i-therm AI-7441 Operation instructions

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1. DISPLAY TYPE : 4- Digit 7 segment LED (Bright White)
STATUS LED : OP 1 : Main Control Output
2. INPUT
Sensor input : TC:J,K,R,S,N,T,B & 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 upto 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
Control Action : ON-OFF/PID (Select)
Control Mode : Heat/Cool (Select)
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
SPECIFICATIONS : - 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 slits 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.
( Models : AI 7441 / 7841 / 7741 / 7941 )
USER’S OPERATING MANUAL FOR PID DIGITAL TEMPERATURE CONTROLLER
AI - 7441
(48 X 48)
1OIM AI-7X41 V2.1 Page 1 of 5
AI - 7841
(48 X 96) AI - 7741 (72 X 72) AI - 7941 (96 X 96)
Model no.
Display height
AI-7441 AI-7841 AI-7741
0.36”
AI-7941
0.56”0.56”0.56”
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
0 ~ 1800 C
o
-100 ~ 450 C
Resolution
Range
o
1 C
o
1 C
o
1 C
}
(R) T/C
(S) T/C
TC - N
TC - T
TC - B
Pt-100(RTD)
Pt-100(RTD 0.1)
o
0 ~ 760 C
o
-99 ~ 1300 C
o
-99 ~ 1300 C
o
-99 ~ 400 C
o
-99.9 ~ 450.0 C
o
1 C
o
1 C
o
1 C
o
1 C
o
1 C
o
0.1 C
o
± 0.3 C
Model no.
Weight (gms.)
AI-7441
130 200 200
AI-7841 AI-7741
240
AI-7941

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OVER ALL DIMENSIONS & PANEL CUT OUT (IN MM)
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.
A
B D
E
G
F
MODEL:-AI-7441/7741/7941
PANEL
CUTOUT
CH
C H
MODEL : AI -7841
B
AE
DG
F
PANEL
CUTOUT
2OIM AI-7X41 V2.1 Page 2 of 5
TABLE : 1
Model
Dim
48
72
96
48
48
72
96
96
8
10
10
10
75
65
45
45
44
68
92
92
44
68
92
44
9
9
9
9
A B HC D F GE
43
66
89
43
AI-7441
AI-7741
AI-7941
AI-7841
ELECTRICAL INSTALLATION
The electrical connection diagram is shown on the controller enclosure as below.
AI - 7441 AI - 7941
123456789
10 11 12 13 14 15 16 17 18
NO NCCM
RELAY
SSR
SUPPLY
LN
123456789
10 11 12 13 14 15 16 17 18
NO NCCM
RELAY
SSR
SUPPLY
LN
AI - 7841
AI - 7741
SUPPLY
L
N
123456
78910 11 12
15
16
13
14
NO NCCM
RELAY
SSR
SUPPLY
LN
12345
678 9 10
11
13
14
15
16
12
NO NCCM
SSR
RELAY
Glows when OP1 is ON & flashes when delay time (dly1) is in operation(if selected mode is ON-OFF)
It will display (1)Measured value of selected input or Error massages. (2) SP value in run mode.
Parameters Values/code in program mode
1
2
OP1 LED
UPPER
DISPLAY
Sr. NAME FUNCTION
( ( (
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 enter in tune mode (with DOWN Key).
1) To increase/alter parameter value in program mode. 2) To Enter in configuration mode
( ( To enter in tune mode (with
UP Key).
1) To decrease / alter parameter value in program mode. 2)
4
5
6
7
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.
FRONT PANEL LAYOUT DESCRIPTION :
AI - 7441 AI - 7741 AI - 7941
FRONT PANEL LAYOUT
3
4
56
12
AI-7441
OP1 °C
SET AT
5 6
3
4
12
OP1
°C
-therm
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AI-7741
SET AT
1
3
456
2
OP1 °C
SET AT
-therm
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AI-7941
AI - 7841
OP1
SET AT
-therm
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AI-7841
°C
1
2
3
5
46

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3OIM AI-7X41 V2.1 Page 3 of 5
(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)
CONTROL LIST : SET & DOWN key simultaneously To enter in this mode press for 3 sec. User can set the control parameters.
PARA
METER
RANGE
DESCRIPTION DEFAULT
DISPLAY
PRORTIONAL
BAND
INTEGRAL
TIME
DERIVATIVE
TIME
CYCLE
TIME
CONTROL
HYS.
0.5
to
99.9°C
o
1 to 100 C
0
to
3600 Sec.
0
to
300 Sec.
1.0
to
100 Sec.
50 %
to
100 %
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.
This parameter will be prompted only if selected control action is PID. It defines how
strongly the Controller will react to the rate of change of PV. Value of this parameter
is automatically set by Auto Tune function. If set to ‘0’, this function will be disabled.
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 5 Sec.
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 hysterisis
minimize the number of ON-OFF operation of load. This increases life of actuators
like contactors but also produces large errors (between PV & SV).
This parameter will be prompted only if selected control action is PID. It sets the time
taken by PID algorithm to remove steady state error. Value of this parameter is
automatically set by Auto Tune function. If set to ‘0’, this function will be disabled.
o
5.0 C
240
60
16.0 Sec.
100 %.
100 %.
2°C
DELAY
0
to
500 Sec.
This parameter will be prompted only if selected control action is ON-OFF. It sets the
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. Also, Delay will be applicable at every power ON.
0 Sec.
0
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.
OUTPUT
POWER
LIMIT
TUNE
OFFSET
0.0 %
TO
100.0 %
This parameter will be prompted only if selected control action is PID. This parameter
will decide the maximum output power in % applied to the load
This parameter will be promted only if selected control action is PID.This parameter
allows the user to carry out Auto Tuning function below the set point. (If tune offset is
set to 50 %, tuning will be carried out at 50 % of the set point and If set to 100 %,
tuning will be carried out at 100 % of the set point.)
OUTPUT
OFF
This parameter will be prompted only if selected control action is PID. With this
parameter O/P will be Completely OFF after the Set Point + Offset Value. If
Disable, O/P will act Depending upon the PID Value after Set Point achieved.
Disable
1 to 10
MODEL
VERSION INPUT HOME
PV
POWER UP :
At power-on, following sequence will be prompted on the display for 1 sec. till it reaches to Home display mode.
PROGRAMMING :
USER LIST : To access the user list, Press & Release SET key once.
(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values/options).
PARA
METER DISPLAY RANGE DESCRIPTION DEFAULT
Control
Set Point LSPL~HSPL
User can change SP value using UP/ DOWN keys. Holding the key, will change the value
at a faster rate. Press SET key to store the value & move on to the next parameter. 0°C

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CONFIGURATION LIST : (1) key simultaneously 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.
(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)
4OIM AI-7X41 V2.1 Page 4 of 5
PROCESS
VALUE
OFFSET
o
0 C
Function of this parameter is to add/subtract a constant value to the measured PV to obtain Final
PV for control applications. This parameter value needs to be be altered for one of the following
reason : -
(i) To compensate for known thermal gradient
(ii)To match the display values with another recorder or indicator measuring the same PV.
HIGHER
SP
LIMIT
o
400 C
Sets the maximum limit for set point adjustment. It can be set from LSPL value to maximum
specified range of selected sensor.
LOWER
SP
LIMIT
o
0 C
Sets the minimum limit for set point adjustment. It can be set from minimum specified range of
selected sensor to HSPL value.
CONTROL
LOGIC
HEAT
This parameter will be prompted only if selected control mode is ON-OFF.
User can select HEAT logic in which OP1 will remain ON till PV < SP.
(PV increases when output is ON.)
This parameter will be prompted 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.)
CONTROL
MODE
PID
User can select between PID or ON-OFF action algorithm to be adopted for output.
INPUT
FILTER 4
Controller is equipped with an adaptive digital filter which is used to filter out any extraneous
pulses on the PV. Filtered PV Value is used for all PV dependent functions. If PV signal is
fluctuating due to noise, increase the filter time constant value.
TC - J
INPUT
TYPE
This parameter value is set according to the type of sensor (Thermocouple or RTD input)
connected to the controller's input terminals.
o
0.3 C
±
Fe-k(J) T/C
Cr-AL(K) T/C
Pt-100(RTD)
Sensor Type Accuracy
o
0 ~ 760 C
o
-99 ~ 1300 C
o
-99 ~ 1300 C
o
-99 ~ 400 C
o
0 ~ 1800 C
o
-100 ~ 450 C
Resolution
Range
o
1 C
o
1 C
o
1 C
}
(R) T/C
(S) T/C
TC - N
TC - T
TC - B
Pt-100(RTD 0.1)
o
-100.0 ~ 450.0 C
o
0 ~ 1700 C
o
0 ~ 1700 C
o
1 C
o
1 C
o
1 C
o
1 C
o
0.1 C
o
1 C
1
±oC
PARA
METER
DESCRIPTION DEFAULT
DISPLAY
0
LOCK
CODE
Set this parameter to 15 (Default LOCK CODE) to access Config. List.
User has a choice to set different Lock Code between 1 to 9999 via USER LOCK CODE in
Config. List.
OVERSHOOT
CONTROL
POINT
DISABLE
This parameter will be prompted only if selected control action is PID. Setting this parameter on higher
side will slows down the rate of rise of PV to minimize overshoot (this may cause delay to reach SP).
Disabling or Setting this parametr on lower side will increase the rate of rise of PV (which may cause
overshoot). Disable this option if delay is not required to reach SP.
(This may cause overshoot w.r.t. SP)
OUTPUT
TYPE RELAY
User has to set this parameter very carefully in accordance with the output used. (Separate
terminal for RELAY & SSR : - Refer electrical installation )
Select Relay if LOAD is connected via contactor. Whenever user selects Relay, Cycle time will
automatically set to 16 sec. User can modify cycle time via Control List.
Select SSR if LOAD is connected via SSR (DC voltage pulses). Whenever user selects SSR ,
Cycle time will automatically set to 1sec. User can modify cycle time via Control List.

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AUTO TUNING MODE : To enter in this mode, Press & hold SHIFT key for minimum 3 sec.
PARA
METER DESCRIPTION DEFAULT
This function will be executed only if selected control action is PID.
Auto-tuning function can be initiated by setting this parameter to ‘YES’. The decimal of LSB
flashes till Auto Tuning function is in progress. During Auto-tuning, Controller learns the process
characteristics by itself & calculates required P, I & D values.
User can cancel or abort this feature by setting this parameter to ‘NO’.
AUTO
TUNING
MODE
NO
DISPLAY
5OIM AI-7X41 V2.1 Page 5 of 5
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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15
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.
USER
LOCK
CODE
SET
POINT 1
ENABLE
If Enabled, User can View & edit the Set point 1 in USER list.
If disabled, User can only View the Set Point 1 but Can not edit it in USER list.
AUTO
TUNE
ENABLE
If Enabled, this parameter will be prompted if user press Up & Down keys Simultaneously for
3Sec.
If Disabled, this parameter will not be prompted if user press Up & Down keys Simultaneously
for 3Sec.
PARA
METER DESCRIPTION DEFAULT
DISPLAY
ON-OFF ACTION : In this mode, Output (Relay/SSR) remains ON till actual temperature reaches to the set point value. 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)
Fig: 3.1
HEAT LOGIC / ON-OFF TIME
0
TEMP ( C)
HYSTERISIS
SP
ON ON ON
AMB
O/P OFF OFF
Fig: 3.2
TIME
COOL LOGIC / ON OFF
O/P O/P
0
TEMP ( C)
AMB HYSTERISIS
ON ON ON
SP
OFF OFF
USER GUIDE :
AUTO TUNING MODE : In this mode, Controller learns the process characteristics by itself and calculates the required P,I &
D values. It can be performed at any time after power ON but, it is best to start it when the process is at Ambient temperature in order
to minimize overshoot & undershoot. Auto tuning is applied in case of :
(1) Initial set up for a new process.
(2) Substantial change in SP from previous auto tuning value.
(3) Control accuracy is not satisfactory.
If the control performance by using auto-tuning is still unsatisfactory, User can apply the further adjustments of P,I & D values as shown
below
Adjust
Proportional Band
Integral Time
Derivative Time
Slow Response
Over Shoot or Oscillations
Slow Response
Instability or Oscillation
Slow Response or Oscillation
High Over Shoot
Decrease PB
Increase PB
Decrease Int
Increase Int
Decrease Dt
Increase Dt
Symptom Solution