Innovative instruments i-therm AI-5441 Operation instructions

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1. DISPLAY TYPE : 4-Digit 7 segment LED (RED)
STATUS LED’S : OP 1 : Main 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
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.
Model no.
Display height
AI-5441 AI-5841 AI-5741 AI-5941
0.36” 0.56”0.56”0.56”
USER’S OPERATING MANUAL FOR DIGITAL TEMPERATURE CONTROLLER
Model no.
Weight (gms.)
AI-5441
130 200 200 240
AI-5841 AI-5741 AI-5941
SPECIFICATIONS: -
(Models: AI 5441 / 5741 / 5841 / 5941)
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 instructions 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 to 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
so, 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.
AI - 5441
(48 X 48) AI - 5741 (72 X 72) AI - 5941 (96 X 96)
AI - 5841
(48 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
OP1 °C
SET
-therm
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AI-5941
OP1 °C
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AI-5741
SET
AI-5441
OP1
SET
OP1
SET
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AI-5841
°C
1OIM AI-5X41 - V2.0 Page 1 of 4

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ELECTRICAL INSTALLATION
The electrical connection diagram is shown on the controller enclosure as below.
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.
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-5441
AI-5741
AI-5941
AI-5841
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
CH
E
G
F
MODEL:-AI-5441/5741/5941
PANEL
CUTOUT
MODEL : AI - 5841
B
AE
D
C H
G
F
PANEL
CUTOUT
AI - 5941 AI - 5841
FRONT PANEL LAYOUT
FRONT PANEL LAYOUT DESCRIPTION :
OP1 LED
DISPLAY
SET
KEY
SHIFT
KEY
Sr. NAME FUNCTION
Glows when OP1 is ON & flashes when delay time (dly) 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) 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 Set SP Offset (with 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.
(1) To decrease/alter parameter value in program mode.
(2) To Enter control mode
4
5
6
AI - 5741
SUPPLY
L
N
123456
78910 11 12
15
16
13
14
NO NCCM
RELAY
SSR
AI - 5441
SUPPLY
LN
12345
67 8 9 10
11
13
14
15
16
12
NO NCCM
RELAY
SSR
123456
10 11 12 13 14 15 16 17 18
789
NO NCCM
RELAY
SSR
SUPPLY
LN
123456789
10 11 12 13 14 15 16 17 18
NO NCCM
RELAY
SSR
SUPPLY
LN
OP1
SET
-therm
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AI-5841
°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 °C
SET
-therm
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AI-5941
AI-5441
OP1
SET
OP1 °C
-therm
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AI-5741
SET
6
5
4
2OIM AI-5X41 - V2.0 Page 2 of 4

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POWER UP :
At power on, following sequence will be prompted on the display till it reaches to Home display mode.
In home display mode, by pressing SET key once user can view SP value.
MODEL HOME
PV
VERSION INPUT
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 next parameter.
o
0 C
LSPL ~ HSPL
CONTROL
SET POINT
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)
(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
PARA
METER
RANGE
DESCRIPTION DEFAULT
DISPLAY
CONTROL LIST : SET & DOWN key simultaneously To enter in this mode, press for 3 sec. User can then set
all the control related parameters as shown below.
0
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.
0.5
to
99.9°C
o
1 to 25 C
0.5
to
100.0 Sec.
0
to
500 Sec.
-25
to
o
25 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).
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 being selected.
For Relay O/P, cycle time should be more than 12 Sec & for SSR O/P, cycle time
should be less than 5 Sec.
This parameter will appear only if selected control action is ON-OFF. It sets the
main output restart time. If set to '0', O/P will be switched without delay. Also,
Delay will be considered in case of every power ON.
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 Relay but, also produces large errors.
o
5.0 C
16.0 Sec.
0 Sec.
2°C
P.BAND
CYCLE
TIME
CONTROL
HYS.
DELAY
LOCK
CODE
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.
(All following selected parameter’s code shown in shaded will be displayed for 1 sec. followed by their values / options)
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.
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 in the range via USER LOCK CODE
in Config. List.
1 ~ 9999
MANUAL
OFF SET
o
0 C
This parameter will appear only if selected C.A is time proportional.
(For more details refer User guide.)
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
3OIM AI-5X41 - V2.0 Page 3 of 4

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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.
PROCESS
VALUE
OFFSET
INPUT
FILTER
CONTROL
MODE
CONTROL
LOGIC
o
0 C
o
1 C
T.P
HEAT
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.
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.
User can select between ON-OFF or T.P action algorithm to be adopted for output.
(Refer User Guide)
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.)
OUTPUT
TYPE RELAY
User has to set this parameter very carefully in accordance with the output used.
(Separate terminals 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.
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
PARA
METER DESCRIPTION DEFAULT
DISPLAY
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.
SET
POINT 1
If Enabled, User can View & edit the Set point in USER list.
If disabled, User can only View the Set Point but Can not edit it in USER list.
ENABLE
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)
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 this value equal and
opposite to the existing offset. (As shown in Fig : 3.4)
TIME PROPORTIONAL ACTION
ACTIVE ZONE
Fig: 3.3
AMB
0
TEMP ( C)
SP
OUT PUT
ON
100 %
ON
100 %
OFF
100 %
PROPORTIONAL BAND (P.BND)
SET BY USER
time
AMB
0
TEMP ( C)
SP
Fig: 3.4
OFFSET
after offset adjustment
TIME
SP : Set Point Value(set temp.)
SSR : Solid State Relay
T.P. : Time Proportional
T/C : Thermocouple
NC : Normally Close terminal of relay
NO : Normally Open terminal of relay
OP1 : Output 1
PV : Process Value (actual temp.)
C.A. : Control Action
CJC : Cold junction compensation
CM : Common terminal of relay
LWC : Lead wire (Length)
compensation
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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OIM AI-5X41 - V2.0 Page 4 of 4