Innovative instruments i-therm AI-7442, i-therm AI-7842, i-therm AI-7742, i-therm AI-7942, i-therm AI-7642 User's Operating Manual

(Models: AI 7442 / 7842 / 7742 / 7942 / 7642)

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

STATUS LED’S : OP1 : Main Control Output

OP2 : Alarm Status

2.
Sensor input : J/K/Pt-100
Range : Refer below Table.

Sampling Time : 200 msec.
Resolution : 1°C
CJC for TC : Built in automatic
LWC for Pt-100 : Built in upto 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:

INPUT

RELAY OUTPUT

SSR DRIVE OUTPUT

FUNCTION
Output 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.
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

ENVIRONMENTAL

POWER SUPPLY

PHYSICAL

SPECIFICATIONS : -

(48 X 48)

(72 X 72)

(96 X 96)(48 X 96) (96 X 48)

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.

SAFETY INSTRUCTION :

GENERAL

MECHANICAL

ELECTRICAL

v

v

v

v

v

v

v

v

v

v

v

v

v

v

Model no.

Display height

AI-7442 AI-7842 AI-7742 AI-7942 AI-7642

0.39” 0.39”0.56”0.56”0.56”

USER’S OPERATING MANUAL FOR PID DIGITAL TEMPERATURE CONTROLLER

Model no.

Weight (gms.)

AI-7442

AI-7842

AI-7742

AI-7942

AI-7642

130

200 200 240 200

1

Document Name : OIM AI-7X42 (Ver 1.2) Page 1 of 6

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-7842

OP1

OP2

1

2

3

4

6

5

RESETSET

-therm

i

AI-7642

OP1

OP2

1

2

4

6

5

3

RESET

SET

AI-7942

-therm

i

OP1

OP2

6

5

1

2

3

4

RESETSET

-therm

i

AI-7742

OP1

OP2

1

2

6

5

4

3

RESETSET

2

OP1 OP2

-therm

i

AI-7442

5

6

4

3

1

RESETSET

MODEL : AI - 7842

B

A

E

D

CH

MODEL : AI - 7642

E

D

C

H

A

B

F

G

A

B

D

C

H

E

G

F

G

F

MODEL:-AI-7442/7742/7942

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-7442
AI-7742
AI-7942
AI-7842
AI-7642

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.

ELECTRICAL INSTALLATION

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

PANEL

CUTOUT

PANEL

CUTOUT

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

NO NCCM

RELAY2

SSR2

NO NCCM

RELAY1

SSR1

SUPPLY

L

N

AI - 7442

AI - 7442

AI - 7742

AI - 7742

AI - 7942

AI - 7942

AI - 7642/7842

AI - 7642

FRONT PANEL LAYOUT

Î

Ï

Ð

Ñ

Ò

Ó

OP1
LED
OP2
LED

DISPLAY

SET

KEY

UP

KEY

DOWN

KEY

NO. NAME FUNCTION

Glows when OP1 is ON & flashes when delay time (dly1) is in operation (if selected
mode is ON-OFF).

Glows when OP2 is ON & flashes when alarm condition persists even after
acknowledged. or delay time (dly2) is in operation(if selected mode is ON-OFF).

It will display Measured value of selected input or Error massages. SP
(Main set point) / SP2 (Aux/Alarm) set value in run mode. Parameters
Value/code in program mode.

ÎÏ

Ð

ÎÏ Ð

Ñ

For SP programming. To access Control mode. To access
Configuration mode along with UP key. To scroll the parameter & to store its
value.

ÎÏ Ð

Ñ

For SP programming. To access Control mode. To access
Configuration mode along with UP key. To scroll the parameter & to store its
value.

ÎÏ

ÐÑ

To increase/alter parameter value in program mode. To Enter in
configuration mode (with SET key). To acknowledge Alarm. To enter in
tune mode (with DOWN Key).

ÎÏTo decrease / alter parameter value in program mode.

.To enter in tune mode (with UP Key)

AI - 7842

NO

NC

CM

RELAY2

SSR2

SUPPLY

L

N

1

2

3

4

5

6

789

10

11

13

14

15

16

12

NO NCCM

RELAY1

SSR1

1234

5

10

9

11 12

131415 16

6

78

2

Document Name : OIM AI-7X42 (Ver 1.2) Page 2 of 6

3

Document Name : OIM AI-7X42 (Ver 1.2) Page 3 of 6

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

0C

o

LSPL ~ HSPL

CONTROL

SET POINT

PARA

METER

RANGE

DESCRIPTION

DEFAULT

DISPLAY

This parameter will be prompted 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.

Î
Ï
Ð

LSPL ~ HSPL

-99 to 99 °C
2to99°C

SET

POINT2

0C

o

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

display mode.

MODEL VERSION HOME

PV

VERSION HOME

PV

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)

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

the control parameters.

PARA

METER

RANGE

DESCRIPTION

DEFAULT

DISPLAY

Proportional

Band

0.5
to

99.9°C

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.

5.0 C

o

Integral

Time

0

to

9999 Sec.

This parameter will be prompted only if selected control action is PID. It
sets the time taken by PID algorithm to remove steady state error. Value
of this parameter is automatically set by Auto Tune function. If set to ‘0’,
this function will be disabled.

0 Sec.

Derivative

Time

0

to

300 Sec.

This parameter will be prompted only if selected control action is PID. It
defines how strongly the Controller will react to the rate of change of PV.
Value of this parameter is automatically set by Auto Tune function. If set to
‘0’, this function will be disabled.

0 Sec.

Cycle

Time

0.5

to

100.0 Sec.

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 12sec &
for SSR O/P, cycle time should be less than 10sec.

16.0 Sec.

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.

This parameter will be prompted only it selected control mode for output2
is auxiliary control or an alarm. The value of this parameter sets the dead
band between on and off switching of output load.

Hysterisis 2

1to25 C

o

2C

o

0
to

500 Sec.

This parameter will be prompted only if output 2 is configured as an
Auxiliary control output. In this mode, O/P once turned OFF will restart
only after set time regardless of the difference between PV and SP2. Time
delay is settable up to 500 seconds. If time delay is set to 0, there is no
delay between output switching.

0 Sec.

Delay 2

Control

Hysterisis

1to25 C

o

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

2°C

0

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.

LOCK
CODE

100 %.

OUTPUT

POWER

LIMIT

0.0 %
TO

100.0 %

This parameter will be prompted only if selected control action is PID. This
parameter will decide the maximum output power in % applied to the load

TUNE

OFFSET

50 %

to

100 %

100 %.

This parameter will be prompted only if selected control action is PID. This
parameter allows the User to carry out Auto Tuning function below the set
point. (If Tune offset is 50 % tuning will be carried out at 50 % of the set
point and if 100 % tuning will be carried out at 100% of the set point.)

.

OUTPUT2

FUNCTION

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

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

AUX.

CONTROL

RAMP

RATE

DSBL

User can set the desired RAMP rate in USER list.

The RATE parameter will not be prompted in USER list.

Overshoot

Control

point

50%

This parameter will be prompted only if selected control action is PID. Setting this
parameter on higher side will proportionally slows down the rate of rise of PV to
minimize overshoot (this may cause delay to reach SP). Disabling or Setting this
parameter on lower side will proportionally increase the rate of rise of PV ( which
may cause overshoot). Disable this option if delay is not required to reach SP.
(This may cause overshoot w.r.t. SP)

CONTROL

LOGIC

FOR OP1

HEAT

This parameter will be prompted 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.

INPUT

FILTER

0.5 C

o

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

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 can be altered :
(i) To compensate for known thermal gradient.
(ii)To match the display values with another recorder or indicator measuring the
same PV.

HIGHER

SP

LIMIT

400 C

o

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

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

4

Document Name : OIM AI-7X42 (Ver 1.2) Page 4 of 6

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).

PARA

METER

DESCRIPTION

DEFAULT

DISPLAY

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.

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

}

PARA

METER

DESCRIPTION

DEFAULT

DISPLAY

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

Abs

This parameter will be prompted only if OUTPUT 2 is selected as an Auxiliary
control output. In this mode, User can set SP2 value independently. The instrument
works as 2-Set point Controller.

This parameter will be prompted 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.
User can set SP2 value with the deviation of ± 99°C w.r.t SP.

OUTPUT 2

MODE

SET

POINT 2

DSBL

This parameter allows the user to edit SP2 parameter in the USER list. Setting this
parameter to ENBL will allow the user to view as well edit the SP2 parameter in
USER list.

This parameter allows the user to edit SP2 parameter in the USER list. Setting this
parameter to DSBL will not allow the user to view as well edit the SP2 parameter in
USER list.

5

Document Name : OIM AI-7X42 (Ver 1.2) Page 5 of 6

PARA

METER

DESCRIPTION

DEFAULT

DISPLAY

PARA

METER

DESCRIPTION

DEFAULT

DISPLAY

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

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

OUTPUT 2

LOGIC

TABLE 4 : Below listed parameters will appear only if OUTPUT 2 is selected as ALARM mode. In ALARM

mode, 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 : -

(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

PARA

METER

DESCRIPTION

DEFAULT

DISPLAY

ALARM
INHIBIT

This parameter can be used to inhibit (suppress) the Alarm activation upon power-up
conditions by setting the parameter value to ‘YES”. 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
valueto‘NO’.

NO

ALARM

LOGIC

DIRECT

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

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

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.

ON-OFF ACTION: In this mode, Output (Relay/SSR) remains ON

till actual temperature reaches to the 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).

USER GUIDE :

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

HEAT LOGIC/ON-OFF

TIME

TEMP ( C)

0

HYSTRISIS

SP

ON ON ON

AMB

O/P

OFF OFF

TIME

COOL LOGIC / ON OFF

O/P

O/P

TEMP ( C)

0

AMB

HYSTERISIS

ON ON ON

SP

OFF OFF

Table: 3

Adjust

Proportional Band

Integral Time

Derivative Time

Slow Response
Over Shoot or Oscillations
Slow Response
Instability or Oscillation
Slow Response or Oscillation
High Over Shoot

Decrease PB
Increase PB
Decrease Int
Increase Int
Decrease Dt
Increase Dt

Symptom Solution

AUTO TUNING MODE : In this mode, Controller learns the

process characteristics by itself and calculates the required P, I
& D values. It can be performed at any time after power ON
but, it is best to start it when the process is at Ambient
temperature in order to minimize overshoot & undershoot. Auto
tuning is applied in case : (1) Initial set up for a new process.
(2) Substantial change in SP from previous auto tuning value.
(3) Control accuracy is not satisfactory.
If the control performance by using auto-tuning is still
unsatisfactory, User can apply further adjustments of P,I&D
values as shown in table 3.

ABBREVIATION :

NC : Normally Close terminal of

Relay

NO : Normally Open terminal of

Relay
OP1 : Output 1
OP2 : Output 2

C.A. : Control Action
CJC : Cold junction

compensation
CM : Common terminal of relay
LWC : Lead wire (Length)

compensation

SP : Set Point Value

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

Fig: 3.1 Fig: 3.2

Auto

tuning

mode

This function will be executed only if selected control action is PID.
Auto-tuning function is enabled by setting this parameter to ‘YES’. The decimal of LSB
flashes till Auto tuning function is in progress. During Auto-tuning, Controller learns
the process characteristics by itself & calculates required P, I & D values. User can
cancel or abort this feature by setting this parameter to ‘NO’.

NO

AUTO TUNING MODE : Toenterinthismode,Press&holdUP&DOWNkeytogetherforminimum3sec.

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

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Document Name : OIM AI-7X42 (Ver 1.2) Page 6 of 6