 2nd

input ﬁtted)

Cascade*

Input 2 Conﬁguration | Input 2 Usage

= Standard

AND

Loop 1 / Master Conﬁguration | Control Mode = Cascade

Ratio*

Input 2 Conﬁguration | Input 2 Usage

= Standard

AND

Loop 1 / Master Conﬁguration | Control Mode = Ratio

Control Conﬁguration: Control Select

Standard PID Control Select = Control Standard

Valve Motor Drive Control Select = VMD (TPSC) Control

Control

Conﬁguration:

Control Type

Control Conﬁguration: Control Select

Standard PID Control Select = Control Standard

Valve Motor Drive Control Select = VMD (TPSC) Control

Control

Conﬁguration:

Control Type

Primary Only Control Type = Single

Primary / Secondary Control Type = Dual

Which outputs will be used for control, and are alarms or event outputs needed?

• Output conﬁguration

• Alarms & Proﬁle Events

What are the sources for the setpoints?

• Local setpoint(s) only, or a remote setpoint input

• Proﬁle Control

Is Input re-conﬁguration required?

• Analogue input calibration & scaling

• Digital input functions

Which other features are to be used?

• Data Recorder.

• Serial Communications.

• USB Interface.

Once you have an understanding of your application and how the controller will be used, continue on to the conﬁguration and use section below.

CAUTION: Conﬁguration & commissioning must be completed before proceeding to Operation Mode. It is the responsibility of the installing engineer to ensure that the conﬁguration is safe.

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GS Chromalox 4081, Chromalox 4082 Installation & Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual