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Controller
6040
Installation & operation manual
Chromalox 6040 Installation & Operation Manual
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Contents
Table of Contents
Bookmarks
Table of Contents
Warranty and Returns Statement
Table of Contents
Introduction
Installation
Unpacking
Panel Cut-Outs
Panel-Mounting
Plug-In Options
Options Modules and Functions
Auto Detection of Option Modules
Preparing to Install or Remove Options Modules
Removing/Replacing Option Modules ("Output" & "Option" Are Interchangeable Terms)
Replacing the Instrument in Its Housing
Wiring Instructions
Installation Considerations
AC Power Wiring - Neutral (for 100 to 240V AC Versions)
Wire Isolation
Use of Shielded Cable
Noise Suppression at Source
Sensor Placement (Thermocouple or RTD)
Thermocouple Wire Identification Chart
Connections and Wiring
Power Connections - Mains Powered Instruments
Power Connections - 24/48V AC/DC Powered Instruments
Universal Input Connections - Thermocouple (T/C)
Universal Input Connections - PT100 (RTD) Input
Universal Input Connections - Linear Volt, MV or Ma Input
Option Slot 1 - Relay Output Module
Option Slot 1 - SSR Driver Output Module
Option Slot 1 - Triac Output Module
Option Slot 1 - Linear Voltage or Madc Output Module
Option Slot 2 - Relay Output Module
Option Slot 2 - SSR Driver Output Module
Option Slot 2 - Triac Output Module
Option Slot 2 - Dual Relay Output Module
Option Slot 2 - Linear Voltage or Madc Output Module
Option Slot 3 - Relay Output Module
Option Slot 3 - SSR Driver Output Module
Option Slot 3 - Linear Voltage or Madc Output Module
Option Slot 3 - Dual Relay Output Module
Option Slot 3 - Transmitter Power Supply Module
Option Slot a Connections - RS485 Serial Communications Module
Option Slot a Connections - Digital Input Module
Option Slot a Connections - Basic Auxiliary Input Module
Option Slot B Connections - Digital Input 2 (Full Auxiliary Module)
Option Slot B Connections - 1/4 DIN & 1/8 DIN Full Auxiliary Input Module
Powering up
Powering up Procedure
Overview of Front Panel
Displays
Keypad
LED Functions
Contents
Messages and Error Indications
Instrument Operation Modes
Select Mode
Entry into the Select Mode
Navigating in Select Mode
Unlock Codes
Automatic Tune Mode
Navigating in Automatic Tune Mode
Product Information Mode
Navigating in the Product Information Mode
Lock Code View
Entry and Navigating in Lock Code View Mode
6040, 8040 & 4040 Controller - Model Group
6040, 8040 & 4040 Controllers - Configuration Mode
Entry into the Configuration Mode
Scrolling through Parameters and Values
Changing Parameter Values
6040, 8040 & 4040 - Setup Mode
Entry into the Setup Mode
Scrolling through Parameters & Values
Changing Parameter Values
6040, 8040 & 4040 Controllers - Operator Mode
6040, 8040 & 4040 Controllers - Extended Operator Mode
Navigating in Operator Mode
Adjusting the Local Setpoint(S)
Adjusting the Setpoint Ramp Rate
Manual Control Mode
Selecting/Deselecting Manual Control Mode
6040, 8040 & 4040 Controllers - Communications Parameters
Bit Parameters
Word Parameters
6040, 8040 & 4040 VMD Controller - Model Group
Special Wiring Considerations for Valve Motor Control
6040, 8040 & 4040 VMD Controllers - Configuration Mode
Entry into the Configuration Mode
Scrolling through Parameters and Values
Changing Parameter Values
6040, 8040 & 4040 Valve Motor Drive - Setup Mode
Entry into the Setup Mode
Scrolling through Parameters & Values
Changing Parameter Values
Adjusting the Valve Parameters
Set Valve Opened Position & Set Valve Closed Position
Valve Position Clamping
6040, 8040 & 4040 Valve Motor Drive - Operator Mode
6040, 8040 & 4040 Valve Motor Drive - Extended Operator Mode
Navigating in Operator Mode
Adjusting the Local Setpoint(S)
Adjusting the Setpoint Ramp Rate
Manual Control Mode
Selecting/Deselecting Manual Control Mode
6040, 8040 & 4040 VMD Controllers - Serial Communications Parameters
Bit Parameters
Word Parameters
Contents
6040 Heater Break Alarm Controller - Model Group
6040 - Configuration Mode
Entry into the Configuration Mode
Scrolling through Parameters and Values
Changing Parameter Values
6040 HBA - Setup Mode
Entry into the Setup Mode
Scrolling through Parameters & Values
Changing Parameter Values
6040 HBA Controllers - Operator Mode
6040, 8040 & 4040 Controllers - Extended Operator Mode
Navigating in Operator Mode
Adjusting the Local Setpoint(S)
Adjusting the Setpoint Ramp Rate
Manual Control Mode
Selecting/Deselecting Manual Control Mode
6040 HBA Controller -Communications Parameters
Bit Parameters
Word Parameters
11 6050 & 4050 Limit Controller - Model Group
6050 & 4050 Limit Controllers - Configuration Mode
Entry into the Configuration Mode
Scrolling through Parameters and Values
Changing Parameter Values
6050 & 4050 Limit Controllers - Setup Mode
Entry into the Setup Mode
Scrolling through Parameters & Values
Changing Parameter Values
6050 & 4050 Limit Controllers - Operator Mode
Navigating in Operator Mode
Limit Setpoint Adjustment
Exceed Condition
Limit Output Function
Limit Annunciator Outputs
Resetting Limit Outputs & Annunciators
Using the Reset Key to Reset Limit Outputs & Annunciators
Resetting Limit Hold and Exceed Time
To Reset the Stored Limit Hold and Exceed Time Values
6050 & 4050 Controllers - Serial Communications Parameters
Bit Parameters
Word Parameters
12 Manually Tuning Controllers
Single Control Tuning (PID with Primary Output Only)
Dual Control Tuning (PID with Primary and Secondary Outputs)
Valve Control Tuning (PI with VMD or Linear Outputs)
Manually Fine Tuning
13 Modbus Serial Communications
Physical Layer
Link Layer
Contents
Device Addressing
Supported Modbus Functions
Function Descriptions
Read Coil/Input Status (Function 01/02)
Read Holding/Input Registers (Function 03/04)
Force Single Coil (Function 05)
Pre-Set Single Register (Function 06)
Loopback Diagnostic Test (Function 08)
Pre-Set Multiple Registers (Function 10 Hex)
Exception Responses
ASCII Communications
Physical Layer
Device Addressing
Session Layer
Type 1 Message
Type 2 Message
Type 3 Message
Type 4 Message
Error Response
15 Calibration Mode
Equipment Required for Checking or Calibrating the Universal Input
Calibration Check
Recalibration Procedure
16 Appendix 1 - Glossary
Active Setpoint Type: Controller Definition
Actual Setpoint Type: Controller Definition
Alarm Hysteresis Type: General Parameter
Alarm Operation Type: General Definition
Alarm Inhibit Type: General Parameter
Annunciator Type: Limit Controller Definition
Automatic Reset (Integral) Type: Controller Tuning Parameter
Auto Pre-Tune Type: Controller Tuning Parameter
Auxiliary Input Type: General Definition
Band Alarm 1 Value Type: General Parameter
Band Alarm 2 Value Type: General Paramete
Bias (Manual Reset) Type: Controller Tuning Parameter
Bumpless Transfer Type: Controller Definition
Boundless VMD Control Type: VMD Controller Definition
Cascade Control Type: Controller Definition
Communications Write Enable Type: General Definition
Control Type Type: Controller Parameter
Controller Type: Controller Definition
CPU Type: General Definition
Current Proportioning Control Type: Controller Definition
Cycle Time Type: Controller Definition
Deadband Type: Controller Parameter
Derivative Type: Controller Parameter
Deviation Alarm 1 Value Type Type: General Parameter
Deviation Alarm 2 Value Type: General Parameter
Differential (On-Off Hysteresis) Type: Controller Parameter
Direct/Reverse Action of Control Outputs Type: Controller Definition
Display Strategy Type: General Parameter
Elapsed Time Type: Indicator Definition
Exceed Time Type: Limit Controller Definition
Heater Current Monitor
Integral Type: Controller Tuning Parameter
Loop Alarm Enable Type: Controller Parameter
Manual Mode Enable Type: Controller Parameter
Offset Type: Controller Parameter
PI Control Type: Controller Definition
Process High Alarm 2 Value Type: General Parameter
Remote Setpoint Upper Limit Type: Controller Parameter
Scale Range Upper Limit Type: General Parameter
Scale Range Lower Limit Type: General Parameter
Secondary Proportional Band Type: Controller Tuning Parameter
Self-Tune Type: Controller Tuning Definition
Contents
Retransmit Output 3 Scale Minimum Type: General Parameter
Serial Communications Option Type: General Definition
Set Valve Closed Position Type: VMD Controller Parameter
Set Valve Opened Position Type: VMD Controller Parameter
Setpoint Type: Controller Definition
Setpoint Upper Limit Type: Controller Parameter
Setpoint Lower Limit Type: Controller Parameter
Setpoint Ramping Enable Type: Controller Parameter
Setpoint Ramp Rate Type: Controller Parameter
Setpoint Select Type: Controller Parameter
Setpoint Select Enable Type: Controller Parameter
Soft Start
Solid State Relay (SSR) Type: General Definition
Solenoid Valve Type: General Definition
Tare Type: Indicator Parameter
Three Point Stepping Control Type: VMD Controller Definition
Time Proportioning Control Type: Controller Definition
Tuning Type: Controller Definition
Triac Type: General Definition
Valve Close Limit Type: VMD Controller Parameter
Valve Motor Drive Control Type: VMD Controller Definition
Valve Position or Flow Indication Type: VMD Controller Definition
Valve Open Limit Type: VMD Controller Parameter
VMD Type: VMD Controller Parameter
17 Appendix 2 - Specification
Universal Input
General Input Specifications
Thermocouple
Thermocouple Ranges Available
Thermocouple Performance
Resistance Temperature Detector (RTD)
RTD Ranges Available
RTD Performance
DC Linear
DC Linear Ranges Available
DC Linear Performance
Auxiliary Inputs
Digital Inputs
Output Specifications
Output Module Types
Specifications of Output Types
Control Specifications
Process Alarms
Digital Communications
Reference Conditions
Operating Conditions
Standards
Physical Specifications
18 Appendix 3 - Order Tables
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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
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8040
4050
4040
6050
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