Chromalox 3101 User manual

3101 3101
High/Low Limit Controller High/Low Limit Controller
Operator’s Manual
0037-75253
Operator’s Manual
0037-75253
Issue Date
November 2007
Issue Date
November 2007

Chromalox 3101 Operator's Manual i
1 Getting Started................................................................. 1
2 Installation ........................................................................ 3
3 Operation ......................................................................... 1
4 Controller Setup PAGEs ................................................. 23
5 Limit Control Operation.................................................. 29
6 Alarms ............................................................................ 35
7 Digital Event Input .......................................................... 41
8 Analog Output Option .................................................... 43
9 Digital Communications ................................................. 45
10 Calibration ...................................................................... 51
11 Specifications................................................................. 57
12 Troubleshooting.............................................................. 61
13 Warranty and Return ...................................................... 63
Appendices
I PAGE/MENU Tables ....................................................... 65
Menu Index
Index ....................................................................................... 73
Table of Contents
Sections
Section Topic Page

ii Chromalox 3101 Operator's Manual
Illustrations
Fig. Topic Page
1.1 Model Identification................................................................ 2
2.1 Sensor Selection Dip Switch Settings ................................... 3
2.2 Mounting Dimensions ............................................................ 5
2.3 Mounting Diagram.................................................................. 5
2.4 Wiring Terminal Identification ................................................. 7
2.5 Thermocouple Connections................................................... 8
2.6 3-Wire RTD Connections ....................................................... 9
2.7 2-Wire Connections ............................................................... 9
2.8 Current Input Wiring (Self-powered) ...................................... 9
2.9 Voltage Input Wiring (Self-powered) .................................... 10
2.10 Current Input Wiring (Loop-powered by controller) ............. 10
2.11 Momentary Contact Pushbutton.......................................... 10
2.12 Relay Output Connections................................................... 11
2.13 Alarm #1 Relay Output......................................................... 12
2.14 Alarm #2 Output................................................................... 12
2.15 100-240 Vac Instrument Power Conn. (3101-11**0) ............ 13
3.1 Front Panel Identification ..................................................... 16
3.2 PAGE/MENU Setup Structure.............................................. 17
3.3 Sample of PAGE/MENU Table ............................................. 19
3.4 Security Levels and PAGE/MENU Contents ........................ 20
3.5 Security Codes and View/Adjust Levels .............................. 21

Chromalox 3101 Operator's Manual iii
Illustrations
Figure Topic Page
5.1 Process Variable Profile—High Limit Control....................... 31
6.1 Low Alarm Inhibit ................................................................. 36
8.1 Analog Output Signal ........................................................... 43
8.2 Process Output Wiring......................................................... 44
9.1 RS422/RS485 Communications Switches........................... 46
9.2 RS232 Wiring Connections.................................................. 46
9.3 RS232 Connector Pin Designations..................................... 47
9.4 RS485 Wiring Connections (4-wire) ..................................... 47
9.5 RS422 Connector Pin Designations..................................... 48
9.6 RS485 Wiring Connections (2-wire) ..................................... 48
9.7 RS485 Connector Pin Designations..................................... 48

iv Chromalox 3101 Operator's Manual

Section 1
Getting Started
The Chromalox 3101 is a compact 1/4 DIN program-
mable high/low limit controller with two independent
alarms. While designed to be low-cost, the 3101 has
many features of high-end limit controllers:
• Universal Sensor Input
• Switching Power Supply allows universal AC
voltage input (100 to 230 Vac)
• U. L. and U. L. (Canadian) Listed
as an Overtemperature Controller
• FM High/Low Limit Controller
• High Impact Plastic Bezel and Housing
• One high/low limit output and two independent
alarm outputs
• Time over/under setpoint display
• Max/Min process variable display
• One programmable Digital Input
• Isolated Serial Communications (optional)
• Analog Process Output (optional)
• Security protection
• 32°F to 149°F Operating Temperature
• ±0.2% Accuracy Specification
• VIEW DATA key on front panel for a quick ac-
cess to Display Page
• Power Down Recovery feature retains limit and
alarm status when power is restored

Model Temperature Controller
3101 Microprocessor-based 1/4 DIN Programmable High/Low Limit Controller.
Universal Sensor Input accepts Thermocouple, RTD, Current or Voltage Inputs.
One Digital Input and One Alarm Output.
Figure 1.1 Model Identification
Model Identification
Before installation, please identify your controller model number. The
model number is written on the tag on the side of the housing.
Code Limit Output #1
1Relay—Form C Contact, 5A @ 120 or 230 Vac
1Relay—Form C Contact, 5A @ 120 or 230 Vac
Code Alarm #1 Output
Code Analog Process Output Option
0None
1Field selectable 4-20mA or 1-5 Vdc
Code Digital Comm. and Alarm #2 Options
0None
1RS422/485 Digital Communications and
Alarm #2 Relay—Form C contact, 5A @
120 or 230 Vac
2RS232 Digital Communications and
Alarm #2 Relay—Form C Contact, 5A @
120 or 230 Vac
Code Power Supply
0100 - 230 Vac
3101 - 1 1 1 2 0 Typical Model Number

Chromalox 3101 Operator's Manual 3
Section 2
Installation
On receipt of your 3101 controller, immediately
make note of any visible damage to the ship-
ment packaging and record this damage on the
shipping documents. Unpack the controller and
carefully inspect it for obvious damage due to
shipment. If any damage has occurred, YOU must
file a claim with the transporter, as they will not
accept a claim from the shipper.
If the controller will not be immediately installed
and placed into operation, it should be stored in
a cool, dry environment in its original protective
packaging until time for installation and operation.
Temperature extremes and excessive moisture
can damage the instrument.
Inspection
and
Unpacking
Switch
Settings
The 3101 has up to seven (7) hardware switches
located on the bottom of the controller. The
switches are accessible through cutouts in the
controller housing and do not require that you
remove the controller from its housing to access
the switches.
Figure 2.1 identifies the switches. Instructions for
switch settings are given in the corresponding
sections of the manual.
Figure 2.1
Sensor Selection
Dip Switch
Settings
Controller Bot-
tom Surface
Switches #1 and #2
Digital Communications
RS422/RS485
Switches #1, #2 and #3
Sensor Input
Switch #4
(not used)
Switch #5
Analog Output
Signal

4 Chromalox 3101 Operator's Manual
Sensor
Selection
Switches
Sensor selection requires that you:
1. Set the sensor switches for the correct sen-
sor type.
2. Program the input sensor type in sensor
selection setup on the INPT Page (see page
36).
It is much easier to set the sensor input switch-
es before you mount and wire the controller.
To set the sensor switches:
1. Locate the sensor switches — #1, #2 and
#3 — on the bottom of the controller, as
shown in Figure 2.1 on the previous page.
2. Place the switches in the appropriate Up or
Down position for your input type:
Switch #
Input Type 1 2 3
T/C Up Up Up
RTD Down Up Up
4-20mA Up Down Down
1-5 Vdc Up Up Down
Figure 2.2, on the following page, shows the
mounting dimensions for the controller:
1. Cut out the square “panel cutout” mounting
hole and install the unit as shown in Figure
2.3.
2. Place the controller through the square
panel cutout and replace the mounting clip.
3. Tighten the mounting clip screw (do not
overtighten) to secure the controller firmly
against the mounting surface.
Mounting

Chromalox 3101 Operator's Manual 5
4.0
(102)
3.5
(90)
3.6
(92)
3.6
(92)
3.8
(96)
3.8
(96)
Figure 2.2 Mounting Dimensions
0.8
(19)
Panel Cutout
Mounting Hole
Figure 2.3 Mounting Diagram
Mounting Tab
Mounting Clip
Panel Cutout
Measurements are shown in inches. Millimeters are shown in parentheses.

6 Chromalox 3101 Operator's Manual
Good Wiring Practices
1. When planning the system wiring, separate
wiring into functionally similar bundles - i.e. power
leads, sensor leads, output signal lines, etc. If the
power leads and sensor leads must cross, they
should cross at a 90° angle to each other (perpen-
dicular).
2. Locate all sources of electrical noise in your
system, and separate these sources from the
control systems—motors, contacts, solenoids,
etc. Electrical noise can affect the function of any
control system. When driving a contactor coil or
other inductive load, an appropriately rated AC
snubber circuit is recommended (Chromalox Part.
No. 0149-01305), as described on page 11, “Re-
lay Output Wiring.”
3. For sensor wiring practices, see Sensor Wiring
Notes, next page.
4. Additional information on good wiring practices
is available from IEEE, 345 East 47th St., NY, NY
10017. Request IEEE Standard No. 518-1982.
Make all electrical wiring connections to the back
of the controller before power is applied to the
unit.
All wiring must comply with local codes, regula-
tions and ordinances. This instrument is intended
for panel mounting and the terminals must be
enclosed within a panel. Use National Electric
Code (NEC) Class 1 wiring for all terminals except
the sensor terminals.
Check the wiring decal on the side of the unit to
verify the model number. The wiring decal shows
the wiring terminations. All wires will be connect-
ed to the terminals on the back of the instrument
case. Specific wiring instructions for different
input and output types are given in this section.
Wiring
Instructions

Chromalox 3101 Operator's Manual 7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Figure 2.4 Wiring Terminal Identification
Sensor Input Wiring
Sensor Input Wiring Notes:
• Sensor leads (thermocouple and RTD) should not be
run together in the same conduit as power wiring.
• Twisted pair, shielded wire is recommended for
sensor connections.
• False process readings can occur if the sensor
wire is exposed to electrical noise.
• Ungrounded thermocouples are recommended.
• If thermocouple extension wire is required, it must
be the same type as the thermocouple (i.e. if a
Type K thermocouple is used, then Type K exten-
sion wire must be used).
• Thermocouple wires should connect directly to
the controller terminals. Do not use copper crimp
terminals or solder terminals to make connections.
• If shielded thermocouple wire is used, the shield
must be grounded at one end only, preferably at
the shield ground terminal on the controller, as
shown in Figure 2.5.
• Three wire RTDs are recommended for greatest
accuracy.
• Standard shielded copper wire is recommended
for RTD extensions.
+24 Vdc Output
Analog Output
Not Used
Common
Sensor Input
RTD TC
Common
Digital
Input
4-20mA
Digital
Comm.
Not Used
Alarm #2
Output AC Common
100/240 Vac or
Shield Ground
Instrument
Power
Limit Control Output
Alarm #1 Output

8 Chromalox 3101 Operator's Manual
Thermocouple Inputs
It is important to observe polarity (+, -) when con-
necting thermocouple leadwires. The table below
shows ANSI color coding for the thermocouples
used with this instrument.
Make the thermocouple wiring connections to
terminals as shown in Figure 2.5.
T/C Type Material Polarity (+) Polarity (-)
B Plat, 30% Rhodium/ Gray Red
Plat, 6% Rhodium
J Iron/Constantan White Red
K Chromel/Alumel Yellow Red
E Chromel/Constantan Purple Red
T Copper/Constantan Blue Red
R Plat, 13% Rhodium/Plat Black Red
S Plat, 10% Rhodium/Plat Black Red
Figure 2.5
Thermocouple
Connections
3-Wire RTD Inputs
When making the 3-wire RTD input connection, it
is important to make the resistance of all three ex-
tension leadwires equal by using the same gauge
and same length of wire for optimum leadwire
compensation. Chromalox recommends 3-wire
RTDs for greatest accuracy, and standard shield-
ed copper wire for RTD extensions. Make 3-wire
RTD connections to terminals 7, 8 and 9 as shown
in Figure 2.6 on the following page.
8
9
+
-
Shield Gnd
18
3101

Chromalox 3101 Operator's Manual 9
18
8
9
7
Figure 2.6
3-Wire RTD
Connections
3101
2-Wire RTD Inputs
If using a 2-wire RTD input, use heavier gauge
leadwires to reduce leadwire resistance. Any
leadwire resistance adds directly to sensor
resistance, thus adding error to the process
temperature measurement. It is also necessary
to jumper terminals 8 and 9 on the instrument to
complete a 2-wire hookup.
Figure 2.7
2-Wire
Connections
7
8
9
3101
Current/Voltage Inputs
7
8
9
4-20mA
+
Figure 2.8
Current
Input Wiring
(Self-powered)
3101
Shield Grnd

10 Chromalox 3101 Operator's Manual
7
8
9
Figure 2.9
Voltage
Input Wiring
(Self-powered)
4-20mA
3
7
+24 Vdc
+
The 3101 has a +24 Vdc power supply which can
be used to power a 4-20mA transmitter.
1-5 Vdc
0-5 Vdc
+
Figure 2.10
Current
Input Wiring
(Loop-powered
by controller)
3101
3101
The digital input can be used to reset the latching
alarms—Limit Output, Alarm #1 and Alarm #2.
Setup for the digital input is shown on the Setup
page (SET PAGE). An external, normally open,
momentary contact can be connected to this
input (100 msec., minimum closure). Use isolated
switches only. Do not tie the Digital Input termi-
nals to ground.
Digital Input
Connections
1
2
{
External
Input
+
-
Figure 2.11
Momentary
Contact
Pushbutton
3101

Chromalox 3101 Operator's Manual 11
The 3101 is supplied with:
• 1 Relay Output for Limit Output Control
• 1 Relay Output for Alarm #1
As an option, it may also include:
• 1 Relay Output for Alarm #2
Output
Wiring
3101
Warning
Incorrect output wiring may cause system/pro-
cess damage.
☛
Limit Control Output Wiring
Figure 2.12
Relay Output Connections
Fuse*
MOV
MOV
AC Neutral
120 or 230 Vac
AC Neutral
11
Normally
Closed
Alarm
Indicator
Light
Normally
Open
Load
10
12
Limit
*Fuse should be sized for the current of the Limit Output.
Note: Relay is shown in De-energized (fail safe) state (Power off
or alarm condition). Relay would be energized in normal opera-
tion (Power on and no alarm condition).

12 Chromalox 3101 Operator's Manual
14
Normally
Closed
Load
Fuse*
Normally
Open
Load
13
15
MOV
MOV
AC Neutral
120 or 230 Vac
AC Neutral
Alarm #1
Output
The independent Alarm #1 relay output is con-
nected as shown in Figure 2.13.
Figure 2.13
Alarm #1 Relay Output
* Fuse should be sized for the current Alarm #1 Output.
3101
Fuse*
MOV
MOV
AC Neutral
120 or 230 Vac
AC Neutral
26
Normally
Open
Load
Normally
Closed
Load
25
27
Alarm #2
Alarm #2
Output
The Form C Relay Output is connected as shown
in Figure 2.14.
Figure 2.14
Alarm #2
Output
* Fuse should be sized for the current of Alarm #2 Output.
3101

Chromalox 3101 Operator's Manual 13
Make 120/230 Vac instrument power connections
to terminals 16-18 as shown in Figure 2.15.
Instrument Power Wiring
Figure 2.15
100-240 Vac
Instrument Power
Connections
(3101-11**0)
100 - 240 Vac
Neutral
Chassis Ground
16
17
18
3101

14 Chromalox 3101 Operator's Manual

Chromalox 3101 Operator's Manual 15
Section 3
Operation
Pushbuttons
and
Indications
Control programming is easily accomplished with
the front panel pushbuttons. The displays provide
a constant overview of the process. Figure 3.1, on
the next page, summarizes the functions of the
pushbuttons and displays.
Normal Display Mode
At powerup, and when the controller is not being
programmed, the upper display shows the Pro-
cess Value and the lower display shows the limit
setpoint.
The setpoint can be changed in the Normal Dis-
play Mode using the and pushbuttons,
if the Security Level allows setpoint changes (see
page 20 for Security Levels).
Section
Contents
Pushbuttons and Indications
Security Codes and Levels
Controller Operation
150
150
▲▼
RESET
150
200
▲▼
RESET
➮
Use ▲and ▼to
change setpoint in
Normal Display Mode.
VIEW
DATA
VIEW
DATA
Disable Lower Display
The lower display may be disabled for applica-
tions where it is desirable to have only the Pro-
cess Variable displayed in the upper display. See
SET PAGE, menu LDSP, page 24.
☛
☛