Innovative instruments AI-5481, AI-5781, AI-5681, AI-5881, AI-5981 User's Operating Manual

USER’S OPERATING MANUAL FOR DIGITAL TEMPERATURE CONTROLLER

(Models: AI 5481 / 5881 / 5781 / 5981 / 5681)

1. DISPLAY TYPE : Dual 4- Digit 7 segment LED
4 Digit Bright Red (PV)
4 Digit Luminous Red (SV)

:

Sampling Time : 200 msec.
Resolution : 1°C
CJC for TC : Built in automatic

LWC for Pt-100 : Built in up to 18E max.
Digital Filter : 1 to 10 Sec.

3.

Contact type : N/O, CM, N/C
Contact Rating : 5A @ 250VAC or 30 VDC
Life expectancy : > 5,00,000 operations
Isolation : Inherent

4.

Drive Capacity : 12V @ 30mA.
Isolation : Non-Isolated.

5.

1:

STATUS LED’S

RELAY OUTPUT

SSR DRIVE OUTPUT

FUNCTION

OP 1 : Main Control Output

2.

Sensor Input : J/K/Pt-100
Range : Refer below table

Output Main Control output
Control Action : ON-OFF/T.P (Select)
Control Mode : Heat/Cool (Select)
Compliance : ----

6.

Operating Range : 0 ~50°C, 5~90% Rh
Storage Humidity : 85% Rh (Non-condensing)

7.

Supply Voltage : 90~270VAC, 50/60Hz.
Consumption : 4W Maximum.

8.

Housing : ABS Plastic.

INPUT

ENVIRONMENTAL

POWER SUPPLY

PHYSICAL

SPECIFICATIONS : -

:SAFETY INSTRUCTION

This controller is meant for temperature control
applications. It is important to read the manual prior to
installing or commissioning of controller. All safety related
instruction appearing in this manual must be followed to
ensure safety of the operating personnel as well as the
instrument.

The controller must be configured correctly for intended
operation. Incorrect configuration could result in damage to
the equipment or the process under control or it may lead
personnel injury.
The controller is generally part of control panel and in such
a case the terminals should not remain accessible to the
user after installation.

The Controller in its installed state must not come in close
proximity to any corrosive/combustible gases, caustic
vapors, oils, steam or any other process by-products.
The Controller in its installed state should not be exposed
to carbon dust, salt air, direct sunlight or radiant heat.
Ambient temperature and relative humidity surrounding the
controller must not exceed the maximum specified limit for

proper operation of the controller.
The controller in its installed state must be protected
against excessive electrostatic or electromagnetic
interferences. Ventilation holes provided on the chassis of
the instrument are meant for thermal dissipation hence
should not be obstructed in the panel.

The controller must be wired as per wiring diagram & it
must comply with local electrical regulation.
Care must be taken not to connect AC supplies to low
voltage sensor input.
Circuit breaker or mains s/w with fuse (275V/1A) must be
installed between power supply and supply terminals to
protect the controller from any possible damage due to high
voltage surges of extended duration.
Circuit breaker and appropriate fuses must be used for
driving high voltage loads to protect the controller from any
possible damage due to short circuit on loads.
To minimize pickup of electrical noise, the wiring for low
voltage DC and sensor input must be routed away from
high current power cables. Where it is impractical to do
this, use shielded ground at both ends.
The controller should not be wired to a 3-Phase supply
with unearthed star connection. Under fault condition such
supply could rise above 264 VAC which will damage the
controller.
The Electrical noise generated by switching inductive
loads might create momentary Fluctuation in display, alarm
latch up, data loss or permanent damage to the instrument.
To reduce this use snubber circuit across the load.

It is essential to install a over Temp. Protection device to
avoid any failure of heating system. Apart from spoiling the
Product, this could damage the process being controlled.

GENERAL

MECHANICAL

ELECTRICAL

v

v

v

v

v

v

v

v

v

v

v

v

v

v

Model no.

Display height (PV)

Display height (SV)

AI-5481

0.39” 0.39” 0.56” 0.8” 0.39”

0.39” 0.39” 0.39” 0.56” 0.39”

AI-5881 AI-5781 AI-5981 AI-5681

1

Document Name : OIM AI-5X81 (Ver 1.2) Page 1 of 4

Model no.

Weight (gms.)

AI-5481 AI-5781 AI-5981 AI-5881 AI-5681

200240 200200130

(48 X 48)

(72 X 72)

(96 X 96)

(48 X 96)

(96 X 48)

Fe-K(J) T/C

Cr-AL(K) T/C

Pt-100 (RTD)

Pt-100 (RTD 0.1)

Sensor Type

Accuracy

±1 C

o

± 0.3 C

o

0 760 C~

o

-99 ~ 1300 C

o

-100 450 C~

o

-100.0 450.0 C~

o

Resolution

Range

1C

o

1C

o

1C

o

0.1 C

o

}

-therm

i

AI-5881

SET

1

2

43

6

5

OP1

-therm

i

AI-5681

SET

1

3

2

6

4

5

OP1

-therm

i

AI-5981

SET

6

4

5

1

2

3

PV

SV

OP1

-therm

i

AI-5781

SET

6

4

5

1

2

3

PV

SV

OP1

MODEL : AI - 5881

B

A

E

D

CH

MODEL : AI - 5681

E

D

C

H

A

B

F

G

A

B

D

C

H

E

G

F

G

F

MODEL:-AI-5481/5781/5981

OVER ALL DIMENSIONS & PANEL CUT OUT (IN MM)

TABLE : 1

Model

Dim

48
72
96
48
96

48
72
96
96
48

8
10
10
10
10

110

65

65
110
110

44
68
92
92
44

44
68
92
44
92

9
9
9
9
9

AB

HCD FGE

43
66
89
43
89

AI-5481
AI-5781
AI-5981
AI-5881
AI-5681

MECHANICAL INSTALLATION

The label on the controller identifies the serial number, wiring connections and batch number.

INSTALLATION GUIDELINES

1. Prepare the cut-out with proper dimension as shown in figure.

2. Remove clamp from controller

3. Push the controller through panel cut-out and secure the
controller in its place by tightening the side clamp.

PANEL

CUTOUT

CAUTION: To prevent the risk of electrical shock, switch off the power before making/removing any connection or removing

the controller from its enclosure.

PANEL

CUTOUT

PANEL

CUTOUT

AI - 5481 AI - 5781 AI - 5981

AI - 5881

FRONT PANEL LAYOUT

AI - 5681

2

Document Name : OIM AI-5X81 (Ver 1.2) Page 2 of 4

ELECTRICAL INSTALLATION

The electrical connection diagram is shown on the controller enclosure as below.

SUPPLY

L

N

1

2

3

4

5

6

7

8

9

10

11

12

15

16

13

14

SSR1

NO NCCM

RELAY1

1

2

3

4

5

6

10

11

12 13 14 15 16 17 18

7

8

9

NO NCCM

RELAY1

SSR1

SUPPLY

L

N

NO NCCM

RELAY1

SSR1

SUPPLY

L

N

AI-5481

AI-5781 AI - 5981 AI - 5681/5881

SUPPLY

L

N

1

2

3

4

5

6

789

10

11

13

14

15

16

12

NO NCCM

RELAY1

1234

5

10

9

11 1 2

131415 16

6

78

SSR

NO. NAME FUNCTION

Î
Ï

Ð

Ñ

Ò

Ó

OP1
LED

UPPER

DISPLAY

LOWER

DISPLAY

SET
KEY

UP

KEY

DOWN

KEY

Glows whenOP1 is ON & flasheswhen delay time (dly1) isin operation & selected mode isON-OFF.

It will display : (1) Measured value of selected input or Error messages in run mode.
(2) Parameters Value in program mode.

It will display : (1) (Main s ) / SP2 (Auxiliary) set value / Set Soak time value/
balance or elapsed soak time in run mode. (2) Parameter code in program mode.

SP1 et point

(1) For SP programming. (2) To access Control mode. (3) To access Configuration mode
alongwith UP key. (4) To scroll the parameter & to store its value.

(1) To increase/alter parameter value in program mode. (2) To Enter in configuration
mode (alongwith SET key) . (3) To acknowledge Alarm. (4) To enter in tune mode
(alongwith DOWN Key).

(1) To decrease / alter parameter value in program mode. (2)

. (3) To start Soak timer.

To enter in tune mode

(alongwith UP Key)

4

SET

-therm

i

AI-5481

5

6

1

2

3

PV

SV

OP1

MANUAL
OFF SET

0C

o

This parameter will appear only if selected C.A is time proportional.
(For more details: refer user guide.)

-25
to

25

o

C

DELAY 1

0

to

500 Sec.

This parameter will be prompted only if selected control action is ON-OFF. It
sets the main output restart time where O/P once turned OFF will turn ON only
after restart time, regardless difference between PV & SP in Heat or Cool mode.
If set to '0', O/P will be switched without delay. Also, Delay will be applicable in
case of every power ON.

120 Sec.

PROGRAMMING :

At power on, following sequence will be prompted on the display for 1 sec. till it reaches to Home Display mode.

USER LIST : To access the user list press SET key once.

LOWER

DISPLAY

UPPER

DISPLAY

PARA

METER

RANGE

DESCRIPTION

DEFAULT

CONTROL LIST :

SET keyTo enter in this mode press for 3 sec. User can set the control parameters as shown below.

User can change SP1 value using UP/ DOWN keys. Holding the key, will change
the value at a faster rate. Press SET key to store the value & move on to the
next parameter.

0C

o

LSPL ~ HSPL

CONTROL

SET POINT

LOWER

DISPLAY

UPPER

DISPLAY

PARA

METER

RANGE

DESCRIPTION

DEFAULT

PROPORTIONAL

BAND

CYCLE

TIME

CONTROL

HYS.

0.5
to

99.9°C

1to25 C

o

0.5

to

100.0 Sec.

This parameter will be prompted only if selected control action is PID. It sets
bandwidth over which the output power is adjusted depending upon the error
(SV-PV). The value of this parameter is automatically set by Auto tune function.

This parameter will be prompted only if selected control action is PID. User can
set this value based on process being controlled & type of output being
selected. For Relay O/P, cycle time should be more than 12sec & for SSR O/P,
cycle time should be less than 10sec.

This parameter will be prompted only if selected control action is ON-OFF. It
sets the dead band between ON & OFF switching of the output. Larger value of
hysterisis minimize the number of ON-OFF operation to the load. This
increases life of actuators like contactors but, also produces large errors
(between PV & SV)

5.0 C

o

16.0 Sec.

2°C

3

Document Name : OIM AI-5X81 (Ver 1.2) Page 3 of 4

UPPER

DISPLAY

LOWER

DISPLAY

MODEL VERSION HOME

PV

SV

POWER UP :

0

LOCK
CODE

1 ~ 9999

Set this parameter to 15 (Default LOCK CODE) to access Control List.
User has a choice to set different Lock Code via USER LOCK CODE in Config.
List.

In home display mode, by pressing SET key once,
user can view SP value.

CONFIGURATION LIST :

key simultaneously(1) To enter in this mode, Press and hold SET & UP for 3 sec.
(2) Press UP or DOWN key to scroll between parameter options.
(3) Press SET key to store the current parameter & move on to the next parameter.

LOWER

DISPLAY

UPPER

DISPLAY

PARA

METER

DESCRIPTION

DEFAULT

Set this parameter to 15 (Default LOCK CODE) to access Config. List.
User has a choice to set different Lock Code via USER LOCK CODE in Config. List.

0

LOCK
CODE

0C

o

Sets the minimum limit for set point adjustment. It can be set from minimum specified
range of selected sensor to HSPL value.

LOWER

SP

LIMIT

J

INPUT
TYPE

This parameter value is set according to the type of sensor (Thermocouple or RTD Input)
connected to the Controller's Input Terminals.

Fe-k(J) T/C

Cr-AL(K) T/C

Pt-100(RTD)

Pt-100(RTD 0.1)

Sensor Type

Accuracy

± 0.3 C

o

0 760 C~

o

-99 1300 C~

o

-100 450 C~

o

-100.0 450.0 C~

o

Resolution

Range

1C

o

1C

o

1C

o

0.1 C

o

±1 C

o

}

.

1)
In this mode, output (Relay/SSR) remains ON till actual
temperature reaches to the set point. On reaching SP,
output turns OFF & remains OFF till actual temperature
drops down (in heat logic) or raises (in cool logic) equal
to hysterisis set by user.
(As shown in Fig : 3.1 & 3.2)

ON-OFF ACTION:

Fig: 3.1 Fig: 3.2

TIME

COOL LOGIC / ON OFF

HEAT LOGIC / ON-OFF

TIME

TEMP ( C)

0

HYSTERISIS

SP

ON ON ON

AMB

O/P

OFF OFF

O/P

O/P

TEMP ( C)

0

AMB

HYSTERISIS

ON ON ON

SP

OFF OFF

USER GUIDE:

Fig: 3.3

AMB

TEMP ( C)

0

SP

OUT PUT

ON

100 %

ON

100 %

OFF

100 %

PROPORTIONAL BAND (P.BND)

SET BY USER

TIME PROPORTIONAL ACTION

ACTIVE ZONE

TIME

AMB

TEMP ( C)

0

SP

Fig: 3.4

OFFSET

after offset adjustment

TIME

2)
In this mode, ON & OFF time of
Output (Relay/SSR) varies
proportionally in every cycle (cycle
time settable by User) depending
on the deviation of PV w.r.t. SP.
This action starts/continues only
when PV enters or is within the
band. (As shown in Fig : 3.3)

TIME PROPORTIONAL ACTION:

3)
In some

application, after adopting-Time
proportionating action, system may
stabilize at particular temperature
over a period of time which can be
different than the set value. This
steady state (error) offset can be
eliminated by setting this value, equal
and opposite to the existing offset.
(As shown in Fig : 3.4)

MANUAL RESET

(OFFSET ADJUSTMENT) :

4

Document Name : OIM AI-5X81 (Ver 1.2) Page 4 of 4

338, New Sonal Link Service Ind. Est. no.2 ,
Link Road, Malad (W), Mumbai - 400064.
Tel: [phone]. Fax: [phone]
E-mail:[e-mail] ;
Website: innovativeinstrument.com

: Innovative InstrumentsMfgd by :-Dealer

SP : Set Point Value(set temp.)
SSR : Solid State Relay
T.P. : Time Proportional
T/C : Thermocouple

NC : Normally Close terminal of relay
NO : Normally Open terminal of relay
OP1 : Output 1
PV : Process Value (actual temp.)

C.A. : Control Action
CJC : Cold junction compensation
CM : Common terminal of relay
LWC : Lead wire (Length)

compensation

ABBREVIATION

INPUT

FILTER

CONTROL

MODE

FOR O/P 1

CONTROL

LOGIC

FOR O/P 1

2.5 C

o

PID

HEAT

The controller is equipped with an adaptive digital filter which is used to filter out any
extraneous pulses on the PV. Filtered PV Value is used for all PV dependent functions. If
PV signal is fluctuating due to noise, increase the filter time constant value.

User can select between TP or ON-OFF action algorithm to be adopted for output.

This parameter will appear only if selected control mode is ON-OFF.
User can select heating logic in which OP1 will remain ON till PV < SP.
(PV increases when output is ON.)

This parameter will appear only if selected control mode is ON-OFF.
User can select cooling logic in which OP1 will remain ON till PV > SP.
(PV decreases when output is ON.)

PROCESS

VALUE

OFFSET

0C

o

Function of this parameter is to add/subtract a constant value to the measured PV to
obtain Final PV for control applications. This parameter value needs to be altered for one
of the following reason : ­(i) To compensate for known thermal gradient
(ii)To match the display values with another recorder or indicator measuring the same PV.

OUTPUT

TYPE

RELAY

User has to set this parameter very carefully in accordance with the output used.
(Separate terminals for RELAY & SSR : - Refer Electrical Installation )
Select Relay if LOAD is connected via contactor. Whenever user selects Relay, Cycle time
will be automatically set to 16 sec. User can modify cycle time via control list.

Select SSR if LOAD is connected via SSR (DC voltage pulses). Whenever user selects SSR,
Cycle time will be automatically set to 1sec. User can modify cycle time via control list.

15

Default USER LOCK CODE is 15 to access Control & Configuration List.
User has a choice to set its own USER LOCK CODE between 1 to 9999, this is to prevent
unauthorized access of Control & Configuration List.

USER
LOCK
CODE

LOWER

DISPLAY

UPPER

DISPLAY

PARA

METER

DESCRIPTION

DEFAULT

HIGHER

SP

LIMIT

Sets the maximum limit for set point adjustment. It can be set from LSPL value to
maximum specified range of selected sensor.

400 C

o