Innovative instruments i-therm AI 5442 Operation instructions

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1. DISPLAY TYPE : 4- Digit 7 segment LED (RED)
STATUS LED’S : OP1 : Main Control Output
OP2 : Alarm Status
: Auxiliary control output
2. INPUT
Sensor Input : 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 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
Output 2 : Programmable
1) Auxiliary control 2) Alarm
Control Action : ON-OFF/T.P (Select)
Control Mode : Heat/Cool (Select)
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
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
poximity 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.
vIt 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.
Model no.
Weight (gms.)
AI-5442 AI-5842 AI-5742 AI-5942
130 200 200 240
USER’S OPERATING MANUAL FOR DIGITAL TEMPERATURE CONTROLLER
(Models: AI 5442 / 5742 / 5842 / 5942)
SPECIFICATIONS : -
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
AI - 5442
(48 X 48) AI - 5742 (72 X 72) AI - 5942 (96 X 96)
AI - 5842
(48 X 96)
OP1
OP2
°C
SET ACK
-therm
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AI-5942
OP1
OP2
°C
-therm
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AI-5742
SET ACK
AI-5442
OP1
OP2
SET ACK
OP1
OP2
SET ACK
-therm
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AI-5842
°C
Model no.
Display height
AI-5442 AI-5842 AI-5742 AI-5942
0.36” 0.56”0.56”0.56”
1OIM AI-5X42 - V2.0 Page 1 of 6

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SUPPLY
L
N
123456
78910 11 12
15
16
13
14
NO NCCM
RELAY2
SSR2
NO NCCM
RELAY1
SSR1
123456
10 11 12 13 14 15 16 17 18
789
NO NCCM
RELAY1
SSR1
NO NCCM
RELAY2
SSR2
SUPPLY
LN
123456789
10 11 12 13 14 15 16 17 18
NO NCCM
RELAY1
SSR1
NO NCCM
RELAY2
SSR2
SUPPLY
LN
AI - 5442 AI - 5742 AI - 5942 AI - 5842
NO
NC CM
RELAY2
SSR2
SUPPLY
LN
12345
678 9 10
11
13
14
15
16
12
NO NCCM
RELAY1
SSR1
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.
MODEL : AI - 5842
B
AE
D
C H
A
B D
CH
E
G
F
G
F
MODEL:-AI-5442/5742/5942
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.
PANEL
CUTOUT
PANEL
CUTOUT
ELECTRICAL INSTALLATION
The electrical connection diagram is shown on the controller enclosure as shown below.
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-5442
AI-5742
AI-5942
AI-5842
FRONT PANEL LAYOUT
FRONT PANEL LAYOUT DESCRIPTION :
OP1 LED
OP2 LED
DISPLAY
SET
KEY
SHIFT
KEY
Sr. NAME FUNCTION
Glows when OP1 is ON & flashes when delay time (dly1) is in operation
(if selected mode is ON-OFF)
Glows when OP1 is ON & flashes when alarm condition persists even after
acknowledged or delay time (dly2) is in operation (if selected mode is ON-OFF).
It will display: (1) Measured value of selected input or Error massages. (2) SP (Main
set point) / SP2 value in run mode. (3) Parameters Value/code in program mode.
(1) For SP programming. (2) To access Control mode along with DN Key.
(3) To access Configuration mode along with UP key. (4) To scroll the parameter &
to store its value.
1
2
3
UP
KEY
DOWN
KEY
(1) To increase/alter parameter value in program mode. (2) To Enter in configuration
mode (with SET key). (3) To acknowledge Alarm.
(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.
(1) To decrease/alter parameter value in program mode.
(2) To Enter control mode along with SET Key.
4
5
6
OP1
OP2
SET
-therm
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AI-5842
°C
1
3
456
2
AI - 5941
2
3
1
AI - 5441
1
2
3
5
46
AI - 5741
1
6
5
4
3
2
AI - 5841
OP1
OP2
°C
SET
-therm
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AI-5942
AI-5442
OP1
OP2
SET
OP1
OP1
°C
-therm
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AI-5742
SET
6
5
4
2OIM AI-5X42 - V2.0 Page 2 of 6

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(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)
PARA
METER
RANGE
DESCRIPTION DEFAULT
DISPLAY
User can change the SP1 value using UP/ DOWN keys. Holding the
key will change the value at a faster rate. Press SET key to store the
value and move on to the next parameter.
o
0 C
LSPL ~ HSPL
CONTROL
SET POINT
This parameter is prompted only if Output 2 is configured as...
Either absolute auxiliary control or as an alarm (High/Low) mode.
Either deviation auxiliary control or as a deviation alarm mode.
As a band alarm.(For all above Sp2 has to be enable)
(1)
(2)
(3)
LSPL ~ HSPL
-99 to 99 °C
2 to 99 °C
SET
POINT2
o
0 C
CONTROL LIST : SET & DOWN key simultaneously To enter in this mode press for 3 sec. User can then set
the control parameters.
MANUAL
OFFSET
o
0 C
This parameter will appear only if selected C.A is time proportional.
(For more details refer user guide.)
PARA
METER
RANGE
DESCRIPTION DEFAULT
DISPLAY
P. BAND
0.5
to
99.9°C
This parameter will appear only if selected control action is T.P. It sets
bandwidth over which the output power is adjusted depending upon
the error (SV-PV).
o
5.0 C
DELAY 1
0
to
500 Sec.
This parameter will appear 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. If set
to '0', O/P will be switched w/o delay. Also, Delay will be considered in
case of every power ON.
120 Sec.
CONTROL
HYS.
o
1 to 25 C
This parameter will appear 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 the load. This increases life of actuators like contactors but, also
produces large errors (between PV & SV).
2°C
This parameter will appear only if selected control mode for output2 is
Auxiliary control or an Alarm. Value of this parameter sets the dead
band between ON & OFF switching of output load.
HYS. 2
o
1 to 25 C
o
2 C
0
to
500 Sec.
-25
to
o
25 C
This parameter will appear 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. If time delay is set to 0, there is no delay executed between
output switching.
0 Sec.
DELAY 2
CYCLE
TIME
0.5
to
100.0 Sec.
This parameter will appear only if selected control action is T.P. User
can set this value based on process being controlled & type of output
selected. For Relay O/P, cycle time should be more than 12sec & for
SSR O/P, cycle time should be less than 5sec.
16.0 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.
POWER UP :
At power on, following sequence will be prompted on the display for 1 sec. till it reaches to Home display mode.
In Home display mode, by pressing SET key once, user can view SP value.
MODELMODEL
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)
HOME
PV
VERSION INPUT
3OIM AI-5X42 - V2.0 Page 3 of 6

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INPUT
FILTER
o
1 C
The 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.
CONTROL
LOGIC
FOR OP1
HEAT
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.)
CONTROL
MODE
FOR
OUTPUT1
T.P
User can select between ON-OFF or T.P action algorithm to be adopted for
output.
OUTPUT2
FUNCTION
This parameter allow the user to select output 2 as an ‘Auxiliary’ control.
For options refer Table 3.
This parameter allow the user to select output 2 as an ‘Alarm’ control.
For options refer Table 4.
AUX.
CONTROL
SET
POINT 2
DSBL
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.
LOWER
SP
LIMIT
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
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.
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.
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.
(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)
PARA
METER
DESCRIPTION DEFAULT
DISPLAY
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.
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.
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
If Enabled, User can View & edit the Set point1 in USER list.
If disabled, User can only View the Set Point1 but Can not edit it in USER list.
4OIM AI-5X42 - V2.0 Page 4 of 6

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If this parameter is set as ‘Reverse’, Relay/SSR de-energizes under Alarm
conditions & remains energized otherwise. Generally ‘Reverse’ setting is used
for tripping the process under Alarm conditions.
DIRECT
ALARM
LOGIC
If this parameter is set as ‘Direct’, Relay/SSR energizes under Alarm condition
& remains De-energized otherwise. Generally ‘Direct’ setting is used for
Audio/Visual Alarm Output.
DEVIATION
ALARM
TYPE
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 in either
direction.
Low Alarm : OP2 activates when PV<SP2.
High Alarm : OP2 activates when PV>SP2.
(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
DISPLAY
PARA
METER DESCRIPTION
DEFAULT
(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)
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
TABLE 4 :
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 : -
Below listed parameters will appear only if OUTPUT 2 is selected as ALARM. In ALARM mode,
TABLE 3 : Below listed options will appear only if OP2 is selected as an Auxiliary control mode .
(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)
HEAT
User can select cooling logic in which OP2 will remain OFF till PV < SP2.
(PV decreases when output2 is ON)
OUTPUT 2
LOGIC
User can select heating logic in which OP2 will remain ON till PV < SP2.
(PV increases when output2 is ON)
This parameter will appear only if OUTPUT 2 is selected as an Auxiliary control
output. In this mode, User can set SP2 value which is always related to SP.
PARA
METER
DESCRIPTION DEFAULT DISPLAY
AbS
This parameter will appear only if OUTPUT 2 is selected as an Auxiliary control
output. In this mode, User can set SP2 value independently. The instrument
OUTPUT 2
MODE
SET
POINT 2
DSBL
If Enabled, User can View & edit the Set point2 in USER list.
If disabled, User can only View the Set Point2 but Can not edit it in USER list.
5OIM AI-5X42 - V2.0 Page 5 of 6

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ALARM
ACK.
AUTO
Once Alarm is activated, it can be de-activated either by pressing UP key or
when PV falls within the alarm limits.
Once Alarm is activated, it remains activated until manually acknowledged by
UP key.
Once Alarm is activated, User has following three options to de-activate it.
When PV falls within the programmed limits, Alarm will be de-activated
automatically.
ALARM
INHIBIT
Setting this parameter value to ‘YES’, will inhibit (suppress) Alarm activation on
power-up condition. From Power-up, the Alarm system remains disabled until
PV is found with in the limits.
If Alarm activation is desired even under Power-up condition, Set this parameter
value to ‘NO’.
NO
1) ON-OFF ACTION:
In this mode, Output (Relay/SSR) remains ON till actual temperature reaches to 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:
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. (Fig. 3.3)
Fig: 3.3
AMB
0
TEMP ( C)
SP
OUT PUT
ON
100 %
ON
100 %
OFF
100 %
PROPORTIONAL BAND (P.BND)
SET BY USER
TIME PROPORTIONAL ACTION
ACTIVE TONE
TIME
Fig: 3.4
AMB
0
TEMP ( C)
SP
OFFSET
after offset adjustment
TIME
3) MANUAL RESET (OFFSET ADJUSTMENT):
In some application, 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 the value of this parameter equal and opposite to the
existing offset. (As shown in Fig.3.4)
NC : Normally Close terminal of relay
NO : Normally Open terminal of relay
OP1 : Output 1
OP2 : Output 2
C.A. : Control Action
CJC : Cold junction compensation
CM : Common terminal of relay
LWC : Lead wire (Length)
compensation
SP : Set Point Value(set temp.)
SSR : Solid State Relay
T.P. : Time Proportional
T/C : Thermocouple
ABBREVIATION :
Innovative Instruments
On
Google Play
206, New Sonal Link Service Industrial Premises Co-op Society Ltd,
Building No.2, Link Road, Malad (W), Mumbai - 400064.
Tel: [phone];
E-mail :
Website :
[e-mail]
www.innovativeinstruments.co.in
Mfgd by: Innovative Instruments & Controls LLP
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6OIM AI-5X42 - V2.0 Page 6 of 6