USER S OPERATING MANUAL FOR PID DIGITAL TEMPERATURE CONTROLLER (Models: AI 7482 / 7882 / 7782 / 7982 / 7682) (72 X 72) Accuracy. ±1 o. ± 0.

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1 USER S OPERATING MANUAL FOR PID DIGITAL TEMPERATURE ONTROLLER (Mdels: AI 78 / 788 / 778 / 78 / 768). TYPE : Dual - Digit 7 Segment LED Digit Bright Red () Digit Luminus Green (SV) STATUS LED S. INPUT Sensr input Range ENVIRONMENTAL Operating Range Strage Humidity POWER SUPPLY Supply Vltage nsumptin PHYSIAL Husing Mdel n. Weight (gms.) : OP : Main ntrl Output OP : Alarm Status : Sak Timer TUNE : Tuning Status (Only fr AI-78) : J/K/R/S/Pt- : Refer belw table. Sampling Time : msec. Reslutin : J fr T : Built in autmatic LW fr Pt- : Built in upt 8E max. Digital Filter : t Sec. 3. RELAY OUTPUT ntact type ntact Rating Life expectancy Islatin : N/O, M, N/ : VA r 3 VD : >,, peratins : Inherent. SSR DRIVE OUTPUT Drive apacity : 3mA. Islatin : Nn-Islated.. FUNTION Output : Main ntrl utput Output : Prgrammable ) Auxiliary cntrl ) Alarm 3) Sak timer ) Alarm + Sak timer ntrl Actin : ON-OFF/T.P (Select) ntrl Mde : Heat/l (Select) mpliance : SPEIFIATIONS : - Mdel n. Display height () Display height (SV) Sensr Type Fe-k(J) T/ r-al(k) T/ (R) T/ (S) T/ Pt-(RTD) Pt-(RTD.) AI-78 (8 X 8) AI-78 AI-788 AI-778 AI-78 AI Range ~ 76 - ~ 3 ~ 7 ~ 7 - ~ -. ~. AI-788 (8 X 6) Reslutin }. : ~, ~% Rh : 8% Rh (Nn-cndensing) : ~7VA, /6Hz. : W Maximum. Accuracy ± ±.3 : ABS Plastic AI-78 AI-778 AI-78 AI-788 AI AI-778 (7 X 7) AI-768 (6 X 8) AI-78 (6 X 6) SAFETY INSTRUTION : This cntrller is meant fr temperature cntrl applicatins. It is imprtant t read the manual prir t installing r cmmissining f cntrller. All safety related instructin appearing in this manual must be fllwed t ensure safety f the perating persnnel as well as the instrument. GENERAL The cntrller must be cnfigured crrectly fr intended peratin. Incrrect cnfiguratin culd result in damage t the equipment r the prcess under cntrl r it may lead persnnel injury. The cntrller is generally part f cntrl panel and in such a case the terminals shuld nt remain accessible t the user after installatin. MEHANIAL The ntrller in its installed state must nt cme in clse prximity t any crrsive/cmbustible gases, caustic vapurs, ils, steam r any ther prcess byprducts. The ntrller in its installed state shuld nt be expsed t carbn dust, salt air, direct sunlight r radiant heat. Ambient temperature and relative humidity surrunding the cntrller must nt exceed the maximum specified limit fr prper peratin f the cntrller. The cntrller in its installed state must be prtected against excessive electrstatic r electrmagnetic interferences. Ventilatin hles prvided n the chassis f the instrument are meant fr thermal dissipatin hence shuld nt be bstructed in the panel. ELETRIAL The cntrller must be wired as per wiring diagram & it must cmply with lcal electrical regulatin. are must be taken nt t cnnect A supplies t lw vltage sensr input. ircuit breaker r mains s/w with fuse (7V/A) must be installed between pwer supply and supply terminals t prtect the cntrller frm any pssible damage due t high vltage surges f extended duratin. ircuit breaker and apprpriate fuses must be used fr driving high vltage lads t prtect the cntrller frm any pssible damage due t shrt circuit n lads. T minimize pickup f electrical nise, the wiring fr lw vltage D and sensr input must be ruted away frm high current pwer cables. Where it is impractical t d this, use shielded grund at bth ends. The cntrller shuld nt be wired t a 3-Phase supply with unearthed star cnnectin. Under fault cnditin such supply culd rise abve 6 VA which will damage the cntrller. The Electrical nise generated by switching inductive lads might create mmentary Fluctuatin in display, alarm latch up, data lss r permanent damage t the instrument. T reduce this use snubber circuit acrss the lad. It is essential t install a ver Temp. Prtectin device t avid any failure f heating system. Apart frm spiling the prduct, this culd damage the prcess being cntrlled. Dcument Name : OIM AI-7X8 (Ver.) Page f 8

2 AUTION: T prevent the risk f electrical shck, switch ff the pwer befre making/remving any cnnectin r remving the cntrller frm its enclsure. MEHANIAL INSTALLATION The label n the cntrller identifies the serial number, wiring cnnectins and batch number. OVER ALL DIMENSIONS & PANEL UT OUT (IN MM) MODEL:-AI-78/778/78 TABLE : A MODEL : AI A B D H E E PANEL UTOUT G PANEL UTOUT F F Mdel Dim AI-78 8 AI AI-78 6 AI AI A B D E F G H B MODEL : AI D H G INSTALLATION GUIDELINES : A B D H E PANEL UTOUT G F. Prepare the cut-ut with prper dimensin as shwn in figure.. Remve clamp frm cntrller 3. Push the cntrller thrugh panel cut-ut and secure the cntrller in its place by tightening the side clamp. ELETRIAL INSTALLATION The electrical cnnectin diagram is shwn n the cntrller enclsure as belw L NNO M N SUPPLY RELAY 6 NO M N RELAY SSR L N 3 6 SUPPLY 7 8 NO M N RELAY NO M N RELAY L N NO M N NO M N 3 6 L SUPPLY NNO M RELAY N NO M RELAY N SSR SSR SSR SUPPLY RELAY RELAY SSR SSR AI-78 AI-778 AI - 78 SSR SSR AI - 768/788 FRONT PANEL LAYOUT 6 3 AI-78 OP 7 AI-78 SV RE START AI-778 OP 7 AI-778 SV RE START 8 AI - 78 AI-78 SV OP TUNE RE START AI OP AI RE 6 8 START 7 OP AI-788 RE 3 8 AI START 7 NO. NAME OP LED LED LED KEY UP KEY DOWN KEY FUNTION Glws when OP is ON & flashes when delay time (dly) is in peratin & selected mde is ON-OFF. Glws when is ON & flashes when alarm cnditin persists even after acknwledged OR delay time (dly) is in peratin & selected mde is ON-OFF. Glws when Sak mde is selected & flashes when Sak timer is in peratin. It will display : () Measured value f selected input r Errr messages in run mde.() Parameters Value in prgram mde. It will display : () SP (Main s et pint) / (Auxiliary) set value / Set Sak time value/ balance r elapsed sak time in run mde. () Parameter cde in prgram mde. () Fr SP prgramming. () T access ntrl mde. (3) T access nfiguratin mde alngwith UP key. () T scrll the parameter & t stre its value. () T increase/alter parameter value in prgram mde. () T Enter in cnfiguratin mde (alngwith key).(3) T acknwledge Alarm. () T enter in tune mde (alngwith DOWN Key). () T decrease / alter parameter value in prgram mde. () T enter in tune mde ( alngwith UP Key). (3) T start Sak timer. Dcument Name : OIM AI-7X8 (Ver.) Page f 8

3 POWER UP: At pwer n, fllwing sequence will be prmpted n the display till it reaches t Hme display mde. In hme display mde, by pressing DOWN key, User can viewthesetvaluefsp&(if=auxiliaryr ALARM mde) r timer value(if = sak mde) sequentially. Here, Lwer display will shw SP-value, -value &. SV Timer-value by pressing DOWN key and it s respective MODEL VERSION HOME parameter cde (SP// ) by pressing UP key. PROGRAMMING USER LIST : T access the user list press key nce. RANGE DESRIPTION ONTROL POINT LSPL ~ HSPL User can change SP value using UP/ DOWN keys. Hlding the key, will change the value at a faster rate. Press key t stre the desired value & mve n t the next parameter. RAMP RATE. t. This parameter will be available nly if Enabled in nfiguratin List. User can set ramp rate/min fr SP (Set Pint) t minimize versht. Disable This parameter is prmpted nly if ntrl Lgic fr Output is cnfigured fr Heat-l. O/p will be autmatically activated /de-activated w.r.t SP & HYS. MODE O/p will be permanently Activated (ON). AUTO O/p will be permanently De-Activated (OFF). POINT This parameter is prmpted nly if utput is cnfigured as... LSPL ~ HSPL Either abslute auxiliary cntrl r as an alarm (High/Lw) mde. - t + Either deviatin auxiliary cntrl r as a deviatin alarm mde. t As a band alarm. Sec t. Hrs. This parameter is prmpted nly if utput is cnfigured as sak timer. ntrller starts the executin f sak time as per the mde selected. Sak timer can be prgrammed using fur different time base in nfig. List. min. ONTROL LIST : T enter in this mde, press key fr 3 sec. User can then set the fllwing cntrl parameters. RANGE DESRIPTION LOK ODE ~ Set this parameter t (Default LOK ODE) t access ntrl List. User has a chice t set different Lck de via USER LOK ODE in nfig. List. PROPORTIONAL BAND INTEGRAL DERIVATIVE YLE OUTPUT POWER LIMIT. t. t Sec. t 3 Sec.. t. Sec.. % TO. % This parameter will be prmpted nly if selected cntrl actin is PID. It sets prprtinal band ver which the utput pwer is adjusted depending upn the errr (SV-). Value f this parameter is autmatically set by Aut tune functin. This parameter will be prmpted nly if selected cntrl actin is PID. It sets the time taken by PID algrithm t remve steady state errr. Value f this parameter is autmatically set by aut tune functin. If set t, this functin will be disabled. This parameter will be prmpted nly if selected cntrl actin is PID. It defines hw strngly the cntrller will react t rate f change f. Value f this parameter is autmatically set by aut tune functin. If set t, this functin will be disabled. This parameter will be prmpted nly if selected cntrl actin is PID. User can set this value based n prcess being cntrlled & type f utput being selected. Fr Relay O/P, cycle time shuld be mre than sec & fr SSR O/P, cycle time shuld be less than sec. This parameter will be prmpted nly if selected cntrl actin is PID. This parameter will decide the maximum utput pwer in % applied t the lad.. Sec. Sec. 6. Sec. % 3 Dcument Name : OIM AI-7X8 (Ver.) Page 3 f 8

4 TUNE OFF ONTROL HYS DELAY RANGE DESRIPTION This parameter will be prmpted nly if selected cntrl actin is PID. % This parameter allws the User t carry ut Aut Tuning functin belw t the set pint. (If tune ffset is set t %, tuning will be carried ut at % % f the set pint and if set t %, tuning will be carried ut at % f the set pint.) This parameter will be prmpted nly if selected cntrl actin is ON - t t Sec. OFF. It sets the dead band between ON & OFF switching f the Output. Larger value f hysterisis minimize the number f ON-OFF peratin t the lad. This increases life f actuatrs like cntactrs but, als prduces large errrs (between & SV). This parameter will be prmpted nly if selected cntrl actin is ON - OFF. It sets the main utput Delay time where O/P nce turned OFF will turn ON nly after Delay time, regardless difference between & SP. Als, Delay will be cnsidered at every pwer ON. % Sec. HYS t This parameter will be prmpted nly if selected cntrl mde fr utput is Auxiliary cntrl r an Alarm. The value f this parameter sets the dead band between ON & OFF switching f utput lad. GAP -. t. This parameter will be prmpted nly if ntrl Lgic fr Output is cnfigured fr Heat-l. SP (set pint) will be cnsider as (SP-Gap) fr heating. GAP -. t. This parameter will be prmpted nly if ntrl Lgic fr Output is cnfigured fr Heat-l. SP (set pint) will be cnsider as (SP+Gap) fr cling. DELAY DELAY t Sec. t Sec. This parameter will be prmpted nly if Output is cnfigured as an Auxiliary cntrl utput OR ntrl Lgic is cnfigured fr Heat-l. In this mde, it sets the utput Delay time where O/P nce turned OFF will turn ON nly after Delay time, regardless difference between &. Als, Delay will be cnsidered at every pwer ON. This parameter will be prmpted nly if selected cntrl mde fr Output is Sak timer. Depending n end f sak strategy, the value f this parameter sets the activatin time fr when Sak timer is ver. Setting this parameter t will make cntinuusly ON at the end f Sak time till User starts the next cycle. Sec. Sec. BAND. t. This parameter defines the permissible deviatin f frm SP during sak time cycle. If falls utside the Sak band during sak cycle, Timer halts. Timer will start nly when falls within the sak band. This parameter is ignred if set t. Sec. ONFIGURATION LIST : () T enter in this mde, press and hld & UP key simultaneusly fr 3 sec. () Press UP r DOWN key t scrll between parameter ptins. (3) Press key t stre current parameter & mve n t the next parameter. LOK ODE DESRIPTION Set this parameter t (Default LOK ODE) t access nfig. List. User have a chice t set different Lck de via USER LOK ODE in nfig. List. This parameter value is set accrding t the type f sensr (Thermcuple r RTD input) cnnected t the cntrller's input terminals. INPUT TYPE Sensr Type Fe-k(J) T/ r-al(k) T/ (R) T/ Range ~ 76 - ~ 3 ~ 7 Reslutin } Accuracy ± J (S) T/ ~ 7 Pt-(RTD) - ~ Pt-(RTD.) -. ~.. ±.3 Dcument Name : OIM AI-7X8 (Ver.) Page f 8

5 DESRIPTION POINT LIMIT Sets the minimum limit fr set pint adjustment. It can be set frm minimum specified range f selected sensr t HSPL value. HIGHER POINT LIMIT Sets the maximum limit fr set pint adjustment. It can be set frm LSPL value t maximum specified range f selected sensr. PROESS VALUE OFF Functin f this parameter is t add/subtract a cnstant value t the measured t btain Final fr cntrl applicatins. This parameter value needs t be altered fr ne f the fllwing reasn : - (i) T cmpensate fr knwn thermal gradient. (ii)t match the display values with anther recrder r indicatr measuring the same. INPUT FILTER The cntrller is equipped with an adaptive digital filter which is used t filter ut any extraneus pulses n the. The filtered Value is used fr all dependent functins. If the signal is fluctuating due t nise, increase the filter time cnstant value. 3 ONTROL MODE FOR O/P User can select between PID r ON-OFF actin algrithm t be adpted fr utput. PID User can select heating lgic in which OP will remain ON till < SP. ( increases when utput is ON.) ONTROL LOGI FOR O/P User can select cling lgic in which OP will remain ON till > SP. ( decreases when utput is ON.) HEAT This parameter will be prmpted nly if selected input is RTD r RTD. and is used fr BOD applicatin. Here OP acts as Heating cntrl & as ling cntrl. OVERSHOOT ONTROL POINT This parameter will be prmpted nly if selected cntrl actin is PID. Setting this parameter n higher side will prprtinally slws dwn the rate f rise f t minimize versht (this may cause delay t reach SP). Setting n lwer side will prprtinally r disabling this parameter will increase the rate f rise f (which may cause versht). Disable this ptin if delay is nt required t reach SP. Disable RAMP RATE This parameter will be prmpted nly if OP (ver sht cntrl pint) is disabled. When enabled, User can set the desired RAMP rate in USER list. When disabled, this parameter will nt be prmpted in USER list. Disable OUTPUT ONTROL This parameter will appear nly if ntrl lgic is Heat-l. will be OFF at Ambient + value irrespective f utput mde. % This parameter allws the user t select utput as an Auxiliary cntrl. Fr ptins refer Table 3. OUTPUT FUNTION This parameter allws the user t select utput as an Alarm cntrl. Fr ptins refer Table. This parameter allws the user t select utput as a Sak mde. Fr ptins refer Table. Auxiliary This parameter allws the user t select utput t functin as bth Alarm & Sak. Fr ptins refer Table &. USER LOK ODE Default USER LOK ODE is t access ntrl & nfiguratin List. User has a chice t set its wn USER LOK ODE between t, this is t prevent unauthrized access f ntrl & nfiguratin List. Dcument Name : OIM AI-7X8 (Ver.) Page f 8

6 TABLE 3 : Belw listed ptins will appear nly if is selected as an Auxiliary ntrl Mde. DESRIPTION INPUT TYPE OUTPUT LOGI If selected, User can set value independently, irrespective f SP. In this mde is always related with SP. User can set value with deviatin f ± w.r.t SP. User can select Heat lgic fr cntrl Output in which will remain ON till < ( increases when utput is ON). User can select l lgic fr cntrl Output in which will remain ON till > ( decreases when utput is ON). ABS HEAT TABLE : Belw listed pints will appear nly if O/P is selected as an Alarm mde. In Alarm mde, ntrller cntinuusly cmpares with either SP (fr deviatin r Band -alarm) r an independent Alarm set pints (fr prcess high and prcess lw alarm). Alarm will ccur when falls utside the set Alarm limits. Als, will energize r de-energize under alarm cnditin as per the Alarm lgic(allg) selected. HYS in ntrl list decides when t switch OFF the Alarm. Instrument supprts fur types f Alarm as described belw : - DESRIPTION Lw Alarm : activates when <. OUTPUT- ON OUTPUT- OFF (Direct acting) High Alarm : activates when >. OUTPUT- OFF OUTPUT- ON (Reverse acting) ALARM TYPE ALARM LOGI ALARM INHIBIT ALARM AK. OUTPUT- OFF (Direct acting) OUTPUT- ON OUTPUT- ON Deviatin Alarm : activates when exceeds SP ± set deviatin value. SP SP OUTPUT OFF OUTPUT ON (Direct acting) (Reverse acting) Band Alarm : activates when falls utside the band w.r.t. SP in either directin. SP SP OUTPUT ON OUTPUT OFF OUTPUT ON (Direct acting) (Reverse acting) User can select direct Alarm Lgic in which will be ON under alarm cnditin; therwise OFF (used fr audi visual alarm). User can select Reverse Alarm Lgic in which will be ON in nrmal cnditins & will be OFF under alarm cnditins (used t trip the prcess in alarm cnditins). If this parameter is set as YES & Alarm cnditin persists, it will Disable Alarm O/P at pwer ON. If this parameter is set as NO & Alarm cnditin persists, it will Enable Alarm O/P at pwer up. Once the Alarm is activated, User has fllwing three ptins t de-activate it. When falls within the prgrammed limits The Alarm will be de-activated autmatically. Once the alarm is activated, it remains activated until acknwledged manually by UP key. Once the alarm is activated, it can be de-activated either by pressing UP key r when falls within the alarm limits. OUTPUT ON (Reverse acting) OUTPUT- OFF OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT OFF DEVIATION DIRET NO AUTO 6 Dcument Name : OIM AI-7X8 (Ver.) Page 6 f 8

7 TABLE : Belw listed ptin will appear nly if is selected as a sak timer. DESRIPTION It defines the behaviur f the cntrller at the end f sak timer cycle. Optins are as belw. If selected, the cntrller maintain at SP indefinitely irrespective f start r end f a sak timer. END OF STRATEGY The cntrller de-energizes OP as sn as the sak time is ver. Here upper display will cntinue t shw & lwer display will shw message "start".next cycle will start nly when user press START key fr 3 sec. BOTH The cntrller energizes fr a time perid prgrammed via (StdL) parameter at the end f a sak time cycle. User can utilise fr audi/visual indicatin. The cntrller executes bth, the Heater OFF and Alarm ON functin as described abve. User can select the timer base f sak time amng the fur ptins as shwn. Minutes & Secnds (Range minutes, secnds). BASE R Minutes (Range minutes). Hurs & Minutes (Range Hurs, minutes). MMMM Hurs (Range Hurs). DIRETION FOR If selected, sak timer will increment (frm t set value) (Nte:- User can alter the new time value which shuld be > elapsed time even if sak timer is running. If user sets new time value < elapsed time, running timer will be terminated & End f sak Strategy will be executed. If selected,sak timer will decrement (frm set value t ). (Nte:- User can alter the new time value even when sak timer is running. In this case, balance time f previus set value will be ignred & new cycle will be executed. DN RE OF RUNNING If set as YES, sak time value will nt be stred at the time f pwer failure. If set as NO at pwer ON, sak time will cntinue frm stred value. (Nte: Secnds will nt be stred.) NO User can define different mdes t start the sak timer as fllws : - In this mde, Timer will start after pressing START key fr 3 sec., irrespective f. In this Mde, after pwer ON Timer starts when >= SV. T cntinue with next cycle, user has t either switch Pwer n & ff OR press START key fr 3 sec when STRT message is displayed n the lwer display. R START MODE In this Mde, Timer will start nly after pressing START key fr 3 sec & >=SV fr any f the fllwing cnditins. () At every Pwer ON. () mpletin f current sak time cycle. (3) Pwer failure during sak time is in prgress. MOD In this Mde, Timer will start nly after pressing START key fr 3 sec & >=SV fr any f the fllwing cnditins. () At every Pwer ON. () mpletin f current sak time cycle. After executing start cmmand, if cycle desn't cmplete due t pwer failure, cycle will cntinue whenever >= SV after restre f pwer. N need t press START key. Nte:-) User can restart sak time at any mment during its executin, by pressing START key fr 3 sec. 7 Dcument Name : OIM AI-7X8 (Ver.) Page 7 f 8

8 AUTO TUNING MODE : T enter in this mde, Press and hld UP & DOWN key tgether fr minimum 3 sec. AUTO TUNING MODE DESRIPTION This functin will be executed nly if selected cntrl actin is PID. The Aut-tuning functin can be initiated by setting this parameter t YES. The decimal f LSB flashes till aut tuning functin is in prgress. During Aut-tuning, The cntrller learns the prcess characteristics by itself & calculates required P, I & D values. User can cancel r abrt this feature by setting this parameter t NO. NO USER GUIDE :- ON-OFF ATION : In this mde, Output (Relay/SSR) remains ON till actual temperature reaches t the set pint value. On reaching t SP, Output turns OFF & remains OFF till actual temperature drps dwn (in Heat Lgic) r raises (in l Lgic) equal t hysterisis set by user. (As shwn in Fig. 3. & 3.) TEMP ( ) HYSTERISIS SP AMB TEMP ( ) HYSTERISIS SP AMB O/P ON OFF ON OFF ON O/P ON OFF ON OFF ON O/P HEAT LOGI / ON-OFF Fig: 3. OOL LOGI / ON OFF Fig: 3. AUTO TUNING MODE : In this mde, ntrller learns the prcess characteristics by itself and calculates the required P,I & D values. It can be perfrmed at any time after pwer ON but, it is best t start it when the prcess is at Ambient temperature in rder t minimize versht & undersht. Aut tuning is applied in case f : () Initial set up fr a new prcess. () Substantial change in SP frm previus aut tuning value. (3) ntrl accuracy is nt satisfactry. If the cntrl perfrmance by using aut-tuning is still unsatisfactry, User can apply further adjustments f P,I &Dvaluesas shwn in Table:3 belw. Table: 3 Adjust Symptm Slutin Prprtinal Band Slw Respnse Over Sht r Oscillatins Decrease PB Increase PB Integral Time Slw Respnse Decrease Int Instability r Oscillatin Increase Int Derivative Time Slw Respnse r Oscillatin Decrease Dt High Over Sht Increase Dt ABBREVIATION :.A. J M LW : ntrl Actin : ld junctin cmpensatin : mmn terminal f relay : Lead wire (Length)- cmpensatin N : Nrmally lse terminal f relay NO : Nrmally Open terminal f relay OP : Output : Output SP SSR T/ : Set Pint Value (set temp.) : Prcess Value (actual Tmp.) : Slid State Relay : Thermcuple Mfgd by : Innvative Instruments Dealer :- 338, New Snal Link Service Ind. Est. n., Link Rad, Malad (W), Mumbai - 6. Tel: -6636/7. Fax: sales@innvativeinstrument.cm ; Website: innvativeinstrument.cm 8 Dcument Name : OIM AI-7X8 (Ver.) Page 8 f 8