Ultra Precision (0.01 °C) Self-Tune PID
Temperature Controller with
Programmable Timer
User Manual
Zenex-ultra
CONTENTS
User Manual
Zenex-ultra
1. FRONT PANEL LAYOUT 1
2. BASIC OPERATION 2
3. 3PAGES & PARAMETERS
4. INSTALLATION PARAMETERS 5
5. CONFIGURATION PARAMETERS 6
6. SUPERVISORY PARAMETERS 7
7. OP-2 FUNCTION PARAMETERS 8
8. OP-3 FUNCTION PARAMETERS 10
9. 11PID CONTROL PARAMETERS
10. HARDWARE ASSEMBLY AND CONFIGURATION 13
11. MECHANICAL INSTALLATION 19
12. ELECTRICAL CONNECTIONS 21
1
Table 1.1
Section 1
READOUTS
The upper readout is a 4 digit, 7-segment bright red LED display and usually displays the PV (Process Value) in 0.01 °C
Resolution. In parameter set-up mode, the upper readout displays parameter values.
The lower readout is a 4 digit, 7-segment bright green LED display and usually displays the SP (Process Setpoint) value in
0.01 Resolution. In parameter set-up mode, the lower readout displays prompts for the parameters.°C
INDICATORS
The Table 1.1 lists each front panel LED and the associated status.
The controller front panel comprises of digital readouts, LED indicators and membrane keys as shown in Figure 1.1 below.
User Manual
Zenex-ultra
FRONT PANEL LAYOUT
Figure 1.1
PPI
zenex-ultra
OP1 OP2
OP3
Upper Readout
Lower Readout
OP-3 Indicator
ENTER Key
UP Key
DOWN Key
PAGE Key
OP-1 Indicator
OP-2 Indicator
S
T
Soak Status Indicator
Balance Soak
Time Indicator
Status
Indicator
S
T
Glows while the Lower Readout shows the Balance Soak Time in Main display
mode.
• Flashes while the Soak Timer is counting down.
• Glows steadily while the Soak Timer is outside the Timer Start Band or Hold
Band (that is, HOLD state).
• Indicates Output-1 ON/OFF status if the Control Output is Relay or SSR drive.
• Remains OFF if the Control Output is DC Linear.
OP1
• Indicates Output-2 status if OP2 function is Auxiliary / Blower Control.
• Flashes Alarm-1 status if OP2 function is Alarm.
OP2
OP3
• Indicates Output-3 status if OP3 function is Auxiliary Control.
• Flashes Alarm-2 status if OP3 function is Alarm.
2
BASIC OPERATIONS
MAIN DISPLAY MODE
After the power-up display sequence, the upper readout starts showing the measured PV (Process Value) and the lower
readout displays the SP (Setpoint) in 0.01°C Resolution.
This is called the MAIN display mode and this is the one that shall be used most often. The MAIN display mode is depicted in
Figure 2.1.
Figure 2.1
PV ERROR INDICATIONS
In case the PV falls below the Minimum Range or rises above the Maximum Range specified for the RTD Pt100 input type or in
case the RTD Pt100 sensor is open / broken; the upper readout flashes the error messages listed in Table 2.1 below. The
Figure 2.2 illustrates an open sensor condition.
Message PV Error Type
Over-range
(PV above Max. Range)
Under-range
(PV below Min. Range)
Open
(Sensor open / broken)
Table 2.1
User Manual
Zenex-ultra
Section 2
PV
SP
PPI
zenex-ultra
OP1 OP2
OP3
S
T
Figure 2.2
PPI
zenex-ultra
OP1 OP2
OP3
S
T
3
ORGANIZATION
The controller requires various user settings that determine how the controller will function or operate. These settings are
called parameters. The various parameters have been grouped as shown in Table 3.1. Each group is assigned a unique PAGE
NUMBER for its access and the parameters within each group are presented depending on the function(s) selected.
The parameters are always presented in a fixed format: The lower readout displays the parameter prompt (Identification Tag)
and the upper readout displays the set value. The parameters appear in the same sequence as listed in their respective
sections.
PAGES & PARAMETERS
Table 3.1
Group
Page
Number
Main Parameters
Installation
Parameters
Configuration
Parameters
Supervisory
Parameters
Output-2
Function
Output-3
Function
10
11
12
13
14
Output Type
Calibration Offset
Control Mode
Overshoot Inhibit
Control Logic
Hysteresis
Digital Filter
Serial Communication
Setpoint Locking
Tune At Setpoint Change
Optimize Command
Function Selection
Process Alarm Settings
Blower Settings
Soak Timer Settings
Function Selection
Process Alarm Settings
Heater Break Alarm
Serial Communication
PID Control
Parameters
Proportional Band
Integral Time
Derivative Time
15
ADJUSTING PARAMETER VALUES
Once a PAGE is accessed, step through the following sequence to adjust the values of the desired parameters:
1. Press and release the ENTER key until the prompt for the required parameter appears in the lower readout. The last
parameter in the list rolls back to the first parameter.
2. Use UP / DOWN keys to adjust the parameter value.
Note that some parameters (examples; Alarm Setpoint, Blower Setpoint, etc.) have numeric values while others
User Manual
Zenex-ultra
Section 3
4
(examples; Control Mode, Alarm Logic, etc.) have a series of options. If adjusting a numeric value; depressing the
UP/DOWN key once, increases/decreases the parameters value by one digit. For parameters having a series of options,
depressing the UP/DOWN key once takes you to the next/previous option. In each case, keeping the UP/DOWN key
pressed speeds up the rate. If the value reaches the maximum / minimum settable value/option, the upper readout flashes
and the UP (if maximum value is reached) or DOWN (if minimum value is reached) key has no effect.
3. Press and release the ENTER key. The new value gets stored in the controller's non-volatile memory and the next
parameter in the list is displayed.
The Figure 3.2 illustrates the example of altering the value for the parameter 'Control Output Type'. As in this example no other
parameter is available in the list, pressing ENTER key will not displayed any other parameter in the list.
Figure 3.2
To exit the set-up mode and return to the MAIN display, press and release PAGE key.
VIEW-ONLY PARAMETERS
While the controller is operating in the PID control mode, the user can view (but not adjust) the instantaneous values of the %
output power. The view facility is available in PAGE-0 and can be availed as described below.
1. Press and release PAGE key. The lower readout shows PAGE and the upper readout shows 0.
2. Press and release ENTER key. The controller enters into view mode.
3. Keep pressing ENTER key to select between the parameters available for viewing.
The prompt for identifying the parameter is indicated in the lower readout and the actual value is indicated in the upper
readout.
To exit view mode and return to the MAIN display mode; press and release PAGE key.
User Manual
Zenex-ultra
Prompt
Parameter
% Output Power
5
The installation parameters are contained in PAGE-10 and are required to be set only at the time of a new installation.
The installation parameters are listed below in Table 4.1, followed by the definitions for each parameter.
INSTALLATION PARAMETERS
Table 4.1
Settings
(Default Value)
Parameter Description
OUTPUT TYPE
The controller is supplied with built-in Relay and DC voltage
pulses (for driving external SSR) as control output signals. The
required output type can be selected by appropriate jumper
settings as described in section 9: Hardware Assembly And
Configurations. The jumper-selected output type must also be set
as a value for this parameter for correct operation. The controller
automatically sets the cycle time for the time-proportioning PID
output in accordance with the selected output type. The Table 4.3
below lists the options available for setting this parameter value.
Refer Table 4.2
(Default : SSR)
Table 4.2
Option
What it means
Cycle Time
Electromechanical Relay contacts
(Common & Normally Open)
DC voltage pulses for driving
external Solid State Relay (SSR)
20 Seconds
1 Second
Note:
In the zenex-ultra, the Temperature Range is restricted to -19.99 to +102.9°C. This Temperature Range is fixed and not available as settable
parameter. The 0.01°C Resolution is available upto 99.99°C. After this, the resolution automatically changes to 0.1°C.
User Manual
Zenex-ultra
Section 4
6
The Configuration parameters are contained in PAGE-11 and are factory set to the appropriate default values. However, for
specific installations the user may need to alter the values. Altering the configuration parameter values affect either the
measured PV and/or the control algorithm implemented by the controller. The parameters are listed in Table 5.1 below,
followed by their definitions.
CONFIGURATION PARAMETERS
Table 5.1
Settings
(Default Value)
Parameter Description
-19.99 to +25.00
(Default : 0.00)
Enable
Disable
(Default : Enable)
Reverse
Direct
(Default : Reverse)
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Zenex-ultra
CONTROL LOGIC
Select Reverse (heat logic) or Direct (cool logic).
OVERSHOOT INHIBIT
(Available for PID control only)
Enabling this feature controls the PV rise or fall upon process
start-up in order to reach the control setpoint with as minimum
overshoot as possible.
CALIBRATION OFFSET
This value is algebraically added to the measured PV to derive the
final PV that is displayed and compared for alarm / control.
Final PV = Measured PV + Offset
CONTROL MODE
Select appropriate Control Algorithm suited for process
requirement.
(Default : PID)
On-Off
PID
0.10 to 25.00
(Default : 0.20)
1.0 to 25.0 Seconds
in steps of 0.5 Seconds
(Default :1.5)
HYSTERESIS
(Available for On-Off or Pulsed On-Off Control only)
Sets differential (dead) band between On-Off switching for OP1.
DIGITAL FILTER FOR PV
Sets the time constant, in seconds, for the low-pass digital filter
applied to the measured PV. The filter helps smoothing /
averaging the signal input and removing the undesired noise.
Note:
The Calibration Offset and Hysterisis parameter values are settable same as that for the PV resolution. Hence, they are also available in
0.01°C resolution. Their settings and default values are modified as per the 0.01°C resolution as shown in the above Table 5.1.
Section 5
7
The Supervisory parameters are available in PAGE-12 and provides communication parameters to the user and also can be
used to exercise control over operator level or to use the controller's in-built ability to improve upon the control performance
under conditions that are beyond the self-detection capabilities of the controller.
The parameters are listed in Table 6.1 below followed by their definitions.
SUPERVISORY PARAMETERS
Table 6.1
Settings
(Default Value)
Parameter Description
This parameter defines the communication speed expressed in
“Bits per Second”. This parameter is settable as 1200, 2400, 4800
or 9600 and must be set in accordance with the communication
speed set for the Master Device.
BAUD RATE
4800
9600
1200
2400
(Default : 4800 )
CONTROLLER ID NUMBER
This parameter, settable from 1 to 8, assigns a unique slave
identity number to the controller that the Master Device uses to
address the controller for data read/write operation.
1 to 8
(Default : 1)
SETPOINT LOCKING
Set to Yes to Lock the SP editing on the Lower Readout.
No
Yes
(Default : No)
SELF-TUNE ON SETPOINT CHANGE
The controller's “X-THERM” algorithm is powered with the ability
to self-detect the need for Tuning / Optimization of the controller if
there is a substantial change in the SP by the user. The algorithm
takes into account the magnitude of SP change and the
Temperature Range. If this parameter is set to ‘Enable’, the
controller, if required, automatically optimizes the control
parameter values while approaching the new SP. The user can set
this parameter to ‘Disable’ if this feature is not desired.
No
Yes
(Default : No)
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Zenex-ultra
Enable
Disable
(Default : Disable)
OPTIMIZE COMMAND
(Available for PID control only)
Set to ‘Yes’ to initiate a new tuning cycle or set to ‘No’ to abort a
tuning operation in progress.
Section 6
8
The Output-2 Function Parameters are available in PAGE-13. The parameters are specified in Table 7.1 below.
OP-2 FUNCTION PARAMETERS
Table 7.1
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Zenex-ultra
Settings
(Default Value)
Parameter Description
Process Low
Process High
Deviation Band
Window Band
Default : Process Low
(Default : 0.00)
0.00 to 99.99
-19.99 to +25.00
(Default : 0.00)
0.30 to +25.00
(Default : 0.30)
ALARM TYPE
Select the Alarm-1 activation type. Selecting ‘None’ will disable
the alarm and suppress all the related parameters for Alarm-1.
ALARM SETPOINT
(Available for Process High or Process Low Alarm-1 Type)
Sets Alarm limit independent of control setpoint.
DEVIATION BAND
(Available for Deviation Band Alarm-1 Type)
Sets positive or negative deviation (offset) limit from control
setpoint for High or Low Alarm-1 activation, respectively.
WINDOW BAND
(Available for Window Band Alarm-1 Type)
Sets symmetrical positive and negative deviation (offset) limits
from control setpoint for both High and Low Alarm-1 activation.
No
Yes
(Default : Yes)
Reverse
Direct
(Default : Direct)
ALARM INHIBIT
Set to Yes to suppress Alarm-1 activation upon power-up or
process start-up.
ALARM LOGIC
(Available if OP2 function is Alarm)
Select ‘Direct’ if Alarm-1 is to activate an Audio / Visual alarm.
Select ‘Reverse’ if Alarm-1 is to Trip the system.
Section 7
9
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Zenex-ultra
BLOWER FUNCTION AND PARAMETERS
The blower on-off operation is depicted in Figure 7.3 below.
PV
Blower ON
SP
Hysteresis Band
Blower Setpoint
Figure 7.3
The Blower Setpoint is set as a positive offset to the process setpoint SP. The Blower is switched ON if the PV equals or
exceeds the setpoint. The Blower is switched OFF when the PV falls below the setpoint by the value set by the Hysteresis
Band. The parameters for the Blower operations are listed in Table 7.3 below, followed by the definitions.
Table 7.3
Settings
(Default Value)
Parameter Description
0.00 to 25.00
(Default : 0.00)
0.10 to 25.00
(Default : 0.20)
BLOWER SETPOINT
(Available if OP2 function is Blower Control)
This parameter value is algebraically added to the Control SP to
obtain the setpoint value for the Blower Control. Can be set as
positive value or negative value.
Blower Control Setpoint = Control Setpoint (SP) + Offset Value
BLOWER HYSTERESIS
(Available if OP2 function is Blower Control)
Differential (dead) band between the blower ON and OFF states.
10
OP-3 FUNCTION PARAMETERS
The Output-3 Function Parameters are available in PAGE-14. The parameters are specified in Table 8.1 below.
Settings
(Default Value)
Parameter Description
0.00 to 99.99
(Default : 0.00)
-19.99 to +25.00
(Default : 0.00)
User Manual
Zenex-ultra
Table 8
Process Low
Process High
Deviation Band
Window Band
Default : Process Low
None
Alarm
(Default : None)
OUTPUT-3 FUNCTION
(Applicable for OP3 hardware module, if fitted)
Select the function / feature to which the OP3 module is to be
logically attached for activation.
ALARM TYPE
(Available if OP3 function is Alarm)
Select the Alarm-1 activation type. Selecting ‘None’ will disable
the alarm and suppress all the related parameters for Alarm-1.
ALARM SETPOINT
(Available for Process High or Process Low Alarm-1 Type)
Sets Alarm limit independent of control setpoint.
DEVIATION BAND
(Available for Deviation Band Alarm-1 Type)
Sets positive or negative deviation (offset) limit from control
setpoint for High or Low Alarm-1 activation, respectively.
WINDOW BAND
(Available for Window Band Alarm-1 Type)
Sets symmetrical positive and negative deviation (offset) limits
from control setpoint for both High and Low Alarm-1 activation.
ALARM INHIBIT
(Available if OP3 function is Alarm)
Set to Yes to suppress Alarm-1 activation upon power-up or
process start-up.
ALARM LOGIC
(Available if OP3 function is Alarm)
Select ‘Direct’ if Alarm-1 is to activate an Audio / Visual alarm.
Select ‘Reverse’ if Alarm-1 is to Trip the system.
Reverse
Direct
(Default : Direct)
Enable
Disable
(Default : Disable)
0.30 to 25.00
(Default : 0.30)
Section 8
11
As described in Section 5: Configuration Parameters, the control mode can be set as ON-OFF or PID. If set as PID, the
controller allows adjustment of various control related parameters that are grouped in PAGE-15. Note that these parameters
are not presented to the user if the set control mode is ON-OFF.
The PID control parameters are listed in Table 9.1 below, followed by their definitions.
PID CONTROL PARAMETERS
Table 9.1
Settings
(Default Value)
Parameter Description
This parameter, expressed in seconds, is applicable only to the
time proportion output associated with Relay or SSR as the
control output. For the time proportion output, the controller
implements the output power by adjusting the ON time of
Relay/SSR as a % of the Cycle Time. The Relay/SSR remains
OFF for the rest of the Cycle Time. For example, if the Cycle Time
is set to 20.0 seconds and if the output power demand is 10%, the
ON and OFF time duration for relay/SSR are computed (and
implemented) as follows:
ON time = 10% X 20 = (10/100) X 20 = 2 Seconds
OFF time = Cycle Time - ON duration = 20 - 2 = 18 Seconds
The Cycle Time, thus, equals 'ON time + OFF time'. The controller
output is 100% (fully on) during ON time and 0% (fully off) during
OFF time.
CYCLE TIME
0.5 to 120.0 Seconds
(in steps of 0.5 secs.)
(Default :
20 sec for relay,
1 sec for SSR)
0.01 to 99.99°C
(Default : )10.00°C
PROPORTIONAL BAND
This parameter value defines the band within which the control
output signal varies proportionally between the maximum (100%)
to the minimum (0%) level depending upon the error (difference
between the control setpoint and PV).
The Proportional Band is expressed in same resolution and unit
as that for PV and accordingly modified to set within 0.01 to 99.99
°C. Though this parameter value is automatically set by the selftune / optimize utility, the user can alter the value manually.
INTEGRAL TIME
This parameter value, expressed in seconds, is a measure of the
time response of the process and defines the time the controller
takes to remove the steady state offset errors within the
proportional band. Though this parameter value is automatically
set by the self-tune / optimize utility, the user can alter the value
manually. Setting this parameter value to 0 cuts-off the integral
action.
0 to 1000 Seconds
(Default : 100 Sec)
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Zenex-ultra
Section 9
12
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Zenex-ultra
(Default : 25 Sec)
0 to 250 Seconds
Settings
(Default Value)
Parameter Description
This parameter value, expressed in seconds, defines how strong
the control output level will change in response to the rate of
change of measured PV. This, in effect, produces larger
proportional and Integral actions should the PV change at a faster
rate. Though this parameter value is automatically set by the selftune / optimize utility, the user can alter the value manually. Setting
this parameter value to 0 cuts-off the derivative action.
DERIVATIVE TIME
13
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Zenex-ultra
HARDWARE ASSEMBLY AND CONFIGURATIONS
The Figure 10.1 above shows the indicator outer-case viewed with front label upright.
ELECTRONIC ASSEMBLY
The basic electronics assembly (without any plug-in modules), comprises of 3 Printed Circuit Boards (PCB). When viewed
from the front; the CPU PCB is to the right, Power-supply PCB is to the left and the Display PCB is behind the bezel.
The electronic assembly can be removed from the plastic enclosure and placed back as described and illustrated in Figure
10.2.
Figure 10.1
Section 10
UP
UP
Front Label
Pullout Grip
Enclosure
Connection Diagram
Rear Terminals
Ventilations
Ratchets
Panel Mounting Clamp
Panel Sealing
Gasket
Bezel
neuro 102
1
2
3
4
5
6
7
8
9
10
1
1
12
13
14
15
16
17
18
N/O
C
+
-
RE LAY
SSR / DC Linea r
OU TPU T 1
Pt100
T/C
mV, V, mA
I
NP
U
T
O
U
T
P
U
T
2
+
S
S
R
/ D
C
L
i
n
e
a
r
R
E
LA
Y
N/O
N/C
C
O
U
T
P
U
T
3
SERIAL
COMMS.
+
SSR / DC Linear
RELA
Y
N/O
N/C
C
PPI
L
N
A
C
D
C
SU PPLY
GND
A
B
AUXILIARY SP
SELECTION
PPI
zenex-ultra
OP1
OP3
S
T
OP2
14
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Removing Assembly from Enclosure
With the indicator upright, hold the Bezel with the fingers on the pullout grips provided on the left and right sides of the bezel.
Pull the bezel outward. The assembly comes out with the bezel.
Placing Assembly Back into Enclosure
With the indicator upright (the UP inscribed on the Enclosure is on the topside), insert the bezel gently with the boards on either
side sliding into the guides provided inside of the Enclosure. Ensure that the bezel fits in tight on the Enclosure-front to secure
the panel-sealing gasket.
Figure 10.2
Power Supply
PCB
CPU PCB
Display
PCB
‘UP’ inscribed on topside
UP
UP
Placing Back
Removal
Pullout Grip
PPI
zenex-ultra
OP1
OP3
neuro 102
1
2
3
4
5
6
7
8
9
10
1
1
12
13
14
15
16
17
18
N/O
C
+
-
RE LAY
SSR / D C Linear
OU TPUT 1
Pt100
T/C
mV, V, mA
I
N
P
U
T
O
U
T
P
U
T
2
+
S
S
R
/
D
C L
i
n
e
a
r
RE
L
A
Y
N/O
N/C
C
O
UT
P
U
T
3
SERIAL
COMMS.
+
SSR / DC Linear
RELAY
N/O
N/C
C
PPI
L
N
A
C
D
C
SU PPLY
GND
A
B
AUXILIARY SP
SELECTION
S
T
OP2
15
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Figure 10.3
INPUT : Jumper Settings
The Input type is user configurable and thus requires, besides parameter selections, proper jumper-settings prior to electrical
connections. The jumper settings are provided in the form of Pins & Shorting-Link arrangements on the CPU PCB towards the
rear end as shown in Figure 10.3.
The Jumper setting marked A is for Input configuration. (Jumper settings marked B & C are unused.) For DC Linear Current
Inputs (0-20mA or 4-20mA), short the Pins using Shorting-Link. For all other Input types, keep the Shorting-Link parked
leaving the Pins open.
MOUNTING PLUG-IN MODULES
The indicator supports up to 3 plug-in modules, viz. Output-2 Module (Relay/SSR), Output-3 Module (Relay/SSR) and Option
Module (RS485 Serial Port or Remote Alarm Acknowledgment). These modules are either pre-fitted while the indicator is
shipped from the factory or can be fitted by the user later.
All 3 plug-in modules are provided with female socket that directly fits into the corresponding male plug provided on either
Power-supply PCB or CPU PCB. The Output-2 and Option Modules fit into plugs provided on Power-supply PCB whereas the
Output-3 Module fits into plug provided on the CPU PCB
OUTPUT-2 & OUTPUT-3 : Modules and Jumper Settings
The Output-2 and Output-3 Modules are identical and, thus, can be fitted interchangeably in Output-2 or Output-3 positions.
These modules can be configured for either Relay or SSR output through proper jumper selection. Two jumper settings A and
B, as shown in Figure 10.4, are required for Relay or SSR selection. Refer Table 10.1 for appropriate jumper setting positions.
CPU PCB
Pins
Shorting
Link
1 2 3
B
C
1
2
3
4
PPI
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}
}
BA
C
16
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B
A
Relay/SSR Module
Table 10.1
Relay
SSR
1
2
3
1
2
3
1
2
3
1
2
3
Output Type Jumper Setting - A Jumper Setting - B
MOUNTING / UN-MOUNTING OF MODULES
The Figures 10.5 & 10.6 illustrates how to mount the plug-in Output-2 & Output-3 module, respectively. Notice the orientation
of the indicator and a few identifying components shown in figures to help locate the plugs for the modules. Ensure that the
socket snap-fits into the plug and the 2 projected parts on the module fit into the 2 slots provided on the Power-Supply / CPU
PCB for proper electrical contacts and secured fitting.
For plugging out the module(s), follow the steps below:
1. Gently pull apart the Power-supply board and the CPU board until the projections of the module board come out of the
slots.
2. Pull the module outward to unlock the socket from the plug.
Figure 10.4
17
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Figure 10.5
Figure 10.6
Mounting Output-2 Module
PPI
Plug & Socket
Connector
Projected
Parts
Slots
Output
Module
Power Supply Board
Front Label Upright
zenex-ultra
Mounting Output-3 Module
Output
Module
Projections
PPI
Plug & Socket
Connector
Slots
CPU Board
Front Label
Upside-down
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18
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The plug for the Serial Communication or Remote Alarm Acknowledgment module is located on the Power-supply PCB. The
Figure 10.7 below illustrates how to plug-in the Serial Communication/Remote Alarm Acknowledgment module. To plug (or
unplug) the module simply insert (or remove) the socket into (or from) the plug.
Figure 10.7
Mounting Serial Communication/
Remote Alarm Acknowledgment Module
PPI
Plug & Socket
Connectors
Serial Communication/
Auxiliary SP Selection
Module
Power Supply Board
Front Label
Upside-down
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The following precautions should be strictly observed while installing the indicator:
1. The place of installation should be free of corrosive/combustible gases and electrically conductive pollution.
2. Ensure that the place of installation is not subject to rapid ambient changes that can cause condensation. Also the Ambient
Temperature and Relative Humidity surrounding the indicator should not exceed the maximum specified for the proper
operation of the Indicator.
3. The place of installation should be adequately protected against excessive electrostatic or electromagnetic interference.
4. The Indicator should not be subject to direct vibration or shock.
5. The Indicator should not be exposed to dust, salt air, direct sunlight or radiant heat.
OUTER DIMENSIONS
The Figure 11.1 shows the outer dimensions of the indicator.
MECHANICAL INSTALLATION
110mm
(4.33in)
10mm (0.39in)
Side View
Figure 11.1
PANEL CUTOUT AND RECOMMENDED MINIMUM SPACING
The Figure 11.2 shows the panel cutout requirements for a single Indicator and also the minimum spacing recommended if
several Indicators are required to be mounted on a single panel.
Panel Cutout
45 X 45 mm
-0, +0.5 mm
(1.77 X 1.77 in)
(-0, +0.02 in)
10mm (0.39in)
38mm (1.5in)
Figure 11.2
Section 11
Front View
PPI
OP1 OP3
48mm
(1.89in)
48mm
(1.89in)
zenex-ultra
OP2
S
T
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PANEL MOUNTING
Follow the steps below for mounting the Indicator on panel:
1. Prepare a square cutout to the size shown in Figure 11.2.
2. Remove the Panel Mounting Clamp from the Indicator Enclosure.
3. Insert the rear of the Indicator housing through the panel cutout from the front of the mounting panel.
4. Hold the Indicator gently against the mounting panel such that it positions squarely against the panel wall, see Figure 11.3.
Apply pressure only on the bezel and not on the front label.
5. Slide the mounting clamp forward until it is firmly in contact with the rear face of the mounting panel and the tongues of the
clamp engage in the ratchets on the Indicator enclosure, as shown in Figure 11.3. Ensure that the springs of the clamp push
firmly against the rear face of the mounting panel for secured mounting.
Figure 11.3
UP
UP
PPI
OP1
HBA
Panel Mounting Clamp
Mounting Panel with
Square Cutout
indicator
Tongues
Springs
Ratchets
Bezel
Slide Forward
zenex-ultra
neuro
1
2
3
4
5
6
7
8
9
10
1
1
12
13
14
15
16
17
18
N/O
C
+
-
RE LAY
SSR / DC Linear
OUT PUT 1
Pt100
T/C
mV, V, mA
I
NP
U
T
O
U
T
P
U
T
2
+
S
S
R
/
D
C
L
i
n
e
a
r
R
E
L
A
Y
N/O
N/C
C
O
U
T
P
UT
3
SERIAL
COMMS.
+
SSR / DC Linear
RELA
Y
N/O
N/C
C
PPI
L
N
A
C
D
C
SUP PLY
GND
A
B
AUXILIARY SP
SELECTION
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User Manual
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ELECTRICAL CONNECTIONS
Section 12
Figure 12.1
SSR
RELAY
OUTPUT 1
mV, V, mA
T/C
INPUT
Pt100
NO
C NC
RS 485
85 ~ 265 V
AC SUPPLY
SSR
RELAY
OUTPUT 2
SSR
RELAY
OUTPUT 3
NO
CNC
NO
C
L
N
1
2
3
4
5
13
7
12
8
14
9
15
16
17
11
18
10
6
PPI
WARNING
MISHANDLING / NEGLIGENCE CAN RESULT IN
PERSONAL DEATH OR SERIOUS INJURY.
WARNING
MISHANDLING / NEGLIGENCE CAN
RESULT IN PERSONAL DEATH OR
SERIOUS INJURY.
1. The user must rigidly observe the Local Electrical Regulations.
2. Do not make any connections to the unused terminals for making a tie-point for other wires (or for any other reasons) as
they may have some internal connections. Failing to observe this may result in permanent damage to the indicator.
3. Run power supply cables separated from the low-level signal cables (like Thermocouple, RTD, DC Linear Current/Voltage,
etc.). If the cables are run through conduits, use separate conduits for power supply cable and low-level signal cables.
4. Use appropriate fuses and switches, wherever necessary, for driving the high voltage loads to protect the indicator from
any possible damage due to high voltage surges of extended duration or short-circuits on loads.
5. Take care not to over-tighten the terminal screws while making connections.
6. Make sure that the Indicator supply is switched-off while making/removing any connections or removing the Indicator from
its enclosure.
CONNECTION DIAGRAM
The Electrical Connection Diagram is shown on the left side of the Indicator enclosure. The diagram shows the terminals
viewed from the REAR SIDE with the Indicator label upright. Refer the label provided on the Rear Side for terminal numbers.
Note that the OUTPUT-2, OUTPUT-3 and the Serial Comm./Remote Alarm Acknowledgment connections are applicable only
if the respective plug-in modules are fitted. Also the DC SUPPLY is applicable only if the Indicator is supplied with 18 to 34 VDC
supply voltage option.
The rear panel electrical wiring connection diagram is shown in Figure12.1 below.
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User Manual
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DESCRIPTIONS
The back panel connections are described as under:
INPUT (Terminals : 1, 2, 3)
The Indicator accepts Thermocouples (J, K, T, R, S, B, N), 3-wire RTD Pt100 and DC Linear Current/Voltage (mA/mV/V) as
input.
Thermocouple
Connect Thermocouple Positive (+) to terminal 1 and Negative (-) to terminal 2 as shown in Figure
12.2 (a). Use the correct type of Thermocouple extension lead wires or compensating cable for the
entire distance ensuring the correct polarity throughout. Avoid joints in the cable.
3
2
1
Figure 12.2 (a)
RTD Pt100, 3-wire
Connect single leaded end of RTD bulb to terminal 1 and the double leaded ends to terminal 2 and 3
(interchangeable) as shown in Figure 12.2 (b). Use copper conductor leads of very low resistance
ensuring that all 3 leads are of the same gauge and length. Avoid joints in the cable.
3
2
1
Figure 12.2 (b)
DC Linear Voltage (mV / V)
Use a shielded twisted pair with the shield grounded at the signal source for connecting mV / V
source. Connect common (-) to terminal 2 and the signal (+) to terminal 1, as shown in Figure 12.2
(c).
Figure 12.2 (c)
3
2
1
DC Linear Current (mA)
Use a shielded twisted pair with the shield grounded at the signal source for connecting mA source.
Connect common (-) to terminal 2 and the signal (+) to terminal 1, as shown in Figure 12.2 (d).
Make sure that the Jumper Pins for Input selection are shorted using the Shorting-Link (Refer
Section 10 Hardware Assembly and Configurations, Input-Jumper Settings).
Figure 12.2 (d)
3
2
1
OUTPUT-1 (Terminals : 4, 6)
DC Linear Current / Voltage Output
The DC Linear (0/4-20 mA) Current or (0-5/10V) Voltage output is also available at Terminal 6 (+)
and Terminal 4 (-) for Retransmission (Recorder) output. Refer Figure 12.3.
Figure 12.3
6
5
4
OUTPUT- 2 (Terminals : 7, 8, 9)
OUTPUT- 3 (Terminals : 16, 17, 18)
The Output-2 and Output-3 are available through plug-in modules that can be configured as Relay or SSR through appropriate
Jumper Settings. The connection descriptions are shown in figures 12.4(a) and 12.4(b).
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User Manual
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Relay
Potential-free Relay changeover contacts N/O (Normally Open) and C (Common) rated 2A/240
VAC (resistive load) are provided as Relay output. Use external auxiliary device like contactor with
appropriate contact rating for driving the actual load.
Drive for SSR
DC Voltage level is generated for switching the external SSR (Solid State Relay). Connect (+) and (-)
terminals of SSR to indicator terminals 9(18) and 7(16), respectively. Use Zero-Crossover, 3 to 30
VDC operated SSR, rated approximately 1.5 times the actual load rating. Use appropriate Heat Sink
for load rating exceeding 10A.
9(18)
N/O
C
Figure 12.4 (a)
8(17)
7(16)
N/C
Figure 12.4 (b)
9(18)
8(17)
7(16)
POWER SUPPLY (Terminals : 12, 13)
Figure 12.5
As standard, the indicator is supplied with power connections suited for 85 to 264 VAC. Use well-insulated copper conductor
2
wire of the size not smaller than 0.5mm for connections. Connect Line (Phase) to terminal 12 and the Neutral (Return) to
terminal 13 as shown in Figure 12.5. The indicator is not provided with fuse and power switch. If necessary, mount them
separately. Use a time lag fuse rated 1A @ 240 VAC.
For DC Supply, connect Signal (+) & Common (-) to indicator terminals 12 & 13, respectively.
Line
Neutral
12 (L)
13 (N)
2 Pole
Isolating Switch
Fuse
Power Supply
Terminal
The indicator is designed for installation in an enclosure which provides adequate
protection against electric shock. Local regulations regarding electrical
installation should be rigidly observed. Consideration should be given to
prevention of access to the Power Supply terminals by unauthorized personnel.
Caution
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User Manual
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If the Optional plug-in communication board is fitted, connect terminal 15 and 14 of the indicator to (+) and (-) terminals of the
Master device. For reliable noise free communication, use a pair of twisted wires inside screened cable as shown in Figure
12.6. The wire should have less than 100 ohms/km nominal DC resistance (Typically 24 AWG or thicker). Connect the
terminating resistor (Typically 100 to 150 ohm) at one end to improve noise immunity.
REMOTE ALARM ACKNOWLEDGMENT INPUTS (Terminals : 14,15)
(Applicable if the Option plug-in module for Remote Alarm Acknowledge is fitted).
Use potential-free push button switch with normally Open contacts for the purpose of Alarm
Acknowledgment. Connect the switch across the terminals14 &15 as shown in figure 12.7.
Figure 12.7
14
15
Figure 12.6
SERIAL COMMUNICATION PORT (Terminals : 14 , 15)
(Applicable if the Option plug-in module for RS485 Serial Port is fitted)
Terminating Resistor
Screened Cable
Twisted
Wire Pair
(100 to 150 Ohms)
15 (B-)
HOST
B-
B+
Master Device
Serial Comm.
Terminals
14 (B+)
25
w w w . p p i i n d i a . n e t
Process Precision Instruments
101, Diamond Industrial Estate, Navghar, Vasai Road (E),
Dist. Palghar - 401 210.Maharashtra, India
0250 - 2391722/33/37/42 07498799226, 09321985369
support@ppiindia.net sales@ppiindia.net,
Mar 2017
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