i therm AI-5982 Digital Temperature Controller Instruction Manual

i therm AI-5982 Digital Temperature Controller

Product Specifications

1. Display Type:
   • Dual 4-Digit 7 segment LED
   • 4-Digit Bright White (PV)
   • 4-Digit Luminous Green (SV)
2. Input Sensor Range:
   • OP1: Main Control Output
   • OP2: Alarm Status
   • SOAK: Soak Timer
   • TC: J,K,R,S & RTD: Pt-100 (Refer below table for ranges)
3. Relay Output:
   • Contact Type: N/O, CM, N/C
   • Contact Rating: 5A @ 250VAC or 30 VDC
   • Life Expectancy: > 500,000 operations
   • Isolation: Inherent
4. SSR Drive Output:
   • Drive Capacity: 12V @ 30mA
   • Isolation: Non-Isolated
5. Function:
   • Output 1: Main Control output
   • Output 2: Programmable (Auxiliary control, Alarm, Soak timer)
   • Control Action: ON-OFF/T.P (user selectable)
   • Control Mode: Heat/Cool (user selectable)
   • Compliance: —-
6. Environmental:
   • Operating Range: —-
   • Storage Humidity: —-
7. Power Supply:
   • Supply Voltage: 90~270VAC, 50/60Hz
   • Consumption: 4W Maximum
8. Physical:
   • Housing: ABS Plastic
   • Model No.: AI-5982
   • Weight: 240gms.

Product Using Instructions

Safety Instructions

This controller is meant for temperature control applications.It is important to read the manual prior to installing or commissioning of the controller. All safety-related instructions appearing in this manual must be followed to ensure the safety of the operating personnel as well as the instrument.

General Instructions

• 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 to personnel injury.
• The controller is generally part of a control panel, and in such a case, the terminals should not remain accessible to the user after installation.

Mechanical Instructions

• The controller in its installed state must not come in close proximity 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 and should not be obstructed in the panel.

Electrical Instructions

• The controller must be wired as per the wiring diagram and it must comply with local electrical regulation.
• Care must be taken not to connect AC supplies to low voltage sensor input.
• A circuit breaker or mains switch with a fuse (275V/1A) must be installed between the power supply and supply terminals to protect the controller from any possible damage due to high voltage surges of extended duration.
• A circuit breaker and appropriate fuses must be used for electrical safety.

SPECIFICATIONS

1. DISPLAY TYPE: Dual 4- Digit 7 segment LED
   • 4 Digit Bright White (PV)
   • 4 Digit Luminous Green (SV)
     Model no.| AI-5982
     ---|---
     Display height (PV)| 0.56”
     Display height (SV)| 0.56”
   • STATUS LED’S
   • OP1: Main Control Output
   • OP2: Alarm Status
   • SOAK: Soak Timer
2. INPUT
   • Sensor: TC:J,K,R,S & RTD: Pt-100
   • Range: Refer below table
     Sensor Type| Range| Resolution| Accuracy
     ---|---|---|---
     Fe-k(J) T/C| 0 ~ 760 o C| 1 o C| ± 1 o C
     Cr-AL(K) T/C| -99 ~ 1300 o C| 1 o C
     (R) T/C| 0 ~ 1700 o C| 1 o C
     (S) T/C| 0 ~ 1700 o C| 1 o C
     Pt-100(RTD)| -100 ~ 450 o C| 1 o C
     Pt-100(RTD 0.1)| -99.9 ~ 450.0 o C| 0.1 o C| ± 0.3 o C
   • 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 up to 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
   3. Soak timer
   • Control Action: ON-OFF/T.P (user selectable)
   • Control Mode: Heat/Cool (user selectable)
   • 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

• 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 proximity 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.

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

INSTALLATION

MECHANICAL INSTALLATION

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

OVER ALL DIMENSIONS & PANEL CUT OUT (IN MM)

MODEL:  AI – 5982

TABLE: 1

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.

ELECTRICAL INSTALLATION

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

FRONT PANEL LAYOUT

FRONT PANEL LAYOUT DESCRIPTION

1

| OP1 LED| Glows when OP1 is ON & flashes when delay time (dly1) is in operation(if selected mode is ON-OFF)
OP2 LED| Glows when OP2 is ON & flashes when alarm condition persists even after acknowledged. or delay time (dly2) is in operation(if selected mode is ON-OFF).
SOAK LED| Glows when Soak mode is selected & flashes when Soak timer is in operation.
2| UPPER DISPLAY| It will display (1) Measured value of selected input or Error massages in run mode.

(2) Parameters Value in program mode.

3| LOWER DISPLAY| It will display (1) SP (Main set point) / SP2 (Auxiliary/Alarm) set value / Set Soak time value/ balance or elapsed soak time in run mode. (2) Parameter code in program mode.
4| SET KEY| (1) For SP programming. (2) To access Control mode. (3) To access Configuration mode along with UP key. (4) To scroll the parameter & to store its value.
5| SHIFT KEY| (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.

6| UP KEY| (1) To increase/alter parameter value in program mode. (2) To Enter in configuration mode (with SET key) . (3) To acknowledge Alarm. (4) To Reset the SOAK timer
7| DOWN KEY| (1) To decrease / alter parameter value in program mode. (2) To start Soak timer.

PROGRAMMING

USER LIST: To access User list press SET key once.

PARA METER| LOWER DISPLAY| UPPER DISPLAY| RANGE| DESCRIPTION| DEFAULT
---|---|---|---|---|---
CONTROL SET POINT| | | ****

LSPL~HSPL

| User can change SP1 value using UP/DOWN keys. Holding the key will change the value at a faster rate. Press SET key to store the desired value & move on to the next parameter.| ****

0°C

SET POINT 2| | **| LSPL~HSPL**| This parameter is prompted only, if output 2 is configured as

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

(2)  Either deviation auxiliary control or as a deviation alarm mode.

(3) As a band alarm (For all above SP2 has to be enable)

| ****

0°C

SOAK TIME| | | 0 min. to 999 min.| This parameter is prompted only, if output 2 is configured for soak timer application.| ****

1 min.

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

CONFIGURATION LIST

1. To enter in this mode, Press and hold SET & UP key simultaneously 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.

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

TABLE 4: Below listed parameters will appear only, if OUTPUT 2 is selected as ALARM mode. 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 the set point. 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. (As shown in Fig : 3.3)

MANUAL RESET (OFFSET ADJUSTMENT)

In some applications, 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 this value, equal and opposite to the existing offset. (As shown in Fig : 3.4)

ABBREVIATION

• C.A.: Control Action
• CJC: Cold Junction Compensation
• CM: Common terminal of relay
• EMI: Electro Magnetic Interference
• LWC: Lead Wire (Length) Compensation
• NC: Normally Close terminal of relay
• NO: Normally Open terminal of relay
• OP1: Output 1
• OP2: Output 2
• PV: Process Value (Actual temperature)
• SP: Set Point Value (Set temp.)
• SSR: Solid State Relay
• T.P.: Time Proportional
• T/C: Thermocouple

Contact

• Mfd by: Innovative Instruments & Controls LLP
• 338, 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: sales@itherm.co.in
• Website: www.itherm.co.in

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Documents / Resources

| i therm AI-5982 Digital Temperature Controller [pdf] Instruction Manual
AI-5982 Digital Temperature Controller, AI-5982, Digital Temperature Controller, Temperature Controller, Controller
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