Extech Instruments 96VFL User manual

USER MANUAL
Process PID Controllers
Model 96VFL DIN Controller
Model 48VFL DIN Controller

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Contents
1. Introduction ...................................................................................................4
2. Safety ............................................................................................................5
3. Panel Cut-out, Dimensions, and Mounting......................................................6
3.1 48VFL Mounting .................................................................................................................6
3.2 96VFL Mounting .................................................................................................................6
4. Wiring............................................................................................................7
4.1 IMPORTANT SAFETY WIRING CONSIDERATIONS ....................................................................7
4.2 AC Power Wiring ................................................................................................................7
4.3 Thermocouple Input ...........................................................................................................7
4.4 Analog Input (4-20mA) optional...........................................................................................7
4.5 RTD Input (2, 3, or 4 wire) ...................................................................................................8
4.6 Control Relay Wiring...........................................................................................................8
4.7 Pulsed DC Trigger Output Wiring..........................................................................................8
4.8 Analog Output Wiring .........................................................................................................9
4.9 Alarm Relay Output ............................................................................................................9
5. Product Description......................................................................................10
5.1 96VFL Front Panel.............................................................................................................10
5.2 48VFL Front Panel.............................................................................................................11
5.3 Keypad Descriptions .........................................................................................................11
5.4 Display Descriptions..........................................................................................................12
6. Process Control ............................................................................................14
6.1 Connect the Inputs ...........................................................................................................14
6.2 Connect the Outputs.........................................................................................................14
6.3 Program the Controller .....................................................................................................14
6.4 Primary Relay Output Control............................................................................................14
6.5 Secondary (optional) Relay Output Control.........................................................................14
6.6 Pulsed DC Trigger Option ..................................................................................................14
6.7 Analog Output Option.......................................................................................................15
6.8 ON-OFF Control................................................................................................................15
6.9 PID Control ......................................................................................................................15
6.10 PID ‘Time Proportioning’ Control .......................................................................................16
6.11 Proportional Control Considerations ..................................................................................17
6.12 Dead-Band Considerations ................................................................................................19
7. Programming Menu Basics...........................................................................20
8. Programming Menu 1 (User level) ................................................................22
9. Programming Menu 2 (Soft Start level).........................................................23
9.1 Soft-Start Utility Overview.................................................................................................23
9.2 Ramp-to-Setpoint (RAMP) Overview ..................................................................................23
10. Programming Menu 3 (PID)..........................................................................24
11. Programming Menu 4 (Option).....................................................................26

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11.1 Input Type Selection .........................................................................................................27
11.2 Low and High Limit Considerations.....................................................................................27
11.3 Alarm Function and Alarm Modes Lists...............................................................................28
11.4 ON-OFF Alarm Timers .......................................................................................................29
11.5 RS-485 Interface Option ....................................................................................................30
12. Programming Menu 5 (Linear Input).............................................................30
13. Automatic Tuning.........................................................................................31
14. Automatic and Manual Control Modes .........................................................31
15. Appendix A: Troubleshooting .......................................................................32
16. Appendix B: Heating Process Example ..........................................................33
17. Specifications...............................................................................................34
17.1 General Specifications.......................................................................................................34
17.2 Thermocouple Input Specifications ....................................................................................34
17.3 RTD Input Specifications....................................................................................................35
17.4 Analog (Linear) Input Specifications ...................................................................................35
17.5 Relay and DC Trigger Control Output Specifications.............................................................35
17.6 ALARM Output Specifications ............................................................................................36
17.7 ANALOG Output Specifications ..........................................................................................36
18. Two-year Warranty......................................................................................36
19. Calibration and Repair Services ....................................................................36
20. Customer Support ........................................................................................37

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1. Introduction
Thank you for selecting the Extech VFL Process Controller. The VFL series uses intelligent
algorithms (including fuzzy logic) to offer highly precise process control. The wide array of
features and functions are easily configured in the four program menu levels.
Controller Wiring
The controller must be wired before use. Inputs, outputs, and AC power are connected on the
rear terminals as described in the Wiring section.
Process Inputs
The VFL series can be ordered in a variety of input configurations. For temperature versions,
the controller accepts a thermocouple or RTD thermometer. For analog versions, the
controller accepts a 4 to 20mA or 1 to 5V dc process signal.
PV (Process Variable) Display
Process inputs values are displayed on the PV (Process Variable) digits on the front panel.
Control Outputs
The VFL series offers three control output options: mechanical relay, pulsed DC Trigger
(24VDC), and analog (4-20mA). Relay and Trigger outputs are ON-OFF control types (pulsed).
The 4-20 output, on the other hand, is a linear signal corresponding to the 0 to 100% output.
Alarm Outputs
The Alarm relays can be used to perform a variety of alarm and timer functions. Alarms can
be used to shut down power in the event of an emergency, switch on an alert signal, control
other variables in a process, and more. Alarm relays can also function as ON and OFF timers.
Setting Value (SV)
The Setting Value (SV), also known as the Setpoint, is the target point for your process. The
SV is changed using the arrow keys. The SV is displayed on the lower LED digits in green.
Programming Menus
The controller has five Programming Menu Levels. Each menu includes a series of
customizable control and tuning parameters.
Tuning the Controller
The controller’s PID settings must be tuned for each application. Run the Auto Tune utility
after the controller is wired and ready for use. Manual tuning adjustments can also be made.
Tuning is key to a stable process.
Contact Extech
Visit the Extech website www.extech.com for customer support, up-to-date user
documentation, and full warranty information. This device is covered by a 2-year limited
warranty.

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2. Safety
The installation, wiring, and maintenance of this process controller must be performed by
qualified electrical technicians. Please read the entire user manual, including all safety
information, before using this device. No user serviceable parts.
WARNINGS
•The electrical power required by this controller is hazardous. Use care when connecting
the controller to power and other devices. Do not touch the rear of the controller when
it is in operation.
•Before wiring, check the model number on the controller label. The model number is
structured to show the input and output hardware options installed. Contact Extech if
you are uncertain.
•To minimize the pick-up of electrical noise, the sensor input wiring should be routed
away from high-current power cables or use shielded cables with the shield grounded
at both ends.
•RFI and EMI can interfere with the controller’s microprocessor. If the display characters
are abnormal or if the controller is performing unusually, take it out of service and have
it repaired; check for the source of the interference before continuing.
•When using a relay output, it may be necessary to fit a filter, suitable for suppressing
the emissions. The filter requirements will depend on the type of load.
•If the controller is operating abnormally or appears damaged, take it out of service and
have it repaired before continuing to use.

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3. Panel Cut-out, Dimensions, and Mounting
FIGURE 3.1: VFL CUT-OUT AND DIMENSIONS
A
B
C
D
E
a
b
c
d
48VFL
48
48
6
100
45
45
45
60
48
96VFL
96
96
10
80
91
92
92
120
96
Units: mm (columns ‘a’and ‘b’are +/- 0.5mm)
3.1 48VFL Mounting
1. Remove the plastic mounting bracket and slide the controller into the panel, through the
cutout.
2. Replace the mounting bracket and tighten the bracket screws. Do not over tighten.
3. Do not obstruct the ventilation openings on the side of the controller.
3.2 96VFL Mounting
1. The 96VFL uses two metal brackets (supplied) affixed to the top and bottom of the
controller to secure it to the panel.
2. Slide the controller into the panel and connect the bracket clips to the insert holes on the
top and bottom of the controller.
3. Tighten the bracket screws to secure the controller in the panel. Do not overtighten.

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4. Wiring
FIGURE 4.1: SERIES VFL WIRING (48VFL ON LEFT, 96VFL ON RIGHT)
4.1 IMPORTANT SAFETY WIRING CONSIDERATIONS
•Before wiring, verify the installed hardware options: Input (TC, RTD, Analog); Output
(relay, analog, dc trigger). The controller label should match the model number ordered,
contact Extech if there is any uncertainty. Improper wiring can cause personal injury and
damage to the controller and connected equipment.
•To avoid noise induction, keep input signal wires away from instrument power lines,
load lines and power lines of other electrical equipment.
4.2 AC Power Wiring
96VFL: Terminals 19 and 20 can safely accept 90 to 260VAC 50/60Hz.
48VFL: Terminals 1 and 2 can safely accept 90 to 260VAC 50/60Hz.
DC power 24VDC is optional.
4.3 Thermocouple Input
96VFL: Terminal 9 (-) and terminal 10 (+).
48VFL: Terminal 8 (-) and terminal 7 (+).
4.4 Analog Input (4-20mA) optional
96VFL Output 1: Terminal 18 (-) and terminal 17 (+).
96VFL Output 2: Terminal 16 (-) and terminal 15 (+).
48VFL Output 1: Terminal 11 (-) and terminal 12 (+).
48VFL Output 2: Terminal 17 (-) and terminal 16 (+).

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4.5 RTD Input (2, 3, or 4 wire)
48/96 VTR: 3-wire RTDs are most common and are wired to 8, 9, and 10 on the 96VFL and
terminals 7, 8, and 9 on the 48VFL as shown in the diagrams above.
96VFL: For 2-wire RTD, connect across terminals 8 and 9 and jump 9 to 10. For 4-wire RTD
connect the resistance across 8 and 9 and connect the remaining two wires to 8 and 10.
48VFL: For 2-wire RTD, connect across terminals 8 and 9 and jump 7 to 8. For 4-wire RTD
connect the resistance across 8 and 9 and connect the remaining two wires to 7 and 9.
4.6 Control Relay Wiring
A basic VFL controller includes one control relay (OUT 1), the second control output (OUT 2)
is optional.
Control relay outputs are single-pole, single-throw (normally open N.O.) mechanical
switches. When the controller activates a control relay, the normally open switch closes. The
relay itself does not provide power. AC or DC power must be wired in series with the relay
and control device as shown below. Relays are rated 5 Amps @ 110V AC or 24VDC (Resistive
Loads).
In the diagram below terminals ‘x’and ‘y’represent the VFL rear terminal designations, see
the table below for the specific terminal numbers.
FIGURE 4.2: NORMALLY OPEN (N.O.) CONTROL OUTPUT WIRING
OUTPUT 1
OUTPUT 2
48VFL (x-y)
Terminals 11 and 12
Terminals 16 and 17
96VFL (x-y)
Terminals 17 and 18
Terminals 15 and 16
4.7 Pulsed DC Trigger Output Wiring
The DC Trigger output delivers 24V DC (approx.) across the same terminals that are used for
the relay outputs. See Control Relay terminals table above.

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4.8 Analog Output Wiring
Analog outputs are optional. Analog outputs are available across the same terminals that
are used for the relay outputs. See Control Relay terminals table above. Parameter ‘Ct’(PID
Menu 3) must be set to ‘0’when using an analog output.
4.9 Alarm Relay Output
One relay is supplied in a standard VFL controller, the second alarm is optional. Alarm relays
are normally open (N.O.) single-pole single-throw mechanical switches. The first alarm relay
is available on terminals 11 and 12. The optional secondary alarm relay is on terminals 12
and 13.
Alarm relays do not supply power and should be wired in series with power and the alarm
device.
Alarm relays are rated 3 Amps @ 110VAC or 24VDC (Resistive Loads).
In the diagram below terminals ‘x’and ‘y’represent the VFL rear terminal designations, see
the table below for the specific terminal numbers.
FIGURE 4.3 - NORMALLY OPEN (N.O.) ALARM WIRING
ALARM 1
ALARM 2
48VFL (x-y)
Terminals 5 and 6
Terminals 3 and 4
96VFL (x-y)
Terminals 13 and 14
Terminals 11 and 12

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5. Product Description
The numbered call-out items below describe the basic operational functions for the displays,
indicators, and keys. Advanced uses are explained in the Keypad Descriptions and Display
Descriptions sections, and throughout this manual.
5.1 96VFL Front Panel
FIGURE 5.1: 96VFL FRONT PANEL
1. Process Variable (PV) display digits (red) show the process input.
2. Setting Variable (SV) display digits (green) show the programmed setpoint.
3. Alarm 1 (A1) and Alarm 2 (A2) relay status indicators.
4. Programming keys: Set, Scroll, Down arrow, Up arrow (left to right). See dedicated
section below.
5. Control Output 1 (C1) and Control Output 2 (C2) status indicators.
6. MANUAL control mode status (rightmost decimal flashes on SV display).
7. AUTO TUNING mode status (rightmost decimal flashes on PV display).