Chromalox 6040 Installation & Operation Manual
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Chromalox 6040 Installation & Operation Manual

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Installation & Operation Manual
6040, 8040, 4040 Temperature & Process Controllers
6040, 8040 & 4040 Valve Motor Drive Controllers
6040 Heater Break Alarm Controller
6050, 4050 Limit Controllers
PK508-2
0037-75514
March 2017
1

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Summary of Contents for Chromalox 6040

  • Page 1 Installation & Operation Manual 6040, 8040, 4040 Temperature & Process Controllers 6040, 8040 & 4040 Valve Motor Drive Controllers 6040 Heater Break Alarm Controller 6050, 4050 Limit Controllers PK508-2 0037-75514 March 2017...

  • Page 2: Warranty And Returns Statement

    Products covered in this issue of the manual: or products. 6040, 8040 & 4040 Temperature & Process Controllers, 6040, 8040 & 4040 Optional Valve Motor Drive (VMD) Controllers, 6040 Optional Heater Break Alarm (HBA) Controllers, 6050 & 4050 Over Temperature / Limit Controllers.

  • Page 3: Table Of Contents

    Table of Contents Contents Page Number Warranty and Returns Statement .........................ii Introduction ..............................1 Installation ............................... 1 Unpacking ................................. 1 Installation ................................. 1 Panel Cut-outs ..............................2 Panel-Mounting ..............................2 Plug-in Options ..............................3 Options Modules and Functions ........................3 Auto Detection of Option Modules ........................
  • Page 4 Valve Position Clamping ........................... 40 6040, 8040 & 4040 Valve Motor Drive - Operator Mode ................42 6040, 8040 & 4040 Valve Motor Drive – Extended Operator Mode ............42 Navigating in Operator Mode ........................42 Adjusting the Local Setpoint(s) ........................44 Adjusting the Setpoint Ramp Rate .........................
  • Page 5 Scrolling through Parameters & Values ....................52 Changing Parameter Values ........................52 6040 HBA Controllers - Operator Mode ......................54 6040, 8040 & 4040 Controllers – Extended Operator Mode ..............54 Navigating in Operator Mode ........................54 Adjusting the Local Setpoint(s) ........................55 Adjusting the Setpoint Ramp Rate .........................
  • Page 6 Contents Page Number Function Descriptions ............................. 75 Read Coil/Input Status (Function 01 / 02) ....................75 Read Holding/Input Registers (Function 03 / 04) ..................76 Force Single Coil (Function 05) ........................ 76 Pre-Set Single Register (Function 06) ...................... 76 Loopback Diagnostic Test (Function 08) ....................76 Pre-Set Multiple Registers (Function 10 Hex) ..................
  • Page 7 Contents Page Number Indicator Type: Indicator Definition ......................... 86 Input Filter Time Constant Type: General Parameter ..................86 Input Range Type: General Definition ......................86 Input Span Type: General Definition ....................... 86 Integral Type: Controller Tuning Parameter ..................... 87 Latching Relay Type: General Definition ......................87 LED Type: General Definition ..........................
  • Page 8 Contents Page Number Scale Range Upper Limit Type: General Parameter ..................95 Scale Range Lower Limit Type: General Parameter ..................95 Secondary Proportional Band Type: Controller Tuning Parameter ..............95 Self-Tune Type: Controller Tuning Definition ....................95 Serial Communications Option Type: General Definition ................96 Set Valve Closed Position Type: VMD Controller Parameter ................
  • Page 9 Select Mode for gaining access to the Setup and Configuration menus, Automatic tuning on controllers and the Product information menus. Section 8: ..... 6040, 8040 & 4040 Model Group - Describes unique operating features of these pro- cess controllers. It covers the Configuration, Setup & Operator menus, Communications parameters, adjusting Setpoint, use of Manual Control and PID auto-tuning.
  • Page 10 This page intentionally left blank.

  • Page 11: Introduction

    1 Introduction These instruments are microprocessor based tempera- above and below setpoint), or control loop types. Mod- ture, process and valve controllers. They can measure, els with a heater current input also have high, low or display or control process variables such as tempera- short circuit heater break alarms based on control load ture, pressure, flow and level from a variety of inputs.

  • Page 12: Panel Cut-Outs

    Panel Cut-outs The mounting panel must be rigid and may be up to Ensure the inside of the panel is with the instru- 6.0mm (0.25 inches) thick. The cut-outs required for ments operating temperature and that there is the instruments are shown below. adequate air flow to prevent overheating.

  • Page 13: Plug-In Options

    3 Plug-In Options Options Modules and Functions Table 1. Option Module vs. Model Matrix A range of plug-in option modules is available to add Module Part additional input, output and communication functions Number to the instruments in the range. These modules can be &...

  • Page 14: Preparing To Install Or Remove Options Modules

    Preparing to Install or Remove Options Modules Take care not to put undue stress on the ribbon cable attaching the display and CPU boards. Before removing the instrument from its hous- ing, ensure that all power has been removed from the rear terminals. Any repair or modi- fication done on the controller is subject to Mounting the requirements of the jurisdiction.

  • Page 15: Replacing The Instrument In Its Housing

    Option Slot B Check for correct orientation of the modules Connectors PL2A, and that all pins locate correctly into the socket. PL2B & PL2C Replacing the Instrument in its Housing With the required option modules correctly located into their respective positions the instrument can be Option Slot 2 replaced into its housing as follows: Connector PL4A...

  • Page 16: Use Of Shielded Cable

    If any wires need to run parallel with any other lines, maintain a minimum space of 150mm between them. If wires MUST cross each other, ensure they do so at 90 degrees to minimize interference. Use of Shielded Cable All analog signals must use shielded cable. This will help eliminate electrical noise induction on the wires.

  • Page 17: Thermocouple Wire Identification Chart

    Thermocouple Wire Identification Chart The table below shows the wire and sheath colors used for most common thermocouple types. The format The different thermocouple types are identified by their used in this table is: wires color, and where possible, the outer insulation as + Wire well.

  • Page 18: Connections And Wiring

    Connections and Wiring The rear terminal connections for 1/16 DIN and 1/4 & 1/8 DIN instruments are illustrated in the following CHECK THE INFORMATION LABEL ON THE diagrams. CASE TO DETERMINE THE CORRECT VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY. In general, all wiring connections are made to the in- strument after it is installed.

  • Page 19: Power Connections - Mains Powered Instruments

    OUTPUT / OUTPUT / Figure 12. Rear Terminals (1/4 DIN & 1/8 DIN Instruments) Power Connections - Mains Powered Instruments CHECK THE INFORMATION LABEL ON THE Mains powered instruments operate from a 100 to CASE TO DETERMINE THE CORRECT VOLTAGE 240V (±10%) 50/60Hz supply.

  • Page 20: Power Connections - 24/48V Ac/Dc Powered Instruments

    Power Connections - Universal Input Connections – 24/48V AC/DC Powered Instruments PT100 (RTD) input 24/48V AD/DC powered instruments will operate from For three wire RTDs, connect the resistive leg and the a 20 to 48V AC or 22 to 55V DC supply. AC power con- common legs of the RTD as illustrated.

  • Page 21: Option Slot 1 - Relay Output Module

    Option Slot 1 – Relay Output Module Option Slot 1 - Linear Voltage or mADC Output module If option slot 1 is fitted with a relay output module, make connections as illustrated. The relay contacts are If option slot 1 is fitted with a DC linear output module, rated at 2 amps resistive, 240 VAC (120V max for direct make connections as illustrated.

  • Page 22: Option Slot 2 - Triac Output Module

    Option Slot 2 - Triac Output Module Option Slot 3 - Relay Output Module If option slot 2 is fitted with a Triac output module, If option slot 3 is fitted with a relay output module, make connections as shown. This output is rated at make connections as illustrated.

  • Page 23: Option Slot 3 - Dual Relay Output Module

    Option Slot 3 - Dual Relay Output Module If option slot 3 is fitted with a dual relay output module, make connections as illustrated. This module has two independent relays, which share a common connec- RS485 RS485 tion terminal. The contacts are rated at 2 amp resistive 240 VAC.

  • Page 24: Option Slot B Connections - Digital Input 2 (Full Auxiliary Module)

    1/16 DIN models 1/16 DIN 1/4 DIN & 1/8 DIN Figure 35 Use only Chromalox supplied current trans- Option Slot B – Digital Input 2 Connections formers. Transformers are non-polar devices. Option Slot B Connections – 1/4 DIN & 1/8...

  • Page 25: Keypad

    Reset or Auto/Manual Key Lower or Down Menu Key Raise or Up Menu Key Function Key 1/16 DIN 1/8 DIN 1/4 DIN Figure 37 Typical front panel and keys Keypad Each instrument has either three or four switches, which are used to navigate through the user menus and make adjustment to the parameter values.

  • Page 26: Messages And Error Indications

    6 Messages and Error Indications The following displays are shown when an error occurs or a hardware change is detected. Table 4. Error/Faults conditions Lower Error/Faults Display Conditions Upper display (where fitted) Configuration & Setup is required. Seen at first turn on or if Goto Conf hardware configuration changed.

  • Page 27: Instrument Operation Modes

    Configuration, Setup and Automatic Tuning modes. Model Group Description An unlock code must be correctly selected using the 6040, 8040 & 4040 Temperature & Process Controllers keys to enter the required mode. An in- Valve Motor Controllers correct entry results in a return to Select Mode. The...

  • Page 28: Product Information Mode

    Indication remains OFF if Pre- Indication remains OFF if Self- Table 8. Automatic Tune Mode Parameters Table 9. Product Information Mode Parameters Upper Display Lower Default Upper/Main Lower Parameter Adjustment Range Display Value Parameter Possible Values Display Display Pre-tune ON or OFF Ptun Input type Universal input...

  • Page 29: Lock Code View

    Automatic Tune Lock Value Code Code. 8 6040, 8040 & 4040 Controller – Model Group These controllers combine technical functionality, Mode option, then press field flexibility and ease of use to give you the best in comprehensive process control. The 6040 1/16-DIN...
  • Page 30 Table 11. 6040, 8040 & 4040 Configuration Mode Parameters Lower Upper Default When Parameter Display Display Description Value Visible Input type & B type: 100 to 1824ºC Always InPt Range B type: 211 to 3315ºF for Europe C type: 0 to 2320ºC C type: 32 to 4208ºF...
  • Page 31 Lower Upper Default When Parameter Display Display Description Value Visible Decimal Decimal point position in non-temperature dPoS InPt = Point ranges. mV, V or Position 0 = XXXX 1 = XXX.X 2 = XX.XX 3 = X.XXX Control Primary control Always Ctyp Sngl...
  • Page 32 Lower Upper Default When Parameter Display Display Description Value Visible Alarm No alarms Inhibited Always Inhi nonE nonE Inhibit Alarm 1 inhibited ALA1 Alarm 2 inhibited ALA2 Alarm 1 and alarm 2 inhibited both Output Primary Power USE1 OPn1 is Usage 1 Secondary Power not nonE...
  • Page 33 Lower Upper Default When Parameter Display Display Description Value Visible Retransmit Range -1999 to 9999 ro3L USE 3 = Output 3 Min. Display value at which output will be minimum rEtS or Scale min. rEtP Display Always diSP 1.2.3.4.5or 6 Strategy (See Operator Mode) Comms...

  • Page 34: 6040, 8040 & 4040 - Setup Mode

    6040, 8040 & 4040 – Setup Mode Scrolling through Parameters & Values This mode is normally selected only after Configuration Press to scroll through the parameters (refer to the Mode has been completed, and is used when a change table below) and their values.
  • Page 35 Table 12. 6040, 8040 & 4040 Set Up Mode Parameters Lower Upper Display When Parameter Display Adjustment Range Default Value Visible Input Filter Time OFF, 0.5 to 100.0 secs in 0.5 sec Always FiLt constant increments Process Variable Offset ±Span of controller...
  • Page 36 Lower Upper Display When Parameter Display Adjustment Range Default Value Visible Process High Alarm 2 Range Min. to Range Max. Range PhA2 ALA2 = P - Hi value* Max. Process Low Alarm 2 Range Min. to Range Max. Range PLA2 ALA2 = P - Lo value* Min.

  • Page 37: 6040, 8040 & 4040 Controllers - Operator Mode

    Display strategy 6 are read only, and can only be Set all Configuration Mode parameters and Set adjusted via Setup mode. Up Mode parameters as required before start- ing normal operations. Table 13. 6040, 8040 & 4040 Operator Mode Displays Upper Lower When Display...

  • Page 38: Adjusting The Local Setpoint(S)

    Upper Lower When Display Display Visible Description If Remote Setpoint Input Setpoint Select. Selects between Local or -- LSP rSP or diGi is fitted, Digital Input Remote Setpoints. is not diS1 in config LSP = local SP, rSP = remote SP, diGi = MANUAL mode and SSEn is en- selection via digital input (if configured).

  • Page 39: 6040, 8040 & 4040 Controllers - Communications Parameters

    6040, 8040 & 4040 Controllers – Communications Parameters The Modbus parameter addresses for the 6040, 8040 & 4040 are detailed below. RO indicates a parameter is read only, R/W indicates it can also be written to. Communications writes will not be implemented if the Communica- tions Write Parameter is disabled.
  • Page 40 Modbus ASCII is no longer Parameter Parameter No. Supported Notes Primary Adjustable 0.0% to 999.9% of input span. Read Proportional Band only when Self-Tuning. Direct / Reverse 1 = Direct Acting, 0 = Reverse Acting Automatic Reset Integral Time Constant value. Time (or Loop Alarm Time value in ON/OFF control 20% to +20% of P8 - P + P8 - 5;...
  • Page 41 Modbus ASCII is no longer Parameter Parameter No. Supported Notes Process Value Modified PV = Actual PV + PV Offset. Limited by Offset Scale Range Maximum and Scale Range Mini- mum. Re-transmit Maximum scale value for retransmit output, 1999 Output Maximum to 9999.
  • Page 42 = Process Variable value ccccc = Primary PID Power value ddddd = Secondary PID Power value eeeee = Controller Status (see above) Equipment ID The four digit model number 6040 Serial Number Digits Unit serial number. aaaa Format aaaa bbbb cccc, (12 BCD digits).

  • Page 43: 6040, 8040 & 4040 Vmd Controller - Model Group

    Linear output which has not been fitted). Read only parameters will return an exception if an attempt is made to write values to them. 9 6040, 8040 & 4040 VMD Controller – Model Group Special Wiring Considerations for Valve...

  • Page 44: 6040, 8040 & 4040 Vmd Controllers - Configuration Mode

    Changing Parameter Values 6040, 8040 & 4040 VMD Controllers - Press to navigate to the required parameter, then Configuration Mode press to set the value as required.
  • Page 45 Table 16. 6040, 8040 & 4040 with VMD Function - Configuration Mode Parameters Lower Upper Default When Parameter Display Display Description Value Visible Input type & B type: 100 to 1824ºC Always InPt Range for Europe B type: 211 to 3315ºF C type: 0 to 2320ºC...
  • Page 46 Lower Upper Default When Parameter Display Display Description Value Visible Decimal Decimal point position in non-temperature InPt = dPoS Point ranges. mV, V or Position 0 = XXXX 1 = XXX.X 2 = XX.XX 3 = X.XXX Control Reverse Acting Always CtrL Action...
  • Page 47 Lower Upper Default When Parameter Display Display Description Value Visible Output Valve Motor Open OPn1 is USE1 Usage 1** not Lin Valve Motor Close or nonE Alarm 1, Direct Acting A1 - d Alarm 1, Reverse Acting A1 - r Alarm 2, Direct Acting A2 - d Alarm 2, Reverse Acting...
  • Page 48 Lower Upper Default When Parameter Display Display Description Value Visible Output 4 Valve Motor Open OPn2 = USE4 A1 - d Usage** dr1Y Valve Motor Close Alarm 1, Direct Acting A1 - d Alarm 1, Reverse Acting A1 - r Alarm 2, Direct Acting A2 - d Alarm 2, Reverse Acting...
  • Page 49 Lower Upper Default When Parameter Display Display Description Value Visible Remote Range -1999 to 9999 AiPA or rSPu Setpoint Max. RSP value to be used when RSP input is at maximum AiPB = Upper Limit Remote Range -1999 to 9999 AiPA or rSPL Setpoint...

  • Page 50: 6040, 8040 & 4040 Valve Motor Drive - Setup Mode

    6040, 8040 & 4040 Valve Motor Drive – Set Valve Opened Position & Set Valve Setup Mode Closed Position This mode is normally selected only after Configuration Hold down and press to enter the Select Mode has been completed, and is used when a change Mode to the process set up is required.
  • Page 51 Table 17. 6040, 8040 & 4040 Valve Motor Drive Set Up Mode Parameters Lower Upper Display When Parameter Display Adjustment Range Default Value Visible Input Filter Time OFF, 0.5 to 100.0 secs in 0.5 sec Always FiLt constant increments Process Variable Offset ±Span of controller...

  • Page 52: 6040, 8040 & 4040 Valve Motor Drive - Operator Mode

    **Note: Once the complete list of Set Up Mode parameters has been displayed, the first Operator Mode display is shown without exiting from Set Up Mode. Display seen is dependent on the Display Strategy and status of MAN/AUTO mode selection. 6040, 8040 & 4040 Valve Motor Drive - 6040, 8040 & 4040 Valve Motor Drive – Operator Mode...
  • Page 53 Table 18. 6040, 8040 & 4040 VMD Operator Mode Displays Upper Lower When Display Display Visible Description PV Value Active SP Display strategy 1, 2 and Process Variable and target value of currently Value 7. (Initial Screen) selected Setpoint. Local SP is adjustable in Strategy 2 & 7...

  • Page 54: Adjusting The Local Setpoint(S)

    Mode, PoEn must temporarily be re-enabled. ramping to be switched OFF. Setpoint ramping can be resumed by decreasing the ramp rate to 9999 or less. 6040, 8040 & 4040 VMD Controllers – Press to select the adjustable setpoint display...

  • Page 55: Word Parameters

    Table 19. 6040, 8040 & 4040 VMD Controllers Communications - Bit Parameters Modbus Parameter Parameter No. Notes Communication Write 1 = Write Enabled, 0 = Write Disabled. A negative ac- Status knowledgement (exception code 3) is sent to write com-...
  • Page 56 Setpoint Select, it will take priority over this parameter 1 = SP1 or LSP, 2 = SP2, 100hex = RSP Equipment ID The four digit model number 6040 Serial Number Low Digits aaaa Unit serial number.

  • Page 57: 6040 Heater Break Alarm Controller - Model Group

    Linear output which has not been fitted). Read only parameters will return an exception if an attempt is made to write values to them. 10 6040 HBA Controller – Model Group This controller has both current sensing and soft start Configuration Mode Lock Code.
  • Page 58 Table 21. 6040 HBA Configuration Mode Parameters Lower Upper Default When Parameter Display Display Description Value Visible Input type B type: 100 to 1824 ºC Always JC for InPt and range Europe B type: 211 to 3315 ºF C type: 0 to 2320 ºC C type: 32 to 4208 ºF...
  • Page 59 Lower Upper Default When Parameter Display Display Description Value Visible Decimal Decimal point position in non-temperature ranges. InPt= mV, dPoS point 0 = XXXX V or mA position 1 = XXX.X 2 = XX.XX 3 = X.XXX Control Primary control Always CtYP SnGL...
  • Page 60 Lower Upper Default When Parameter Display Display Description Value Visible Output 1 Primary Power OPn1 is USE1 Useage not nonE Secondary Power Alarm 1, Direct Acting Not linear A1_d Alarm 1, Reverse Acting Not linear A1_r Alarm 2, Direct Acting Not linear A2_d Alarm 2, Reverse Acting...
  • Page 61 Lower Upper Default When Parameter Display Display Description Value Visible Output 3 As for output 1 OPn2 is USE3 A1_d Useage not nonE Linear As for output 1 OPn3 = tyP3 0_10 Output 3 Range Retransmit -1999 to 9999 Range Max. USE3 = ro3H Output 3...

  • Page 62: 6040 Hba - Setup Mode

    Operator Mode screen sequence has been completed. Note: Entry into Setup Mode is security-protected by the Setup Mode lock code. Table 22. 6040 Set Up Mode Parameters Lower Upper Display When Parameter...
  • Page 63 Lower Upper Display When Parameter Display Adjustment Range Default Value Visible Setpoint Upper Limit Current Setpoint value to Scale Range Always SPuL Range Maximum Maximum Setpoint Lower limit Scale Range Minimum to current Range Always SPLL Setpoint value Minimum Primary (Heat) Output 0% to 100% of full power Pb_P is not 0.0 OPuL...

  • Page 64: 6040 Hba Controllers - Operator Mode

    Set Up Mode. Display seen is dependent on the Display Strategy and sta- tus of Auto/Manual mode selection. 6040 HBA Controllers - Operator Mode 6040, 8040 & 4040 Controllers – Extended Operator Mode This is the mode used during normal operation of the instrument.

  • Page 65: Adjusting The Local Setpoint(S)

    Table 23. 6040, 8040 & 4040 Operator Mode Displays Upper Lower When Display Display Visible Description PV Value Active SP Display strategy 1 and 2. Process Variable and target value of currently Value (Initial Screen) selected Setpoint. Local SP is adjustable in Strategy 2...

  • Page 66: Manual Control Mode

    6040 HBA Controller – Communications Parameters The Modbus parameter addresses and parameter indents for the 6040 are detailed below. RO indicates a param- eter is read only, R/W indicates it can also be written to. Communications writes will not be implemented if the Communications Write Parameter is disabled.
  • Page 67 Word Parameters Table 25. 6040 Communications - Word Parameters Modbus Parameter Parameter No. Notes Process Variable Current value of PV. If under-range = 62976 (<??>5 ASCII) If over-range = 63232 (<??>0 ASCII) If Sensor break = 63488 (ASCII = n/a) Setpoint Value of currently selected setpoint.
  • Page 68 Modbus Parameter Parameter No. Notes Setpoint Upper Limit Max. setpoint value. Current SP to Input Range Max. Setpoint Lower Limit Min. setpoint value. Current SP to Input Range Min. Setpoint Ramp Rate 0 = 0ff, 1 to 9999 increments / hour. Dec Point position as for input range.
  • Page 69 = Primary PID Power value ddddd = Secondary PID Power value eeeee = Controller Status (see above) Equipment ID The four digit model number 6040 Serial Number Low Digits aaaa Unit serial number. Format aaaa bbbb cccc, (12 BCD digits).

  • Page 70: 11 6050 & 4050 Limit Controller - Model Group

    11 6050 & 4050 Limit Controller – Model Group Limit Controllers protect processes that could be dam- Note: Entry into this mode is security-protected by the aged or become hazardous under fault conditions. Configuration Mode Lock Code. Refer to the Unlock Code section for more details.
  • Page 71 Table 26. 6050 & 4050 Configuration Mode Parameters Lower Upper Default When Parameter Display Display Description Value Visible Input type & B type: 100 to 1824ºC Always InPt Range for Europe B type: 211 to 3315ºF C type: 0 to 2320ºC C type: 32 to 4208ºF for USA E type: 0 to 1000ºC...
  • Page 72 Lower Upper Default When Parameter Display Display Description Value Visible Decimal Decimal point position in non-temperature ranges. InPt = dPoS Point 0 = XXXX mV, V or Position 1 = XXX.X 2 = XX.XX 3 = X.XXX ±Span of controller (see CAUTION note at end of section) Process Always OFFS...
  • Page 73 Lower Upper Default When Parameter Display Display Description Value Visible Output 2 Limit Output Relay A2 - d when USE2 L--t OPn1 = Useage OPn2 is not linear output Alarm 1, Direct Acting Not linear A1 - d type, Alarm 1, Reverse Acting Not linear A1 - r Alarm 2, Direct Acting...

  • Page 74: 6050 & 4050 Limit Controllers - Setup Mode

    Lower Upper Default When Parameter Display Display Description Value Visible Commu- Addr OPnA = A unique address for each instrument between 1 nications r485 to 255 (Modbus), or 1 to 99 (ASCII) Address Commu- Always r - U U Read only. Comms writes ignored r - o nications CoEn...
  • Page 75 Table 27. 6050 & 4050 Set Up Mode Parameters Lower Upper Display When Parameter Display Adjustment Range Default Value Visible Limit Setpoint value Scaled Range Minimum to Scaled Range when Always Range Maximum CtrL=Hi Range Min. when CtrL=Lo Limit Hysteresis 1 LSD to full span in display units, Always HYST...

  • Page 76: 6050 & 4050 Limit Controllers - Operator Mode

    6050 & 4050 Limit Controllers - Operator Mode Set all Configuration Mode parameters and This is the mode used during normal operation of the Setup Mode parameters as required before instrument. It can be accessed from Select Mode, and starting normal operations. is the usual mode entered at power-up.

  • Page 77: Limit Setpoint Adjustment

    Limit Setpoint Adjustment Resetting Limit Outputs & Annunciators Adjustment of the Limit Setpoint can be only made A reset instruction can be given by any of the following from Setup Mode. methods. The front panel Reset key, the Digital Input (if fitted) or via Serial Communications command if an RS485 Communications module is fitted.

  • Page 78: 6050 & 4050 Controllers - Serial Communications Parameters

    6050 & 4050 Controllers – Communications Write Parameter is disabled. Refer to the Modbus and ASCII Communications sections of Serial Communications Parameters this manual for details of the protocols used. The Modbus parameter addresses and the possible Bit Parameters ASCII message types and parameters indents for the 6050 &...
  • Page 79 Modbus ASCII is no longer Parameter Parameter No. Supported Notes Alarm 1 Value Alarm 1 active at this level Alarm 2 Value Alarm 2 active at this level Scale Range Lower limit of scaled input range Lower Limit Scale Range Upper limit of scaled input range Upper Limit Decimal Point...
  • Page 80 Modbus ASCII is no longer Parameter Parameter No. Supported Notes Bits Meaning Controller Status Alarm 1 status: 0 = Activated, 1 = Safe Alarm 2 status: 0 = Activated, 1 = Safe Not used Change Indicator: 0 = No changes, since Controller Status was last read.

  • Page 81: 12 Manually Tuning Controllers

    Modbus ASCII is no longer Parameter Parameter No. Supported Notes Input status Input status. Read Only. Bit 0: Sensor break flag Bit 1: Under-range flag Bit 2: Over-range flag Option Slot 2 2224 Maximum scale value for retransmit output in slot Re-transmit 2, 1999 to 9999.

  • Page 82: Dual Control Tuning (Pid With Primary And Secondary Outputs)

    Dual Control Tuning (PID with Primary and a linear (mA/VDC) signal for its positioning circuitry. It determines values for the Primary Proportional Band Secondary Outputs) (Pb - P), and Integral Time Constant (ArSt). The De- This simple tuning technique balances the need to rivative Time Constant (rAtE) is normally set to zero reach setpoint quickly, with the wish to limit setpoint (OFF).
  • Page 83 START Apply Power to the load. Does the Tim e continuously Osc ill ate? Note the time Are the interval T Oscillations decaying to zero? Note the period = 0.8% of the decaying oscillations (T Multiply setting by 1.5 Multiply setting by 1.5 The controller is now tuned.

  • Page 84: Manually Fine Tuning

    Manually Fine Tuning Note: Allow enough time for the controller and process to adjust. A separate cycle time adjustment parameter is provid- 4. Initially add rate at a value between 1/4th and 1/10th ed for each time proportioning control output. of the automatic reset value.

  • Page 85: Device Addressing

    Data is encoded for each character as binary data, Function Modbus transmitted LSB first. Code Description Meaning For a QUERY the address field contains the address (decimal) AddR parameter in Configuration Mode. This address is of the slave destination. The slave address is given Pre-set Writes up to 1 word param- together with the Function and Data fields by the Ap-...

  • Page 86: Force Single Coil (Function 05)

    Force Single Coil (Function 05) Pre-Set Multiple Registers (Function 10 Hex) Writes a single binary value to the Specified Instrument Writes a consecutive word (two-byte) value to the Bit address. specified address range. Table 35. Force Single Coil (Modbus Function 05) Table 38.

  • Page 87: Ascii Communications

    14 ASCII Communications – NOT RECOMMENDED This is simple ASCII protocol provides backwards All characters are in ASCII code. See the following compatibility with some older products. ASCII is not Parameter Key table for details of the parameters in available in all models in the range. WE DO NOT REC- brackets { }.

  • Page 88: Type 2 Message

    The reply from an active slave is (where I = Hex 49) indicating that the slave device is ready to implement the command. If the parameter L {N} ? A * specified is invalid or is not modifiable or if the desired An inactive device will give no reply.

  • Page 89: 15 Calibration Mode

    15 Calibration Mode Table 41. Input Calibration phases 50 mV iP - 1 CALIBRATION IS ONLY REQUIRED FOR INSTRU- MENTS IN WHICH CALIBRATION ERRORS HAVE 10 V iP - 2 BEEN ENCOUNTERED. REFER TO CALIBRA- 20 mA iP - 3 TION CHECK BELOW.

  • Page 90: 16 Appendix 1 - Glossary

    16 Appendix 1 - Glossary Active Setpoint This Glossary explains the technical terms and param- eters used in this manual. The entry type is also shown: Type: Controller Definition General Definition: Terms normally applicable all The Active Setpoint is the setpoint used as the current models.

  • Page 91: Alarm Hysteresis Type: General Parameter

    Alarm Hysteresis below. E.g. a high alarm’s hysteresis band is below the Type: General Parameter high alarm value, and a low alarm’s hysteresis is above the low alarm value. An adjustable band on the “safe” side of an alarm point, Also refer to Alarm Operation.

  • Page 92: Alarm Operation Type: General Definition

    Alarm Operation Type: General Definition The different alarm types are shown below, together with the action of any outputs. Also refer to Alarm Hysteresis, Alarm Inhibit, Band Alarm, Deviation Alarm, Latching Relay, Logical Alarm Combina- tions, Loop Alarm, Process High Alarm and Process Low Alarm Output Off .Output On Process High Alarm...

  • Page 93: Alarm Inhibit Type: General Parameter

    Alarm Inhibit Band Alarm 1 Value Type: General Parameter Type: General Parameter Inhibits an alarm at power-up or when the controller This parameter is applicable only if Alarm 1 is selected Setpoint is switched, until that alarm goes inactive. The to be a Band Alarm.

  • Page 94: Boundless Vmd Control Type: Vmd Controller Definition

    Boundless VMD Control Communications Write Enable Type: VMD Controller Definition Type: General Definition - Refer to Open Loop VMD. Enables/disables the changing of parameter values via the RS485 communications link, if the communications option is installed. Possible settings are read only or Cascade Control read/write.

  • Page 95: Current Proportioning Control Type: Controller Definition

    Cycle Time Display code = diFP for primary only differential, diFS Type: Controller Definition for secondary only differential & diFF for primary and secondary differential. For time proportioning outputs, it is used to define time Also refer to Input Span and On-Off Control. period over which the average on vs.

  • Page 96: Exceed Time Type: Limit Controller Definition

    Short Circuit Heater Break Alarm Exceed Time Type: Limit Controller Definition The total accumulated time that a Limit Controller has been in the Exceed Condition since this parameter was last reset. Also refer to Elapsed Time, Exceed Condition and Limit Controller.

  • Page 97: Integral Type: Controller Tuning Parameter

    Integral Limit Hysteresis Type: Controller Tuning Parameter Type: Limit Controller Definition Refer to Automatic Reset. An adjustable band on the “safe” side of the Limit Set- point. For a high limit, the hysteresis band is below the limit setpoint value, for a low limit, the hysteresis Latching Relay is above the limit setpoint value.

  • Page 98: Loop Alarm Enable Type: Controller Parameter

    Loop Alarm Enable Manual Mode Type: Controller Parameter Type: Controller Definition Enables or disables a loop alarm. A loop alarm is a If Manual Mode is enabled in Set-Up mode, pressing special alarm, which detects faults in the control feed- the MAN/AUTO key in operator mode will cause a con- back loop, by continuously monitoring process variable troller to enter or leave manual control mode.

  • Page 99: Manual Mode Enable Type: Controller Parameter

    Manual Mode Enable Modulating Valve Type: Controller Parameter Type: VMD Controller Definition Determines whether operator selection and de-selec- A valve that can be positioned anywhere between fully tion of manual control is enabled. If the mode is en- closed and fully open by means of an incorporated mo- abled in Set-Up mode, pressing the AM key in Opera- tor.

  • Page 100: Offset Type: Controller Parameter

    either higher or lower. This procedure is repeated for Also refer to Differential, PID, Process Variable, Prima- up to nine breakpoints, but if any scale value is set to ry Proportional Band, Secondary Proportional Band, 100% if automatically becomes the last in the series. Setpoint, Time Proportioning Control and Valve Motor Drive Control.
  • Page 101 OVERLAP Proportional Band 1 WITH PID Proportional Band 2 Output 1 Output 2 Output 2 Output 1 Process Variable Overlap (positive value) DEADBAND Proportional Proportional WITH PID Band 2 Band 1 Output 1 Output 2 Output 2 Output 1 Process Variable Deadband (negative value) Proportional...

  • Page 102: Pi Control Type: Controller Definition

    PI Control When Pre-Tune is completed, the PID control output Type: Controller Definition power is applied using the calculated values. Pre-Tune limits the possibility of setpoint overshoot when the Proportional and Integral (PI) Control is used to con- controller is new or the application has been changed. trol Modulating Valves.

  • Page 103: Process High Alarm 2 Value Type: General Parameter

    Process Variable Offset Also refer to Alarm Operation, Process High Alarm 2 Type: General Parameter Value, Process Variable, Scale Range Lower Limit and Scale Range Upper Limit. - Refer to Offset. Process High Alarm 2 Value Rate (Derivative) Type: General Parameter Type: Controller Tuning Parameter This parameter, applicable only when Alarm 2 is se- Rate is adjustable in the range 0 seconds (OFF) to 99...

  • Page 104: Remote Setpoint Upper Limit Type: Controller Parameter

    RSP value is always constrained within the Setpoint less than that for Retransmit Output 1 Scale Minimum, Upper Limit and Setpoint Lower Limits. the relationship between the process variable/setpoint value and the retransmission output is reversed. Display code = rSPL, default value = PV input range minimum.

  • Page 105: Scale Range Upper Limit Type: General Parameter

    value. It is similar to Retransmit Output 1 Scale Maxi- and can be set to a value more than (but not within 100 mum. units of) the Scale Range Upper Limit, in which case the sense of the input is reversed. Display code = ro3H, default value = Scale Range Up- per Limit.

  • Page 106: Serial Communications Option Type: General Definition

    before calculating a set of PID values. Successive de- the valve is fully opened. The valve must drive to its viation oscillation causes values to be recalculated so “Open” end stop before setting this parameter. that the controller rapidly converges on optimal control. It must not be used to limit valve movement, separate When the controller is switched off, the final PID terms Valve Close and Open Limit parameters are available...

  • Page 107: Setpoint Ramping Enable Type: Controller Parameter

    Setpoint Ramping Enable available in operator mode. If Setpoint Select is dis- Type: Controller Parameter abled again, the active setpoint will remain at its cur- rent status. Enables or disables the viewing and adjustment of the Display code = SSEn, default setting = diSA (dis- Setpoint Ramp Rate in Operator Mode.

  • Page 108: Tare Type: Indicator Parameter

    Triac amount (low flame). A controller output opens the so- Type: General Definition lenoid valve when the process requires additional heat (high flame). A small internal solid state device, which can be used Also refer to Modulating Valves and Time Proportioning in place of a mechanical relay in applications switching Control.

  • Page 109: Valve Open Limit Type: Vmd Controller Parameter

    not attempt to drive the valve past. It can be set be- the Setpoint when the Display Strategy is set to 7. tween 100 (fully open) and the Valve Closed Limit val- Valve Position Feedback is usually provided by means ue +1, expressed as a percentage of the valve’s “fully of a potentiometer linked to the valve.

  • Page 110: Thermocouple

    Thermocouple Ranges Available Sensor Range Min Range Max Range Min Range Max Resolution Type in °C in °C in °F in °F J (default) -200 1200 -328 2192 1° -128.8 537.7 -199.9 999.9 0.1° -240 -400 1° -128.8 400.0 -199.9 752.0 0.1°...

  • Page 111: Rtd Performance

    RTD Performance Type: Three-wire Pt100. Calibration: Complies with BS1904 and DIN43760 (0.00385Ω/Ω/°C). Measurement Accuracy: ±0.1% of span ±1LSD. Linearization Accuracy: Better than ±0.2°C any point, any 0.1°C range (±0.05°C typical). Better than ±0.5°C any point, any 1°C range. Temperature Stability: 0.01% of span/°C change in ambient temperature.

  • Page 112: Auxiliary Inputs

    Auxiliary Inputs Input Sampling rate: 4 per second Input Resolution: 13 bits minimum Input types: 4 to 20mA, 0 to 20mA, 0 to 10V, 2 to 10V, 0 to 5V, 1 to 5V. The Full Auxiliary input in Option Slot B also supports 0 to 100mv and Potenti- ometer (2KΩ...

  • Page 113: Specifications Of Output Types

    Specifications of Output Types Single Relay: Contact Type: Single pole double throw (SPDT). Control Rating: 2A resistive at 240V AC (120V when directly driving motorized valves). Limit Controller has a fixed 5A latching relay, in Option Slot 1. Alarm Rating: 2A resistive at 240V AC Control/Alarm Lifetime: >500,000 operations at rated...

  • Page 114: Control Specifications

    Linear DC: Resolution: Eight bits in 250mS (10 bits in 1 second typical, >10 bits in >1 second typical). Update Rate: Every control algorithm execution. Ranges: 0 to 10V 0 to 5V 2 to 10V 0 to 20mA 4 to 20mA (default) Load Impedance: 0 to 20mA &...

  • Page 115: Process Alarms

    Process Alarms Maximum Number of Alarms Two “soft” process alarms (high, low, deviation or band) plus Loop Alarm. (Controllers): Maximum Number of Alarms Five “soft” alarms (process high or low) (Indicators): (When available) Combinatorial Alarms: Logical OR or AND of alarms to any suitable output. Digital Communications Type: Asynchronous Serial.

  • Page 116: Physical Specifications

    Physical Specifications Dimensions: Depth behind panel: 110mm (1/16 DIN instruments). 100mm (1/8 & 1/4 DIN instruments). Front bezel size (w x h): 48 x 48mm (1/16 DIN instruments). 48 x 96mm (1/8 DIN controllers). 96 x 96mm (1/4 DIN instruments). Mounting: Plug-in with panel mounting fixing strap.

  • Page 117: 18 Appendix 3 - Order Tables

    SSR (0/10 VDC, 500 Ω Minimum load) Analog (0-10V, 0-20mA, 0-5V, 2-10V, 4-20mA) Isolated Power Supply 24 VDC (910Ω min) Dual Relay Output - 2 Amp, Form A (Not available on the 6040 model) Code Feature Option A None RS485 (ModBus/RTU) Digital Comms...
  • Page 118 Code Power Supply 100 - 240V AC 24 - 48V AC/DC 4050 - Typical Model Number Limited Warranty: Please refer to the Chromalox limited warranty applicable to this product at http://www.chromalox.com/customer-service/policies/termsofsale.aspx. Chromalox, Inc. 1347 Heil Quaker Boulevard Lavergne, TN 37086 (615) 793-3900 www.chromalox.com...

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