i-therm AI-5982 Operation instructions

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Model No.
Weight (gms.)
AI-5982
240
1OIM AI-5X82 V2.1 Page 1 of 6
USER’S OPERATING MANUAL FOR DIGITAL TEMPERATURE CONTROLLER
(Models: AI - 5982 )
AI - 5982
(96 X 96)
Fe-k(J) T/C
Cr-AL(K) T/C
Sensor Type Accuracy
o
± 1 C
o
0 ~ 1700 C
o
0 ~ 1700 C
o
-100 ~ 450 C
Resolution
Range
o
1 C
o
1 C
o
1 C
}
(R) T/C
(S) T/C
Pt-100(RTD)
Pt-100(RTD 0.1)
o
0 ~ 760 C
o
-99 ~ 1300 C
o
-99.9 ~ 450.0 C
o
1 C
o
1 C
o
0.1 C
o
± 0.3 C
SAFETY INSTRUCTION :
This controller is meant for temperature control
applications. It is important to read the manual prior to
installing or commissioning of controller. All safety related
instruction appearing in this manual must be followed to
ensure safety of the operating personnel as well as the
instrument.
GENERAL
vThe controller must be configured correctly for intended
operation. Incorrect configuration could result in damage
to the equipment or the process under control or it may
lead personnel injury.
vThe controller is generally part of control panel and in
such a case the terminals should not remain accessible
to the user after installation.
MECHANICAL
vThe Controller in its installed state must not come in close
proximity to any corrosive/combustible gases, caustic
vapors, oils, steam or any other process by-products.
vThe Controller in its installed state should not be exposed
to carbon dust, salt air, direct sunlight or radiant heat.
vAmbient temperature and relative humidity surrounding
the controller must not exceed the maximum specified
limit for proper operation of the controller.
vThe controller in its installed state must be protected
against excessive electrostatic or electromagnetic
interferences. Ventilation holes provided on the chassis
of the instrument are meant for thermal dissipation hence
should not be obstructed in the panel.
ELECTRICAL
vThe controller must be wired as per wiring diagram & it
must comply with local electrical regulation.
vCare must be taken not to connect AC supplies to low
voltage sensor input.
vCircuit breaker or mains s/w with fuse (275V/1A) must be
installed between power supply and supply terminals to
protect the controller from any possible damage due to
high voltage surges of extended duration.
vCircuit breaker and appropriate fuses must be used for
driving high voltage loads to protect the controller from
any possible damage due to short circuit on loads.
vTo minimize pickup of electrical noise, the wiring for low
voltage DC and sensor input must be routed away from
high current power cables. Where it is impractical to do
this, use shielded ground at both ends.
vThe controller should not be wired to a 3-Phase supply
with unearthed star connection. Under fault condition
such supply could rise above 264 VAC which will damage
the controller.
vThe Electrical noise generated by switching inductive
loads might create momentary Fluctuation in display,
alarm latch up, data loss or permanent damage to the
instrument. To reduce this use snubber circuit across the
load.
v It is essential to install a over Temp. Protection device to
avoid any failure of heating system. Apart from spoiling
the product, this could damage the process being
controlled.
SPECIFICATIONS : -
1. DISPLAY TYPE : Dual 4- Digit 7 segment LED
4 Digit Bright White (PV)
4 Digit Luminous Green (SV)
STATUS LED’S : OP1 : Main Control Output
OP2 : Alarm Status
SOAK : Soak Timer
2. INPUT
Sensor : TC:J,K,R,S & RTD: Pt-100
Range : Refer below table
Sampling Time : 125 msec.
Resolution : 1°C/0.1°C(Only for RTD)
CJC for TC : Built in automatic
LWC for Pt-100 : Built in up to 18E max.
Digital Filter : 1 to 10 Sec.
3. RELAY OUTPUT
Contact Type : N/O, CM, N/C
Contact Rating : 5A @ 250VAC or 30 VDC
Life Expectancy : > 5,00,000 operations
Isolation : Inherent
4. SSR DRIVE OUTPUT
Drive Capacity : 12V @ 30mA.
Isolation : Non-Isolated.
5. FUNCTION
Output 1 : Main Control output
Output 2 : Programmable
1) Auxiliary control
2) Alarm
3) Soak timer
Control Action : ON-OFF/T.P (user selectable)
Control Mode : Heat/Cool (user selectable)
Compliance : ----
6. ENVIRONMENTAL
Operating Range : 0 ~50°C, 5~90% Rh
Storage Humidity : 95% Rh (Non-Condensing)
7. POWER SUPPLY
Supply Voltage : 90~270VAC, 50/60Hz.
Consumption : 4W Maximum.
8. PHYSICAL
Housing : ABS Plastic.
Model no.
Display height (PV)
Display height (SV)
0.56”
0.56”
AI-5982

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ELECTRICAL INSTALLATION
The electrical connection diagram is shown on the controller enclosure as below.
123456
10 11 12 13 14 15 16 17 18
789
NO NCCM
RELAY1
SSR1
NO NCCM
RELAY2
SSR2
SUPPLY
LN
AI - 5982
MECHANICAL INSTALLATION
The label on the controller identifies the serial number, wiring connections and batch number.
CAUTION: To prevent the risk of electrical shock, switch off the power before making/removing any connection or removing
the controller from its enclosure.
INSTALLATION GUIDELINES
1. Prepare the cut-out with proper dimension as shown in figure.
2. Remove clamp from controller.
3. Push the controller through panel cut-out and secure the
controller in its place by tightening the side clamp.
OVER ALL DIMENSIONS & PANEL CUT OUT (IN MM)
MODEL:- AI - 5982
A
B D
E
G
F
PANEL
CUTOUT
TABLE : 1
Model
Dim
96 96 10 45 92
92 9
A B HC D F GE
89
AI-5982
FRONT PANEL LAYOUT
AI - 5982
1
4
5
7
2
3
OP1
OP2
SOAK
PV
SV
SET RESET START
-therm
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AI-5982
6
FRONT PANEL LAYOUT DESCRIPTION :
Sr. NAME FUNCTION
Glows when OP1 is ON & flashes when delay time (dly1) is in operation(if selected mode is ON-OFF)
1
OP1 LED
Glows when Soak mode is selected & flashes when Soak timer is in operation.
OP2 LED
SOAK LED
( ( (
along with UP key. (4) To scroll the parameter & to store its value.
1) For SP programming. 2) To access Control mode. 3) To access Configuration mode
( (
(with SET key) . (3) To acknowledge Alarm. (4) To Reset the SOAK timer
1) To increase/alter parameter value in program mode. 2) To Enter in configuration mode
( (1) To decrease / alter parameter value in program mode. 2) To start Soak timer.
It will display (1) Measured value of selected input or Error massages in run mode.
(2) Parameters Value in program mode.
It will display (1) SP (Main set point) / SP2 (Auxiliary/Alarm) set value / Set Soak time value/
balance or elapsed soak time in run mode. (2) Parameter code in program mode.
2
3
4
5
6
7
UPPER
DISPLAY
LOWER
DISPLAY
SET
KEY
SHIFT
KEY
UP
KEY
DOWN
KEY
(1) To increase/alter parameter value in program mode with Up / Dn Key.
(2) Press for 3Sec in Programming this will help to go back to previous parameter.
Glows when OP2 is ON & flashes when alarm condition persists even after acknowledged.
delay time (dly2) is in operation(if selected mode is ON-OFF).
or
2OIM AI-5X82 V2.1 Page 2 of 6

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3OIM AI-5X82 V2.1 Page 3 of 6
PROGRAMMING :
USER LIST : To access User list press SET key once.
PARA
METER
LOWER
DISPLAY
UPPER
DISPLAY RANGE DESCRIPTION DEFAULT
CONTROL
SET POINT LSPL~HSPL 0°C
0°C
User can change SP1 value using UP/DOWN keys. Holding the key will
change the value at a faster rate. Press SET key to store the desired value &
move on to the next parameter.
SET
POINT 2 LSPL~HSPL
This parameter is prompted only, if output 2 is configured as
(1) Either absolute auxiliary control or as an alarm (High/Low) mode.
(2) Either deviation auxiliary control or as a deviation alarm mode.
(3) As a band alarm (For all above SP2 has to be enable)
SOAK
TIME
0 min. to
999 min.
This parameter is prompted only, if output 2 is configured for soak timer
application. 1 min.
At power on, following sequence will be prompted on the display till it reaches to Home Display mode.
POWER UP:
UPPER
DISPLAY
LOWER
DISPLAY
MODEL
VERSION INPUT HOME
PV
SV
In home display mode, by pressing DOWN key, user
can view SP1 & SP2 value (If OP2 = AUXILIARY or
ALARM mode) or Timer value (If OP2 = SOAK
mode). By pressing UP key, user can view the
parameter code (SP1/SP2/SOAK TIME) of
respective set value. If soak time is in operation,
lower display will show either elapsed time (E.tmr) if
stdr=up or balance time (r.tmr), if stdr=dn.
PARA
METER
LOWER
DISPLAY
UPPER
DISPLAY RANGE DESCRIPTION DEFAULT
LOCK
CODE 1 ~ 9999
Set this parameter to 15 (Default LOCK CODE) to access Control List. User
has a choice to set different Lock Code via USER LOCK CODE in Config.
List.
0
PROPOR
TIONAL
BAND
0.5
to
999.9°C
This parameter will be prompted only, if selected control action is PID. It sets
bandwidth over which the output power is adjusted depending upon the error
(SV-PV). The value of this parameter is automatically set by Auto tune
function.
5.0°C
CYCLE
TIME
1
to
100.0 sec.
This parameter will be prompted only, if selected control action is PID. User
can set this value based on process being controlled & type of output being
selected. For Relay O/P, cycle time should be more than 12sec & for SSR
O/P, cycle time should be less than 10sec.
16.0 sec.
CONTROL
HYS. 1 to100°C
1 to 100°C
This parameter will be prompted only, if selected control action is ON-OFF. It
sets the dead band between ON & OFF switching of the output. Larger value
of hysteresis minimize the number of ON-OFF operation to the load. This
increases the life of actuators like contactors but also produces large errors
(between PV & SV)
2°C
2°C
DELAY 1
DELAY 2
0
to
500 sec.
0
to
500 sec.
This parameter will be prompted only, if selected control action is ON-OFF. It
sets the main output restart time where o/p once turned off will turn ON only
after restart time, regardless difference between PV & SP in Heat or Cool
mode. If set to ‘0', o/p will be switched without delay. Delay will be applicable
also in case of every power ON.
120 sec.
HYS. 2
This parameter will be prompted only, if selected control mode for output2 is
auxiliary control or an alarm. The value of this parameter sets the dead band
between ON & OFF switching of output load.
This parameter will be prompted only, if output 2 is configured as an auxiliary
control output. In this mode, output once turned off will restart only after set
time regardless of the difference between PV and SP2. The time delay is
settable upto 500 seconds. If time delay is set to 0, there is no delay
executed between output switching.
0 sec.
10 sec.
0
to
100 sec.
SOAK
TIME
DELAY
This parameter will be prompted only, if selected control mode for output2 is
Soak timer. Depending on end of soak strategy selected by user, the value of
this parameter sets the activation time for OP2 when Soak timer is over.
Setting this parameter to 0 will make OP2 continuously ON at the end of soak
time till user starts the next cycle.
-25 to 25°C This parameter will appear only, if selected C.A. is time proportional (For
more details, refer User guide). 0°C
MANUAL
RESET
MODE
CONTROL LIST : To enter in this mode, press SET & DOWN key simultaneously for 3sec. User can then set the
following control parameters.

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4OIM AI-5X82 V2.1 Page 4 of 6
CONFIGURATION LIST :
key simultaneously (1) To enter in this mode, Press and hold SET & UP for 3 sec.
(2) Press UP or DOWN key to scroll between parameter options.
(3) Press SET key to store the current parameter & move on to the next parameter.
PARA
METER
LOWER
DISPLAY
UPPER
DISPLAY DESCRIPTION DEFAULT
LOCK
CODE
INPUT
TYPE
Set this parameter to 15 (Default LOCK CODE) to access Config. List.
User has a choice to set different Lock Code via USER LOCK CODE in Config. List. 0
This parameter value is set according to the type of sensor (Thermocouple or RTD
input) connected to the Controller’s Input Terminals.
}
Sensor Type Range Resloution Accuracy
Fe-k(J) T/C
Cr-AL(K) T/C
(R) T/C
(S) T/C
Pt-100(RTD)
Pt-100(RTD 0.1)
0 ~ 760°C
-99 ~ 1300°C
0 ~ 1700°C
0 ~ 1700°C
-100 ~ 450°C
-99.9 ~ 450.0°C
1°C
1°C
0.1°C
1°C
± 1°C
1°C
1°C
± 0.3°C
LOWER
SET
POINT
LIMIT
HIGHER
SET
POINT
LIMIT
Sets the minimum limit for set point adjustment. It can be set from minimum specified
range of selected sensor to HSPL value. 0°C
0°C
Sets the maximum limit for set point adjustment. It can be set from LSPL value to
maximum specified range of selected sensor. 400°C
PROCESS
VALUE
OFFSET
Function of this parameter is to add/subtract a constant value to the measured PV to
obtain the final PV for control applications. This parameter value can be altered
(1) To compensate for known thermal gradient.
(2) To match the display values with another recorder or indicator measuring the same
PV.
INPUT
FILTER
The controller is equipped with an adaptive digital filter which is used to filter out any
extraneous pulses on the PV. The filtered PV value is used for all PV dependent
functions. If the PV signal is fluctuating due to noise, increase the filter time constant
value.
4
CONTROL
MODE
FOR O/P 1
User can select between TP or ON-OFF action algorithm to be adopted for output. PID
CONTROL
LOGIC
FOR O/P 1
This parameter will appear only, if selected control mode is ON-OFF.
User can select heating logic in which OP1 will remain ON till PV < SP.
(PV increases when output is ON).
This parameter will appear only, if selected control mode is ON-OFF.
User can select cooling logic in which OP1 will remain ON till PV > SP.
(PV decreases when output is ON).
HEAT
OUTPUT 2
FUNCTION
This parameter allows the user to select output 2 as an ‘Auxiliary’ control.
For options refer Table 3.
This parameter allows the user to select output 2 as a ‘Soak timer’ mode.
This parameter allows the user to select output 2 as an ‘Alarm’ control.
For options refer Table 4.
Auxiliary
tC-J

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5OIM AI-5X82 V2.1 Page 5 of 6
TABLE 4 :
Below listed parameters will appear only, if OUTPUT 2 is selected as ALARM mode. In ALARM mode, controller
continuously compares PV with either SP (For Deviation or Band alarm) or an independent ALARM SP2 (For
process high and process low Alarm). Alarm will occur when PV falls outside the set alarm limits. Also, OP2 will
energize or de-energize under Alarm condition as per the Alarm logic(AL.LG) selected. HYS2 in control List
decides when to switch OFF the alarm. Instrument supports four types of Alarm as described below :-
(Direct acting)
(Direct acting)
OUTPUT-2 ON
OUTPUT-2 OFF
SP2
PV
(Direct acting)
SP2
OUTPUT-2 OFF
OUTPUT-2 ON PV
(Reverse acting)
OUTPUT-2 OFF
OUTPUT-2 ON
SP2
PV
(Direct acting)
SP2
OUTPUT-2 ON
OUTPUT-2 OFF PV
(Reverse acting)
(Reverse acting)
(Reverse acting)
OUTPUT ON
SP2
PV
SP1
OUTPUT OFF
OUTPUT ONOUTPUT ON
PV
SP1
SP2SP2
OUTPUT OFF
OUTPUT OFF OUTPUT OFF
PV
SP1
SP2SP2
OUTPUT ON
OUTPUT OFF
SP2
PV
SP1
OUTPUT ON
PARA
METER
LOWER
DISPLAY
UPPER
DISPLAY DESCRIPTION DEFAULT
ALARM
TYPE DEVIATION
Low Alarm : OP2 activates when PV < SP2.
High Alarm : OP2 activates when PV > SP2.
Deviation Alarm : OP2 activates when PV exceeds SP1 ± set deviation value.
Band Alarm : OP2 activates when PV falls outside the band w.r.t SP1 either direction
TABLE 3 :
Below listed options will appear only, if OP2 is selected as an Auxiliary control mode.
PARA
METER
LOWER
DISPLAY
UPPER
DISPLAY DESCRIPTION DEFAULT
INPUT
TYPE
If selected, User can set SP2 value independently, irrespective of SP1.
Abs
In this mode, SP2 is always related with SP1.
User can set SP2 value with deviation of ± 99°C w.r.t SP1.
OUTPUT 2
LOGIC
User can select Heat logic for control Output 2 in which OP2 will remain ON till PV < SP
(PV increases when output is ON)
User can select Cool logic for control Output 2 in which OP2 will remain ON till PV > SP
(PV decreases when output is ON)
Heat
SET
POINT
1
SET
POINT
2
If Enabled, User can view & edit the Set Point (SP1) in USER list.
If Enabled, User can view & edit the Set Point (SP2) in USER list.
If Disabled, User cannot view or edit Set Point (SP1) in USER list.
If Disabled, User cannot view or edit Set Point (SP2) in USER list.
Enable
Enable
USER
LOCK
CODE
Default USER LOCK CODE is 15 to access Control & Configuration List.
User has a choice to set its own USER LOCK CODE between 1 to 9999, this is to
prevent unauthorized access of Control & Configuration List.
15

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6OIM AI-5X82 V2.1 Page 6 of 6
338, New Sonal Link Service Industrial Premises Co-op Society Ltd,
Building No.2, Link Road, Malad (W), Mumbai - 400064.
Tel: [phone];
E-mail : [e-mail]
Website : www.itherm.co.in
Mfgd by: Innovative Instruments & Controls LLP
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USER GUIDE :
1) ON-OFF ACTION :
In this mode, output (Relay/SSR) remains ON, till
actual temperature reaches to the set point. On
reaching SP, output turns OFF & remains OFF, till
actual temperature drops down (in heat logic) or
raises (in cool logic) equal to hysterisis set by user.
(As shown in Fig : 3.1 & 3.2)
TEMP (°C)
SP
AMB
O/P ON ON ONOFF OFF
TIME
HEAT LOGIC / ON-OFF
Fig: 3.1
HYSTERISIS
TEMP (°C)
SP
AMB
O/P O/PON ONON OFFOFF
TIME
HYSTERISIS
COOL LOGIC / ON-OFF
Fig: 3.2
2) TIME PROPORTIONAL ACTION :
In this mode, ON & OFF time of Output (Relay/SSR)
varies proportionally in every cycle (cycle time
settable by User) depending on the deviation of PV
w.r.t SP. This action starts/continues only, when PV
enters or is within the band. (As shown in Fig : 3.3) TIME
TEMP (°C)
SP
AMB
Fig: 3.3
ON
100%
ON
100%
OFF
100%
OUTPUT
TIME PROPORTIONAL ACTION
ACTIVE ZONE
PROPORTIONAL BAND (P.BAND)
SET BY USER
3) MANUAL RESET (OFFSET ADJUSTMENT) :
In some applications, after adopting Time
Proportionating action, system may stabilize at
particular temperature over a period of time which
can be different than the set value. This steady state
(error) offset can be eliminated by setting this value,
equal and opposite to the existing offset. (As shown
in Fig : 3.4)
TEMP (°C)
SP
AMB
TIME
Fig: 3.4
OFFSET
After offset adjustment
ALARM
LOGIC
If this parameter is set as ‘Direct’, Relay/SSR energizes under Alarm condition &
remains de-energized otherwise. ‘Direct’ setting is generally used for Audio/Visual alarm
output.
If this parameter is set as ‘Reverse’, Relay/SSR de-energizes under Alarm condition &
remains energized otherwise. ‘Reverse’ setting is generally used for tripping the process
under alarm conditions.
ALARM
INHIBIT
If this parameter is set to ‘YES’ & Alarm condition persists, it will disable Alarm O/P at
power ON.
If this parameter is set to ‘NO’ & Alarm condition persists, it will enable Alarm O/P at
power up.
DIRECT
NO
ALARM
ACK.
Once the Alarm is activated, User has following three options to de-activate it. When PV
falls within the programmed limits, the alarm will be de-activated automatically.
Once the alarm is activated, it remains activated until acknowledged manually by UP
key.
Once the alarm is activated, it can be de-activated either by pressing UP key or when
PV falls within the alarm limits.
AUTO
PARA
METER
LOWER
DISPLAY
UPPER
DISPLAY DESCRIPTION DEFAULT
NC : Normally Close terminal of relay
NO : Normally Open terminal of relay
OP1 : Output 1
OP2 : Output 2
PV : Process Value (Actual temperature)
C.A.: Control Action
CJC: Cold Junction Compensation
CM : Common terminal of relay
EMI : Electro Magnetic Interference
LWC: Lead Wire (Length) Compensation
SP : Set Point Value (Set temp.)
SSR : Solid State Relay
T.P. : Time Proportional
T/C : Thermocouple
ABBREVIATION