Innovative instruments i-therm AI 5442, i-therm AI-5942, i-therm AI-5842, i-therm AI-5742 User's Operating Manual

i

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

STATUS LED’S : OP1 : Main Control Output

OP2 : Alarm Status

: Auxiliary 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
Output 2 : Programmable

1) Auxiliary control 2) Alarm
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

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.

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 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

poximity 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 holes 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
this, 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.

Model no.

Weight (gms.)

AI-5442 AI-5842 A I- 57 42

AI-5942

130 200 200 240

USER’S OPERATING MANUAL FOR DIGITAL TEMPERATURE CONTROLLER

(Models: AI 5442 / 5742 / 5842 / 5942)

SPECIFICATIONS : -

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

AI - 5442

(48 X 48)

AI - 5742

(72 X 72)

AI - 5942

(96 X 96)

AI - 5842

(48 X 96)

OP1

OP2

°C

SET ACK

-therm

i

AI-5942

OP1

OP2

°C

-therm

i

AI-5742

SET ACK

AI-544 2

OP1

OP2

SET ACK

OP1

OP2

SET ACK

-therm

i

AI-5842

°C

Model no.

Display height

AI-5442

AI-5842

AI-5742

AI-5942

0.36” 0.56”0.56”0.56”

1

OIM AI-5X42 - V2.0 Page 1 of 6

i

SUPPLY

L

N

1

2

3

4

5

6

7

8

9

10

11

12

15

16

13

14

NO NCCM

RELAY2

SSR2

NO NCCM

RELAY1

SSR1

1

2

3

4

5

6

10

11

12 13 14 15 16 17 18

7

8

9

NO NCCM

RELAY1

SSR1

NO NCCM

RELAY2

SSR2

SUPPLY

L

N

1

2

3

4

5

6

7

8

9

10

11

12 13 14 15 16 17 18

NO NCCM

RELAY1

SSR1

NO NCCM

RELAY2

SSR2

SUPPLY

L

N

AI - 5442 AI - 5742 AI - 5942

AI - 5842

NO

NC

CM

RELAY2

SSR2

SUPPLY

L

N

1

2

3

4

5

6

7

8 9

10

11

13

14

15

16

12

NO

NCCM

RELAY1

SSR1

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.

MODEL : AI - 5842

B

A

E

D

C H

A

B D

C

H

E

G

F

G

F

MODEL:-AI-5442/5742/5942

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

PANEL

CUTOUT

ELECTRICAL INSTALLATION

The el ectrical conn ecti on dia gram is shown on the cont roll er enc losure as shown b elow.

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-5442
AI-5742
AI-5942
AI-5842

FRONT PANEL LAYOUT

FRONT PANEL LAYOUT DESCRIPTION :

OP1 LED

OP2 LED

DISPLAY

SET

KEY

SHIFT

KEY

Sr.

NAME FUNCTION

Glo ws w hen OP1 is ON & flashes w hen del ay time (dly1) is in operation
(if sel ect ed mode is ON- OFF )

Glo ws w hen OP1 is ON & flashes w hen ala rm conditi on persists e ven aft er
ack now led ged or delay time (dl y2) is in o peration ( if s ele cte d mode is O N-O FF) .

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) / S P2 v alu e in run mo de. (3) Parameters Val ue/ cod e in pr ogr am m ode .

(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 ackn ow ledge A larm.

(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 a long wit h S ET Key.

4

5

6

OP1

OP2

SET

-therm

i

AI-5842

°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

OP2

°C

SET

-therm

i

AI-5942

AI-544 2

OP1

OP2

SET

OP1

OP1

°C

-therm

i

AI-5742

SET

6

5

4

2

OIM AI-5X42 - V2.0 Page 2 of 6

i

(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

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

o

0 C

LSPL ~ HSPL

CONTROL

SET POINT

This parameter is prompted only if Output 2 is configured as...

Either absolute auxiliary control or as an alarm (High/Low) mode.
Either deviation auxiliary control or as a deviation alarm mode.

As a band alarm.(For all above Sp2 has to be enable)

(1)
(2)
(3)

LSPL ~ HSPL

-99 to 99 °C
2 to 99 °C

SET

POINT2

o

0 C

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

MANUAL

OFFSET

o

0 C

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

PARA

METER

RANGE

DESCRIPTION

DEFAULT

DISPLAY

P. BAND

0.5
to

99.9°C

This parameter will appear only if selected control action is T.P. It sets
bandwidth over which the output power is adjusted depending upon
the error (SV-PV).

o

5.0 C

DELAY 1

0

to

500 Sec.

This parameter will appear only if selected control action is ON-OFF.
It sets the output restart time where O/P once turned OFF will turn ON
only after restart time, regardless difference between PV & SP. If set
to '0', O/P will be switched w/o delay. Also, Delay will be considered in
case of every power ON.

120 Sec.

CONTROL

HYS.

o

1 to 25 C

This parameter will appear 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
of the load. This increases life of actuators like contactors but, also
produces large errors (between PV & SV).

2°C

This parameter will appear only if selected control mode for output2 is
Auxiliary control or an Alarm. Value of this parameter sets the dead
band between ON & OFF switching of output load.

HYS. 2

o

1 to 25 C

o

2 C

0

to

500 Sec.

-25
to

o

25 C

This parameter will appear only if output 2 is configured as an
Auxiliary control output. In this mode, output once turned off will
restart only after set time regardless of the difference between PV
and SP2. If time delay is set to 0, there is no delay executed between
output switching.

0 Sec.

DELAY 2

CYCLE

TIME

0.5
to

100.0 Sec.

This parameter will appear only if selected control action is T.P. User
can set this value based on process being controlled & type of output
selected. For Relay O/P, cycle time should be more than 12sec & for
SSR O/P, cycle time should be less than 5sec.

16.0 Sec.

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.

POWER UP :

At pow er on, follow ing seque nce will be pro mpted on th e display f or 1 s ec. till it r eaches to H om e display m ode.

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

MODELMODEL

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)

HOME

PV

VERSION INPUT

3

OIM AI-5X42 - V2.0 Page 3 of 6

i

INPU T

FILTER

o

1 C

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.

CONTROL

LOGIC

FOR OP1

HEAT

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.)

CONTROL

MODE

FOR

OUTPUT1

T.P

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

OUTPUT2

FUNCTION

This parameter allow the user to select output 2 as an ‘Auxiliary’ control.
For options refer Table 3.

This parameter allow the user to select output 2 as an ‘Alarm’ control.
For options refer Table 4.

AUX.

CONTROL

SET

POINT 2

DSBL

o

0 C

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

PROCESS

VALUE

OFFSET

o

0 C

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.

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.

HIGHER
SP
LIMIT

o

400 C

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

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

PARA
METER

DESCRIPTION

DEFAULT

DISPLAY

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.

0

LOCK
CODE

Set this parameter to 15 (Default LOCK CODE) to access Config List.
User has a choice to set different Lock Code between 1 to 9999 via USER
LOCK CODE in Config. List.

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

If Enabled, User can View & edit the Set point1 in USER list.

If disabled, User can only View the Set Point1 but Can not edit it in USER list.

4

OIM AI-5X42 - V2.0 Page 4 of 6

i

If this parameter is set as ‘Reverse’, Relay/SSR de-energizes under Alarm
conditions & remains energized otherwise. Generally ‘Reverse’ setting is used
for tripping the process under Alarm conditions.

DIRECT

ALARM

LOGIC

If this parameter is set as ‘Direct’, Relay/SSR energizes under Alarm condition
& remains De-energized otherwise. Generally ‘Direct’ setting is used for
Audio/Visual Alarm Output.

DEVIATION

ALARM

TYPE

Deviation Alarm : OP2 activates when PV exceeds SP1 ± set deviation value.

Band Alarm : OP2 activates when PV falls outside the band w.r.t. SP1 in either
direction.

Low Alarm : OP2 activates when PV<SP2.

High Alarm : OP2 activates when PV>SP2.

(Direct acting)

(Direct acting)

OUTPUT-2 ON

OUTPUT-2 OFF

SP2

PV

(Direct acting)

SP2

OUTPUT-2 OFF

OUTPUT-2 ON

PV

(Reverse acting)

OUTPUT-2 OFF

OUTPUT-2 ON

SP2

PV

(Direct acting)

SP2

OUTPUT-2 ON

OUTPUT-2 OFF

PV

(Reverse acting)

(Reverse acting)

(Reverse acting)

OUTPUT ON

SP2

PV

SP1

OUTPUT OFF

OUTPUT ONOUTPUT ON

PV

SP1

SP2SP2

OUTPUT OFF

OUTPUT OFF

OUTPUT OFF

PV

SP1

SP2SP2

OUTPUT ON

OUTPUT OFF

SP2

PV

SP1

OUTPUT ON

DISPLAY

PARA

METER

DESCRIPTION

DEFAULT

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

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

TABLE 4 :
Controller continuously compares PV with either SP (for Deviation or Band alarm) or an independent ALARM
SP2 (for process high and process low Alarm). Alarm will occur when PV falls outside the set Alarm limits.
Also, OP2 will energize or de-energize under Alarm condition as per the Alarm logic(AL.LG) selected. HYS2
in Control list decides when to switch OFF the Alarm. Instrument supports four types of Alarm as described
below : -

Below listed parameters will appear only if OUTPUT 2 is selected as ALARM. In ALARM mode,

TABLE 3 : Below listed options will appear only if OP2 is selected as an Auxiliary control mode .

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

HEAT

User can select cooling logic in which OP2 will remain OFF till PV < SP2.
(PV decreases when output2 is ON)

OUTPUT 2
LOGIC

User can select heating logic in which OP2 will remain ON till PV < SP2.
(PV increases when output2 is ON)

This parameter will appear only if OUTPUT 2 is selected as an Auxiliary control
output. In this mode, User can set SP2 value which is always related to SP.

PARA
METER

DESCRIPTION

DEFAULT

DISPL AY

AbS

This parameter will appear only if OUTPUT 2 is selected as an Auxiliary control
output. In this mode, User can set SP2 value independently. The instrument

OUTPUT 2
MODE

SET

POINT 2

DSBL

If Enabled, User can View & edit the Set point2 in USER list.

If disabled, User can only View the Set Point2 but Can not edit it in USER list.

5

OIM AI-5X42 - V2.0 Page 5 of 6

i

ALARM

ACK.

AUTO

Once Alarm is activated, it can be de-activated either by pressing UP key or
when PV falls within the alarm limits.

Once Alarm is activated, it remains activated until manually acknowledged by
UP key.

Once Alarm is activated, User has following three options to de-activate it.
When PV falls within the programmed limits, Alarm will be de-activated
automatically.

ALARM
INHIBIT

Setting this parameter value to ‘YES’, will inhibit (suppress) Alarm activation on
power-up condition. From Power-up, the Alarm system remains disabled until
PV is found with in the limits.

If Alarm activation is desired even under Power-up condition, Set this parameter
value to ‘NO’.

NO

1) ON-OFF ACTION:

In this mode, Output (Relay/SSR) remains ON till actual temperature reaches to Set point value.
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).

Fig: 3.1

HEAT LOGIC/ON-OFF

TIME

0

TEMP ( C)

HYSTERISIS

SP

ON ON ON

AMB

O/P

OFF OFF

Fig: 3.2

TIME

COOL LOGIC / ON OFF

O/P

O/P

0

TEMP ( C)

AMB

HYSTERISIS

ON ON ON

SP

OFF OFF

USER GUIDE:

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. (Fig. 3.3)

Fig: 3.3

AMB

0

TEMP ( C)

SP

OUT PUT

ON

100 %

ON

100 %

OFF

100 %

PROPORTIONAL BAND (P.BND)

SET BY USER

TIME PROPORTIONAL ACTION

ACTIVE TONE

TIME

Fig: 3.4

AMB

0

TEMP ( C)

SP

OFFSET

after offset adjustment

TIME

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 the value of this parameter equal and opposite to the
existing offset. (As shown in Fig.3.4)

NC : Normally Close terminal of rela y
NO : Normally Open terminal of relay
OP1 : Output 1
OP2 : Output 2

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

SP : Set Point Value(set tem p.)
SSR : Solid State Relay
T.P. : Time Pr oportional
T/C : Thermocouple

ABBREVIATION :

Innovative Instruments

On

Google Play

206, New Sonal Link Service Industrial Premises Co-op Society Ltd,
Building No.2, Link Road, Malad (W), Mumbai - 400064.
Tel: [phone];
E-mail :
Website :

[e-mail]

www.i nn ov at iv ei ns tr um en ts .c o. in

Mfgd by: I nnovative Instruments & Cont rol s LL P

i

6

OIM AI-5X42 - V2.0 Page 6 of 6