Chromalox 1603 User manual

1603
Issue Date
June 1999 USER’S MANUAL
0037-75214
Temperature Controller
❑

Chromalox 1603 User's Manual i
Model Identification..................................Page ii
Dimensions and Panel Cut Out ........................ 1
Wiring.........................................................................2
Thermocouple Inputs.................................... 2
RTD Inputs........................................................ 3
Relay Outputs .................................................. 3
Voltage Outpus ...............................................5
Power Line and Grounding ........................ 6
Configuration Procedure.....................................7
Advanced Configuration ...................................10
Operator Mode .....................................................12
Pushbutton Functions ........................................13
Manual Reset of Alarms ...................................13
SMART Function..................................................14
Direct Access to Setpoint Modification ......15
Output Power OFF...............................................15
Lamp Test ...............................................................15
1603 Operator Parameters ...............................16
Error Messages ....................................................18
Error Descriptions................................................19
Calibration Procedure ........................................21
Warranty and Return..........................................26
Contents

ii Chromalox 1603 User's Manual
Model Identification
Model
1603 1/16 DIN Temperature Controller, Dual Display
Code Output 1 - Heat or Cool
1 Relay, 3 Amps at 250 Vac (Resistive)
6 SSR Drive, 14 Vdc at 20 mA
Code Output 2 - Cool or Alarm
1 Relay, 1 Amp at 250 Vac (Resistive Load)
Code
0 Add to complete model number
Code Instrument Power
3 100-240 Vac
5 24 Vac/dc
Code
0 Add to complete model number
1603 - 61030Typical Model Number

Chromalox1603User'sManual 1
1600
SMART
SMART
FUNC
ALM
OUT
˚F
Figure 1
DimensionsandP anelCutOut 3.0
(75)
2.4
(60)
1.9
(48)
1.77
(45)
1.9
(48)
3.9
(100)
Dimensionsininches(mminparenthesis)
1.77
(45)

2Chromalox1603User'sManual
Figure 2
Wiring
6
7
8
8
9
10
8
1
2
3
4
5
INST.PWR.
T/C
RTD
+
-
OUT2
+
-
SSR(OutputCode6only)
MAINRELAY(OutputCode1only)
NO C NC
"C" "NO"
SensorInputs
Note:
Any external components (like Zener diodes, etc.)
connected between sensor and input terminals may cause
errors in measurement due to excessive and/or not
balanced line resistance or possible leakage currents.
TC Input
Figure 3
ThermocoupleInputW iring
Wiring Guidelines
3
2
+
-
3
2
+
-

Chromalox1603User'sManual 3
Notes:
1.Do not run input wires with power cables.
2.For TC wiring use proper compensating cable (use
type J TC extension wire with type J TC
connections), preferably shielded.
3.Shielded cable should be grounded at one end only.
RTD Input
Figure 4
RTDInputWiring
Notes:
1.Do not run input wires together with power cables.
2.Observe the line resistance; a high line resistance
may cause measurement errors.
3.When shielded cable is used, it should be grounded
at one end only to avoid ground loop currents.
4.The resistance of the 3 wires must be the same.
TCInputs(continued)
Relay Outputs
Figure 5
RelayOutputs
123123
RTD RTD
OUT1
6
7
8
5
4
OUT2
NC
C
NO
C
NO

4Chromalox1603User'sManual
Relay Outputs (continued)
The OUT 1 NO contact and the OUT 2 contact are
protected by varistor against inductive loads with
inductive components up to 0.5 A.
OUT 1 contact rating is 3A/250Vac resistive load.
OUT 2 contact rating is 1A/250Vac resistive load.
The number of operations is 1 x 105at specified rating.
Notes:
1.To avoid electric shock, connect power line at the
end of the wiring procedure.
2.For power connections use No 16 AWG or larger
wires rated for at last 75 °C.
3.Use copper conductors only.
4.Do not run input wires together with power cables.
Inductive Loads
Employing the following recommendations will help
avoid serious problems that may occur when relay outputs
are used with inductive loads.
High voltage transients may occur when switching
inductive loads. Through the internal contacts these
transients may introduce disturbances that can affect the
performance of the controller.
For all the outputs, the internal protection (varistor)
assures a correct protection up to 0.5 A of inductive
component.
The same problem may occur when a switch is used in
series with the internal contacts as shown in Figure 8.
Figure 6
ExternalSwitchinSerieswiththeInternalContact
CR
Load
Power
Line

Chromalox1603User'sManual 5
The SSR Drive Output is a time proportioning output.
Logic Level 0:Vout < 0-5 Vdc
Logic Level 1:14V ±20% @ 17mA
+24V ±20% @ 1mA
Maximum = 17mA
Notes:
1.This output is not isolated. An external solid state
relay with 2600V isolation must be used to isolate
the controller output and power supply for CE
compliance. The Chromalox Series 4115, 7710,
4001, and 4003 meet these isolation requirements.
2.To determine Output #1 output type, check the tag
on your controller and compare it to the model
identification table on page ii.
Inductive Loads (continued)
Warnings:
When a relay output is used to drive an inductive
load, it is suggested that you connect an external
snubber network (RC) across the terminals using
Chromalox P/N 0149-01305.
Voltage Outputs for SSR Drive
Figure 7
SSRDriveOutputWiring
8
7
+
-+
-˜

6Chromalox1603User'sManual
Power Line and Grounding
Figure 8
PowerSupply
10
9
N
Power Supply
100 to 240 Vac
or 24 Vac/Vdc
Notes:
1. Before connecting the power line, check that the
voltage is correct (see Model Identification, pg. ii).
2. For supply connections use 16 AWG or larger wires
rated for at least 75 °C.
3. Use copper conductors only.
4. Do not run input wires with power cables.
5. Polarity does not matter for 24 Vdc wiring.
6. The power supply input is NOT fuse protected.
Please provide external fusing.
When the fuse is damaged, it is advisable to verify the
power supply circuit. Return the controller to Chromalox
for test and verification.
7. Safety requirements for permanently connected
equipment:
• Include a switch or circuit-breaker in the
installation.
• Place the switch in close proximity to the
equipment and within easy reach of the
operator.
• Mark the switch as the disconnecting device for
the equipment.
Note:
A single switch or circuit-breaker can drive more
than one controller.
8. When the NEUTRAL line is present, connect it to
terminal 10.
9. To avoid shock and possible controller damage,
connect power last.
Power supply Type Current Voltage
24 V AC/DC T 500 mA 250 V
100/240 V AC T 125 mA 250 V

Chromalox1603User'sManual 7
General Operation
There are two setup modes for the 1603:
• Configuration Mode
• Operator Mode
In general, the Configuration Mode is the initial setup of
the controller when first installed. Input type and alarm
setup are examples of Configuration Mode settings. The
Operator Mode includes settings that might be adjusted
frequently with daily control operations such as setpoints
and PID parameters.
Pushbutton Functionality
During Configuration Procedure
FUNC =Must be pressed to store the new value of a
selected parameter and increments to the
next parameter.
SMART= In configuration Mode, scrolls parameters
back (in reverse order) without storing the
new parameter value.
▲ = Increases the value of the selected parameter .
▼ = Decreases the value of the selected parameter.
Configuration Procedure
1. Remove the controller from its case.
2. Set the internal switch V2 (see Fig. 9) in open
condition.
3. Reinsert the controller in the case.
4. Switch the controller “ON”.
Note: If “CAL” indication is immediately displayed,
press the ▲pushbutton to return to the configuration
mode “CnF.”
5. Push the FUNC pushbutton. The lower display will
show the parameter alphanumeric and the upper
display will show the parameter value.
+
+
1
34
2
PZ3
PZ4
PZ5
V2
B
L4
C6
C10
C5
C8
L3
L2
C7
R7
R8
J6
J5
2
C14
C2 R4
R5
R11
Q2
R3
PZ2
PZ1
C15
K2
C9
Figure 9
V2

8Chromalox1603User'sManual
P1 - Input Type and Standard Range
0 =TCtype L range 0/ +800 °C
1 =TCtype J range 0/ +800 °C
2 =TCtype K range 0/ +999 °C
3 =TCtype N range 0/ +999 °C
4 =RTDtype Pt100 range -199/+500 °C
5 =RTDtype Pt100 range -19.9/+99.9 °C
6 =TCtype T range 0/+400 °C
8 =TCtype L range 0/ +999 °F
9 =TCtype J range 0/ +999 °F
10 =TCtype K range 0/ +999 °F
11 =TCtype N range 0/ +999 °F
12 =RTDtype Pt100 range -199/+999 °F
13 =TCtype T range 0/+752 °F
Note: To set the display for °C engineering units, place
the °C sticker label on the controller faceplate. The label
is located in the shipping box.
P2 = Initial Scale Value
Not present when P1 = 5
Enter the initial and full scale values which are going to
be used by the PID algorithm to calculate the input span.
When this parameter is modified, rL (setpoint lower
limit) is automatically modified to the same value.
P3 = Full Scale Value
Not present when P1 = 5
When this parameter is modified, rH (setpoint upper
limit) is automatically modified to the same value. The
initial and full scale values determine the input span
which is used by the PID algorithm, the SMART and the
alarm functions.
Note: The minimum input span (P3 - P2) is 600°F
(300°C) for TC input and 200°F (100°C) for RTD input.
P4 = Main Output Action
The 1603 skips this parameter when P5 = 5 (cooling)
r = reverse action (heating)
d = direct action (cooling)
P5 = Output 2 Functions
0 = None
1 = Process alarm (absolute)
2 = Band alarm (+ and - deviation)
3 = Deviation alarm (+ or - deviation)
4 = Controller failure indicator (under- or over-range,
CJC or A-D converter failure)
5 = Cooling output
Note: When P5 = 5, the P4 parameter is forced to “r”.

Chromalox1603User'sManual 9
P6 = Output 2 Operative Mode
P6 is available only when P5 is different from 0.
When P5 = 1, 2, or 3:
H.A. = high alarm (outside boand) with automatic reset
L.A. = low alarm (inside band) with automatic reset
H.L. = high alarm (outside band) with manual reset
L.L = low alarm (inside band) with manual reset
When p5 = 4, the selections H.A. and L.A. are controller
failure indicator alarms with automatic reset. The H.L.
and L.L. selections are controller failure indicator alarms
with manual reset.
When P5 = 5, this parameter selects the cooling medium:
AIr= Air
OIL = Oil
H20 = Water
Note: Different set of cooling medium produces the
automatic modification of the relative cooling gain and of
the cooling cycle time.
P7 = Alarm Action
Present only when P5 is different from 0 or 5.
r = reverse (relay de-energized in alarm condition)
d = direct (relay energized in alarm condition)
P8 = Alarm Inhibit
Present only when P5 is different from 0,4 or 5.
OFF = Inhibit disabled
ON = Inhibit enabled
Note: If the alarm is programmed as band or deviation
alarm, this function disables the alarm condition after a
setpoint change or at the controller startup until the
process variable passes the alarm setpoint plus or minus
hysteresis. If the alarm is programmed as a process alarm,
this function disables the alarm condition at controller
startup until the process variable passes the alarm setpoint
plus hysteresis.
P9 = OFFSET Applied to the Measured Temperature
This OFFSET is applied along the whole range.
When P1 = 5 P9 is programmable from -19.9 to
19.9 °C.
When P1 ≠5 P9 is programmable from -199 to
199 °C or °F.
P10 = Threshold of the “Soft Start” Function
Enter the Threshold value, in °C or °F, for the automatic
start of the “Soft Start” function (limiting output power).
If the unit powers up below the Threshold value, the
“Soft Start” function is enabled and limits the power
output to “OLH” for “tOL” minutes. “OLH” and “tOL”
are set in the Operator Mode.
P6 C (cycle time) rC (cool gain)
Air 10(s) 1
Oil 4(s) 0.8
H2O 2(s) 0.4

10 Chromalox1603User'sManual
P11 = User Defined Security Code
0 = Security lock disabled. All Operator Mode
parameters can be modified.
1 = Security lock enabled. No parameters can be
modified except the setpoint.
2 to 499 = Select the security code (to be stored).
During the “Operator Mode” the security code
setting will display:
a. The controller is “Unlocked”
and all parameters can be
modified. To make the device
Locked,” insert a number
different from the security code.
Now none of the parameters can
be modified except the SP.
b. The controller is “locked” and
none of the parameters can be
modified except the SP.
To “Unlock” the device, insert
the security code.
500 to 999 = Selecting a security code between these two
numbers, everything will occur as explained above except
that when the device is “Locked” the only parameters
that can be modified are the setpoint and the alarm
setpoint.
P12 = Control Output Maximum Rate of Rise
Programmable from 1% to 10% of the output per second.
The ramp is applied when the controller changes the
percent of output desired. Above 10%, the display will
show “InF”, meaning that no ramp is imposed and the
output immediately changes to the PID calculated value.
P12 not used if ON/OFF control selected.
Advanced Configuration
When the standard configuration procedure is completed,
the controller shows “-,-,-,-,” on both displays. When it is
desired to end the configuration procedure, push the
FUNC pushbutton. The display will show “COnF”.
To access the advanced configuration parameter, procede
as follows:
1. using ▲and ▼pushbuttons, set the 219 code.
2. push the FUNC pushbutton.

Chromalox1603User'sManual 11
P14 = Display of the Operator Parameters
This parameter is available only if P11 is different from 0.
This parameter allows you to enable/disable the display of
the operator parameters.
OFF = parameter cannot be displayed
ON = parameter can be displayed, but not changed
P15 = SMART Function Enabling/Disabling
0 = The SMART function is disabled
1 = The SMART function enabling/disabling is NOT
protected by the Security Code (P11).
2 = The SMART function enabling/disabling is
protected by the Security Code (P11).
P16 = Maximum Value of the Proportional Band by
the SMART Function
This parameter may be programmed from P17 or P18
value to 99.9.
P17 = Minimum Value of the Proportional Band Set
by the SMART Function in Heating Control
Only
This parameter is present only if P5 is different from 5.
It may be programmed from 1.0% to P16 value.
P18 = Minimum Value of the Proportional Band Set
by the SMART Function in Heating/Cooling
Control Only
This parameter is present only when P5 is equal to 5.
This parameter may be programmed from 1.5% to P17.
P19 = Automatic Modification of Relative Cooling
Gain
This parameter is present only when P5 is equal to 5.
OFF = The SMART function does not modify the
“relative cooling gain” parameter.
ON = The SMART function modifies the “relative
cooling gain” parameter (rC).
P20 = Minimum Value of Integral Time Set by
SMART Function
P20 is programmable from 00.1 (10 seconds) to 02.0
(2 minutes).
P21 = Extension of the Anti-Reset-Windup
Range: from -30 to +30% of the proportional band
Note: A positive value increases the high limit of the
anti-reset-windup (over setpoint), while a negative value
decreases the low limit of the anti-reset-windup (under
setpoint).
End of Advanced Configuration
When the advanced configuration procedure is
completed, the controller displays “CnF”.
To restart Configuration
Push FUNC to begin the Configuration Mode.

12 Chromalox1603User'sManual
+
+
1
34
2
PZ3
PZ4
PZ5
V2
B
L4
C6
C10
C5
C8
L3
L2
C7
R7
R8
J6
J5
2
C14
C2 R4
R5
R11
Q2
R3
PZ2
PZ1
C15
K2
C9
Operator Mode
1. Remove the controller from its case.
2. Set the internal switch V2 in closed condition.
3. Reinsert the controller in its case.
4. If, during the configuration procedure, a display in °C
has been selected, it is necessary to put the °C sticker
label on the front of the controller. The additional
label is located in the shipping box.
5. The 1603 displays the measured temperature on the
upper display and the programmed set point on the
lower display. This display is known as the “normal
display mode.” If error 400 message is displayed, press
the ▲or ▼ simultaneously until normal display mode
appears.
V2
°C
ClosedPosition
Indicators
SMART= Flashes when the first part of the SMART
algorithm is active. Lit when the second
part of the SMART algorithm is active.
OUT = Lit when OUT 1 is in ON condition.
ALM = Lit when Alarm 1 is in alarm condition or
when this output is used as a time
proportioning cooling control output.
Figure 10

Chromalox1603User'sManual 13
Pushbutton Functions
FUNC =Must be pressed to store the new value of a
selected parameter and increments to the
next parameter. Parameter values are
displayed on the upper display; parameter
name is displayed on the lower display.
SMART= Enables or Disables the SMART function,
when held for 1.5 seconds.
Scrolls operator parameters back
(in reverse order).
▲ = Increases the value of the selected parameter.
▼ = Decreases the value of the selected parameter.
▼+ FUNC = Press together to perform an LED/
indicator test. Press both again to turn
LED/ indicator test “off”.
Note: A 10 second time out occurs during parameter
modification. If, during parameter modification, no
pushbutton is pressed for more than 10 seconds, the
controller automatically reverts to the “normal display
mode”. The new setting of the last parameter modified is
stored, prior to the time out, only if the FUNC
pushbutton was depressed.
Manual Reset of Alarms
If the alarm has been configured as a latching alarm, the
alarm status persists after the alarm condition disappears
until the alarm is reset.
To reset the alarm, press the FUNC pushbutton to select
the “n.rS” parameter. The displays will show “n.rS” and
“OFF”. Using ▲and ▼, select “ON” and push the FUNC
pushbutton again.
The alarm reset action will only occur if the alarm
condition no longer exists.

14 Chromalox1603User'sManual
SMART Function
The SMART function automatically calculates the
optimum PID control parameters. To enable the SMART
function, push and hold the SMART pushbutton for more
than 1.5 seconds, when the controller is in normal display
mode. The SMART LED will light or flash according to
the algorithm automatically selected. When the SMART
function is enabled, it is possible to display but not to
modify the control parameters (PB, TI, TD and rC).
When the traditional control (PID) is desired, push and
hold the SMART pushbutton for more than 1.5 seconds
again to turn the “SMART” OFF. The controller
maintains the last set of SMART calculated control
parameters and allows parameters to be adjusted.
Notes:
1. During the SMART function operation, the relative
cooling gain (if present and controlled by SMART) is
limited within the following ranges:
Cooling Medium Range
Air 0.85 to 1.00
Oil 0.80 to 0.90
H2O 0.30 to 0.60
2. The SMART function uses a derivative time equal to
1/4 of the integral time.
3. The limits of the proportional band set by the SMART
function are programmed by P16, P17, and P18
parameters.
4. The lower limit of the integral time set by SMART
function is programmed by P20 parameter.
5. When ON/OFF control is programmed (PB = 0), the
SMART function is disabled.
6. The SMART enabling/disabling can be protected by
the safety lock (see P15 parameter).

Chromalox1603User'sManual 15
Direct Access to Setpoint Modification
When direct access to setpoint modification is required,
proceed as follow:
1. Push, for more than 3 seconds, the ▲or ▼pushbutton;
the set point value, shown on the lower display, will
start to change.
2. Using the ▲and ▼pushbuttons, set the desired value.
3. When the desired value is reached, do not push any
pushbutton for more than 3 seconds. The new setpoint
will become operative 3 seconds after the pushbutton is
released.
If, during this procedure, there is no interest in
memorizing the new value, push the FUNC pushbutton;
the controller returns automatically to the normal display
mode without having memorized the new setpoint.
Output Power OFF
To turn the output signal OFF, press and hold the ▲
pushbutton then push FUNC.
Pressing both pushbuttons for more than 3 seconds, will
cause the controller will show “OFF” instead of the set
point value.
In the output power OFF condition, the parameters can
always be viewed and modified. When control is disabled
(output power off), the alarms are not in an alarm
condition. The alarm output status depends on the type of
alarm action.
When the output is OFF, all parameters can be reviewed
and modified. The SMART function will be disabled
during the OFF condition. If power is lost, the unit will
power-up in the OFF condition.
To return to normal control, press and hold the ▲and
then push FUNC for more than 3 seconds. The controller
then automatically goes to the NORMAL DISPLAY
MODE.
The alarm inhibit function, if configured, will be
activated as if it were a powerup.
Lamp Test
To verify operation of the display LED, push ▼and
FUNC together. The instrument LEDs will flash until the
Lamp Test is turned off.
To turn off the Lamp Test, press ▼and FUNC together.
No pushbutton functions are operable during the Lamp
Test.

16 Chromalox1603User'sManual
1603 Operator Parameters
Push the FUNC pushbutton. The lower display will show
the cue while the upper display will show the value of the
selected parameter. Not all parameters will be displayed
due to specific unit configuration.
Cue Description
SPSetpoint—rangesetatP1-SensorSelection.May
belimitedbysettinglowandhighlimitsatP2
andP3(seeconfigurationparameters).
n.rS Manualresetoflatchingalarms.Press▲toset
ON,thenpressFUNCtoresetthealarm.
nnnSecuritycodeforparameterprotection.
ON=thecontrollerisinLOCKcondition
OFF=thecontrollerisinUNLOCKcondition
WhenitisdesiredtoswitchfromLOCKto
UNLOCKcondition,setavalueequaltoP11
parameter.
WhenitisdesiredtoswitchfromUNLOCKto
LOCKcondition,setavaluedifferentfromP11
parameter.
Cue Description
ALAlarmsetpoint—rangeforaprocessalarmset
atP1-SensorSelectionandmaybelimitedby
settinglowandhighlimitsatP2andP3
(seeConfigurationParameters).Rangefora
bandalarm0-500,rangeforadeviationalarm
-199to500.
HSAAlarm hysteresis—deadband range from 0.1 to10.0 %.
PbProportionalband—rangefrom1.0to99.9%of
span(P3-P2)forheatorcoolcontroland1.5to
99.9% of span (P3-P2) for heat/cool control. When
Pb=0thecontrollerperformsasanON/OFF
controlandti,td,C,C2,rC,OLP,OLhandtOL
parametersareskipped.
HSHysteresis (deadband for ON/OFF control action
(Pb = 0)—range from 0.1 to 10 % of input span
(P3-P2).
tiIntegraltime—rangefrom0minutesand10
secondsto20minutesand0seconds(minutes.
seconds);abovetheupperlimitthedisplay
blanksoutandtheintegralactionisexcluded.
tdDerivativetime—rangefrom0.00to9.59

Chromalox1603User'sManual 17
1603 Operator Parameters (continued)
(minutes.seconds).td=0,turnsoffderivative
action.
Cue Description
IP IntegralPreLoad—range0to100%forone
controloutput,-100to100%fortwocontrol
outputs(P5=5).Thisparameterdoesnot
appearwhenPb(ProportionalBand)=0.
CHeating cycle time—range from 1 to 200 seconds (30
seconds or greater recommended for relay outputs).
C2Coolingcycletime—rangefrom1to200
seconds(30secondsorgreaterrecommended
forrelayoutputs).AvailableifP5=5.
rCRelativecoolinggain—rangefrom0.20to1.00.
ThisparameterdoesnotappearifP5≠5or
PB=0.
OLPDeadzone/Overlap—rangefrom-20%to+50%
oftheproportionalband.Anegativevalueisa
deadzoneandapositivevaluecreatesan
overlap.AvailableifP5=5andPB≠0.
rLSPlowlimit—rangefromtheinitialscalevalue
(P2)torHvalue.
Cue Description
rHSPhighlimit—rangefromtherLvaluetothefull
scalevalue(P3).
OLHOutputpowermaximumvalue—range0to100%
heating,-100to100%heat/cool,limitspower
continuously(tOL=Inf)oronstartuppertOL
setting.PB ≠0.
tOLTimeintervalforOLHpoweroutputlimit,range
1to100minutesorif“Inf”infinite.Thetimer
startsonpowerupiftheactualtemperatureis
lessthanP10(thresholdvalue).AnewTOL
valuewillnotbecomeactiveuntiltheunitis
poweredup.IfPB=0,thisparameterwillnot
bedisplayed.