WIKA CS4R User Manual

Operating Instructions

Temperature Indicating Controller, Model CS4R

WIKA Operating Instructions CS4R V1.2 • 05/2006

WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Phone [phone]
Fax [phone]
E-Mail [e-mail]
www.wika.de

Operating Instructions Temperature Indicating Controller CS4R

Preface

Thank you for the purchase of our microcomputer based temperature indicating controller CS4R.
This manual contains instructions for the mounting, functions, operations and notes when operating the CS4R.
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 not 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 CS4R 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
to follow the directions for usage.

Caution may be linked to serious results, so be sure

Warning

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

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.

V1.2 • 05/2006 - 2 -

Operating Instructions Temperature Indicating Controller CS4R

List of contents

1. Model name and order code......................................................................................................... 4

2. Name and functions of the sections............................................................................................ 5

3. Mounting to the control panel ...................................................................................................... 5

3.1 Site selection............................................................................................................................. 5

3.2 External dimension ................................................................................................................... 6

3.3 CT (current transformer) external dimension............................................................................ 6

3.4 Mounting to DIN rail .................................................................................................................. 6

4. Wiring connection.......................................................................................................................... 7

5. Setup ............................................................................................................................................... 9

5.1 Operation flow chart .................................................................................................................. 10

5.2 Main setting mode..................................................................................................................... 11

5.3 Sub setting mode ...................................................................................................................... 11

5.4 Auxiliary function setting mode 1 .............................................................................................. 12

5.5 Auxiliary function setting mode 2 .............................................................................................. 14

5.6 Control output manipulated variable indication......................................................................... 17

6. Converter function......................................................................................................................... 18

7. Running........................................................................................................................................... 19

8. Action explanations....................................................................................................................... 19

8.1 OUT action................................................................................................................................ 19

8.2 OUT ON/OFF action ................................................................................................................. 20

8.3 Event (Alarm) action ................................................................................................................. 21

8.4 Event (Heater burnout Alarm) action ........................................................................................ 21

9. PID auto-tuning of the CS4R......................................................................................................... 22

10. Specifications................................................................................................................................. 23

10.1 Standard specifications ........................................................................................................... 23

10.2 Optional specifications ............................................................................................................ 27

11. Troubleshooting............................................................................................................................. 28

11.1 Indication................................................................................................................................. 28

11.2 Key operation .......................................................................................................................... 29

11.3 Control..................................................................................................................................... 29

12. Character table............................................................................................................................... 30

V1.2 • 05/2006 - 3 -

Operating Instructions Temperature Indicating Controller CS4R

1. Model Name and Order Code

CS4R - 3 E - / M - - - Series name: CS4R
Control action 3 PID
Alarm output 1 E alarm action is selectable by key operation

relay

R

Control output

Multi-function input

Power supply

Digital interface

logic level DC 0/12 V for solid state relay

S

analogue current signal (4 ... 20 mA)

A

M settable input configuration

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

without

Z

RS485

5

ZZZ without
W10 single phase system (max. 5 A)

Heater burnout Alarm

W11 single phase system (max. 10 A)
W12 single phase system (max. 20 A)
W15 single phase system (max. 50 A)

Necessary accessory for current input

Instrument configuration

Additional order info

Z without
R shunt resistor 50 Ω

B factory adjustment
K to customer specification

Z without
T additional text

(1) PID, PI, PD, P and ON/OFF action are programmable.
(2) Alarm action (9 types and no alarm) and Energized/Deenergized are selectable by key operation.
(3) The controller with control output analogue current signal (4 … 20 mA) can be configured for use as

temperature transmitter.

(4) Thermocouple, RTD, DC current and DC voltage are selectable by key operation.

(1)

(4)

(3)

(2)

V1.2 • 05/2006 - 4 -

Operating Instructions Temperature Indicating Controller CS4R

2. Name and functions of the sections

(1) EVT EVT indicator

A red LED lights up when Event output (Alarm, Loop break
alarm or the option Heater burnout alarm) is ON.

(2) OUT OUT indicator

A green LED lights up when OUT output is ON.
For DC current output type, this blinks in a 0.25 second cycle
corresponding to the output manipulated variable .

(3) T/R T/R indicator

A yellow LED blinks during serial communication TX output
(transmission)

(4) AT Auto tuning indicator

A yellow LED blinks while PID auto-tuning is being performed.

(5) PV PV display

Indicates the input value (PV) with a red LED.

(6) SV SV display

Indicates the setting value (SV) with a green LED.

Increase-key

(7)

Increases the numeric value.

Decrease-key

(8)

Decreases the numeric value.

MODE MODE–key

(9)

Changes the setting mode or registers the setting value.

(Resisters the setting value by pressing the MODE-key.) (FIG. 2-1)

(10)

Submode-key]

Brings up Auxiliary function setting mode 2 in combination with the mode key.

(1)

(2)

(5)

(6)

(7)

(8)

(3)

(4)

(9)

(10)

Caution

When setting the specifications and functions of this controller, connect the terminals 1 and 2 for power
source first, then set them referring to “5. Setup” before performing “3. Mounting”
and “4. Wiring”.

3. Mounting

3.1 Site selection
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 absence of corrosive gases

• No flammable, explosive gasses

• Few mechanical vibrations or shocks

• No exposure to direct sunlight, an ambient temperature of 0 … 50°C (32 … 122°F) without rapid change

• 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

controller

, Pollution degree 2

V1.2 • 05/2006 - 5 -

Operating Instructions Temperature Indicating Controller CS4R

3.2 External dimensions

75

22.5

(Fig. 3.2-1)

3.3 CT (current transformer) external dimensions

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

(Fig. 3.3-1)

3.4 Mounting to DIN rail

97

100

DIN rail

4

Caution

Mount the DIN rail horizontally.
When DIN rail is mounted vertically, be sure to use commercially available fastening plates at
the end of CS4R series.
Mount the CS4R series to the DIN rail so that the CS4R series may be fixed.
However, if the DIN rail is mounted horizontally in a position susceptible to vibration or
shock, the fastening plates must be used as well.

V1.2 • 05/2006 - 6 -

Operating Instructions Temperature Indicating Controller CS4R

1

Hook 1 of the CS4R on the upper side of the DIN rail. (Fig. 3.4-1)

2

Making 1 part of the CS4R as a support, fit the lower part of the CS4R to the DIN rail.

CS4R will be completely fixed to DIN rail with a “Click” sound. (Fig.3.4-1)

(Fig. 3.4-1)

4. Wiring connection

(2)

(1)

Warning

Turn the power supplied to the instrument OFF before wiring or checking it.
Working or touching the terminal with the power switched ON may result in Electric
Shock causing severe injury or death.

Caution

• Do not leave wire chips into the CS4R when wiring, because they could cause fire, malfunction

and trouble.

• Insert the connecting cable into the designated connector securely. Not doing so could cause
malfunction due to imperfect contact.

• Connect the AC power to the designated terminal as is written in this instruction manual.

Otherwise it may burn and damage the CS4R.

• Do not apply a commercial power source to the sensor connected to the input terminal nor allow
the power source to come into contact with the sensor.

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

• This unit does not have built-in power switch, circuit breaker or fuse. Therfore it is necessary to

install them in the circuit near the external unit.
(Recommended fuse: Time-lag fuse, Rated voltage 250V AC, Rated current 2A)

• Tighten the terminal scre w with the specified torque. Excessive force could damage the terminal
screw and deform the case.

• Use a thermocouple and compensating lead wire that corresponds to the sensor input specification of
this unit.

• Use the 3-wire RTD that corresponds to the sensor input specification of this unit.

• When using DC voltage and current inputs, be careful not to confuse the polarity when wiring.

• Keep input wires (Thermocouple, RTD, etc.) away from power source and load wires when wiring.

V1.2 • 05/2006 - 7 -

Operating Instructions Temperature Indicating Controller CS4R

• Note

Tighten the terminal screw properly referring to the table below.

Terminal screw Terminal No. Torque

M2.6 1 to 4 Max. 0.5 Nm

Terminal arrangement

M2.0 5 to 9 Max. 0.25 Nm

POWER SUPPLY

24V AC/DC

Lower part of main body

POWER SUPPLY

100 to 240V AC

MAIN OUTPUT

3A
250V AC

0.1A
24V DC

Communication
(RS-485)

CT input

(Fig. 4-1)

TC

RTD

DC V

DC mA

50Ω

EVENT

OUTPUT

(shunt resistor)

RS-485

No.1
No.6

No.1
No.6

No.1
No.2
No.3
No.4
No.5
No.6

COM

NC

YB(+)
YA(-)
NC

COM

• MAIN OUTPUT : Control output

• EVENT OUTPUT : Outputs when Alarm, Loop break alarm or Heater burnout alarm (option) is ON.

• RS-485 : Serial communication

• TC : Thermocouple

• RTD : Resistance temperature detector

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

• Shunt resistor : Shunt resistor 5

0Ω for input signal DC current

• Option: Heater burnout Alarm

(1) This alarm is not available for detecting current

under phase control.

(2) Use the current transformer (CT) provided, and pass a

CT

CT input socket

Power
supply

lead wire of the heater circuit into a hole of the CT.

(3)When wiring, keep the CT wire away from any AC source

or load wires to avoid the external interference.

Heater

(Fig. 4-2)

V1.2 • 05/2006 - 8 -

Operating Instructions Temperature Indicating Controller CS4R

5. Setup

The sensor input character and temperature unit are indicated on the PV display for approx. 3 seconds after

the power is turned on, and the input range high limit value is indicated on the SV display. (Table 5-1)

(If any other value is set during the Scaling high limit setting, it is indicated on the SV display.)
During this time all outputs and the LED indicators are in OFF status. After that the control starts indicating

actual temperature on the PV display and setting value on the SV display.

(Table 5-1)

Input Scale range Resolution

K

J –200 ...1000 °C –320 ...1800 °F 1°C (°F)
R
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 ... 20mA DC
0 ... 20mA DC
0 ... 1V DC –1999 ... 9999 *1 1
0 ... 5V DC
1 ... 5V DC –1999 ... 9999 *1 1

0 ... 10V DC –1999 ... 9999 *1 1

*1: Input range and decimal point place can be changed.
*2: 50Ω shunt resistor (sold optionally) must be connected between the input terminals.

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

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

0 ... 1760 °C 0 ... 3200 °F 1°C (°F)

–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 *1, *2 1
–1999 ... 9999 *1, *2 1

–1999 ... 9999 *1 1

V1.2 • 05/2006 - 9 -

Operating Instructions Temperature Indicating Controller CS4R

pp

5.1 Operation flow chart

PV/SV display mode

MODE

[Main setting mode] [Sub setting mode] [Auxiliary function setting mode 1] [Auxiliary function setting mode 2]

Set value

[

]

MODE MODE MODE MODE

OUT Proportional band setting

MODE MODE MODE

Integral time

MODE MODE MODE

Derivate time setting

MODE MODE MODE

ARW Anti-reset windup setting

MODE MODE

Out Proportional cycle setting

MODE MODE

Manual reset setting

MODE MODE

Alarm setting

MODE MODE

Heater burnout alarm setting

MODE MODE

Loop break alarm action time

MODE MODE

Loop break alarm action span

MODE MODE

Alarm hysteresis setting

SVTC bias setting

Controller/Converter function

Output status selection when

•

+ MODE: Press the MODE key while the key is being pressed.
+ MODE (Approx. 3s): Press the MODE key while the key is being pressed.

•

•

+ MODE (Approx. 3s): Press the MODE key while the key is being pressed.

For setting and selecting in each setting mode press

V1.2 • 05/2006 - 10 -

MODE (Approx. 3s)

+ MODE + MODE (Approx. 3s) + MODE (Approx. 3s)

PID auto-tuning Perform/Cancel

setting [

setting [

MODE MODE

selection [

MODE MODE

input burnout [

MODE MODE

Control output manipulated
variable indication

Setting value lock selection

[ ]

Sensor correction setting

[

]

Communication protocol

[

]

Instrument number setting

]

[

Data transfer rate selection

[

]

Parity selection

[

]

Stop bit selection

[

[

]

[

]

[

]

]

]

]

]

]

or key.

Control output ON/OFF action

Alarm action selection

Alarm action Energized/

Alarm HOLD function selection

Alarm action delayed timer

Direct/Reverse action selection

AT bias setting

MODE

[ ]

[ ]

sele ction [ ]

[ ]

[ ]

[ ]

[ ]

Dotted lines show options, which are
indicated only when the options are
a

Input type selection

Scaling high limit setting

Scaling low limit setting

Decimal point place selection

PV filter time constant setting

Control output high limit setting

Control output low limit setting

hysteresis [ ]

Deenergized [ ]

MODE

setting [ ]

lied.

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[ ]

[

[ ]

[ ]

]