WIKA CS4L User Manual

Operating Instructions

Temperature Indicating Controller, Models CS4H and CS4L

WIKA Operating Instructions CS4H / CS4L V1.1 • 07/2006

WIKA Alexander Wiegand GmbH & Co. KG Alexander-Wiegand-Straße 30 63911 Klingenberg/Germany Phone (+49) 93 72/132-0 Fax (+49) 93 72/132-406 E-Mail www.wika.de

info@wika.de

Operating Instructions Temperature Indicating Controller CS4H / CS4L

Preface

Thank you for the purchase of our microcomputer based temperature indicating controllers CS4H or CS4L. This manual contains instructions for the mounting, functions, operations and notes when operating the CS4H or CS4L. For model confirmation and unit specifications, please read this manual carefully before starting operation. To prevent accidents arising from the misuse of this controller, please ensure the operator using it receives this manual.

Caution

• This instrument should be used according to the specifications described in the manual. If it is used according to the specifications, it may malfunction or cause fire.

• Be sure to follow the warnings, cautions and notices. If not, it could cause serious injury or malfunction.

• Specifications of the CS4H and CS4L and the contents of this instruction manual are subject to change without notice.

• Care has been taken to assure that the contents of this instruction manual are correct, but if there are any doubts, mistakes or questions, please inform our sales department.

• This instrument is designed to be installed in a control panel. If not, measures must be taken to ensure that the operator cannot touch power terminals or other high voltage sections.

• Any unauthorized transfer or copying of this document, in part or in whole, is prohibited.

• WIKA is not liable for any damages or secondary damages incurred as a result of using this product, including any indirect damages.

SAFETY PRECAUTIONS (Be sure to read these precautions before using our products.)

The safety precautions are classified into categories: “ Warning” and “ Caution”. Depending on circumstances, procedures indicated by “ sure to follow the directions for usage.

Caution” may be linked to serious results, so be

Warning

Procedures, which may lead to dangerous conditions and cause death or serious injury, if not carried out properly.

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Caution

Procedures which may lead to dangerous conditions and cause superficial to medium injury or physical damage or may degrade or damage the product, if not carried out properly.

Operating Instructions Temperature Indicating Controller CS4H / CS4L

1. Installation precautions

Caution

This instrument is intended to be used under the following environmental conditions (IEC61010-1): Overvoltage category Mount the controller in a place with:

• A minimum of dust, and an absense of corrosive gasses

• No flammable, expolsive gasses

• No mechanical vibrations or shocks

• No exposure to direct sunlight, an ambient temperature of 0 ... 50°C (32 ... 122°F) that does not change suddenly

• An ambient non-condensing humidity of 35 ... 85%RH

• No large capacity electromagnetic switches or cables through which large current is flowing.

• No water, oil or chemicals or where the vapors of these substances can come into direct contact with the unit

Note: Do not install this instrument near flammable material even though the case of this

instrument is made of flame resisting resin. Avoid setting this instrument directly on flammable material.

2. Wiring precautions

, Pollution degree 2

Caution

• Use the solderless terminal with an insulation sleeve that fits in the M3 screw when wiring the CS4H or CS4L.

• The terminal block of this instrument is designed to be wired from the left side. The lead wire must be inserted from the left side of the terminal, and fastened with the terminal screw.

• Tighten the terminal screw within the specified torque. If excessive force is applied to the screw when tightening, the screw or case may be damaged.

• Do not apply a commercial power source to the sensor which is connected to the input terminal nor allow the power source to come into contact with the sensor, as the input circuit may be burnt out.

• This controller has no built-in power switch, circuit breaker or fuse. It is necessary to install them near the controller. (Recommended fuse: Time-lag fuse, rated voltage 250V AC, rated current 2A)

• When using a 24V AC/DC for the power source, do not confuse the polarity when it is DC.

3. Running and maintenance precautions

Caution

• It is recommended that PID auto-tuning be performed on the trial run.

Do not touch live terminals. This may cause electric shock or problems in operation.

•

• Turn the power supplied to the instrunment OFF when retightening the terminal and

cleaning. Working or touching the terminal with the power switched ON may result in Electric Shock causing severe injury or death.

• Use a soft, dry cloth when cleaning the instrument.

(If paint thinner is used, it might deform or tarnish the unit.)

• As the display section is vulnerable, do not strike or scratch it with a hard object or press

hard on them

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

List of contents

1. Model informations

1.1 Model name ····················································································································· 6

1.2 Rated input ······················································································································· 7

2. Name and functions of the sections ········································································ 8

3. Mounting to control panel

3.1 Site selection ·················································································································· 10

3.2 External dimension ········································································································· 10

3.3 Panel cutout ····················································································································11

3.4 CT (current transformer) external dimension ···································································11

3.5 Mounting ························································································································ 12

4. Wiring connection

4.1 Terminal arrangement ···································································································· 13

4.2 Wiring connection example ···························································································· 14

5. Setup

5.1 Setup flow chart ············································································································· 17

5.2 Main setting mode SV1 ································································································································· 19 SV2 ································································································································· 19

5.3 Sub setting mode AT setting/Auto-reset setting ··························································································· 19 OUT1 proportional band setting ······················································································ 19 OUT2 proportional band setting ······················································································ 19 Integral time setting ········································································································· 20 Derivative time setting ····································································································· 20 ARW (Anti-reset windup) setting ····················································································· 20 OUT1 proportional cycle setting ······················································································ 20 OUT2 proportional cycle setting ······················································································ 20 A1 setting ························································································································ 20 A2 setting ························································································································ 20 HB (Heater burnout alarm) setting ··················································································· 21 LA (Loop break alarm) action time setting ······································································· 21 LA (Loop break alarm) action span setting ······································································ 21

5.4 Auxiliary function setting mode 1 Setting value lock selection ····························································································· 22 SV high limit setting ········································································································· 22 SV low limit setting ·········································································································· 22 Sensor correction setting ································································································· 22 Communication protocol selection ··················································································· 22 Instrument number setting ······························································································· 22 Data transfer rate selection ····························································································· 23 Parity selection ················································································································ 23 Stop bit selection ············································································································· 23

5.5 Auxiliary function setting mode 2 Sensor selection ·············································································································· 24 Scaling high limit setting ·································································································· 24 Scaling low limit setting ··································································································· 24 Decimal point place selection ·························································································· 25 PV filter time constant setting ·························································································· 25 OUT1 high limit setting ···································································································· 25 OUT1 low limit setting ····································································································· 25 OUT1 ON/OFF action hysteresis setting ········································································· 25 OUT2 action mode selection ··························································································· 25 OUT2 high limit setting ···································································································· 25 OUT2 low limit setting ····································································································· 25 Overlap band/Dead band setting ····················································································· 26 OUT2 ON/OFF action hysteresis setting ········································································· 26 A1 action selection ·········································································································· 26

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

A2 action selection ·········································································································· 26 A1 action Energized/Deenergized selection ···································································· 26 A2 action Energized/Deenergized selection ···································································· 26 A1 hysteresis setting ······································································································· 26 A2 hysteresis setting ······································································································· 26 A1 action delayed timer setting ······················································································· 27 A2 action delayed timer setting ······················································································· 27 Direct/Reverse action selection ······················································································· 27 AT bias setting ················································································································· 27 SVTC bias setting ············································································································ 27 SV2 indication selection ·································································································· 27 Output status selection when input burnout ····································································· 27 OUT/OFF key function selection ····················································································· 27

5.6 Control output OFF function ··························································································· 29

5.7 Auto/Manual control function ·························································································· 29

5.8 Output manipulated variable indication ·········································································· 29

6. Running ·························································································································· 30

7. Action explanation

7.1 OUT1 action ··················································································································· 31

7.2 Heater burnout alarm action (option) ·············································································· 31

7.3 OUT1 ON/OFF action ····································································································· 32

7.4 OUT2 (Heating/Cooling control) action (option) ····························································· 33

7.5 A1 and A2 actions ·········································································································· 36

7.6 SV1/SV2 external selection action ················································································· 37

8. Control action explanations

8.1 PID ································································································································· 37

8.2 PID auto-tuning of this controller ···················································································· 38

8.3 Auto-reset (offset correction) ·························································································· 39

9. Specifications

9.1 Standard specifications ·································································································· 40

9.2 Optional specifications ··································································································· 45

10.Troubleshooting

10.1 Indication ······················································································································ 47

10.2 Key operation ··············································································································· 48

10.3 Control ·························································································································· 49

11. Character table ··········································································································· 49

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

1. Model informations

1.1 Model name and order code

CS4 - 3 A / M - B - - -... Series name CS4_ Model

Control

characteristic

Alarm 1 (A1) A Process value monitoring, output relay Control output

Input M Multi-function input (input configuration setable)

Case colour B Black

Options

(1) PID, PI, PD, P and ON/OFF action are programmable. (2) 9 types of alarm action, no alarm action and energized/deenergized are selectable by key operation. (3) The input configuration can be selected from the user by the front keys. (4) Only 2 options can be added from Alarm output 2, Heater burnout alarm and 2. control output. (5) For control output analogue current signal heater burnout alarm cannot be added. (6) When serial communication is added, SV1/SV2 external selection (standard function) does not work. (7) 2. control output and heater burnout alarm cannot be added, when transmitter supply DC 24 V is added.

CS4H: W48 x H96 x D100mm CS4L: W96 x H96 x D100mm

3 PID (setable control parameter)

R Relay S Logic level (DC 0/12 V) for solid state relay A Analogue current signal (4 ... 20 mA)

H AC 100 ... 240 V, 50 ... 60 Hz Power supply L AC/DC 24 V

B Factory adjustment Instrument configuration # (?) To customers specification

(4)

2AS

Alarm output 2: process value monitoring

(4)

2AR

Alarm output 2: control loop monitoring

(4)

2AL

Alarm output 2: process value and control loop moni-

toring with common terminals

Heater burnout alarm for 1 phase (max. 5 A)

Heater burnout alarm for 1 phase (max. 10 A)

Heater burnout alarm for 1 phase (max. 20 A) Heater burnout alarm for 1 phase (max. 50 A)

2. control output (three step control) relay

2. control output (three step control) logic level DC 0/12 V for solid state relay

2. control output (three step control) analogue current signal (4 ... 20 mA)

Serial interface RS 485

Transmitter supply DC 24 V max. 30 mA

Shunt resistor 50

Ω for input signals 0/4 ... 20 mA

W10 W11 W12 W15 DR2 DS2

DA2

CR5 P24 R50

(4) (5)

(4)

(6)

(7)

KAB Terminal cover

(1)

(2)

(3)

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

1.2 Rated input

Input type Input range Resolution

–200 ... 1370 °C –320 ... 2500 °F 1 °C (°F)

–199.9 ... 400.0 °C –199.9 ... 750.0 °F 0.1 °C (°F)

–200 ... 1000 °C –320 ... 1800 °F 1 °C (°F) R 0 ... 1760 °C 0 ... 3200 °F 1 °C (°F) S 0 ... 1760 °C 0 ... 3200 °F 1 °C (°F) B 0 ... 1820 °C 0 ... 3300 °F 1 °C (°F) E

–200 ... 800 °C –320 ... 1500 °F 1 °C (°F) T –199.9 ... 400.0 °C –199.9 ... 750.0 °F 0.1 °C (°F) N –200 ... 1300 °C –320 ... 2300 °F 1 °C (°F)

PL- 0 ... 1390 °C 0 ... 2500 °F 1 °C (°F)

C(W/Re5-26) 0 ... 2315 °C 0 ... 4200 °F 1 °C (°F)

Pt100

JPt100

4 … 20 mA DC –1999 ... 9999 0 … 20 mA DC –1999 ... 9999 0 … 1 V DC

0 … 5 V DC 1 … 5 V DC –1999 ... 9999 0 … 10 V DC –1999 ... 9999

–199.9 ... 850.0 °C –199.9 ... 999.9 °F 0.1 °C (°F)

–200 ... 850 °C –300 ... 1500 °F 1 °C (°F)

–199.9 ... 500.0 °C –199.9 ... 900.0 °F 0.1 °C (°F)

–200 ... 500 °C –300 ... 900 °F 1 °C (°F)

–1999 ... 9999 –1999 ... 9999

(1)(2)

(1)

(1) For DC input, input range and decimal point place can be changed. (2) Connect 50 Ω shunt resistor (sold optionally) between input terminals.

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

2. Name and functions of the sections

(1)

(2)

(3)

(4)

(5)

(6) (7)

(8)

(9)

(10)

(11)

(14)

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(10)

(11)

(14)

(12)

(13)

(15)

(12)

(13)

(15)

(Fig. 2-1)

Indications:

(1) PV: PV display Indicates the process variable (PV) with a red LED. (2) SV: SV display Indicates the setting value (SV) or manipulated variable (MV) with a green LED. (3) SV1: Set value 1 indicator When set value 1 (SV1) is selected, a green LED lights. (4) SV2: Set value 2 indicator When set value 2 (SV2) is selected, a yellow LED lights. (5) OUT1: Control output 1 (OUT1) indicator When OUT1 or Heating output is ON, a green LED lights. (In the case of DC current output type, it blinks in a 0.25 second cycle corresponding to the output manipulated variable.) (6) OUT2: Control output 2 (OUT2) indicator When OUT2 is ON, a yellow LED lights. (In the case of DC current output type, it blinks in a 0.25 second cycle corresponding to the output manipulated variable.) (7) HB: HB indicator When Heater burnout alarm output or Sensor burnout alarm output is ON, a red LED lights. (When Heater burnout Alarm is added, a red LED also lights when the indication is overscale or underscale) (8) AT: Auto-tuning (AT) indicator When Auto-tuning or Auto-reset is active, a yellow LED blinks. (9) TX/RX: TX/RX indicator When serial communication TX (transmitting) is outputted, a yellow LED lights. (10) A1: Alarm 1 (A1) indicator When A1 output is ON, a red LED lights. (11) A2/LA: Alarm 2 (A2/LA) indicator When A2 output is ON, a red LED lights.

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

Keys:

(12)

▲: Increase key

Increases numeric value of the setting value. (13)

▼: Decrease key

Decreases numeric value of the setting value. (14) MODE: Mode key Switches the setting mode and registers the setting value and selected value. (Setting value and selected value are registered by pressing the mode key.) (15)

OUT

• When

OUT

OFF

key

OFF

OUT

function is selected in the

OFF

off. By pressing

OUT

key function selection, control output can be turned on or

OFF

key for approx. 1 second from any mode, control output OFF function works.

OFF

Once the control output OFF function is enabled, the function cannot be released even if the power to the instrument is turned OFF and ON again. Control output OFF function keeps working. To cancel the function, press the

• When Auto/Manual control function is selected in the starts when the power to the controller is turned on. If the manual control starts. If the

OUT

key again for approx. 1 second.

OFF

OUT

key is pressed again during manual control, the control reverts to

OFF

OUT

key function selection, automatic control

OFF

OUT

key is pressed again in this status,

OFF

automatic one. However, Auto/Manual function can be switched only in the PV/SV display mode.

Notice

When setting the specifications and functions of this controller, connect the terminals 2 and 3 for power source first, then set them referring to “5. Setup” before performing “3. Mounting to control panel” and “4. Wiring connection”.

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

3. Mounting to control panel

3.1 Site selection This instrument is intended to be used under the following conditions (IEC61010-1): Overvoltage category Mount the controller in a place with: (1) A minimum of dust, and an absence of corrosive gases (2) No flammable, explosive gasses (3) No mechanical vibrations or shocks (4) No exposure to direct sunlight, an ambient temperature of 0 ... 50°C (32 ... 122°F) that does not

change suddenly (5) An ambient non-condensing humidity of 35 ... 85%RH (6) No large capacity electromagnetic switches or cables through which large current is flowing. (7) No water, oil or chemicals or where the vapors of these substances can come into direct contact with

the unit

3.2 External dimension

• CS4H

• CS4L

, Pollution degree 2

Gasket A Screw type mounting bracket

11.5 98.5

(Fig. 3.2-1)

Gasket A Screw type mounting bracket

96 11.5 98.5

(Fig. 3.2-2)

106.2

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

3.3 Panel cutout

• CS4H

+0.8

130

+0.8

n x 48-3

+0.5

Lateral close mounting, n: Number of units mounted

+0.5

Caution: When lateral close mounting is used for the controller,

IP66 specification is not fulfilled.

(Fig. 3.3-1)

• CS4L

＋

130

n×96-3

0.5 0

+0.8

+ 0.8

Lateral close mounting, n: Number of units mounted

Caution: When lateral close mounting is used used for for the

controller, IP66 specification is not fulfilled.

(Fig. 3.3-2)

3.4 CT (Current transformer) external dimension

CTL-6S (for 5A, 10A, 20A) CTL-12-S36-10L1 (for 50A)

5.8

0.5

2.8

7.5

10.5

21 40

10040

1540

30 2- 3.5

2-M3

(Fig. 3.4-1)

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

3.5 Mounting (both CS4H and CS4L)

Warning

As the case is made of resin, do not use excessive force while screwing in the mounting bracket, or the case could be damaged. The torque is approximately 0.12 Nm.

To fulfill the Dust-proof/Drip-proof IP66 specification, mount this unit vertically and check the rigidity of the panel where this unit is mounted. If rigidity is not enough, Dust-proof/Drip-proof IP66 specification may not be guaranteed. Mounting panel thickness: Within 1 ... 15 mm Insert this unit from the front side of the panel. Attach the mounting brackets by the holes at the top and bottom of the case and secure the controller in place with the screws.

Down

(Fig. 3.5-1)

Down

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

4. Wiring connection

Warning

Turn the power supply to the instrument off before wiring or checking. Working or touching the terminal with the power switched on may result in Electric Shock causing severe injury or death. Moreover, the instrument must be grounded before the power supply to the instrument is turned on.

4.1 Terminal arrangement

POWER SUPPLY

24V AC/DC

GND

POWER SUPPLY

100to240V AC

OUT1

3A 250V AC

P24

(Fig. 4.1-1)

24V DC 30mA

OUT2 /HB

3A 250V AC

DC mA

• OUT1 : Control output 1 (Heating)

• OUT2 : Control output 2 (Cooling)

• A1 : Alarm 1 output

• A2/LA : Alarm 2/Loop break alarm output

• HB : Heater burnout alarm output

• P24 : Transmitter supply output

• RS-485 : Serial communication (RS-485)

• SV2 : Second set value (external selection)

• CT : CT input

• TC : Thermocouple

• RTD : Resistance temperature detector

• DC : DC voltage (DC V) or DC current (DC mA)

• 50 Ω : Shunt resistor 50 Ω for input DC current

RS-485

50Ω

YA (-)

YB (+)

SV2

RTD

A2/LA (HB)

3A 250V AC

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

Caution

• The terminal blocks of the CS4H and CS4L are designed to be wired from the left side. The lead wire must be inserted from the left side of the terminal, and fastened with the terminal screw.

• Dotted lines show options. If the option is not designated, there are no terminals.

• When A2 (option) and Heater burnout alarm (option) are applied together, use terminals 12-13 for A2, and 9-10 for Heater burnout alarm.

• When Heating/Cooling control (option) and Heater burnout Alarm (option) are applied together, use terminals 9-10 for the Heating/Cooling control and 12-13 for the Heater burnout alarm.

• When A2 (option) and LA (option) are applied, they use common output terminals.

• When Isolated power output (option) is applied, Heating/Cooling control (option) and Heater burnout Alarm (option) cannot be applied with it.

Lead wire solderless terminal Use a solderless terminal with isolation sleeve that fits in the M3 screw as shown below. Designate the torque 0.6 Nm to 1.0 Nm.

3.2mm3.2mm

5.8mm or less

(Fig. 4.1-2)

4.2 Wiring connection example

5.8mm or less

Caution

• Use a thermocouple and compensating lead wire according to the sensor input specifications of this controller.

• Use a 3-wire RTD system according to the sensor input specifications of this controller.

• This controller has no built-in power switch or fuse. It is necessary to install them in the circuit

near the external controller.

(Recommended fuse: Time-lag fuse, rated voltage AC 250V, rated current 2A)

• When using a AC/DC 24V for the power source, do not confuse the polarity when it is DC.

• When using a relay contact output type, use a relay according to the capacity of the load to protect the built-in relay contact.

• When wiring, keep input wires (thermocouple, RTD, etc.) away from AC sources or load wires to avoid external interference.

• Use a thick wire (1.25 … 2.0 mm

) for the earth ground.

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Operating Instructions Temperature Indicating Controller CS4H / CS4L

[Heater burnout alarm output]

(1) This alarm is not available for detecting

heater current under phase control.

CT input terminal

(2) Use current transformer (CT) provided,

and pass one lead wire of heater circuit into the hole of the CT.

Power source

(3) When wiring, keep CT wire away from

any AC sources and load wires to avoid the external interference.

Heater

(Fig. 4.2-1)

[CS4H-R/M]

3-phase

Electro-

magnetic

switch

Alarm unit

Heater

Electric furnace

Thermocouple

(Fig. 4.2-2)

• To prevent the unit from harmful effects of unexpected high level noise, it is recommended that a

surge absorber be installed between the electromagnetic switch coils.

• AC or DC is available to supply voltage 24 V. Do not confuse the polarity when it is DC.

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