Innovative instruments I-therm AI 5442 Betriebsanleitung

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

STATUS LED’S : OP1 : Main Control Output

OP2 : Alarm Status

: Auxiliary control output

2. INPUT

Sensor Input : TC:J,K,R,S & RTD: Pt-100

Range : Refer below table

Sampling Time : 125 msec.

Resolution : 1°C/0.1°C(Only for RTD)

CJC for TC : Built in automatic

LWC for Pt-100 : Built in upto 18E max.

Digital Filter : 1 to 10 Sec.

3. RELAY OUTPUT

Contact type : N/O, CM, N/C

Contact Rating : 5A @ 250VAC or 30 VDC

Life expectancy : > 5,00,000 operations

Isolation : Inherent

4. SSR DRIVE OUTPUT

Drive Capacity : 12V @ 30mA.

Isolation : Non-Isolated.

5. FUNCTION

Output 1 : Main Control output

Output 2 : Programmable

1) Auxiliary control 2) Alarm

Control Action : ON-OFF/T.P (Select)

Control Mode : Heat/Cool (Select)

Compliance : ----

6. ENVIRONMENTAL

Operating Range : 0 ~50°C, 5~90% Rh

Storage Humidity : 95% Rh (Non-condensing)

7. POWER SUPPLY

Supply Voltage : 90~270VAC, 50/60Hz.

Consumption : 4W Maximum.

8. PHYSICAL

Housing : ABS Plastic

SAFETY INSTRUCTION :

This controller is meant for temperature control

applications. It is important to read the manual prior to

installing or commissioning of controller. All safety related

instruction appearing in this manual must be followed to

ensure safety of the operating personnel as well as the

instrument.

GENERAL

vThe 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.

vThe controller is generally part of control panel and in such

a case the terminals should not remain accessible to the

user after installation.

MECHANICAL

vThe Controller in its installed state must not come in close

poximity to any corrosive/combustible gases, caustic

vapors, oils, steam or any other process by-products.

vThe Controller in its installed state should not be exposed

to carbon dust, salt air, direct sunlight or radiant heat.

vAmbient temperature and relative humidity surrounding

the controller must not exceed the maximum specified limit

for proper operation of the controller.

vThe controller in its installed state must be protected

against excessive electrostatic or electromagnetic

interferences. Ventilation holes provided on the chassis of

the instrument are meant for thermal dissipation hence

should not be obstructed in the panel.

ELECTRICAL

vThe controller must be wired as per wiring diagram & it

must comply with local electrical regulation.

vCare must be taken not to connect AC supplies to low

voltage sensor input.

vCircuit 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.

vCircuit 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.

vTo 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.

vThe 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.

vThe 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.

vIt is essential to install a over Temp. Protection device to

avoid any failure of heating system. Apart from spoiling the

product, this could damage the process being controlled.

Model no.

Weight (gms.)

AI-5442 AI-5842 AI-5742 AI-5942

130 200 200 240

USER’S OPERATING MANUAL FOR DIGITAL TEMPERATURE CONTROLLER

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

SPECIFICATIONS : -

Fe-k(J) T/C

Cr-AL(K) T/C

Sensor Type Accuracy

± 1 C

0 ~ 1700 C

-100 ~ 450 C

Resolution

Range

1 C

}

(R) T/C

(S) T/C

Pt-100(RTD)

Pt-100(RTD 0.1)

0 ~ 760 C

-99 ~ 1300 C

-99.9 ~ 450.0 C

1 C

0.1 C

± 0.3 C

AI - 5442

(48 X 48) AI - 5742

(72 X 72) AI - 5942

(96 X 96)

AI - 5842

(48 X 96)

OP1

OP2

°C

SET ACK

-therm

AI-5942

OP1

OP2

°C

-therm

AI-5742

SET ACK

AI-5442

OP1

OP2

SET ACK

OP1

OP2

SET ACK

-therm

AI-5842

°C

Model no.

Display height

AI-5442 AI-5842 AI-5742 AI-5942

0.36” 0.56”0.56”0.56”

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

SUPPLY

123456

78910 11 12

NO NCCM

RELAY2

SSR2

NO NCCM

RELAY1

SSR1

123456

10 11 12 13 14 15 16 17 18

789

NO NCCM

RELAY1

SSR1

NO NCCM

RELAY2

SSR2

SUPPLY

123456789

10 11 12 13 14 15 16 17 18

NO NCCM

RELAY1

SSR1

NO NCCM

RELAY2

SSR2

SUPPLY

AI - 5442 AI - 5742 AI - 5942 AI - 5842

NC CM

RELAY2

SSR2

SUPPLY

12345

678 9 10

NO NCCM

RELAY1

SSR1

OVER ALL DIMENSIONS & PANEL CUT OUT (IN MM)

MECHANICAL INSTALLATION

The label on the controller identifies the serial number, wiring connections and batch number.

CAUTION: To prevent the risk of electrical shock, switch off the power before making/removing any connection or

removing the controller from its enclosure.

MODEL : AI - 5842

C H

B D

MODEL:-AI-5442/5742/5942

INSTALLATION GUIDELINES

1. Prepare the cut-out with proper dimension as shown in figure.

2. Remove clamp from controller

3. Push the controller through panel cut-out and secure the

controller in its place by tightening the side clamp.

PANEL

CUTOUT

PANEL

CUTOUT

ELECTRICAL INSTALLATION

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

TABLE : 1

Model

Dim

A B HC D F GE

AI-5442

AI-5742

AI-5942

AI-5842

FRONT PANEL LAYOUT

FRONT PANEL LAYOUT DESCRIPTION :

OP1 LED

OP2 LED

DISPLAY

SET

KEY

SHIFT

KEY

Sr. NAME FUNCTION

Glows when OP1 is ON & flashes when delay time (dly1) is in operation

(if selected mode is ON-OFF)

Glows when OP1 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: (1) Measured value of selected input or Error massages. (2) SP (Main

set point) / SP2 value in run mode. (3) Parameters Value/code in program mode.

(1) For SP programming. (2) To access Control mode along with DN Key.

(3) To access Configuration mode along with UP key. (4) To scroll the parameter &

to store its value.

KEY

DOWN

KEY

(1) To increase/alter parameter value in program mode. (2) To Enter in configuration

mode (with SET key). (3) To acknowledge Alarm.

(1) To increase/alter parameter value in program mode with Up / Dn Key.

(2) Press for 3Sec in Programming this will help to go back to previous parameter.

(1) To decrease/alter parameter value in program mode.

(2) To Enter control mode along with SET Key.

OP1

OP2

SET

-therm

AI-5842

°C

456

AI - 5941

AI - 5441

AI - 5741

AI - 5841

OP1

OP2

°C

SET

-therm

AI-5942

AI-5442

OP1

OP2

SET

OP1

°C

-therm

AI-5742

SET

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

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

PARA

METER

RANGE

DESCRIPTION DEFAULT

DISPLAY

User can change the SP1 value using UP/ DOWN keys. Holding the

key will change the value at a faster rate. Press SET key to store the

value and move on to the next parameter.

0 C

LSPL ~ HSPL

CONTROL

SET POINT

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

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

Either deviation auxiliary control or as a deviation alarm mode.

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

(1)

(2)

(3)

LSPL ~ HSPL

-99 to 99 °C

2 to 99 °C

SET

POINT2

0 C

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

the control parameters.

MANUAL

OFFSET

0 C

This parameter will appear only if selected C.A is time proportional.

(For more details refer user guide.)

PARA

METER

RANGE

DESCRIPTION DEFAULT

DISPLAY

P. BAND

0.5

99.9°C

This parameter will appear only if selected control action is T.P. It sets

bandwidth over which the output power is adjusted depending upon

the error (SV-PV).

5.0 C

DELAY 1

500 Sec.

This parameter will appear only if selected control action is ON-OFF.

It sets the output restart time where O/P once turned OFF will turn ON

only after restart time, regardless difference between PV & SP. If set

to '0', O/P will be switched w/o delay. Also, Delay will be considered in

case of every power ON.

120 Sec.

CONTROL

HYS.

1 to 25 C

This parameter will appear only if selected control action is ON-OFF.

It sets the dead band between ON & OFF switching of the Output.

Larger value of hysterisis minimize the number of ON-OFF operation

of the load. This increases life of actuators like contactors but, also

produces large errors (between PV & SV).

2°C

This parameter will appear only if selected control mode for output2 is

Auxiliary control or an Alarm. Value of this parameter sets the dead

band between ON & OFF switching of output load.

HYS. 2

1 to 25 C

2 C

500 Sec.

-25

25 C

This parameter will appear only if output 2 is configured as an

Auxiliary control output. In this mode, output once turned off will

restart only after set time regardless of the difference between PV

and SP2. If time delay is set to 0, there is no delay executed between

output switching.

0 Sec.

DELAY 2

CYCLE

TIME

0.5

100.0 Sec.

This parameter will appear only if selected control action is T.P. User

can set this value based on process being controlled & type of output

selected. For Relay O/P, cycle time should be more than 12sec & for

SSR O/P, cycle time should be less than 5sec.

16.0 Sec.

LOCK

CODE 1 ~ 9999

Set this parameter to 15 (Default LOCK CODE) to access Control

List.

User has a choice to set different Lock Code via USER LOCK CODE

in Config. List.

POWER UP :

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

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

MODELMODEL

PROGRAMMING

USER LIST : To access the user list Press & Release SET key once.

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

HOME

VERSION INPUT

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

INPUT

FILTER

1 C

The controller is equipped with an adaptive digital filter which is used to filter

out any extraneous pulses on the PV. Filtered PV Value is used for all PV

dependent functions. If PV signal is fluctuating due to noise, increase the filter

time constant value.

CONTROL

LOGIC

FOR OP1

HEAT

This parameter will appear only if selected control mode is ON-OFF.

User can select heating logic in which OP1 will remain ON till PV < SP.

(PV increases when output is ON)

This parameter will appear only if selected control mode is ON-OFF.

User can select cooling logic in which OP1 will remain ON till PV > SP.

(PV decreases when output is ON.)

CONTROL

MODE

FOR

OUTPUT1

T.P

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

output.

OUTPUT2

FUNCTION

This parameter allow the user to select output 2 as an ‘Auxiliary’ control.

For options refer Table 3.

This parameter allow the user to select output 2 as an ‘Alarm’ control.

For options refer Table 4.

AUX.

CONTROL

SET

POINT 2

DSBL

0 C

Sets the minimum limit for set point adjustment. It can be set from minimum

specified range of selected sensor to HSPL value.

LOWER

LIMIT

PROCESS

VALUE

OFFSET

0 C

Function of this parameter is to add/subtract a constant value to the measured

PV to obtain Final PV for control applications. This parameter value needs to be

altered for one of the following reason :

(I) To compensate for known thermal gradient (ii)To match the display values

with another recorder or indicator measuring the same PV.

INPUT

TYPE

This parameter value is set according to the type of sensor (Thermocouple or

RTD Input) connected to the Controller's Input Terminals.

HIGHER

LIMIT

400 C

Sets the maximum limit for set point adjustment. It can be set from LSPL value

to maximum specified range of selected sensor.

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

PARA

METER

DESCRIPTION DEFAULT

DISPLAY

CONFIGURATION LIST :

key simultaneously (1) To Enter in this mode, Press and hold SET & UP for 3 sec.

(2) Press UP or DOWN key to scroll between parameter options.

(3) Press SET key to store the current parameter & move on to the next parameter.

LOCK

CODE

Set this parameter to 15 (Default LOCK CODE) to access Config List.

User has a choice to set different Lock Code between 1 to 9999 via USER

LOCK CODE in Config. List.

Fe-k(J) T/C

Cr-AL(K) T/C

Sensor Type Accuracy

± 1 C

0 ~ 1700 C

-100 ~ 450 C

Resolution

Range

1 C

}

(R) T/C

(S) T/C

Pt-100(RTD)

Pt-100(RTD 0.1)

0 ~ 760 C

-99 ~ 1300 C

-99.9 ~ 450.0 C

1 C

0.1 C

± 0.3 C

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

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

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

If this parameter is set as ‘Reverse’, Relay/SSR de-energizes under Alarm

conditions & remains energized otherwise. Generally ‘Reverse’ setting is used

for tripping the process under Alarm conditions.

DIRECT

ALARM

LOGIC

If this parameter is set as ‘Direct’, Relay/SSR energizes under Alarm condition

& remains De-energized otherwise. Generally ‘Direct’ setting is used for

Audio/Visual Alarm Output.

DEVIATION

ALARM

TYPE

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

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

direction.

Low Alarm : OP2 activates when PV<SP2.

High Alarm : OP2 activates when PV>SP2.

(Direct acting)

OUTPUT-2 ON

OUTPUT-2 OFF

SP2

(Direct acting)

SP2

OUTPUT-2 OFF

OUTPUT-2 ON PV

(Reverse acting)

OUTPUT-2 OFF

OUTPUT-2 ON

SP2

(Direct acting)

SP2

OUTPUT-2 ON

OUTPUT-2 OFF PV

(Reverse acting)

OUTPUT ON

SP2

SP1

OUTPUT OFF

OUTPUT ONOUTPUT ON

SP1

SP2SP2

OUTPUT OFF

SP1

SP2SP2

OUTPUT ON

OUTPUT OFF

SP2

SP1

OUTPUT ON

DISPLAY

PARA

METER DESCRIPTION

DEFAULT

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

Default USER LOCK CODE is 15 to access Control & Configuration List.

User has a choice to set its own USER LOCK CODE between 1 to 9999, this is

to prevent unauthorized access of Control & Configuration List.

USER

LOCK

CODE

TABLE 4 :

Controller continuously compares PV with either SP (for Deviation or Band alarm) or an independent ALARM

SP2 (for process high and process low Alarm). Alarm will occur when PV falls outside the set Alarm limits.

Also, OP2 will energize or de-energize under Alarm condition as per the Alarm logic(AL.LG) selected. HYS2

in Control list decides when to switch OFF the Alarm. Instrument supports four types of Alarm as described

below : -

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

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

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

HEAT

User can select cooling logic in which OP2 will remain OFF till PV < SP2.

(PV decreases when output2 is ON)

OUTPUT 2

LOGIC

User can select heating logic in which OP2 will remain ON till PV < SP2.

(PV increases when output2 is ON)

This parameter will appear only if OUTPUT 2 is selected as an Auxiliary control

output. In this mode, User can set SP2 value which is always related to SP.

PARA

METER

DESCRIPTION DEFAULT

DISPLAY

AbS

This parameter will appear only if OUTPUT 2 is selected as an Auxiliary control

output. In this mode, User can set SP2 value independently. The instrument

OUTPUT 2

MODE

SET

POINT 2

DSBL

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

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

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

ALARM

ACK.

AUTO

Once Alarm is activated, it can be de-activated either by pressing UP key or

when PV falls within the alarm limits.

Once Alarm is activated, it remains activated until manually acknowledged by

UP key.

Once Alarm is activated, User has following three options to de-activate it.

When PV falls within the programmed limits, Alarm will be de-activated

automatically.

ALARM

INHIBIT

Setting this parameter value to ‘YES’, will inhibit (suppress) Alarm activation on

power-up condition. From Power-up, the Alarm system remains disabled until

PV is found with in the limits.

If Alarm activation is desired even under Power-up condition, Set this parameter

value to ‘NO’.

1) ON-OFF ACTION:

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

On reaching SP, output turns OFF & remains OFF till actual temperature drops down (in heat logic)

Or raises (in cool logic) equal to hysterisis set by user. (As shown in Fig. 3.1 & 3.2).

Fig: 3.1

HEAT LOGIC/ON-OFF TIME

TEMP ( C)

HYSTERISIS

ON ON ON

AMB

O/P OFF OFF

Fig: 3.2

TIME

COOL LOGIC / ON OFF

O/P O/P

TEMP ( C)

AMB HYSTERISIS

ON ON ON

OFF OFF

USER GUIDE:

2) TIME PROPORTIONAL ACTION:

In this mode, ON & OFF time of Output (Relay/SSR) varies proportionally in every cycle (cycle time

Settable by user) depending on the deviation of PV w.r.t. SP. This action starts/continues only

when PV enters or is within the band. (Fig. 3.3)

Fig: 3.3

AMB

TEMP ( C)

OUT PUT

100 %

OFF

100 %

PROPORTIONAL BAND (P.BND)

SET BY USER

TIME PROPORTIONAL ACTION

ACTIVE TONE

TIME

Fig: 3.4

AMB

TEMP ( C)

OFFSET

after offset adjustment

TIME

3) MANUAL RESET (OFFSET ADJUSTMENT):

In some application, after adopting-Time proportionating action system may stabilize at particular

temperature over a period of time which can be different than the set value. This steady state

(Error) offset can be eliminated by setting the value of this parameter equal and opposite to the

existing offset. (As shown in Fig.3.4)

NC : Normally Close terminal of 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

ABBREVIATION :

Innovative Instruments

Google Play

206, New Sonal Link Service Industrial Premises Co-op Society Ltd,

Building No.2, Link Road, Malad (W), Mumbai - 400064.

Tel: 022-66939916/17/18;

E-mail :

Website :

sales@innovativeinstruments.co.in

www.innovativeinstruments.co.in

Mfgd by: Innovative Instruments & Controls LLP

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

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