itherm AI-5742 Digital Temperature Controller User Manual

: June 13, 2024
: Itherm

itherm AI-5742 Digital Temperature Controller

Product Information

The Digital Temperature Controller is available in three models:
AI-5442 (48 x 48), AI-5742 (72 x 72), and AI-5942 (96 x 96). It features a 4-digit 7 segment LED display with a bright white color. The controller supports various sensor inputs including thermocouples (J, K, R, S), RTD (Pt-100), and has a sampling time of 125 msec. It has relay outputs with N/O, CM, and N/C contact types, with a contact rating of 5A @ 250VAC or 30 VDC. The controller also has an SSR drive output with a drive capacity of 12V @ 30mA. It operates on a supply voltage of 90~270VAC, 50/60Hz and consumes a maximum of 4W. The housing is made of ABS plastic.

Product Usage Instructions

Read the safety instructions in the manual before installing or commissioning the controller.
Ensure correct configuration of the controller for intended operation.
Install the controller in a control panel, ensuring that the terminals are not accessible to the user after installation.
Wire the controller according to the wiring diagram and comply with local electrical regulations.
Do not connect AC supplies to low voltage sensor inputs.
Use a circuit breaker or mains switch with a fuse (275V/1A) for protection.
Switch off the power before making/removing any connection or removing the controller from its enclosure to prevent the risk of electrical shock.

Mechanical Installation

Follow the steps below for mechanical installation:

Prepare the cut-out with the proper dimensions as shown in the figure.
Remove the clamp from the controller.
Push the controller through the panel cut-out.
Secure the controller in its place by tightening the side clamp.
Note: Refer to Table 1 for the overall dimensions and panel cut-out dimensions of each model.

SPECIFICATIONS

DISPLAY TYPE
4- Digit 7 segment LED (Bright White)
STATUS LED’S
- OP1 : Main Control Output
- OP2
- Alarm Status
- Auxiliary control output
INPUT
- Sensor Input : TC:J,K,R,S & RTD: Pt-100
- Range : Refer below table
  Sensor Type| Range| Resolution| Accuracy
  ---|---|---|---
  Fe-k(J) T/C| 0 ~ 760oC| 1 oC| } ± 1 oC
  Cr-AL(K) T/C| -99 ~ 1300oC| 1 oC
  (R) T/C| 0 ~ 1700oC| 1 oC
  (S) T/C| 0 ~ 1700oC| 1 oC
  Pt-100(RTD)| -100 ~ 450oC| 1 oC
  Pt-100(RTD 0.1)| -99.9 ~ 450.0oC| 0.1 oC| ± 0.3 oC
- 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.
RELAY OUTPUT
- Contact type : N/O, CM, N/C
- Contact Rating : 5A @ 250VAC or 30 VDC
- Life expectancy : > 5,00,000 operations
- Isolation : Inherent
SSR DRIVE OUTPUT
- Drive Capacity : 12V @ 30mA.
- Isolation : Non-Isolated.
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 : —-
ENVIRONMENTAL
- Operating Range : 0 ~50°C, 5~90% Rh
- Storage Humidity : 95% Rh (Non-condensing)
POWER SUPPLY
- Supply Voltage : 90~270VAC, 50/60Hz.
- Consumption : 4W Maximum.
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

The controller must be configured correctly for intended operation. Incorrect configuration could result in damage to the equipment or the process under control or it may lead personnel injury.
The controller is generally part of control panel and in such a case the terminals should not remain accessible to the user after installation.

MECHANICAL

The 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.
The Controller in its installed state should not be exposed to carbon dust, salt air, direct sunlight or radiant heat.
Ambient temperature and relative humidity surrounding the controller must not exceed the maximum specified limit for proper operation of the controller.
The controller in its installed state must be protected against excessive electrostatic or electromagnetic interferences. Ventilation holes provided on the chassis of the instrument are meant for thermal dissipation hence should not be obstructed in the panel.

ELECTRICAL

The controller must be wired as per wiring diagram & it must comply with local electrical regulation.
Care must be taken not to connect AC supplies to low voltage sensor input.
Circuit breaker or mains s/w with fuse (275V/1A) must be installed between power supply and supply terminals to protect the controller from any possible damage due to high voltage surges of extended duration.
Circuit breaker and appropriate fuses must be used for driving high voltage loads to protect the controller from any possible damage due to short circuit on loads.
To minimize pickup of electrical noise, the wiring for low voltage DC and sensor input must be routed away from high current power cables. Where it is impractical to do this, use shielded ground at both ends.
The controller should not be wired to a 3-Phase supply with unearthed star connection. Under fault condition such supply could rise above 264 VAC which will damage the controller.
The Electrical noise generated by switching inductive loads might create momentary Fluctuation in display, alarm latch up, data loss or permanent damage to the instrument.
To reduce this use snubber circuit across the load. It is essential to install a over Temp. Protection device to avoid any failure of heating system. Apart from spoiling the product, this could damage the process being controlled.

MECHANICAL INSTALLATION

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

OVER ALL DIMENSIONS & PANEL CUT OUT (IN MM)

itherm-AI-5742-Digital-Temperature-Controller-FIG-2

Dim Model	A	B	C	D	E	F	G	H
AI-5442	48	48	8	75	43	44	44	9
AI-5742	72	72	10	65	66	68	68	9
AI-5942	96	96	10	45	89	92	92	9

INSTALLATION GUIDELINES

Prepare the cut-out with proper dimension as shown in figure.
Remove clamp from controller.
Push the controller through panel cut-out and secure the controller in its place by tightening the side clamp.

ELECTRICAL INSTALLATION

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

itherm-AI-5742-Digital-Temperature-Controller-FIG-3

FRONT PANEL LAYOUT

itherm-AI-5742-Digital-Temperature-Controller-FIG-4

FRONT PANEL LAYOUT DESCRIPTION

itherm-AI-5742-Digital-Temperature-Controller-FIG-5

POWER UP

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

itherm-AI-5742-Digital-Temperature-Controller-FIG-6

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

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)

itherm-AI-5742-Digital-Temperature-Controller-FIG-7

CONTROL LIST
To enter in this mode press SET & DOWN key simultaneously for 3 sec. User can then set the control parameters. (All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)

itherm-AI-5742-Digital-Temperature-Controller-FIG-8

CONFIGURATION LIST

To Enter in this mode, Press and hold SET & UP key simultaneously for 3 sec.
Press UP or DOWN key to scroll between parameter options.
Press SET key to store the current parameter & move on to the next parameter.
(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)

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)

itherm-AI-5742-Digital-Temperature-Controller-FIG-13

TABLE 4 :

Below listed parameters will appear only if OUTPUT 2 is selected as ALARM. In ALARM mode, Controller continuously compares PV with either SP (for Deviation or Band alarm) or an independent ALARM SP2 (for process high and process low Alarm). Alarm will occur when PV falls outside the set Alarm limits.
Also, OP2 will energize or de-energize under Alarm condition as per the Alarm logic(AL.LG) selected. HYS2 in Control list decides when to switch OFF the Alarm. Instrument supports four types of Alarm as described below :

USER GUIDE

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).
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)
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)