Innovative instruments i-therm AI-5441, i-therm AI-5841, i-therm AI-5741, i-therm AI-5941 User's Operating Manual

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1. DISPLAY TYPE : 4-Digit 7 segment LED (RED)

STATUS LED’S : OP 1 : Main Control Output

2. INPUT
Sensor Input : TC:J,K,R,S & RTD: Pt-100
Range : Refer below table

Sampling Time : 125 msec.
Resolution : 1°C/0.1°C(Only for RTD)
CJC for TC : Built in automatic
LWC for Pt-100 : Built in upto 18E max.
Digital Filter : 1 to 10 Sec.

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

4. SSR DRIVE OUTPUT
Drive Capacity : 12V @ 30mA.
Isolation : Non-Isolated.

5. FUNCTION
Output 1 : Main Control output
Control Action : ON-OFF/T.P (Select)
Control Mode : Heat/Cool (Select)
Compliance : ----

6. ENVIRONMENTAL
Operating Range : 0 ~50°C, 5~90% Rh
Storage Humidity : 95% Rh (Non-condensing)

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

8. PHYSICAL
Housing : ABS Plastic.

Model no.

Display height

AI-5441

AI-5841

AI-5741

AI-5941

0.36” 0.56”0.56”0.56”

USER’S OPERATING MANUAL FOR DIGITAL TEMPERATURE CONTROLLER

Model no.

Weight (gms.)

AI-5441

130 200 200 240

AI-5841 AI-5741

AI-5941

SPECIFICATIONS: -

(Models: AI 5441 / 5741 / 5841 / 5941)

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 instructions appearing in this manual must be
followed to ensure safety of the operating personnel as
well as the instrument.

GENERAL

v 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 to personnel injury.

v The controller is generally part of control panel and in

such a case the terminals should not remain accessible
to the user after installation.

MECHANICAL

v 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.
v The Controller in its installed state should not be
exposed to carbon dust, salt air, direct sunlight or radiant
heat
v Ambient temperature and relative humidity surrounding

the controller must not exceed the maximum specified

limit for proper operation of the controller.
v The controller in its installed state must be protected

against excessive electrostatic or electromagnetic

interferences. Ventilation slits provided on the chassis

of the instrument are meant for thermal dissipation hence

should not be obstructed in the panel.

ELECTRICAL
v The controller must be wired as per wiring diagram & it

must comply with local electrical regulation.
v Care must be taken not to connect AC supplies to low

voltage sensor input.
v 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.
v 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.
v 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

so, use shielded ground at both ends.
v 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.
v 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.
v 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.

AI - 5441

(48 X 48)

AI - 5741

(72 X 72)

AI - 5941

(96 X 96)

AI - 5841

(48 X 96)

Fe-k(J) T/C

Cr-AL(K) T/C

Sensor Type

Accuracy

o

± 1 C

o

0 ~ 1700 C

o

0 ~ 1700 C

o

-100 ~ 450 C

Resolution

Range

o

1 C

o

1 C

o

1 C

}

(R) T/C

(S) T/C

Pt-100(RTD)

Pt-100(RTD 0.1)

o

0 ~ 760 C

o

-99 ~ 1300 C

o

-99.9 ~ 450.0 C

o

1 C

o

1 C

o

0.1 C

o

± 0.3 C

OP1

°C

SET

-therm

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AI-5941

OP1

°C

-therm

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AI-5741

SET

AI-544 1

OP1

SET

OP1

SET

-therm

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AI-5841

°C

1

OIM AI-5X41 - V2.0 Page 1 of 4

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ELECTRICAL INSTALLATION

The el ectrical conn ecti on dia gram is shown on th e cont roll er enclosure as b elow.

OVER ALL DIMENSIONS & PANEL CUT OUT (IN MM)

MECHANICAL INSTALLATION

The label on the controll er identifie s the serial number, wiring connections and batch number.

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

removing the controller from its enclosure.

TABLE : 1

Model

Dim

48
72
96
48

48
72
96
96

8
10
10
10

75
65
45
45

44
68
92
92

44
68
92
44

9
9
9
9

A B

HC D F GE

43
66
89
43

AI-5441
AI-5741
AI-5941
AI-5841

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.

A

B D

C

H

E

G

F

MODEL:-AI-5441/5741/5941

PANEL

CUTOUT

MODEL : AI - 5841

B

A

E

D

C H

G

F

PANEL

CUTOUT

AI - 5941

AI - 5841

FRONT PANEL LAYOUT

FRONT PANEL LAYOUT DESCRIPTION :

OP1 LED

DISPLAY

SET
KEY

SHIFT

KEY

Sr.

NAME FUNCTION

Glo ws w hen OP1 is ON & flashes w hen del ay time (dly) is i n operation
(if sel ect ed mode is ON- OFF )

It w ill display: (1) Mea sur ed v alu e of se lected inp ut o r Error ma ssa ges. (2 ) SP (Ma in
set poi nt) value in r un m ode . (3) P ara met ers Value/code in p rog ram mode.

(1) Fo r S P pr og ra mming . ( 2) To ac ce ss Con tr ol mode a lo ng wit h D N K ey.
(3) To a ccess Co nf igura ti on mode a lo ng wit h U P ke y. ( 4) To sc roll t he pa ramet er &
to sto re it s valu e.

1

2

3

UP

KEY

DOWN

KEY

(1) To in cr ea se/al te r pa ra me ter va lu e in progr am mode. (2) To En te r in co nfigu ra ti on
mode (w it h SE T key) . (3 ) To Set SP Of fset (w it h DO WN Key) .

(1) To inc rease /a lt er para me te r value i n pr ogram m od e wi th Up / Dn Ke y.
(2) Pre ss f or 3 Sec in Pr og rammi ng t hi s will he lp t o go back t o pr ev ious pa ra meter.

(1) To d ecrea se /a lter p ar am eter v al ue in p ro gr am mod e.
(2) To E nter c on tr ol mod e

4

5

6

AI - 5741

SUPPLY

L

N

1

2

3

4

5

6

7

8

9

10

11

12

15

16

13

14

NO NCCM

RELAY

SSR

AI - 5441

SUPPLY

L

N

1

2

3

4

5

6

7 8 9

10

11

13

14

15

16

12

NO NCCM

RELAY

SSR

1

2

3

4

5

6

10

11

12 13 14 15 16 17 18

7

8

9

NO NCCM

RELAY

SSR

SUPPLY

L

N

1

2

3

4

5

6

7

8

9

10

11

12 13 14 15 16 17 18

NO NCCM

RELAY

SSR

SUPPLY

L

N

OP1

SET

-therm

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AI-5841

°C

1

3

4

5

6

2

AI - 5941

2

3

1

AI - 5441

1

2

3

5

4

6

AI - 5741

1

6

5

4

3

2

AI - 5841

OP1

°C

SET

-therm

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AI-5941

AI-544 1

OP1

SET

OP1

°C

-therm

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AI-5741

SET

6

5

4

2

OIM AI-5X41 - V2.0 Page 2 of 4

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POWER UP :

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

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

MODEL HOME

PV

VERSION INPUT

User can cha nge SP v alue using UP/ D OWN keys. Ho lding the key, will change the
value at a faster rate. Press SET key to store the va lue & move on t o next param eter.

o

0 C

LSPL ~ HSPL

CONTROL

SET POINT

PROGRAMMING

USER LIST : To access the user list Press & Release SET key once.

(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)

(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)

PARA

METER

RANGE

DESCRIPTION

DEFAULT

DISPLAY

PARA

METER

RANGE

DESCRIPTION

DEFAULT

DISPLAY

CONTROL LIST : SET & DOWN key simultaneously To enter in this mode, press for 3 sec. User can then set

all the control related parameters as shown below.

0

1 ~ 9999

Set this paramet er to 15 (Default L OCK CODE) to access Control List.
User has a choice t o set different Lock Code via USER LOCK CODE in Config .
List.

0.5
to

99.9°C

o

1 to 25 C

0.5

to

100.0 Sec.

0

to

500 Sec.

-25
to

o

25 C

This parameter w ill appear only if selected control action is T.P. It sets
bandwidth over w hich t he output power is adjusted depending upon the erro r
(SV-PV).

This parame ter will appear only if selected control action is T.P. User can set
this value base d on process being cont rolled & type of output bei ng selected.
For Relay O/P, cycle ti me should be more than 12 Sec & for S SR O/P, cycle time
should be less than 5 Sec .

This parameter wi ll appear only if selected control action is ON-OFF. It set s the
main output restart time. If set to '0', O/P will be swi tched witho ut delay. Als o,
Delay will be considered in case of every power ON.

This parameter wi ll appear only if selected control action is ON-OFF. It set s the
dead band between ON & OFF switch ing of the Output. Larger value of
hysterisis minimize the number of ON-OFF operation of t he loa d. Thi s
increases life o f actuators like Relay but, also pr oduces large err ors.

o

5.0 C

16.0 Sec.

0 Sec.

2°C

P.BAND

CYCLE

TIME

CONTROL

HYS.

DELAY

LOCK
CODE

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.

(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)

J

INPUT
TYPE

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

PARA
METER

DESCRIPTION

DEFAULT

DISPLAY

0

LOCK
CODE

Set this paramet er to 15 (Default L OCK CODE) to access Config. List.
User has a choice t o set different Lock Code in the range via USER LOCK CODE
in Config. List.

1 ~ 9999

MANUAL

OFF SET

o

0 C

This parameter will appear only i f sele cted C.A is time proportional .
(For more details refer User guid e.)

Fe-k(J) T/C

Cr-AL(K) T/C

Sensor Type

Accuracy

o

± 1 C

o

0 ~ 1700 C

o

0 ~ 1700 C

o

-100 ~ 450 C

Resolution

Range

o

1 C

o

1 C

o

1 C

}

(R) T/C

(S) T/C

Pt-100(RTD)

Pt-100(RTD 0.1)

o

0 ~ 760 C

o

-99 ~ 1300 C

o

-99.9 ~ 450.0 C

o

1 C

o

1 C

o

0.1 C

o

± 0.3 C

3

OIM AI-5X41 - V2.0 Page 3 of 4

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4

HIGHER
SP
LIMIT

o

400 C

Sets the maximum limit for set point adjustment. It can be set fr om L SPL value to
maximum specified range of selec ted sensor.

PROCESS

VALUE

OFFSET

INPUT

FILTER

CONTROL

MODE

CONTROL

LOGIC

o

0 C

o

1 C

T.P

HEAT

Function of this parameter is to add/subtract a cons tant value to the measured PV to
obtain Final PV for control applications. This pa rameter valu e needs to be altered for one
of the following reaso n :
(i) To com pensate for know n ther mal gradie nt.
(ii)To match the display v alues with anoth er rec order or indicat or measuri ng the same PV.

Controller is equipped with an ad aptive digital filter which is us ed to filter out any
extraneous pulses on the PV. Filtered PV Value is used for all PV dep endent func tions. If
PV signal is fluctuati ng due to noise, in crease the filte r time constant value.

User can select between ON-O FF or T.P action algorithm to be adopted for output.
(Refer User Guid e)

This parameter w ill appear only if selected control mode is ON-OFF.
User can select heating logic in wh ich OP 1 will remain ON ti ll PV < SP.
(PV increases wh en output is ON.)

This parameter w ill appear only if selected control mode is ON-OFF.
User can select cooling logic in wh ich OP 1 will remain ON ti ll PV > SP.
(PV decreases wh en output is ON.)

OUTPUT

TYPE

RELAY

User has to set thi s parameter very carefully in accordance with the o utput used.
(Separate terminals for RELAY & SSR : - Re fer Electrical I nstallation)
Select Relay if LOAD i s connected v ia Contactor. Whenever u ser selects R elay, Cycle time
will automatically set to 16 sec. U ser can modify cycle time via Contr ol Lis t.

Select SSR if LOAD is connected via SSR (DC voltage pu lses). Whenever user s elects
SSR , Cycle time wi ll automatically set to 1sec. User can modify cycle time via Control L ist.

15

Default USER LOC K CODE is 15 to access Control & Confi guration List.
User has a choice t o set its own USER LOCK CODE between 1 to 9999, this is to p revent
unauthorized access of Control & Confi guration L ist.

USER
LOCK
CODE

PARA

METER

DESCRIPTION

DEFAULT

DISPLAY

LOWER

SP

LIMIT

o

0 C

Sets the minimum limit for set point adjust ment. It can be set from minimum spec ified
range of selecte d sensor to HSPL value.

SET

POINT 1

If Enabled, User can View & edit the Set point in USER list.

If disabled, User can only View the Set Point but Can not edit it in USER list.

ENABLE

2) TIME PROPORTIONAL ACTION:
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)

3) MANUAL RESET

(OFFSET ADJUSTMENT):

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)

TIME PROPORTIONAL ACTION

ACTIVE ZONE

Fig: 3.3

AMB

0

TEMP ( C)

SP

OUT PUT

ON

100 %

ON

100 %

OFF

100 %

PROPORTIONAL BAND (P.BND)

SET BY USER

time

AMB

0

TEMP ( C)

SP

Fig: 3.4

OFFSET

after offset adjustment

TIME

SP : Set Point Valu e(set temp. )
SSR : Solid State R elay
T.P. : Time Pr oportional
T/C : Ther mocouple

NC : Normally Close terminal of re lay
NO : Normally Op en terminal o f relay
OP1 : Output 1
PV : Process Value (actual tem p.)

C.A. : Control Action
CJC : Cold juncti on compensa tion
CM : Co mmon termin al of relay
LWC : Lead wire (Le ngth)
compensat ion

ABBREVIATION :

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E-mail :
Website :

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OIM AI-5X41 - V2.0 Page 4 of 4