Chromalox 6040 User manual

1
Installation & Operation Manual
6040, 8040, 4040 Temperature & Process Controllers
6040, 8040 & 4040 Valve Motor Drive Controllers
6040 Heater Break Alarm Controller
PK508-2
0037-75514
March 2017
6050, 4050 Limit Controllers

ii
This manual supplements the Quick Start Product
manual supplied with each instrument at the time of
shipment. Information in this installation, wiring and
operation manual is subject to change without notice.
Copyright © December 2012, Chromalox Corporation,
all rights reserved. No part of this publication may be
reproduced, transmitted, transcribed or stored in a re-
trieval system, or translated into any language in any
form by any means without the written permission of
Chromalox.
Copies of this manual are available in electronic for-
mat on the Chromalox web site (www.chromalox.com)
Printed versions are available from Chromalox or its
agents at the price published on the front cover.
Note: It is strongly recommended that applications in-
corporate a high or low limit protective device, which
will shut down the equipment at a preset process con-
dition in order to prevent possible damage to property
or products.
THE INTERNATIONAL HAZARD SYMBOL IS IN-
SCRIBED ADJACENT TO THE REAR CONNEC-
TION TERMINALS. IT IS IMPORTANT TO READ
THIS MANUAL BEFORE INSTALLING OR COM-
MISSIONING THE UNIT.
Products covered by this manual are suitable for In-
door use, Installation Category II, Pollution category 2
environments.
Products covered in this issue of the manual:
6040, 8040 & 4040 Temperature & Process Controllers,
6040, 8040 & 4040 Optional Valve Motor Drive (VMD)
Controllers, 6040 Optional Heater Break Alarm (HBA)
Controllers, 6050 & 4050 Over Temperature / Limit
Controllers.
Warranty and Returns Statement
These products are sold by Chromalox under the war-
ranties set forth in the following paragraphs. Such war-
ranties are extended only with respect to a purchase
of these products, as new merchandise, directly from
Chromalox or from a Chromalox distributor, repre-
sentative or reseller and are extended only to the first
buyer thereof who purchases them other than for the
purpose of resale.
Warranty
These products are warranted to be free from function-
al defects in material and workmanship at the time the
products leave Chromalox factory and to conform at
that time to the specifications set forth in the relevant C
instruction manuals sheet or sheets, for such products
for a period of three years.
THERE ARE NO EXPRESSED OR IMPLIED WAR-
RANTIES, WHICH EXTEND BEYOND THE WARRAN-
TIES HEREIN AND ABOVE SET FORTH. CHROMAL-
OX MAKES NO WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE WITH
RESPECT TO THE PRODUCTS.
Limitations
Chromalox shall not be liable for any incidental damag-
es, consequential damages, special damages, or any
other damages, costs or expenses excepting only the
cost or expense of repair or replacement as described
above. Products must be installed and maintained in
accordance with Chromalox instructions. There is no
warranty against damage to the product resulting from
corrosion. Users are responsible for the suitability of
the products to their application.
For a valid warranty claim, the product must be re-
turned carriage paid to the supplier within the war-
ranty period. The product must be properly packaged
to avoid damage from Electrostatic Discharge or other
forms of harm during transit.

iii
Table of Contents
Contents Page Number
Warranty and Returns Statement .........................................................................................................................ii
1 Introduction ..................................................................................................................................................... 1
2 Installation ....................................................................................................................................................... 1
Unpacking......................................................................................................................................................... 1
Installation......................................................................................................................................................... 1
Panel Cut-outs.................................................................................................................................................. 2
Panel-Mounting ................................................................................................................................................ 2
3Plug-in Options ................................................................................................................................................. 3
Options Modules and Functions....................................................................................................................... 3
Auto Detection of Option Modules ................................................................................................................... 3
Preparing to Install or Remove Options Modules ............................................................................................ 4
Removing/Replacing Option Modules (“Output” & “Option” are interchangeable terms)................................ 4
Replacing the Instrument in its Housing .......................................................................................................... 5
4 Wiring Instructions.......................................................................................................................................... 5
Installation Considerations ............................................................................................................................... 5
AC Power Wiring - Neutral (for 100 to 240V AC versions)................................................................................ 5
Wire Isolation .................................................................................................................................................... 5
Use of Shielded Cable ..................................................................................................................................... 6
Noise Suppression at Source .......................................................................................................................... 6
Sensor Placement (Thermocouple or RTD) ...................................................................................................... 6
Thermocouple Wire Identification Chart ........................................................................................................... 7
Connections and Wiring ................................................................................................................................... 8
Power Connections - Mains Powered Instruments .................................................................................... 9
Power Connections - 24/48V AC/DC Powered Instruments ................................................................... 10
Universal Input Connections - Thermocouple (T/C) ................................................................................. 10
Universal Input Connections – PT100 (RTD) input ................................................................................... 10
Universal Input Connections - Linear Volt, mV or mA input ..................................................................... 10
Option Slot 1 – Relay Output Module....................................................................................................... 11
Option Slot 1 - SSR Driver Output Module............................................................................................... 11
Option Slot 1 - Triac Output Module......................................................................................................... 11
Option Slot 1 - Linear Voltage or mADC Output module.......................................................................... 11
Option Slot 2 - Relay Output Module ....................................................................................................... 11
Option Slot 2 - SSR Driver Output Module............................................................................................... 11
Option Slot 2 - Triac Output Module......................................................................................................... 12
Option Slot 2 - Dual Relay Output Module............................................................................................... 12
Option Slot 2 - Linear Voltage or mADC Output module.......................................................................... 12
Option Slot 3 - Relay Output Module ....................................................................................................... 12
Option Slot 3 - SSR Driver Output Module............................................................................................... 12
Option Slot 3 - Linear Voltage or mADC Output module.......................................................................... 12
Option Slot 3 - Dual Relay Output Module............................................................................................... 13
Option Slot 3 - Transmitter Power Supply Module ................................................................................... 13
Option Slot A Connections - RS485 Serial Communications Module...................................................... 13
Option Slot A Connections - Digital Input Module ................................................................................... 13
Option Slot A Connections – Basic Auxiliary Input Module ..................................................................... 13
Option Slot B Connections – Digital Input 2 (Full Auxiliary Module) ........................................................ 14
Option Slot B Connections – 1/4 DIN & 1/8 DIN Full Auxiliary Input Module........................................... 14
5 Powering Up.................................................................................................................................................. 14
Powering Up Procedure.................................................................................................................................. 14
Overview of Front Panel.................................................................................................................................. 14
Displays .......................................................................................................................................................... 14
Keypad............................................................................................................................................................ 15
LED Functions................................................................................................................................................. 15

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6 Messages and Error Indications.................................................................................................................. 16
7 Instrument Operation Modes....................................................................................................................... 17
Select Mode.................................................................................................................................................... 17
Entry into the Select Mode....................................................................................................................... 17
Navigating in Select Mode ...................................................................................................................... 17
Unlock Codes ................................................................................................................................................. 17
Automatic Tune Mode..................................................................................................................................... 17
Navigating in Automatic Tune Mode ........................................................................................................ 17
Product Information Mode.............................................................................................................................. 18
Navigating in the Product Information Mode ........................................................................................... 18
Lock Code View.............................................................................................................................................. 19
Entry and Navigating in Lock Code View Mode....................................................................................... 19
8 6040, 8040 & 4040 Controller – Model Group ............................................................................................. 19
6040, 8040 & 4040 Controllers - Configuration Mode.................................................................................... 19
Entry into the Configuration Mode ........................................................................................................... 19
Scrolling through Parameters and Values ................................................................................................ 19
Changing Parameter Values ..................................................................................................................... 19
6040, 8040 & 4040 – Setup Mode .................................................................................................................. 24
Entry into the Setup Mode ....................................................................................................................... 24
Scrolling through Parameters & Values .................................................................................................... 24
Changing Parameter Values ..................................................................................................................... 24
6040, 8040 & 4040 Controllers - Operator Mode ........................................................................................... 27
6040, 8040 & 4040 Controllers – Extended Operator Mode .................................................................... 27
Navigating in Operator Mode ................................................................................................................... 27
Adjusting the Local Setpoint(s) ....................................................................................................................... 28
Adjusting the Setpoint Ramp Rate ................................................................................................................. 28
Manual Control Mode ..................................................................................................................................... 28
Selecting/deselecting Manual Control Mode ........................................................................................... 28
6040, 8040 & 4040 Controllers – Communications Parameters..................................................................... 29
Bit Parameters.......................................................................................................................................... 29
Word Parameters...................................................................................................................................... 29
9 6040, 8040 & 4040 VMD Controller – Model Group .................................................................................... 33
Special Wiring Considerations for Valve Motor Control.................................................................................. 33
6040, 8040 & 4040 VMD Controllers - Configuration Mode........................................................................... 34
Entry into the Configuration Mode ........................................................................................................... 34
Scrolling through Parameters and Values ................................................................................................ 34
Changing Parameter Values ..................................................................................................................... 34
6040, 8040 & 4040 Valve Motor Drive – Setup Mode..................................................................................... 40
Entry into the Setup Mode ....................................................................................................................... 40
Scrolling through Parameters & Values .................................................................................................... 40
Changing Parameter Values ..................................................................................................................... 40
Adjusting the Valve Parameters ...................................................................................................................... 40
Set Valve Opened Position & Set Valve Closed Position ......................................................................... 40
Valve Position Clamping........................................................................................................................... 40
6040, 8040 & 4040 Valve Motor Drive - Operator Mode ................................................................................ 42
6040, 8040 & 4040 Valve Motor Drive – Extended Operator Mode ......................................................... 42
Navigating in Operator Mode ................................................................................................................... 42
Adjusting the Local Setpoint(s) ....................................................................................................................... 44
Adjusting the Setpoint Ramp Rate ................................................................................................................. 44
Manual Control Mode ..................................................................................................................................... 44
Selecting/deselecting Manual Control Mode ........................................................................................... 44
6040, 8040 & 4040 VMD Controllers – Serial Communications Parameters.................................................. 44
Bit Parameters......................................................................................................................................... 44
Word Parameters...................................................................................................................................... 45
Contents Page Number

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10 6040 Heater Break Alarm Controller - Model Group.................................................................................. 47
6040 - Configuration Mode............................................................................................................................. 47
Entry into the Configuration Mode ........................................................................................................... 47
Scrolling through Parameters and Values ................................................................................................ 47
Changing Parameter Values ..................................................................................................................... 47
6040 HBA – Setup Mode ................................................................................................................................ 52
Entry into the Setup Mode ....................................................................................................................... 52
Scrolling through Parameters & Values .................................................................................................... 52
Changing Parameter Values ..................................................................................................................... 52
6040 HBA Controllers - Operator Mode ......................................................................................................... 54
6040, 8040 & 4040 Controllers – Extended Operator Mode .................................................................... 54
Navigating in Operator Mode ................................................................................................................... 54
Adjusting the Local Setpoint(s) ....................................................................................................................... 55
Adjusting the Setpoint Ramp Rate ................................................................................................................. 55
Manual Control Mode ..................................................................................................................................... 56
Selecting/deselecting Manual Control Mode ........................................................................................... 56
6040 HBA Controller –Communications Parameters ..................................................................................... 56
Bit Parameters.......................................................................................................................................... 56
Word Parameters...................................................................................................................................... 56
11 6050 & 4050 Limit Controller – Model Group.............................................................................................. 60
6050 & 4050 Limit Controllers - Configuration Mode ..................................................................................... 60
Entry into the Configuration Mode ........................................................................................................... 60
Scrolling through Parameters and Values ................................................................................................ 60
Changing Parameter Values ..................................................................................................................... 60
6050 & 4050 Limit Controllers – Setup Mode................................................................................................. 64
Entry into the Setup Mode ....................................................................................................................... 64
Scrolling through Parameters & Values .................................................................................................... 64
Changing Parameter Values ..................................................................................................................... 64
6050 & 4050 Limit Controllers - Operator Mode ............................................................................................ 66
Navigating in Operator Mode ................................................................................................................... 66
Limit Setpoint Adjustment .............................................................................................................................. 67
Exceed Condition ........................................................................................................................................... 67
Limit Output Function ..................................................................................................................................... 67
Limit Annunciator Outputs.............................................................................................................................. 67
Resetting Limit Outputs & Annunciators......................................................................................................... 67
Using The Reset Key To Reset Limit Outputs & Annunciators................................................................. 67
Resetting Limit Hold and Exceed Time .......................................................................................................... 67
To reset the stored Limit Hold and Exceed Time values .......................................................................... 67
6050 & 4050 Controllers – Serial Communications Parameters..................................................................... 68
Bit Parameters.......................................................................................................................................... 68
Word Parameters...................................................................................................................................... 68
12 Manually Tuning Controllers ....................................................................................................................... 71
Single Control Tuning (PID with Primary Output only) .................................................................................... 71
Dual Control Tuning (PID with Primary and Secondary Outputs) ................................................................... 72
Valve Control Tuning (PI with VMD or Linear Outputs).................................................................................... 72
Manually Fine Tuning ...................................................................................................................................... 74
13 Modbus Serial Communications ................................................................................................................. 74
Physical Layer................................................................................................................................................. 74
Link Layer........................................................................................................................................................ 74
Device Addressing .......................................................................................................................................... 75
Supported Modbus Functions........................................................................................................................ 75
Contents Page Number

vi
Function Descriptions..................................................................................................................................... 75
Read Coil/Input Status (Function 01 / 02) ................................................................................................ 75
Read Holding/Input Registers (Function 03 / 04) ..................................................................................... 76
Force Single Coil (Function 05) ................................................................................................................ 76
Pre-Set Single Register (Function 06) ...................................................................................................... 76
Loopback Diagnostic Test (Function 08) .................................................................................................. 76
Pre-Set Multiple Registers (Function 10 Hex) .......................................................................................... 76
Exception Responses............................................................................................................................... 76
14 ASCII Communications ................................................................................................................................ 77
Physical Layer................................................................................................................................................. 77
Device Addressing .......................................................................................................................................... 77
Session Layer ................................................................................................................................................. 77
Type 1 Message ....................................................................................................................................... 77
Type 2 Message ....................................................................................................................................... 78
Type 3 Message ....................................................................................................................................... 78
Type 4 Message ....................................................................................................................................... 78
Error Response ............................................................................................................................................... 78
15 Calibration Mode........................................................................................................................................... 79
Equipment Required For Checking or Calibrating the Universal Input........................................................... 79
Calibration Check ........................................................................................................................................... 79
Recalibration Procedure ................................................................................................................................. 79
16 Appendix 1 – Glossary .................................................................................................................................. 80
Active Setpoint Type: Controller Definition ..................................................................................................... 80
Actual Setpoint Type: Controller Definition..................................................................................................... 80
Alarm Hysteresis Type: General Parameter .................................................................................................... 81
Alarm Operation Type: General Definition....................................................................................................... 82
Alarm Inhibit Type: General Parameter ........................................................................................................... 83
Annunciator Type: Limit Controller Definition.................................................................................................. 83
Automatic Reset (Integral) Type: Controller Tuning Parameter ....................................................................... 83
Auto Pre-Tune Type: Controller Tuning Parameter.......................................................................................... 83
Auxiliary Input Type: General Definition .......................................................................................................... 83
Band Alarm 1 Value Type: General Parameter ............................................................................................... 83
Band Alarm 2 Value Type: General Paramete ................................................................................................. 83
Bias (Manual Reset) Type: Controller Tuning Parameter................................................................................. 83
Bumpless Transfer Type: Controller Definition................................................................................................ 83
Boundless VMD Control Type: VMD Controller Definition .............................................................................. 84
Cascade Control Type: Controller Definition................................................................................................... 84
Communications Write Enable Type: General Definition ................................................................................ 84
Control Type Type: Controller Parameter........................................................................................................ 84
Controller Type: Controller Definition.............................................................................................................. 84
CPU Type: General Definition ......................................................................................................................... 84
Current Proportioning Control Type: Controller Definition .............................................................................. 85
Cycle Time Type: Controller Definition............................................................................................................ 85
Deadband Type: Controller Parameter ........................................................................................................... 85
Derivative Type: Controller Parameter ............................................................................................................ 85
Deviation Alarm 1 Value Type Type: General Parameter................................................................................. 85
Deviation Alarm 2 Value Type: General Parameter ......................................................................................... 85
Differential (On-Off Hysteresis) Type: Controller Parameter............................................................................ 85
Direct/Reverse Action of Control Outputs Type: Controller Definition............................................................ 85
Display Strategy Type: General Parameter ..................................................................................................... 85
Elapsed Time Type: Indicator Definition.......................................................................................................... 85
Exceed Condition Type: Limit Controller Definition ........................................................................................ 85
Exceed Time Type: Limit Controller Definition................................................................................................ 86
Heater Current Monitor................................................................................................................................... 86
Contents Page Number

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Indicator Type: Indicator Definition ................................................................................................................. 86
Input Filter Time Constant Type: General Parameter ..................................................................................... 86
Input Range Type: General Definition ............................................................................................................. 86
Input Span Type: General Definition ............................................................................................................... 86
Integral Type: Controller Tuning Parameter..................................................................................................... 87
Latching Relay Type: General Definition ......................................................................................................... 87
LED Type: General Definition .......................................................................................................................... 87
Limit Controller Type: Limit Controller Definition ............................................................................................ 87
Limit Hysteresis Type: Limit Controller Definition ........................................................................................... 87
Limit Setpoint Type: Limit Controller Definition............................................................................................... 87
Lock Codes Type: General Parameter............................................................................................................ 87
Logical Combination of Alarms Type: General Definition ............................................................................... 87
Loop Alarm Enable Type: Controller Parameter.............................................................................................. 88
Loop Alarm Time Type: Controller Parameter................................................................................................. 88
mADC Type: General Definition ...................................................................................................................... 88
Manual Mode Type: Controller Definition........................................................................................................ 88
Manual Mode Enable Type: Controller Parameter ......................................................................................... 89
Master & Slave Type: Controller Definition...................................................................................................... 89
Minimum Motor On Time Type: VMD Controller Parameter ........................................................................... 89
Modulating Valve Type: VMD Controller Definition ......................................................................................... 89
Motor Travel Time Type: VMD Controller Parameter ...................................................................................... 89
Multi-Point Scaling Enable Type: Indicator Parameter ................................................................................... 89
Multi-Point Scaling Set Up Type: Indicator Parameter ................................................................................... 89
Offset Type: Controller Parameter .................................................................................................................. 90
On-Off Control Type: Controller Definition...................................................................................................... 90
On-Off Differential (Hysteresis) Type: Controller Parameter............................................................................ 90
Open Loop VMD Type: VMD Controller Definition.......................................................................................... 90
Overlap/Deadband Type: Controller Parameter.............................................................................................. 90
PI Control Type: Controller Definition.............................................................................................................. 92
PID Control Type: Controller Definition ........................................................................................................... 92
PLC Type: General Definition.......................................................................................................................... 92
Pre-Tune Type: Controller Definition ............................................................................................................... 92
Primary Output Power Limit Type: Controller Parameter................................................................................ 92
Primary Proportional Band Type: Controller Tuning Parameter ...................................................................... 92
Process High Alarm 1 Value Type: General Parameter................................................................................... 92
Process High Alarm 2 Value Type: General Parameter .................................................................................. 93
Process Low Alarm 1 Value Type: General Parameter.................................................................................... 93
Process Low Alarm 2 Value Type: General Parameter.................................................................................... 93
Process Variable (PV) Type: General Definition............................................................................................... 93
Process Variable Offset Type: General Parameter.......................................................................................... 93
Rate (Derivative) Type: Controller Tuning Parameter ...................................................................................... 93
Remote Setpoint (RSP) Type: Controller Definition......................................................................................... 93
Remote Auxiliary Input Range Type: Controller Parameter ........................................................................... 93
Remote Setpoint Lower Limit Type: Controller Parameter ............................................................................. 93
Remote Setpoint Upper Limit Type: Controller Parameter ............................................................................. 94
Remote Setpoint Offset Type: Controller Parameter ...................................................................................... 94
Retransmit Output Type: General Definition ................................................................................................... 94
Retransmit Output 1 Scale Maximum Type: General Parameter.................................................................... 94
Retransmit Output 1 Scale Minimum Type: General Parameter..................................................................... 94
Retransmit Output 2 Scale Maximum Type: General Parameter.................................................................... 94
Retransmit Output 2 Scale Minimum Type: General Parameter..................................................................... 94
Retransmit Output 3 Scale Maximum Type: General Parameter.................................................................... 95
Retransmit Output 3 Scale Minimum Type: General Parameter..................................................................... 95
Reset Type: Controller Tuning Parameter ....................................................................................................... 95
Reverse Acting Type: Controller Definition ..................................................................................................... 95
Contents Page Number

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Scale Range Upper Limit Type: General Parameter ...................................................................................... 95
Scale Range Lower Limit Type: General Parameter ....................................................................................... 95
Secondary Proportional Band Type: Controller Tuning Parameter ................................................................. 95
Self-Tune Type: Controller Tuning Definition................................................................................................... 95
Serial Communications Option Type: General Definition................................................................................ 96
Set Valve Closed Position Type: VMD Controller Parameter .......................................................................... 96
Set Valve Opened Position Type: VMD Controller Parameter......................................................................... 96
Setpoint Type: Controller Definition ................................................................................................................ 96
Setpoint Upper Limit Type: Controller Parameter........................................................................................... 96
Setpoint Lower Limit Type: Controller Parameter........................................................................................... 96
Setpoint Ramping Enable Type: Controller Parameter ................................................................................... 97
Setpoint Ramp Rate Type: Controller Parameter............................................................................................ 97
Setpoint Select Type: Controller Parameter.................................................................................................... 97
Setpoint Select Enable Type: Controller Parameter ....................................................................................... 97
Soft Start......................................................................................................................................................... 97
Solid State Relay (SSR) Type: General Definition ........................................................................................... 97
Solenoid Valve Type: General Definition ......................................................................................................... 97
Tare Type: Indicator Parameter ....................................................................................................................... 98
Three Point Stepping Control Type: VMD Controller Definition ...................................................................... 98
Time Proportioning Control Type: Controller Definition ................................................................................. 98
Tuning Type: Controller Definition ................................................................................................................... 98
Triac Type: General Definition ......................................................................................................................... 98
Valve Close Limit Type: VMD Controller Parameter....................................................................................... 98
Valve Motor Drive Control Type: VMD Controller Definition............................................................................ 98
Valve Position or Flow Indication Type: VMD Controller Definition................................................................. 98
Valve Open Limit Type: VMD Controller Parameter ....................................................................................... 99
VMD Type: VMD Controller Parameter .......................................................................................................... 99
17 Appendix 2 - Specification............................................................................................................................. 99
Universal Input ................................................................................................................................................ 99
General Input Specifications .................................................................................................................... 99
Thermocouple ........................................................................................................................................ 100
Thermocouple Ranges Available .................................................................................................................. 100
Thermocouple Performance ......................................................................................................................... 100
Resistance Temperature Detector (RTD) ................................................................................................ 100
RTD Ranges Available .................................................................................................................................. 100
RTD Performance ......................................................................................................................................... 101
DC Linear................................................................................................................................................ 101
DC Linear Ranges Available ......................................................................................................................... 101
DC Linear Performance ................................................................................................................................ 101
Auxiliary Inputs ....................................................................................................................................... 102
Digital Inputs .......................................................................................................................................... 102
Output Specifications............................................................................................................................. 102
Output Module Types ......................................................................................................................... 102
Specifications of Output Types .......................................................................................................... 103
Control Specifications................................................................................................................................... 104
Process Alarms............................................................................................................................................. 105
Digital Communications................................................................................................................................ 105
Reference Conditions ................................................................................................................................... 105
Operating Conditions.................................................................................................................................... 105
Standards...................................................................................................................................................... 105
Physical Specifications ................................................................................................................................. 106
18 Appendix 3 - Order Tables.......................................................................................................................... 107
Contents Page Number

ix
How to use this manual
This manual is structured to give easy access to the information required for all aspects of the installation and use
and of the products:
Section 1: ..................... Introduction - A brief description of the product range.
Section 2: ..................... Installation - Unpacking, installing and panel mounting instructions.
Section 3: ..................... Plug-in Options - Installation of the plug-in option modules.
Section 4: ..................... Wiring Guidelines - Guidance on good wiring practice, noise avoidance, wiring dia-
grams and input/output connections.
Section 5: ..................... Powering Up - Powering up procedure and descriptions of displays & switches.
Section 6: ..................... Messages & Error Indications - Display Messages and fault indications.
Section 7: ..................... Operation Modes - Describes operating modes common across the range. These in-
clude Select Mode for gaining access to the Setup and Configuration menus, Automatic
tuning on controllers and the Product information menus.
Section 8: ..................... 6040, 8040 & 4040 Model Group - Describes unique operating features of these pro-
cess controllers. It covers the Configuration, Setup & Operator menus, Communications
parameters, adjusting Setpoint, use of Manual Control and PID auto-tuning.
Section 9: ..................... 6040, 8040 & 4040 Optional VMD Model Group - Describes unique operating features
of these valve motor controllers. It covers the Configuration, Setup & Operator menus,
Communications parameters, adjusting Setpoint, use of Manual Control and PID auto-
tuning.
Section 10: ................... 6040 Optional Heater Break Alarm Model Group - Describes the unique operating
features of these process controllers. It covers the Configuration, Setup & Operator
menus, Communications parameters and adjusting Setpoint
Section 11: ................... 6050 & 4050 Model Group - Describes unique operating features of these limit control-
lers.
It covers the Configuration, Setup & Operator menus, Communications parameters,
adjusting the Limit Setpoint and resetting the Limit Output.
Section 12: ................... Manually Tuning Controllers - Advice on manually adjusting the Process and Valve
Controllers tuning parameters.
Section 13: ................... Modbus Serial Communications - Details the physical layer and message formats
used for the Modbus communications protocol common to all products in the range.
Section 14: ................... ASCII Serial Communications - Details the physical layer and message formats used
for the ASCII serial communications protocol available on some products.
Section 15: ................... Calibration Mode - Step-by-step instructions to calibrate the instrument. This section is
intended for use by suitably qualified personnel.
Appendix 1:.................. Glossary - Explanations of the terms used and product features.
Appendix 2:.................. Specification - Technical specifications for all products in the range.
Appendix 3:.................. Product Coding - Product model/ordering codes.

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1
1 Introduction
2 Installation
These instruments are microprocessor based tempera-
ture, process and valve controllers. They can measure,
display or control process variables such as tempera-
ture, pressure, flow and level from a variety of inputs.
Depemding on the model group, three sizes are avail-
able: 1/16 DIN (48 x 48 mm front). 1/8 DIN (48 x 96mm
front) and 1/4 DIN (96 x 96mm front).
The operating voltage is either 100-240V at 50/60 Hz or
24V-48V AC/DC depending on the model purchased.
EEPROM technology protects against data or configu-
ration loss during power outages.
Inputs are user configurable for connection to thermo-
couple and RTD probes, as well as linear process signal
types such as mVDC, VDC or mADC. Output options
include relays, SSR drivers, triacs or linear mV/voltage
modules. These can be used for process control, valve
control, alarms or retransmission of the process vari-
able or setpoint to external devices such as data re-
corders or PLC’s. A Transmitter Power Supply option
module can provide an unregulated 24V DC (22mA)
auxiliary output voltage for external signal transmitters.
Alarm indication is standard on all instruments. Alarms
may be set as process high or low, deviation (active
above or below controller setpoint), band (active both
above and below setpoint), or control loop types. Mod-
els with a heater current input also have high, low or
short circuit heater break alarms based on control load
current. These alarms can be linked to any suitable
output. Alarm status is indicated by LED’s or the alarm
status screen.
Controllers can be programmed for on-off, time pro-
portioning, or current proportioning control implemen-
tations, depending on the output modules fitted, and
feature manual or automatic tuning of the PID param-
eters. A secondary control output is available when ad-
ditional output modules are fitted. Valve Motor Drive
(Three Point Stepping Control) is possible on some
models. Optional analog controller Remote Setpoint
inputs included in the range. Control functions, alarm
settings and other parameters are easily adjusted from
the front keypad or via PC based configuration soft-
ware.
Limit Controllers shut down a process in order to pre-
vent possible damage to equipment or products. They
have latching relay, which cannot be reset until the pro-
cess is in a safe condition. Limit controllers work inde-
pendently of the normal process controller and have
approvals for safety critical applications.
Unpacking
1. Remove the product from its packing. Retain the
packing for future use, in case it is necessary to
transport the instrument to a different site or to re-
turn it to the supplier for repair/testing.
2. The instrument is supplied with a panel gasket and
push fit fixing strap. A single sheet concise manual
is also supplied in one or more languages. Examine
the delivered items for damage or defects. If any are
found, contact your supplier immediately.
Installation
Installation and configuration should be per-
formed only by personnel who are technically
competent and authorized to do so. Local reg-
ulations regarding electrical installation and
safety must be observed.
Figure 1. Main Dimensions
1/4 - DIN & 1/16 - DIN Instruments
1/8 - DIN Instruments

2
Panel Cut-outs
The mounting panel must be rigid and may be up to
6.0mm (0.25 inches) thick. The cut-outs required for
the instruments are shown below.
Figure 2. Panel cut-out sizes
45mm
+0.5 –0.0
92mm
+0.5 –0.0
92mm
+0.5 –0.0
92mm
+0.5 –0.0
45mm +0.5
–
0.0
45mm
+0.5 –0.0
1/4 DIN 1/8 DIN
1/16 DIN
Panel Mounting
Figure 3. Panel-Mounting the instrument
Hold firmly in
position (apply
pressure to
bezel only)
Mounting Panel
Instrument Housing
Ratchets
Gasket
Slide mounting clamp
over the instrument
housing, towards rear face
of mounting panel, until
the tongues engage in
ratchets and instrument is
clamped in position.
Ensure the inside of the panel is with the instru-
ments operating temperature and that there is
adequate air flow to prevent overheating.
Do not remove the panel gasket, as this may
result in inadequate clamping and sealing of
the instrument to the panel.
Once the instrument is installed in its mounting panel,
it may be subsequently removed from its housing, if
necessary, as described in the Fitting and Removing
Option Modules section.
Instruments may be mounted side-by-side in a multiple
installation, but instrument to panel moisture and dust
sealing will be compromised. The cut-out width (for n
instruments) is shown below.
1/8 - & 1/16 - DIN Instruments:
(48n - 4) mm or (1.89n - 0.16) inches.
1/4 - DIN Instruments:
(96n - 4) mm or (3.78n - 0.16) inches
If panel sealing must be maintained, mount each in-
strument into an individual cut-out with 6mm or more
clearance between the edges of the holes.
Note: The mounting clamp tongues may engage the
ratchets either on the sides or the top/bottom faces of
the Instrument housing. When installing several Instru-
ments side-by-side in one cut-out, use the ratchets on
the top/bottom faces.

3
3 Plug-In Options
Options Modules and Functions
A range of plug-in option modules is available to add
additional input, output and communication functions
to the instruments in the range. These modules can be
either pre-installed at the time of manufacture, or retro-
fitted in the field.
NOTE: Field replacement of plug-in modules is eas-
ily done via this Instruction manual. However, without
having the ability to perform a full factory validation test
after the replacement, the warranty becomes voided.
The heater break function has a dedicated in-
put for a current transformer. This inout is NOT
a plug-in feature or module. Other limitaitons
on plug-in modules, the heater break alarm and
soft start function may apply to this model type.
The modules are installed between the instruments
main circuit boards into the four option slots. These
are designated as Slots 1, 2, 3, A & B. Installation is
detailed below.
Note: Slot 1 modules cannot be fitted into Slot 2 or 3.
Slot 2 & 3 modules cannot be fitted into Slot 1. Some
Slot 2 & 3 modules should only be fitted into one of the
two slots. This is detailed in the - Option Module vs.
Model Matrix below.
PSU
BOARD
CP
U
BO
ARD
Figure 4
Typical rear view (uncased)
& main board positions
Auto Detection of Option Modules
The instrument automatically detects which option
modules have been fitted into each slot.
In Configuration Mode, the menus will change to reflect
the options compatible with the hardware fitted. The
modules fitted can be viewed in the products informa-
tion menu, as detailed in the Product Information Mode
section of this manual.
Table 1. Option Module vs. Model Matrix
Module Part
Number
& Function
6040 8040 4040 6040 with VMD 8040 with VMD 4040 with VMD 6040 HBA 6050 4050
Option Slot 1
0149-50039
Relay
Fitted w/
fixed Limit
Relay
0149-50040
SSR Driver
0149-50042
Triac
0149-50041
Linear mA/V DC
Option Slot 2
0149-50045
Relay
0149-50046
SSR Driver
0149-50048
Triac
0149-50047
Linear mA/V DC
0149-50049
Dual Relay
Option Slot 3
0149-50045
Relay
0149-50046
SSR Driver
0149-50047
Linear mA/V DC
0149-50053
TransmitterPSU
0149-50049
Dual Relay
Option Slot A
0149-50055
RS485 Comms
0149-50056
Digital Input
0149-50057
Basic Aux Input
Option Slot B
0149-50059
Full Aux Input
Software & Accessories
0149-50060
Config Software
Key
Option
Possible
Option Not
Possible

4
Preparing to Install or Remove
Options Modules
Before removing the instrument from its hous-
ing, ensure that all power has been removed
from the rear terminals. Any repair or modi-
fication done on the controller is subject to
the requirements of the jurisdiction. The ju-
risdiction can be defined as plant safety or
chief engineer, city, county or state electrical
inspector, etc. Modules / boards should only
be replaced by a trained and qualified techni-
cian per the latest edition of the NEC (National
Electric Code).
1. Remove the instrument from its housing by grip-
ping the side edges of the front panel (there is a
finger grip on each edge) and pull the instrument
forwards. This will release the instrument from the
rear connectors in the housing and will give access
to the PCBs.
2. Take note of the orientation of the instrument for
subsequent replacement into the housing. The po-
sitions of the main and option PCBs in the instru-
ment are shown below.
Removing/Replacing Option Modules
(“Output” & “Option” are interchangeable
terms)
With the instrument removed from its housing:
1. To remove or replace modules into Option Slots 1,
A or B, it is necessary to gently separate the CPU
and PSU PCBs. This is achieved by detaching the
main boards (PSU and CPU) from the front mold-
ing by lifting first the upper and then lower mount-
ing struts as shown. This frees the boards from the
front. If only Option slots 2 or 3 are to be changed,
this stage is not required as these slots are acces-
sible without separating the main boards from the
front.
Figure 5
Location of Option Modules - 1/16 DIN Instruments
Option
Slot 2 Option Slot 3
Option
Slot A
Optio
n
Slot 1
Mounting
Struts
Take care not to put undue stress on the ribbon
cable attaching the display and CPU boards.
Figure 6
Location of Option Modules
1/8 & 1/4 DIN Instruments
Option
Sl
ot 2
Option
Slot A
Option
Slot B
Option
Slot 3
Option
Slot 1
Mounting
Struts
Take care not to put undue stress on the ribbon
cable attaching the display and CPU boards.
2. Remove or fit the modules into the Option slots as
required. The location of the connectors is shown
below. Tongues on each option module locate into a
slots cut into the main boards, opposite each of the
connectors.
Figure 7
Option Module Connectors
1/16 DIN Instruments
Option Slot 3
Connector PL4B
Option Slot 2
Connector PL4A
Option Slot A
Connectors
PL5 & PL6
Option Slot 1
Connectors
PL7 & PL8
Check for correct orientation of the modules
and that all pins locate correctly into the socket.

5
Figure 8
Option Module Connectors
1/8 & 1/4 DIN Instruments
Option Slot 2
Connector PL4A
Option Slot
A
Connectors
PL5 & PL6
Option Slot B
Connectors PL2A,
PL2B & PL2C
Option Slot
3
Connectors
PL4B
Option Slot 1
Connectors
PL7 & PL8
Check for correct orientation of the modules
and that all pins locate correctly into the socket.
Replacing the Instrument in its Housing
With the required option modules correctly located
into their respective positions the instrument can be
replaced into its housing as follows:
1. If required, move the CPU and PSU boards back
together, taking care to locate the option module
tongues into the slots in the board opposite. Hold
the main boards together whilst relocating them
back into the mounting struts on the front panel.
2. Align the CPU and PSU PCBs with their guides and
connectors in the housing.
3. Slowly and firmly, push the instrument in position.
Ensure that the instrument is correctly ori-
entated. A mechanical stop will operate if an
attempt is made to insert the instrument in
the wrong orientation, this stop MUST NOT be
over-ridden.
4 Wiring Instructions
Options Modules and Functions
Electrical noise is a phenomenon typical of industrial
environments. As with any instrumentation, these
guidelines should be followed to minimize the effect of
noise.
Installation Considerations
Ignition transformers, arc welders, mechanical contact
relays and solenoids are all common sources of electri-
cal noise in an industrial environment and therefore the
following guidelines MUST be followed.
1. If the instrument is being installed in existing equip-
ment, the wiring in the area should be checked to
ensure that good wiring practices have been fol-
lowed.
2. Noise-generating devices such as those listed
should be mounted in a separate enclosure. If this
is not possible, separate them from the instrument,
by the largest distance possible.
3. If possible, eliminate mechanical contact relays and
replace with solid-state relays. If a mechanical relay
being powered by an output of this instrument can-
not be replaced, a solid-state relay can be used to
isolate the instrument.
4. A separate isolation transformer to feed only the
instrumentation should be considered. The trans-
former can isolate the instrument from noise found
on the AC power input.
AC Power Wiring - Neutral (for 100 to 240V
AC versions)
It is good practice to ensure that the AC neutral is at or
near ground (earth) potential. A proper neutral will help
ensure maximum performance from the instrument.
Wire Isolation
Four voltage levels of input and output wiring may be
used with the unit:
1. Analog input or output (for example thermocouple,
RTD, VDC, mVDC or mADC)
2. Relays & Triac outputs
3. SSR Driver outputs
4. AC power
The only wires that should run together are
those of the same category.

6
If any wires need to run parallel with any other lines,
maintain a minimum space of 150mm between them.
If wires MUST cross each other, ensure they do so at
90 degrees to minimize interference.
Use of Shielded Cable
All analog signals must use shielded cable. This will
help eliminate electrical noise induction on the wires.
Connection lead length must be kept as short as pos-
sible keeping the wires protected by the shielding. The
shield should be grounded at one end only. The pre-
ferred grounding location is at the sensor, transmitter
or transducer.
Noise Suppression at Source
Usually when good wiring practices are followed, no
further noise protection is necessary. Sometimes in
severe electrical environments, the amount of noise is
so great that it has to be suppressed at source. Many
manufacturers of relays, contactors, etc., supply ‘surge
suppressors,’ which mount on the noise source. For
those devices that do not have surge suppressors sup-
plied, Resistance-Capacitance (RC) networks and/or
Metal Oxide Varistors (MOV) may be added.
Inductive coils: MOVs are recommended for transient
suppression in inductive coils, connected in parallel and
asclose as possible tothe coil. Additionalprotectionmay
be provided by adding an RC network across the MOV.
Figure 9
Transient suppression with inductive coils
Contacts: Arcing may occur across contacts when
they open and close. This results in electrical noise as
well as damage to the contacts. Connecting a properly
sized RC network can eliminate this arc.
For circuits up to 3 amps, a combination of a 47 ohm
resistor and 0.1 microfarad capacitor (1000 volts) is
recommended. For circuits from 3 to 5 amps, connect
two of these in parallel.
Figure 10
Contact noise suppression
Sensor Placement (Thermocouple or RTD)
If the temperature probe is to be subjected to corrosive
or abrasive conditions, it must be protected by an ap-
propriate thermowell. The probe must be positioned to
reflect true process temperature:
1. In a liquid media - the most agitated area
2. In air - the best circulated area
The placement of probes into pipe work some
distance from the heating vessel leads to trans-
port delay, which results in poor control.
For a two wire RTD a wire link should be used in place
of the third wire. Two wire RTDs must only be used with
lead lengths less than 3 meters. Use of three wire RTDs
is strongly recommended.

7
Thermocouple Wire Identification Chart
The different thermocouple types are identified by their
wires color, and where possible, the outer insulation as
well. There are several standards in use throughout the
world.
The table below shows the wire and sheath colors used
for most common thermocouple types. The format
used in this table is:
Table 2. Thermocouple Extension Wire Colors
Type
International
IEC584-3
USA ANSI
MC 96.1
British
BS1843
French
NFC 42-324
German
DIN 43710
J +* Black
Black
White
Black
Yellow
Black
Yellow
Black
Red
Blue
-White Red Blue Black Blue
T + Brown
Brown
Blue
Blue
White
Blue
Yellow
Blue
Red
Brown
-White Red Blue Blue Brown
K + Green
Green
Yellow
Yellow
Brown
Red
Yellow
Yellow
Red
Green
-* White Red Blue Purple Green
N + Pink
Pink
Orange
Orange
Orange
Orange
-White Red Blue
B + Grey
Grey
Grey
Grey
Red
Grey
-White Red Grey
R & S + Orange
Orange
Black
Green
White
Green
Yellow
Green
Red
White
-White Red Blue Green White
C
(W5)
+White
White
-Red
*Wire is magnetic
+ Wire
Blue
- Wire

8
Connections and Wiring
The rear terminal connections for 1/16 DIN and 1/4
& 1/8 DIN instruments are illustrated in the following
diagrams.
In general, all wiring connections are made to the in-
strument after it is installed. Copper wires must be
used for all connections (except thermocouple signal
wires).
TO AVOID ELECTRICAL SHOCK, AC POWER
WIRING MUST NOT BE CONNECTED TO THE
SOURCE DISTRIBUTION PANEL UNTIL ALL WIR-
ING PROCEDURES ARE COMPLETED.
CHECK THE INFORMATION LABEL ON THE
CASE TO DETERMINE THE CORRECT VOLTAGE
BEFORE CONNECTING TO A LIVE SUPPLY.
Note: The wiring diagram below shows all possible
combinations. The actual connections required de-
pend upon the features available on the model and the
modules and options fitted.
TO AVOID ELECTRICAL SHOCK, AC POWER
WIRING MUST NOT BE CONNECTED TO THE
SOURCE DISTRIBUTION PANEL UNTIL ALL WIR-
ING PROCEDURES ARE COMPLETED.
CHECK THE INFORMATION LABEL ON THE
CASE TO DETERMINE THE CORRECT VOLTAGE
BEFORE CONNECTING TO A LIVE SUPPLY.
Note: The following wiring diagram shows all possible
combinations. The actual connections required de-
pend upon the features available on the model and the
modules and options fitted.
Figure 11. Rear terminals (1/16 DIN Instruments)
OUTPUT
/
OUTPUT
/
OUTPUT
/

9
Figure 12. Rear Terminals (1/4 DIN & 1/8 DIN Instruments)
OUTPUT
/
OUTPUT
/
OUTPUT 1
Power Connections - Mains Powered
Instruments
Mains powered instruments operate from a 100 to
240V (±10%) 50/60Hz supply. Power consumption is
7.5VA. Connect the line voltage (live and neutral) as il-
lustrated via a two-pole isolating switch (preferably
located near the equipment) and a 1amp anti-surge
fuse. If the instrument has relay outputs with contacts
carrying mains voltage, it is recommended that the re-
lay contacts supply should be switched and fused in a
similar manner, but should be separate from the instru-
ments mains supply.
1/16 DIN
1/4 DIN & 1/8 DIN
Figure 13
Mains Power Connections
9
10
13
14
L
N
L
N
CHECK THE INFORMATION LABEL ON THE
CASE TO DETERMINE THE CORRECT VOLTAGE
BEFORE CONNECTING TO A LIVE SUPPLY.
THIS EQUIPMENT IS DESIGNED FOR INSTAL-
LATION IN AN ENCLOSURE THAT PROVIDES
ADEQUATE PROTECTION AGAINST ELECTRIC
SHOCK.
Note: The wiring diagram below shows all possible
combinations. The actual connections required de-
pend upon the features available on the model and the
modules and options fitted.

10
Power Connections -
24/48V AC/DC Powered Instruments
24/48V AD/DC powered instruments will operate from
a 20 to 48V AC or 22 to 55V DC supply. AC power con-
sumption is 7.5VA max, DC power consumption is 5
watts max. Connection should be via a two-pole isolat-
ing switch (preferably located near the equipment) and
a 315mA slow-blow (anti-surge type T) fuse.
1/16 DIN
1/4 DIN & 1/8 DIN
Figure 14
24/48V AC/DC Power Connections
9
10
_
+
13
14
_
+
CHECK THE INFORMATION LABEL ON THE
CASE TO DETERMINE THE CORRECT VOLTAGE
BEFORE CONNECTING TO A LIVE SUPPLY.
This equipment is designed for installation in
an enclosure that provides adequate protec-
tion against electric shock.
Note: The wiring diagram below shows all possible
combinations. The actual connections required de-
pend upon the features available on the model and the
modules and options fitted.
Universal Input Connections -
Thermocouple (T/C)
Use only the correct thermocouple wire or compensat-
ing cable from the probe to the instrument terminals
avoiding joints in the cable if possible. Failure to use
the correct wire type will lead to inaccurate readings.
Ensure correct polarity of the wires by cross-referenc-
ing the colors with a thermocouple reference table
1/16 DIN 1/4 DIN & 1/8 DIN
Figure 15
Thermocouple Input Connections
3
2 +
_
4
5 +
_
Universal Input Connections –
PT100 (RTD) input
For three wire RTDs, connect the resistive leg and the
common legs of the RTD as illustrated. For a two wire
RTD a wire link should be used in place of the third wire
(shown by dotted line). Two wire RTDs should only be
used when the leads are less than 3 meters long. Avoid
cable joints.
1/16 DIN 1/4 DIN & 1/8 DIN
Figure 16
RTD Input Connections
DTRDTR
4
5
6
3
2
1
Four wire RTDs can be used, provided that the fourth
wire is left unconnected. This wire should be cut short
or tied back so that it cannot contact any of the termi-
nals on the rear of the instrument.
Universal Input Connections -
Linear Volt, mV or mA input
Linear DC voltage, millivolt or milliamp input connec-
tions are made as illustrated. Carefully observe the po-
larity of the connections.
1/16 DIN 1/4 DIN & 1/8 DIN
Figure 17
DC Volt, mV & mA Input Connections
4
5
6
+
+
_
_
mA
mV/V
4
3
2
1
+
_
_
+
mA
mV/V