Chromalox

2104

Chromalox

®

Temperature Controller

C

Issue Date

May 1996

Technical Manual

0037-75276

Table of Contents

6

7

4

5

2

3

Sections

Section

1

Topic Page

Getting Started ..................................................... 1

Installation ........................................................... 3

Operation ............................................................. 21

Controller Setup Pages ........................................ 33

Ramp/Soak Operation ......................................... 41

Alarms ................................................................. 47

Digital Input and AUX Function ......................... 59

8

9

10

11

Remote Setpoint & Analog Process Output ........ 67

Digital Communications ...................................... 71

Calibration ........................................................... 75

Specifications ...................................................... 83

12

13

I

Appendices

Troubleshooting ................................................... 87

Warranty and Return ............................................ 89

Setup Pages .......................................................... 91

Menu Index

Index .............................................................................................. 103

Chromalox 2104 Technical Manual i

2.13

2.14

2.15

2.16

2.17

2.18

2.7

2.8

2.9

2.10

2.11

2.12

2.19

2.20

2.21

2.22

2.23

2.24

2.1

2.2

2.3

2.4

2.5

2.6

Illustrations

Figure Topic

1.1

1.2

Page

Application ............................................................. 1

Model Identification............................................... 2

Sensor Selection Dip Switch Settings ................... 3

Mounting Dimensions ............................................ 5

Mounting Diagram ................................................. 5

Wiring Terminal Identification .............................. 7

Thermocouple Connections................................... 8

3-Wire RTD Connections ...................................... 9

2-Wire Connections ............................................... 9

Current Input Wiring (Self-powered) .................... 9

Voltage Input Wiring .............................................. 10

Current Input Wiring (Loop-power) ..................... 10

Event Input Connections External Switch ............ 10

Momentary Contact Pushbutton for Ramp/Soak .. 10

Relay Output Connections .................................... 11

SSR Drive Output Jumper Positions ...................... 12

Solid State Relay Drive Output Connections ....... 13

Current/Voltage Output Jumper Positions ............. 14

Triac Output Connections ..................................... 15

4-20mA Analog Output Connections ................... 15

1-5 Vdc Output Connections ................................ 15

Dual Relay Output Wiring ..................................... 16

Dual Triac Output Wiring ...................................... 16

Dual Analog Output Wiring .................................. 16

Dual SSR Drive Output Wiring ............................. 16

Dual 1-5 Vdc Output Wiring ................................. 17 ii Chromalox 2104 Technical Manual

8.1

8.2

8.3

8.4

8.5

8.6

9.1

9.2

9.3

9.4

5.1

5.2

5.3

5.4

6.1

3.1

3.2

3.3

3.4

3.5

2.28

2.29

2.30

2.31

2.32

Illustrations

Figure Topic

2.25

2.26

2.27

Page

Dual Output SSR/Relay Wiring ............................. 17

Dual Output SSR/Triac Wiring .............................. 17

Dual Output Analog/Relay Wiring ........................ 18

Dual Output Analog/Triac Wiring ......................... 18

100-240 Vac Instrument Power Connections ........ 19

12-24 Vac/Vdc Instrument Power Connections .... 19

Alarm/Event Outputs #3 and #4 ............................ 19

Alarm/Event Output #5 ......................................... 20

Front Panel Identification ...................................... 22

PAGE/MENU Setup Structure .............................. 23

Sample of PAGE/MENU Table .............................. 25

Security Levels and PAGE/MENU Contents ........ 26

Security Codes and View/Adjust Levels ................ 27

Ramp/Soak Profile .................................................. 41

Event Outputs in Ramp/Soak Profile ..................... 41

Looping Intervals .................................................... 42

Guaranteed Soak .................................................... 42

CLP Alarm Connections ........................................ 55

Remote Setpoint Input Signal ............................... 67

2-Wire 4-20mA Transmitter (Loop-powered) ....... 68

2-Wire 4-20mA, 1-5 Vdc Transmitter (Self-powered) ... 68

3-Wire 4-20mA, 1-5 Vdc Transmitter ................... 68

Analog Process Output Signal ............................... 69

Process Output Wiring ........................................... 70

RS422/RS485 Communications Switches ............. 72

RS232 Wiring Connections ................................... 72

RS422A Wiring Connections (4-wire) ................. 73

RS485 Wiring Connections (2-wire) ..................... 73

Chromalox 2104 Technical Manual iii

iv Chromalox 2104 Technical Manual

Section 1

Getting Started

The Chromalox 2104 1/4 DIN temperature and process controller is a low-cost, high-performance, single-loop controller that can be used for temperature, flow, pressure and level control applications. With universal sensor inputs and front panel operator setup, one 2104 controller can be easily field configured for a wide variety of applications, and simply reconfigured as application needs change. This makes it an exceptional choice for OEMs with multiple control needs, manufacturing facilities, testing facilities and testing applications.

Figure 1.1

Typical Application

Shutdown

Contactor

Output #5

Control Loop

Protection

Recorder

Computer

ChromaSoft™

RS485

Digital

Com.

Remote/Local

Setpoint Switch

SCR

Heat

Output #1

Cool

Output #2

High Alarm-Output #3

Shutdown

Low Alarm-Output #4

SCR

Heat

Output #1

Cool

Output #2

High Alarm-Output #3

Shutdown

Low Alarm-Output #4

Process

Remote Setpoint from DCS

Chromalox 2104 Technical Manual 1

Model Identification

Before installation, please identify your controller model number. The model number is written on the tag on the side of the housing.

Figure 1.2 Model Identification

Model Temperature Controller

2104 Microprocessor-based 1/4 DIN Temperature Controller. Universal Sensor Input accepts Thermocouple, RTD, Current or Voltage Inputs. PID, ON/OFF with

Fuzzy Logic Control Capability. One Digital Input and Analog Remote Set Point.

AR

AT

SR

ST

RR

TT

AA

SS

Code Outputs #1—Single Output Control

RO

TO

AO

Output #1 Single Output Control Relay/SSR Drive (jumper selectable)

Relay—N.O. Form A Contact, 1A at 120 or 230 Vac

SSR Drive—24Vdc at 40mA

Triac—1 Amp at 120 or 230 Vac

Analog—4-20mA or 1-5 Vdc, non-isolated

Outputs #1 & #2 - Heat/Cool Control

Relay/Relay

Triac/Triac

Analog/Analog

SSR Drive/SSR Drive

Analog/Relay

Analog/Triac

SSR Drive/Relay

SSR Drive/Triac

Code Outputs #3 & #4 (Alarm/Event Outputs)

0

1

None

Dual Relay—Two (2) Form A contacts, 1A at 120 or

230 Vac with shared common terminal

3

4

0

1

Code Isolated Digital Communications,

Output #5 (Alarm/Event Output), and Analog Output Option

2

5

None

RS-422/485 Digital Communications and

Output #5

RS-232 Digital Communications and

Output #5

Analog Output Option

RS-422/485 Digital Communications,

Output #5 and Analog Output Option

RS-232 Digital Communications,

Output #5 and Analog Output Option

Code Power Supply

0

1

100 - 240 Vac or Vdc

12-24 Vdc or Vac

1 1 0 2104-

2

RO Typical Model Number

Chromalox 2104 Technical Manual

Section 2

Installation

Inspection and

Unpacking

On receipt of your 2104 controller, immediately make note of any visible damage to the shipment packaging and record this damage on the shipping documents.

Unpack the controller and carefully inspect it for obvious damage due to shipment. If any damage has occurred, YOU must file a claim with the transporter, as they will not accept a claim from the shipper.

If the controller will not be immediately installed and placed into operation, it should be stored in a cool, dry environment in its original protective packaging until time for installation and operation. Temperature extremes and excessive moisture can damage the instrument.

Switch

Settings

Figure 2.1

Sensor Selection

Dip Switch

Settings

The 2104 has up to seven (7) hardware switches located on the bottom of the controller. The switches are accessible through cutouts in the controller housing and do not require that you remove the controller from its housing to access the switches.

Figure 2.1 identifies the switches. Instructions for switch settings are given in the corresponding sections of the manual.

Switches #1 and #2

Digital Communications

RS422/RS485

Controller

Bottom Surface

Switches #1, #2 and #3

Sensor Input

Switch #4

Remote Setpoint

Input Signal

Switch #5

Analog Output

Signal


4

Sensor

Selection

Switches

Sensor selection requires that you:

1. Set the sensor switches for the correct sensor type.

2. Program the input sensor type in sensor selection setup on the INPT Page (see page 36).

It is much easier to set the sensor input switches before you mount and wire the controller.

To set the sensor switches:

1. Locate the sensor switches—#1, #2 and #3— on the bottom of the controller, as shown in

Figure 2.1 on the previous page.

2. Place the switches in the appropriate Up or

Down position for your input type:

Input Type

T/C

RTD

4-20mA

1-5 Vdc

Switch #

1 2 3

Up Up

Down Up

Up

Up

Down

Up

Up

Up

Down

Down

Mounting

Figure 2.2, on the following page, shows the mounting dimensions for the controller:

1. Cut out the square “panel cutout” mounting hole and install the unit as shown in

Figure 2.3.

2. Place the controller through the square panel cutout and replace the mounting clip.

3. Tighten the mounting clip screw (do not over- tighten) to secure the controller firmly against the mounting surface.


Figure 2.2 Mounting Dimensions

3.8

(96)

0.8

(19)

4.0

(102)

3.8

(96)

3.5

(90)

3.6

(92)

Measurements are shown in inches. Millimeters are shown in parentheses.

3.6

(92)

Figure 2.3 Mounting Diagram

Mounting Hole

Mounting Clip

Mounting Tab


Panel Cutout

5

6

Wiring

Instructions

Good Wiring Practices

1. When planning the system wiring, separate wiring into functionally similar bundles - i.e., power leads, sensor leads, output signal lines, etc. If the power leads and sensor leads must cross, they should cross at a 90

° angle to each other (perpendicular).

2. Locate all sources of electrical noise in your system, and separate these sources from the control systems— motors, contacts, solenoids, etc. Electrical noise can affect the function of any control system. When driving a contactor coil or other inductive load, an appropriately rated AC snubber circuit is recommended (Chromalox Part. No. 0149-01305), as described on page 11, “Relay Output Wiring.”

3. For sensor wiring practices, see Sensor Wiring

Notes, next page.

4. Additional information on good wiring practices is available from IEEE, 345 East 47th St., NY, NY

10017. Request IEEE Standard No. 518-1982.

Make all electrical wiring connections to the back of the controller before power is applied to the unit.

All wiring must comply with local codes, regulations and ordinances. This instrument is intended for panel mounting and the terminals must be enclosed within a panel. Use National Electric Code (NEC) Class 1 wiring for all terminals except the sensor terminals.

Check the wiring decal on the side of the unit to verify the model number. The wiring decal shows the wiring terminations. All wires will be connected to the terminals on the back of the instrument case. Specific wiring instructions for different input and output types are given in this section.


Figure 2.4 Wiring Terminal Identification

Digital

Input

Common

+24 Vdc Output

Analog Output

Remote Setpoint Input

Common

Sensor Input

1

4

5

2

3

8

9

6

7

24

25

26

RTD TC 4-20mA

27

19

20

21

22

23

10

11

Digital

Communications

12

13

Not Used

Output #5

14

15

16

17

18

Output #1 and #2

Output #3 Relay

Output #4 Relay

100/240 Vac or

12/24 Vac/Vdc

AC Common

Shield Ground

Instrument

Power

Sensor Input Wiring

Sensor Input Wiring Notes:

• Sensor leads (thermocouple and RTD) should not be run together in the same conduit as power wiring.

• Twisted pair, shielded wire is recommended for sensor connections.

• False process readings can occur if the sensor wire is exposed to electrical noise.

• Ungrounded thermocouples are recommended.

• If thermocouple extension wire is required, it must be the same type as the thermocouple (i.e., if a

Type K thermocouple is used, then Type K extension wire must be used).

• Thermocouple wires should connect directly to the controller terminals. Do not use copper crimp terminals or solder terminals to make connections.

• If shielded thermocouple wire is used, the shield must be grounded at one end only, preferably at the shield ground terminal on the controller, as shown in Figure 2.5.

• Three wire RTDs are recommended for greatest accuracy.

• Standard shielded copper wire is recommended for

RTD extensions.


8

Thermocouple Inputs

It is important to observe polarity (+, -) when connecting thermocouple leadwires. The table below shows ANSI color coding for the thermocouples used with this instrument.

J

T/C Type Material

B Plat, 30% Rhodium/

Plat, 6% Rhodium

Iron/Constantan

K

E

T

R

S

Chromel/Alumel

Chromel/Constantan

Copper/Constantan

Plat, 13% Rhodium/Plat

Plat, 10% Rhodium/Plat

Polarity (+)

Gray

White

Yellow

Purple

Blue

Black

Black

Polarity (-)

Red

Red

Red

Red

Red

Red

Red

Make the thermocouple wiring connections to terminals as shown in Figure 2.5.

Figure 2.5

Thermocouple

Connections

+

-

8

2104

9

Shield Gnd

18

3-Wire RTD Inputs

When making the 3-wire RTD input connection, it is important to make the resistance of all three extension leadwires equal by using the same gauge and same length of wire for optimum leadwire compensation.

Chromalox recommends 3-wire RTDs for greatest accuracy, and standard shielded copper wire for RTD extensions. Make 3-wire RTD connections to terminals 7, 8 and 9 as shown in Figure 2.6 on the following page.


Figure 2.6

3-Wire RTD

Connections

8

9

2104

7

18 Shield Grnd

Figure 2.7

2-Wire

Connections

2-Wire RTD Inputs

If using a 2-wire RTD input, use heavier gauge leadwires to reduce leadwire resistance. Any leadwire resistance adds directly to sensor resistance, thus adding error to the process temperature measurement. It is also necessary to jumper terminals 8 and 9 on the instrument to complete a

2-wire hookup.

2104

7

8

9

Current/Voltage Inputs

Figure 2.8

Current

Input Wiring

(Self-powered)

4-20mA

+

2104

7

8

9


Figure 2.9

Voltage

Input Wiring

(Self-powered)

1-5 Vdc

0-5 Vdc

+

8

9

2104

7

The 2104 has a +24 Vdc power supply which can be used to power a 4-20mA transmitter.

Figure 2.10

Current

Input Wiring

(Loop-powered by controller)

4-20mA

+

2104

3

+24 Vdc

7

10

Digital Input

Connections

The digital input can be used in a number of ways:

• to control ramp/soak operations

• to switch between two setpoints, PID parameters, or Auto/Manual control

• to reset an alarm

• to disable the control output.

Setup for the digital input is shown on the CTRl setup page. An external switch, pushbutton or dry contact can be connected to this input. Use isolated switches only. Do not tie the Digital Input terminals to ground.

Figure 2.11

Digital Input

Connections

External Switch

-

+

2104

1

{

External

Input

2

Figure 2.12

Momentary

Contact

Pushbutton for

Ramp/Soak

+

2104

1

-

2


Output

Wiring

☛

The 2104 is supplied with either:

• 1 Control Output for Single Output

Control (#1)

• 2 Control Outputs for Heat/Cool Control

(#1 and #2)

The output wiring varies depending on the control type and applications. The wiring instructions are presented separately for each of these two controller types/applications.

Warning

Incorrect output wiring may cause system/process damage.

Single Output Control Wiring

Relay Output

Output Code “RO” on the 2104 (2104 - RO***) gives you the option of SSR Drive or Relay control for output #1. When shipped from the factory, the relay output is active.

Figure 2.13

Relay Output Connections

Relay

Contacts

{

10

Internal

MOV

11

Load

Snubber

120 or 230 Vac

AC Neutral

SSR Drive Output

For SSR drive output applications, you must move an internal jumper on the Output #1 module to select SSR drive output. Remove the controller from its housing, and locate the output module as shown in Figure 2.14 on the following page. Reposition the jumper to select SSR Drive output.


Figure 2.14

SSR Drive Output

Jumper Position

Top

Output #1 Module

12

Relay

(as shipped from factory)

SSR Drive

Controller Rear View

Output Module


Solid State Relay Drive Connections

The solid state relay drive output drives solid-state relays, such as the Chromalox 4115 or 4117 power modules, which accept 3 to 32 Vdc input ON signals and 0 Vdc OFF signals. See Figure 2.15 for solid state relay drive output connections.

Note: Negative lead connects to Terminal #2.

Figure 2.15

Solid State Relay Drive Output Connections

+

Output 1

{

12

2

-

4115

Fuse

Load

120 or 230 Vac

AC Neutral

Current/Voltage Output

Controllers with output codes “AO,” “AA,” “AR” and “AT” give you the option of 4-20mA or 1-5 Vdc output. When shipped from the factory, these control outputs are configured for 4-20mA output.

For 1-5 Vdc output, you must access the internal output board and move the jumper(s) to the 1-5

Vdc position, as shown in Figure 2.16 on the following page.


Figure 2.16

Current/Voltage

Output Jumper Positions

Top

Output Module

14

Controller Rear View

Output #1*

4-20mA 1-5 Vdc

Output #2

4-20mA 1-5 Vdc

*All controllers with Analog Output (output codes AR, AT) for output #1 use same 4-20mA/1-5 Vdc jumper positions as shown here.


Figure 2.17

Triac Output Connections

2104

10 Heat Load

Fuse

11

AC Neutral

120 Vac or 230 Vac

Figure 2.18

4-20mA Analog Output Connections

2104

+24 Vdc

4-20mA

10

11

+

-

Power

Controller or Valve

(0-800 ohms)

Figure 2.19

1-5 Vdc Output Connections

2104

1-5 Vdc 10

11

12

NC

+

Input

-

GND


16

Heat/Cool Control

Output Wiring

Figure 2.20

Dual Relay Output Wiring

2104

10

Output #1

11

Output #2

12

Heat

Load

Fuse

Cool

Load

Figure 2.21

Dual Triac Output Wiring

Output #1

Output #2

2104

10

11

12

Heat

Load

Fuse

Cool

Load

AC Neutral

120 Vac or 230 Vac

AC Neutral

AC Neutral

120 Vac or 230 Vac

AC Neutral

Figure 2.22

Dual Analog Output Wiring

Output #1

2104

+24 Vdc

4-20mA

Output #2

10

+24 Vdc

4-20mA

11

12

Figure 2.23

Dual SSR Drive Output Wiring

2104

+24 Vdc

(Output #1)

(Output #2)

+24 Vdc

10

11

12

+

+

-

-

Solid

State

Relay

Solid

State

Relay

Fuse

Heat

Load

Fuse

Cool

Load

-

-

+

Heat Control

(0-800 Ohm)

Cool Control

(0-800 Ohm)

+

120 Vac or 230 Vac

AC Neutral

120 Vac or 230 Vac

AC Neutral


Heat/Cool Control Output Wiring

(continued)

Figure 2.24

Dual 1-5 Vdc Output Wiring*

Output #1

Output #2

2104

1-5 Vdc

10

11

1-5 Vdc

12

+

Input

GND

Heat

Control

-

-

+

GND

Input

Cool

Control

*Note: See page 14 for Analog/Voltage jumper positions.

Figure 2.25

Dual Output SSR/Relay Wiring

2104

(Output #1)

(Output #2)

-

11

MOV

12

10

2

Fuse

+

-

Fuse

Solid

State

Relay Heat

Load

120 Vac or 230 Vac

Cool

Load

AC Neutral

120 Vac or

230 Vac

AC Neutral

Figure 2.26

Dual Output SSR/Triac Wiring

2104

(Output #1)

10

2

-

(Output #2)

11

12

Fuse

+

-

Fuse

Solid

State

Relay

Heat

Load

120 Vac or 230 Vac

Cool

Load

AC Neutral

120 Vac or

230 Vac

AC Neutral


18

Heat/Cool Control Output Wiring

(continued)

Figure 2.27

Dual Output Analog/Relay Wiring

2104

(Output #1)

4-20mA

Common

(Output #2)

10

2

11

MOV

12

Fuse

Cool

Load

+

-

Heater

Power

Controller

120 Vac or 230 Vac

AC Neutral

Figure 2.28

Dual Output Analog/Triac Wiring

2104

(Output #1)

4-20mA

Common

(Output #2)

10

2

Fuse

11

12

Cool

Load

+

-

Heater

Power

Controller

120 Vac or 230 Vac

AC Neutral


Instrument Power Wiring

Make 120 Vac or 230 Vac instrument power connections to terminals 16-18 as shown in

Figure 2.29.

Figure 2.29

100-240 Vac

Instrument

Power

Connections

(2104-****0)

2104

16

17

18

100 - 240 Vac

Neutral

Chassis Ground

Figure 2.30

12-24 Vac/Vdc

Instrument

Power

Connections

(2104-****1)

2104

16

17

18

12-24 Vac/Vdc

Common

Chassis Ground

Alarm/Events

Outputs

#3 & #4

The two independent alarm (Output #3 or #4) relay outputs are connected as shown in Figure 2.31.

Figure 2.31

Alarm/Event Outputs #3 and #4

2104

Output #3

Output #4

13

MOV

14

MOV

15

Load

Fuse*

Load

AC Neutral

120 or 230 Vac

AC Neutral

* Fuse should be sized for the combined current of Output #3 and #4.


Alarm/Event

Output #5

The Form C Relay Output is connected as shown in

Figure 2.32.

Figure 2.32

Alarm/Event

Output #5

2104

Output #5

Normally

Open

Normally

Closed

25

MOV

26

MOV

27

Load

Fuse*

Load

* Fuse should be sized for the current of Output #5.

AC Neutral

120 or 230 Vac

AC Neutral

20 Chromalox 2104 Technical Manual

Section 3

Operation

Section

Contents

Pushbuttons and Indications

Security Codes and Levels

Controller Operation

Pushbuttons and

Indications

Control programming is easily accomplished with the front panel pushbuttons. The displays provide a constant overview of the process. Figure 3.1, on the next page, summarizes the functions of the pushbuttons and displays.

Normal Display Mode

At powerup, and when the controller is not being programmed, the upper display shows the Process

Value and the lower display shows the setpoint.

The setpoint can be changed in the Normal Display

Mode using the ▲ and ▼ pushbuttons, if the Security

Level allows setpoint changes (see page 26 for Security

Levels).

RESET AUX

▲ ▼

➮

RESET AUX

▲ ▼

Use ▲ and ▼ to change setpoint in Normal

Display Mode.


Figure 3.1

Front Panel

Identification

• Process Variable Display in

Normal Display Mode

• Alphanumeric Menu display in Setup Mode

LEDs indicate Control

Output #1 or #2 ON

LEDs indicate Alarm or Event Output ON

RESET

Pushbutton

• Reset Latching Alarm

• Hold for more than

3 seconds to enter or exit Setup Mode

• Scrolls through

MENUs in

Setup Mode

AUX

Programmable Pushbutton

• PID1/PID2 Toggle Switch

• Auxiliary Setpoint Enable

• Remote Setpoint Enable

• Output Disable

• Ramp/Soak Operations

• Auto/Manual Selector

22

LEDs indicate

°

F or

°

C selected for

Process Variable

LED indicates an

Auxiliary function is active

Active Setpoint

Display

• In Normal Display Mode, pushbuttons adjust Setpoint.

• In Setup Mode, pushbuttons increase/decrease MENU values.

• Ramp to Setpoint, press once to determine target setpoint.

• For Ramp/Soak Operation:

Start

Hold

}

Press together to Stop


PAGE/MENU

Setup

All control parameters, selections and calibration procedures for the 2104 are accomplished through simple MENU selections. These MENU selections are organized into PAGES. On each PAGE you will find a specific set of related functions.

This organization allows you to go directly to the parameter to be adjusted, without stepping through a long series of unrelated entries. Figure 3.2 illustrates the 2104 PAGE/MENU setup structure. Only pages that apply to your unit will be displayed (i.e. if you do not have Digital Communications option, this page will not appear).

Figure 3.2

PAGE/MENU Setup Structure

RESET AUX

▲ ▼

Display

C

TRL

RESET AUX

▲ ▼

Control

I N

P

T

RESET AUX

▲ ▼

Input

RESET AUX

▲ ▼

Ramp/

Soak

S C

A

L

RESET AUX

▲ ▼

Custom

Input/Output

Scaling

RESET AUX

▲ ▼

Output #1

O

UT2

Output #2

RESET AUX

▲ ▼

RESET AUX

▲ ▼

Output #3

O

UT4

RESET AUX

▲ ▼

Output #4

O

UT5

RESET AUX

▲ ▼

Output #5

RESET AUX

▲ ▼

Digital

Communications


24

Accessing a MENU is accomplished by entering the

Setup Mode, then selecting a PAGE and MENU.

To enter Setup Mode:

Hold down the RESET pushbutton for longer than 3 seconds.

L

O C

H

RESET AUX

▲ ▼

Hold for at least

3 seconds.

➮

RESET AUX

▲ ▼

Setup Mode entered.

To select a PAGE:

Press and hold the Reset pushbutton, while pressing the ▲ or ▼ Pushbutton. The upper display will increment (or decrement) through the

PAGEs, and PAGE will be displayed in the lower display.

RESET AUX

▲ ▼

C

TRL

➮

RESET

P

A

GE

▲

AUX

▼

N

P

T

➮

RESET AUX

▲ ▼

O

U T

1

➮

RESET AUX

▲ ▼

Hold Press ▲ or ▼

Hold Press ▲ or ▼ Hold Press ▲ or ▼

To select a MENU:

After reaching the correct PAGE, press RESET to move through the MENUs. The alpha cue for the

MENU will appear on the upper display, and the current value will appear in the lower display.

O

UT 1

P

A

GE

▲

RESET AUX

▼

C Y

CL

➮

RESET AUX

▲ ▼

➮

RESET AUX

▲ ▼


To change a MENU value:

After the MENU is selected and displayed, use the

▲ and ▼ pushbuttons to change the value. For large adjustments (for example, 100 to 200), hold the pushbutton pressed and the display will change more quickly.

C

Y CL

RESET AUX

▲ ▼

C

Y CL

➮

RESET AUX

▲ ▼

To return to Operating Mode:

Press and hold RESET for more than 3 seconds. The controller will automatically return to operating mode after 10 minutes of no pushbutton activity.

STB Y

RESET AUX

▲ ▼

Hold for at least

3 seconds.

Figure 3.3

Sample of

PAGE/MENU

Table

C

TRL

P

A

GE

RESET AUX

▲ ▼

Control Page

MENU

L

O C

Description

Security Lock

A

U

Setpoint

Auxiliary SP

26

TUN

E

Self Tune

29

Available Settings

0 to 9999

Security

A

Instrument sensor span

Auxiliary setpoint is accessible only if AUX pushbutton or Event

Input is setup for Auxiliary Setpoint.

Instrument Sensor Span

B

Self-Tune automatically adjusts PID C parameters on powerup (PRUP) or on demand (BEGN).

OFF

PRUP

BEGN

= Self-tuning disabled

= Power-up tuning

= Begin tuning


Security

Levels

Every parameter or selection in the 2104 controller’s setup PAGEs has an identifying MENU. Each

MENU is assigned one of four Security Levels, A-D.

In each level you may view certain MENUs , and

adjust certain MENUs. This allows you to set the

Security level that is appropriate for your operating environment, prohibiting unauthorized access to or accidental changing of control parameters.

Figure 3.4

Security Levels and PAGE/MENU Contents

Level

A

Code

---

Description

Display Page and Security Lock

B

C

D

123

458

736

Setpoint and Auxiliary Setpoint

Settings for:

Control

Input

Ramp/Soak


Calibration Security Codes

Entering the

Security Code

The Security Code is entered on the Control PAGE

CTRL, at the MENU LOCK. This code determines which MENUs may be viewed and adjusted.

The controller is set at Security Level A (view only, no adjustments) when you receive it from

Chromalox.


To access and enter the Security Code:

1. Press and hold RESET for more than 3 seconds to enter Setup Mode. Security Lock is the first menu that will appear.

L

O C

H

RESET

AUX

▲ ▼

Security Codes

Figure 3.5 lists the Security Codes for each of the four Security Levels, along with the levels that may be viewed and adjusted.

Figure 3.5

Security Codes &

View/Adjust

Levels

Security

Level

A

B

C

D

Security

Code

- - -

123

458

736

View

Level

A

A, B

A, B, C

A, B, C, D

Adjust

Level

A

A, B

A, B, C

A, B, C, D

If a number other than one of the three codes listed above is entered at LOCK on the CTRL PAGE, adjustment of all parameters is locked out. An additional security number can be added using the menu for User Selectable Security Code (CTRL

PAGE, menu CODE).


RESET

AUX

▲ ▼

RESET

RESET

28

Control

Operation

O O

L

▲

AUX

H

T

CL

▲

AUX

O O

L

RESET

A

IR

▲

AUX

▼

▼

▼

The 2104 Controller is capable of single output and heat/cool PID control. The selection for single or heat/cool control is made in the Controller Type menu (CTRL PAGE, CONT) with PID settings also in the Control Page. Additionally, the 2104 features ramp to setpoint and ramp/soak capabilities.

Control Algorithms

PID is the standard control algorithm of the 2104.

ON/OFF control action is selected by setting the proportional band (CTRL

PAGE, PB1 or PB2) to zero.

Two sets of PID and ON/OFF control parameters are located in the Control Page for increased flexibility.

Additionally, a Fuzzy Logic algorithm can be used to help prevent overshoot at power-up or during upsets.

Standard Single Output Control

In standard single output control (CTRL

PAGE,

CONT = HEAT or COOL) the Sensor Input is used to measure the process variable and Output #1 is used to control the process. PID1 parameters (CTRL

PAGE, DBL, ARL, RATL) are used to determine the response of the control loop.

Heat/Cool Control

In heat/cool control (CTRL

PAGE, CONT

=

HTCL)

Outputs #1 and #2 are used to control the process.

Output #1 acts as the Heat output and Output #2 acts as the Cool output. PID1 parameters (CTRL

PAGE, PBL, ARL, RATL) are used to determine the response of the Heat output and PID2 parameters

(CTRL PAGE, PB2, AR2, RAT2) are used for the cool output.

One way to automatically set the PID2 parameters is via the cooling medium parameters. These are setup at menu COOL on the CTRL

PAGE.

Cooling Medium parameters automatically establish the optimum PID2 cooling parameters, based on the cooling medium used/selected. If air, oil or water cooling medium is selected, and PID1 parameters change (during self-tune OR Manually), PID2 parameters will also be adjusted. If “PID2” is selected

(PAGE CTRL, COOL = PID2, no cooling medium specified), the PID2 parameters will change only if changed in Menus PB2, AR2 and RAT2.


Control

Operation

(continued)

RESET

PR

U

P

▲

AUX

▼

RESET

AUX

▲ ▼

Self-Tuning

The 2104 tuning algorithm establishes PID constants (PBL, ARL, RATL) that will bring the process to setpoint as quickly as possible with little overshoot. Tuning can be performed at powerup

(CTRL

PAGE, TUNE = PRUP) or can be initiated immediately (CTRL

PAGE, TUNE = BEGN). When tuning, the 2104 will flash “TUNE” in the lower display.

If the process variable is not at least 50

°

F (28

°

C) away from setpoint, the 2104 will turn off the control output until the process temperature is 50

°

F from setpoint. If the 50

°

F temperature difference is not reached within 30 minutes, “TERR” will be displayed, indicating that tuning was not successful

(tuning error). Press RESET to clear “TERR”. After successfully tuning, tuning is turned OFF in the tuning menu (TUNE).

Heat/Cool Self-Tuning

For heat/cool control applications, when the cooling medium is specified (PAGE CTRL, COOL =

AIR, H2O, OIL), both heat (PID1) and cool (PID2) parameters are computed during a heat tune

(tuning is invoked while the process temperature is at least 50

°

F below setpoint). If no cooling medium is specified (PAGE CTRL, COOL = PID2) the PID2 parameters (PB2, AR2, RAT2) will not change during a self-tune.

A cool tune (tuning is invoked while the process temperature is at least 50

°

F above setpoint) will compute PID parameters for cooling only. One way to initiate a cool tune is to first heat tune, then lower the setpoint by 50

°

F (28

°

C) and initiate selftuning for cooling (CTRL PAGE, TUNE = BEGN). A cool tune will change PID2 settings if Heat/Cool control is selected for the control type (CTRL PAGE,

CONT HTCL).


Control

Operation

(continued)

RESET

F

O

N

▲

AUX

R R

L

A

T

▼

RESET

AUX

▲ ▼

Fuzzy Logic Overshoot Protection

Fuzzy Logic Overshoot Protection (CTRL

PAGE ,

FL) works to minimize the overshoot that accompanies standard PID control. The 2104 actively learns the characteristics of the load and adjusts the PID control algorithm to reduce overshoot. Overshoot Protection, when combined with PID constants established by the 2104 tuning algorithm, produces a response that brings the process to setpoint with a minimum of overshoot.

Fuzzy Logic overshoot protection is not possible with

ON/OFF type control. It is recommended that Fuzzy

Logic is always enabled.

Ramp to Setpoint

(CTRL PAGE, RRAT = 1 to 9999 degrees/hour or OFF)

The Ramp to Setpoint feature allows the control setpoint to be ramped to the final value at powerup or during operation when the setpoint is adjusted.

At powerup, the setpoint is ramped from the current measured process temperature to the control setpoint. During operation, the setpoint is ramped from the current value to the new value. When enabled, Ramp to Setpoint will begin in any of the following situations:

• Powerup

• Change of setpoint from front panel

• Change of setpoint from digital communications

• Digital Input or Aux Key used to change between the local and auxiliary setpoints

• Digital Input or Aux Key used to change between the local and remote setpoints

• Remote Setpoint is active and the remote device changes the setpoint faster than the programmed ramp rate


Control

Operation

(continued)

RESET

A

UTO

AUX

▲ ▼

Manual Operation

Manual operation allows the controller output command to be controlled from the front panel

Keyboard. On initial powerup, the controller enters

Automatic control mode (closed loop). When Manual

Mode is entered, the output command appears in the lower display. The output command can be adjusted using the up and down arrow keys. The manual mode can be entered by using the Aux Key or the Digital

Input (CTRL PAGE, ENTI or AUTO). Manual Operation is not possible when ramp/soak is enabled. In the heat/cool control mode, only the currently active control output can be adjusted.

The transfer between Automatic and Manual operation is bumpless and balanceless. When switching from automatic to manual control, the controller assumes the last output command from automatic mode. When returning to automatic control, the output is forced to be the last manual mode output command.

If automatic reset is enabled (CTRL PAGE,

AR = non-zero value) the integral value slowly changes the output value until it reaches the correct automatic

(PID) output value. If automatic reset is not enabled, the output is ramped from the last manual output command to the current automatic output command at a rate determined by the disintergration time menu

(CTRL PAGE

, AUTO).



Section 4

Controller Setup PAGEs

Section

Contents

This section contains detailed information for the following controller setup pages:

DISP:

Display

CTRL: Control

INPT:

Input

SCAL: Custom Scaling

OUT1:

Output #1

OUT2: Output #2

Setup PAGEs specific to certain functions are located in the section of this manual that addresses that function specifically.

6

8

Section

5

9

Page

41

47

67

71

Topic

Ramp/Soak

Setup PAGE

RSPG

Alarms and Events

OUT3, OUT4, OUT5

Remote Setpoint Input and

CTRL, INPT, SCAL

Analog Output Option


DIG

More

Info.

Throughout the following Setup PAGEs you will find these symbols

40

. This indicates a section of this

User’s Manual where more specific information on a parameter/application/feature can be found.


RESET

AUX

▲ ▼

The Display Page is for status only.

None of the settings can be changed.

Display Page

MENU Description

Process Variable

A

O

SP

UT1

O

UT2

Active Setpoint

Output #1 Command

Output #2 Command


Ramp/Soak Status

Displays

Sensor Span

Sensor Span

Sensor Span

OFF

= Program not running

RUN

= Program running

HOLD

Program in hold

STB Y

Program in standby

= Guaranteed soak

Security

A

L

L

A

E

EFT

OOP

LR

NT

Ramp/Soak Interval Number

Ramp/Soak Time Left in Interval

Ramp/Soak Loops Remaining

Alarm Output Status

Event Output Status

NONE

No alarms

= Alarm Output #3

= Alarm Output #4

A 4

3

= Alarm Outputs #4 and #3

= Alarm Output #5

A 5

3


A 5

4


A54

3

Alarms 5, 4 and 3

NONE

All off

E

3

= Event Output #3

E

4

E

5

= Event Output #4

E 4

3

= Event Outputs #4 and #3

= Event Output #5

E 5

3


E 5

4


E54

3

Events 5, 4 and 3


AU

SP

TUN

E

RESET

AUX

▲ ▼

Control Page

MENU

O C

H

Description

Security Lock

Setpoint

Auxiliary SP

Self-Tune

26

29

Available Settings

0 to 9999

Security

A


Auxiliary setpoint is accessible only if AUX pushbutton or Event

Input is set up for Auxiliary Setpoint.


B

Self-Tune automatically adjusts PID C parameters on powerup (PRUP) or on demand (BEGN).

OFF

= Self-tuning disabled

PRUP

= Power-up tuning

BEGN

= Begin tuning

pushbutton or Digital Input.

RA T

Proportional Band 1

Automatic Reset 1

Rate 1

Dead Band 1

0

°

F to sensor range

0

°

F displays as OnOF to indicate ON/OFF control

0.00 to 99.99 repeats/minute

0 to 500 seconds

C

DB1 is not used unless PB1 is set to zero.

1 to 100

°

F

0.01 to 6.25% span for analog inputs

control, can be used for Output #1, if switched via AUX pushbutton or Digital

Input.

PB

2

Proportional Band 2 0

°

F to sensor range

0

°

F displays as OnOF to indicate ON/OFF control

AR

RA

D B

2

T

2

Automatic Reset 2

Rate 2

Dead Band 2


0 to 500 seconds

DB2 is not used unless PB2 is set to zero.

1 to 100

°

F



RESET

AUX

▲ ▼

Control Page (continued)

MENU

OFS

O

L

A

RNG

OOP

UTO

R R

C

A

T

T

ONT

Description

Manual Reset

Fuzzy Logic

29

Open Sensor Output Command

Available Settings

-99.9 to 99.9

OFF

= Disabled

ON

= Enabled

In the event of an open sensor, control output will automatically adjust to % output preset. For

Heat Only or Cool Only control, adjustable 0.0 to 100.0%.

For Heat/Cool Control, adjustable:

-100.0 to 100.0%:

-100.0 to -0.1 for cooling

0.1 to 100.0 for heating

Security

C

Control Loop Protection Timer

55

OFF, 0.1 to 999.9 minutes

Auto/Manual Disintegration Timer 0 to 100 seconds

Ramp Rate

OFF

1 to 9999 degrees/hour

Controller Type

28

Controller type can be used as heat/cool (HTCL) only if controller is equipped with Output#1 (Heat) and

Output #2 (Cool).

HEAT =

Reverse Acting Single

Output Controller

C

R

E

O O

SP

NTI

L

Cooling Medium

Remote Setpoint Enable

Event/Digital Input

Function

28

59

COOL

= Direct Acting Single

Output Controller

HTCL

= Heat/Cool Controller

PID2

= Uses PID2 settings for cooling

AIR

= Air Cooling

OIL

= Oil Cooling

H2O

= Water Cooling

OFF

ON

NONE =

Disabled

PID2

= PID2 enable

AUSP =

Auxiliary SP enable

RSP

= Remote SP enable

OUTD =

Output disable

RS

= Ramp/Soak

AUTO =

Auto/Manual

ALR

= Alarm Reset


RESET

AUX

▲ ▼

Control Page (continued)

MENU

C

S E

O D

N

E

Description

Auxiliary Pushbutton

Function

Analog Output Assignment

Ramp/Soak

User Selected

Security Code

60

70

41

26

Available Settings

NONE =

Disabled

PID2

= PID2 enable

AUSP =

Auxiliary SP enable

RSP

= Remote SP enable

OUTD =

Output disable

AUTO =

Auto/Manual

NONE =

Disabled

PROC =

Process Variable

ASP

= Active Setpoint

OUT1

= Control Output 1

OUT2 =

Control Output 2

Ramp/Soak “On” enables the

Ramp/Soak Setup Page (R5PG)

OFF

ON

Security

C

Allows you to establish your own D user-defined security code.

0-122 = Level A

123-457 = Level B

458-735 = Level C

736-999 = Level D


RESET

AUX

▲ ▼

Input Page

MENU Description Available Settings Security

S E

N

Sensor Type

Display Units

4

Sensor Type selected here must agree with dip switch settings.

C

J

= J Thermocouple

K

= K Thermocouple

T

= T Thermocouple

E

= E Thermocouple

R

= R Thermocouple

S

= S Thermocouple

B

= B Thermocouple

RTD

= 100

Ω

Pt RTD (

α

= .00385)

4-20 = 4 to 20mA

0-5

= 0 to 5 Vdc

1-5

= 1 to 5 Vdc

RTDT = 100

Ω

Pt RTD

(0.1

°

resolution)

NONE = no units

°

°

F

C

=

=

Degrees Fahrenheit

Degrees Celsius

C

O

Display/Calibration

Offset

82

Display/Calibration Offset offsets temperature process reading.

-100

°

F to 100

°

F

Setpoint Limits prevent setpoints from being adjusted above or below these pre-established limits.

Setpoint Low Limit

Setpoint Upper Limit



Sensor Calibration

INLO

INHI

DONE

D

CAL

R

Remote Setpoint Calibration

INLO

INHI

DONE

0 to 4095

A

O

0

A

R

O

5

EC

CC

Analog Output Zero Calibration

Analog Output Span Calibration

Factory Calibration Recovery

0 to 4095

RDY = Ready

--- = Wait

DONE = Finished

FILT) can be used to stabilize a fluctuating 0.1

°

resolution process variable display. To stabilize the display, increase the menu value

(adjustable from 1 to 60 seconds).

F I

L

H I

L

O

L

PRC

A

A

Digital Filter

High (max.) Process Input

Low (min.) Process Input

High (max.) Ambient Temp.

Low (min.) Ambient Temp.

0 to 60 seconds

Instrument Sensor Span





S C

A

P

A

GE

RESET

AUX

▲ ▼

This PAGE appears only when Analog Input is selected, Remote SP is enabled, or Analog

Output is enabled on CTRL PAGE.

Custom Scaling Page

MENU Description

Analog Input Decimal Pts.

9

I N

L

I N

H

O T

O T

L

H

Analog Input Low

Analog Input High

Analog Output Low

Analog Output High

Remote SP Input Low

Remote SP Input High

9

9

70

70

67

67

Available Settings

0 = none

1

= 123.4

2 =

12.34

3 =

1.234

-500 to 5000

-500 to 5000

-500 to 5000

-500 to 5000

-500 to 5000

-500 to 5000

Security

C

O

UT1

P

A

GE

RESET

AUX

▲ ▼

Output #1 Page

MENU

C

Y

Description

Output #1 Cycle Time

Output #1 Limit

Heat Offset

Available Settings

0.0 to 60.0 seconds

0.0 = Voltage/Current algorithm

Security

C

0.0 to 100.0%

0

°

F to PB1 setting

P

A

GE

RESET

AUX

▲ ▼

Output #2 Page

MENU Description

C

Y

Output #2 Cycle Time

O L

2

C

OFF

Output #2 Limit

Heat Offset


This PAGE is visible only if setup for heat/cool control on CtrL PAGE.

Available Settings

0.0 to 60.0 seconds


Security

C

0.0 to 100.0%

0

°

F to Pb2 setting

39


Section 5

Ramp/Soak Operation

Figure 5.1

Ramp/Soak Profile

The 2104 controller features a Ramp/Soak Program.

The program consists of 16 intervals plus a standby interval. The time span and setpoint for each interval are individually adjustable. These intervals make up a

Ramp/Soak Profile. An example of a typical 8-interval

Ramp/Soak program is shown below.

+ Dev. Alarm

Setpoint

Standby

Low Alarm

Time

Event

Outputs

Event Outputs may be configured to turn ON or OFF during each of the intervals. Event outputs are merely timed outputs that are either ON or OFF during an entire interval.

Examples of event outputs might be annunciation of a soak interval, an indicator light or addition of a product to the process. Outputs #3, #4 and #5 (if your controller was purchased with these options) may be setup as event outputs. For Outputs #3, #4 or #5 to be used as Events, the output must be set up as an Event on its setup page (i.e. OUT3). For example, for Output

#3 to turn on during interval 2, set menu 2E (interval

2 event) to E3 (Output #3 on). See page 43 for details.

Figure 5.2

Event Outputs in Ramp/Soak Profile

+ Dev. Alarm

Setpoint

Low Alarm

Time

Event 1 (Out #3)

Event 2 (Out #4)

ON


ON

ON

ON

ON

ON

ON

ON

ON

41

Looping

Intervals

Looping means that intervals within a Program may be repeated 1 to 9999 times. If a loop is inserted in the program shown in Figure 5.1, so that intervals 4,

5 and 6 will be repeated 2 times in addition to the single Program run of these intervals, the final profile would look Figure 5.3.

Figure 5.3

Looping Intervals

INT 1 INT 2 INT 3 INT 4 INT 5 INT 6 INT 4 INT 5 INT 6 INT 4 INT 5 INT 6 INT 7 INT 8

42

1 st

Loop 2 nd

Loop

Guaranteed

Soak

This Ramp/Soak feature of the 2104, when enabled, assures that the “soaking” time in a “soak” interval does not begin until the process reaches setpoint or is within the guaranteed soak differential band. A soak interval has the same setpoint at the beginning and end of the interval.

Figure 5.4

Guaranteed Soak

1 Hour

Programmed Setpoints

Time

Actual Process Temp

Guaranteed Soak is enabled on the RSPG PAGE by setting the differential band to a value greater than 0. It is adjustable from 1

°

F to the sensor span.


P

A

GE

RESET

AUX

▲ ▼

This setup PAGE appears only if Ramp/Soak control is turned on. The Ramp/Soak Enable parameter is the next to the last menu on

CTRL PAGE, Menu CONT.

Ramp/Soak Page

MENU

STB

C

Y

ONT

Description

Time Units

Standby Setpoint

Interval 1 Time

•

Setpoint 1

• Intervals 2-15

• Time and Setpoint

Interval 16 Time

Setpoint 16

Continuous Program

Loop from the end of interval

To the beginning of interval

42

Number of times

Standby Events

41

Interval 1 Events

Interval 16 Event

41

41

Guaranteed Soak differential

42

Available Settings

SEc

= seconds (1 to 9999)

MIN

= minutes (0.1 to 999.9)

HR

= hours (0.01 to 99.99)


Security

C see Time Units Menu (above)

Instrument Sensor Span see Time Units Menu (above)


OFF

ON

1 to 16

1 to 16

0 to 9999

OFF

= All off

E3

= Event Output 3 On

E4

= Event Output 4 On

E43

= Event Outputs 4 & 3 On

E5

= Event Output 5 On

E53


E54


E543

= Event Outputs 5, 4, 3 On

OFF

= All off

E3

= Event Output 3 On

E4

= Event Output 4 On

E43


E5

= Event Output 5 On

E53


E54


E543

= Event Outputs 5, 4, 3 On same as above

OFF, 1

°

F to sensor range


44

Control

Operation

In order to use the Ramp/Soak program, it must be enabled on the CTRL Page, RSEN = ON. Control of ramp/soak operation (Start, Stop and Hold) can be accomplished via the front panel. In the Setup mode, first return to the Normal Display Mode by holding the reset button for 3 seconds. Pressing the up arrow key Starts the program, pressing the down arrow key Holds the program, and pressing both together Stops the program.

To Start Ramp/Soak Program:

R/S Indicator

ON

▲ Starts the Ramp/

Soak program or if the program is on Hold, continues the program

RESET AUX

▲ ▼

Press ▲

To Hold Ramp/Soak Program:

RESET AUX

▲ ▼

R/S Indicator

Flashes

▼ (Hold) Stops the program in progress and “holds” the program until the

▲ (Start) button is pressed.

Press ▼

To Stop Ramp/Soak Program:

R/S Indicator

OFF

▼ and ▲ together

(Stop Pushbutton) return the Ramp/Soak program to the

Standby setpoint.

RESET AUX

▲ ▼

Press ▲ and ▼ together


Control

Operation

(continued)

☛

Ramp/Soak (continued)

Alternately, the Digital Input or Chromasoft™ can be used to control program operation. The ramp/soak indicator LED (right-most decimal point in the lower display) is ON when a program is running, OFF in standby, and flashes in hold mode.

Note: If the Aux key function is set to none

TRL P

A

GE

,

A

U

status will be displayed when the Aux key is pressed.

RESET AUX

▲ ▼

➮

RESET AUX

▲ ▼

L

EFT

➮

RESET AUX

▲ ▼

L

OOP

➮

RESET AUX

▲ ▼

Status: Run # Intervals Left # Loops Left



Section 6

Alarms

The 2104 controller can provide up to three alarm outputs using Output #3, #4 and #5. These optional outputs are indicated by the following controller model numbers:

Optional Outputs Model Number

Outputs #3 and #4 2104 - **1**

Output #5 2104 - ***1*

2104 ***2*

2104 - ***4*

2104 ***5*

Each alarm is individually setup with a high and low setpoint on its own Page:

• OUT3 PAGE

• OUT4 PAGE

• OUT5 PAGE

Outputs #3, #4 and #5 can be individually setup as

Alarms or Events, and can be individually disabled.

To function as an alarm, the output type must be specified as an alarm output, ALR, in the first menu, output type (TYP3, TYP4, TYP5). If the function is an

Event, the output type must be specified as ENT. The

Events then are enabled in the Ramp/Soak (RSPG) page, menus SBET (Standby Event) through I16E.

A

GE

▲

RESET

AUX

▼

➮

RESET

A L

R

▲

AUX

▼


48

Alarm Types

Each of the alarms can be set up for the following alarm types:

High Alarm—Absolute Temperature Alarm

L

O

Low Alarm—Absolute Temperature Alarm

L

O

High/Low Alarm—Absolute Temperature Alarm

P

D

E

+Deviation Alarm—Setpoint Tracking Alarm

--

D

E

D

E

L

O O

P

-Deviation Alarm—Setpoint Tracking Alarm

±

Deviation Alarm—Setpoint Tracking Alarm

Control Loop Protection Alarm—System Alarm

(see page 53 for detailed information)

The Absolute Temperature Alarms are set to a specific value; i.e. if the High Alarm is set for 100

°

F, the alarm will turn on at 100

°

F. The Deviation

Alarms, or Setpoint Tracking Alarms, track the process setpoint. If the Alarm = 5

°

F and the setpoint is 70

°

F, the Alarm will energize at 75

°

F.

Alarm

Inhibit

When enabled, the Alarm Inhibit feature prevents false alarms during initial powerup. For example, the low alarm will not be set until after the process temperature has initially reached setpoint. Alarm

Inhibit is adjustable for each alarm output.

O

N

▲

RESET AUX

▼

Alarm

Wiring

Wiring instructions for Outputs #3, #4 and #5 are given on pages 19-20.


Alarm

Relay

Action

Output Relays #3, #4 and #5 can be set to be normally energized or de-energized, latching or non-latching. A normally de-energized relay is in its non-energized state when not in alarm. For example, Outputs #3 and

#4 are normally-open contacts. When setup as normally de-energized, the relays will be open when not in alarm, and closed when in alarm.

A non-latching relay will not stay in alarm if the alarm condition goes away. A latching relay will not go out of alarm until the alarm condition no longer exists and

RESET

is pressed.

Alarm

Operation

Latching alarms can be reset by pressing the RESET pushbutton on the controller front panel. The alarm cannot be reset until the process is out of the alarm condition. The Digital Input can be setup to function as a remote alarm reset button (see pages 59-63).

RESET AUX

▲ ▼


RESET

AUX

▲ ▼

This setup PAGE appears only if the controller is equipped with Outputs #3 and #4.

Output #3 Page


T

A

R

Y

LR3

L

P3

Y 3

Output #3 Type

Alarm #3 Type

Alarm #3 Relay Action

47

48

49

OFF

= Disabled

ALR

= Alarm Output

ENT

= Event Output

(Setup Event Output parameters on Ramp/Soak Page)

C

NONE =

Disabled (off)

Hi

= High Alarm

Lo

= Low Alarm

HiLo

= High-Low Alarm

PDE

= Plus Deviation Alarm

-DE

= Minus Deviation Alarm

DE

= Plus/Minus Deviation Alarm

LooP

= Control Loop Protection Alarm

NDE

= Normally de-energized non-latching

NE

= Normally energized non-latching

NDEL

= Normally de-energized latching

NEL

= Normally energized latching

Low Setpoint is used for low and -deviation setpoints

A L

O3

Alarm #3 Low Setpoint Instrument Sensor Span

High Setpoint is used for high and +deviation setpoints

A H

I3

Alarm #3 High Setpoint

Output #3 Dead Band

(Alarm Hysteresis)


0 to 100

°

F

Alarm #3 Inhibit

48

OFF

ON


P

A

GE

RESET

AUX

▲ ▼

This setup PAGE appears only if the controller is equipped with Outputs #3 and #4.

Output #4 Page


TY

RL

P4

Y

Output #4 Type

Alarm #4 Type


47

48

49

OFF

= Disabled

ALR

= Alarm Output

ENT

= Event Output


C

NONE

= Disabled (off)

HI

= High Alarm

LO

= Low Alarm

HILO

= High-Low Alarm

PDE


-DE


DE


LOOP


NDE


NE


NDEL


NEL



A L

O4



A H

I4

Alarm #4 High Setpoint

Output #4 Dead Band

(Alarm Hysteresis)


0 to 100

°

F

Alarm #4 Inhibit

48

OFF

ON


O

UT5

RESET

AUX

▲ ▼

This setup PAGE appears only if the controller is equipped with Output #5.

Output #5 Page

MENU

T

A

R

Y P5

LR5

L

Y 5

Description

Output #5 Type

Alarm #5 Type

47

48


49

Available Settings Security

OFF

= Disabled

ALR

= Alarm Output

ENT

= Event Output


C

NONE

= Disabled (off)

HI

= High Alarm

LO

= Low Alarm

HILO

= High-Low Alarm

PDE


-DE


DE


LOOP


NDE


NE


NDEL


NEL



A L

O5



A H

I5

Alarm #5 High Setpoint Instrument Sensor Span

0 to 100

°

F Output #5 Dead Band

(Alarm Hysteresis)

Alarm #5 Inhibit

48

OFF

ON


Control Loop Protection Alarm (CLP)

Control Loop Protection (CLP) monitors the controller’s process variable input and load output to detect and respond to conditions indicating a failure in the control loop (Sensor, Controller Output, Load or

Process flow). CLP is selected by setting the LOOP Timer on the CTRL PAGE menu to a value from 0.1 to 999.0

minutes (0.0 disables CLP).

L

OOP

P

A

GE

▲

RESET AUX

▼

➮

RESET AUX

▲ ▼

Loop Timer

Time (in minutes)

The timer setting should be chosen according to the response time of the system. The minimum time seting should be 0.25% of span divided by the normal load response rate to full ON or full OFF condition

(whichever is slower).

Minimum Timer Setting = Span x .0025

Slowest Response Rate (Heat or Cool)

Response Rate = Process Response (in degrees/minute) when

100% ON or 100% OFF

Example: For a controller with type J T/C (span -100

°

F to 1400

°

F), 0.25% of span is 3.75

°

F. If the heating response is 2

°

F/min., and the cooling response is 1

°

F/ min., the minimum Loop Timer setting would be 3.8

minutes. To prevent false alarms, it is recommended that you start by doubling the setting to 7.6 minutes.

The CLP Alarm sequence begins when the control output reaches 0.0% or 100.0% (process variable outside of the proportional band). The controller then measures the time for the process variable to respond (increase or decrease the process variable) and compares the measured time to the Loop Timer value.


Control Loop Protection Alarm (continued)

If the control loop does not respond with a change in the process variable of 0.25% of span (3.75

°

F for a J thermocouple) within the programmed loop time, a Loop Error will result and the control output will turn off. The error will be indicated by the lower display flashing LOOP and Loop Alarm Output

(Output #3, #4, or #5 as selected on the menu) will be activated. The Loop Alarm is cleared by pressing

RESET.

L

OOP

O

FF

▲

RESET AUX

▼

Press RESET to clear Loop Alarm

☛

Warning

The CLP is not a substitute for safety shutdown devices such as flow switches or overtemperature monitors. The CLP Alarm responds to specific conditions that may provide early warning of system loop failures or aid in troubleshooting failures.


CLP Loop Alarm Conditions

The following table details conditions that activate a loop alarm, and gives the controller response to the condition.

Figure 6.1 CLP Loop Alarm Conditions

Probable Cause

Loss of process flow

Control Output Response

Turns control output off

Display

L

OOP

Flashing

In a control application where the process is being heated at one point and measured at a point downstream, CLP Alarm could be used to detect a flow failure. If the process flow is interrupted and heat is no longer transferred to the sensor, the controller output will increase to 100%, the Loop alarm will start timing the load response and when the preset

Loop Timer value is reached, the Loop Alarm will be activated and the control output will be turned off. The failure will be indicated by the lower display flashing LOOP. Loop Alarm

Output (Output #3, #4 or #5) will be activated if selected.

Probable Cause Control Output Response Display

Load Power is interrupted Turns control output off

(blown fuse or tripped circuit

L

OOP breaker)

Flashing

If load power is interrupted by the circuit protection devices (user supplied fuse or circuit breaker), the Loop Alarm will be activated when the process variable goes outside of the proportional band for a time greater than the preset Loop Timer value. The control output will be turned off and the failure will be indicated by the lower display flashing LOOP. Loop

Alarm Output (Output #3, #4, or #5) will be activated If selected.

Probable Cause

Load fails (open circuit)



Display

L

OOP

Flashing

If the load fails open, the Loop Alarm will be activated when the process variable goes outside of the proportional band for a time greater than the preset Loop Timer value. The control output will be turned off and the failure will be indicated by the lower display flashing LOOP. Loop Alarm Output (Output #3, #4, or #5) will be activated if selected.

Probable Cause

Load fails (short circuit)


Turns control output Off

Display

L

OOP

Flashing

If the load fails shorted, power to the load will be interrupted by the circuit protection devices (user supplied fuse or circuit breaker). The Loop Alarm will be activated when the process variable goes outside of the proportional band for a time greater than the preset

Loop Timer value. The control output will be turned off and the failure will be indicated by the lower display flashing LOOP. Loop Alarm Output (Output #3, #4, or #5) will be activated if selected.

(continue on the next page)


Figure 6.1 CLP Loop Alarm Conditions (continued)


Controller or remote power control output fails (open circuit)


L

O O

P

Flashing

If the controller output or the remote power control device (SCR or contactor) fails open, the Loop Alarm will be activated when the process variable goes outside of the proportional band for a time greater than the preset Loop Timer value. The failure will be indicated by the lower display flashing LOOP. Loop Alarm Output (Output #3, #4, or #5) will be activated if selected.


Controller or remote power None control output fails (short circuit) (load must be interconnected with alarm)

L

OOP

Flashing

If the controller output or the remote power control device (SCR or contactor) fails shorted, the Loop Alarm will be activated when the process variable goes outside of the proportional band for a time greater than the preset Loop Timer value. The failure will be indicated by the lower display flashing LOOP. Loop Alarm Output (Output #3, #4, or #5) will be activated. To protect the loop under this condition, the Loop Alarm Output (Output

#3, #4 of #5) should be interconnected to remove power from the load.


Sensor wiring reversed

(thermocouple only)


L

OOP

Flashing

If the sensor wiring is reversed, the Loop Alarm will be activated when the process variable goes outside of the proportional band for a time greater than the preset Loop Timer value.

The control output will be turned off and the failure will be indicated by the lower display flashing LOOP. Loop Alarm Output (Output #3, #4, or #5) will be activated if selected.


Sensor loses contact with process


L

OOP

Flashing

If the sensor loses contact with the process (sensor becomes dislodged or pulled loose), the Loop Alarm will be activated when the process variable goes outside of the proportional band for a time greater than the preset Loop Timer value. The failure will be indicated by the lower display flashing LOOP. Loop Alarm Output (Output #3, #4, or #5) will be activated if selected.

Probable Cause

Sensor fails (open circuit)


Defaults to preset (0-100%)

Display

Flashing

If the sensing device fails open, the controller defaults to the preset output condition

(0-100% ORNG setting selected on the CTRL PAGE menu) and uses both displays to indicate OPEN SENS. The Loop alarm is not activated for this condition. Alarms selected as Low, High-Low, + Deviation or +/- Deviation will actuate if selected.

56

(continued on the next page)


Figure 6.1 CLP Loop Alarm Conditions (continued)

Probable Cause

Sensor fails

(short circuit, RTD only)



Display

Flashing

If the RTD sensing device fails shorted, the controller defaults to the preset output condition (0-100% ORNG setting selected on the CTRL PAGE menu) and uses both displays to indicate OPEN SENS. The Loop alarm is not activated for this condition. Alarms selected as Low, High-Low, - Deviation or +/- Deviation will actuate if selected.


Controller Self Diagnostic

(signal conversion)


E

R R

4

Flashing

If a failure occurs in the signal conversion circuit of the controller, the controller defaults to the preset output condition (0-100% ORNG setting selected on the CTRL PAGE menu) and displays ERR4 on the lower display. Loop Alarm Output (Output #3, #4, or #5) will be activated if selected.

Probable Cause

Controller Self Diagnostic



Display

E

R R

3

Flashing

If a failure occurs in the control circuitry of the controller, the control output will be turned off and ERR3 will be displayed on the lower display. Loop Alarm Output (Output #3, #4, or

#5) will be activated if selected.



Section 7

Digital Input and AUX Function

The 2104 controller gives you two different options for actuation of any one of several field-selectable controller functions:

1. A Digital Input that is hardwired to terminals 1 and 2 of the controller.

2. The AUX pushbutton located on the controller front faceplate.

You may choose to use either the Digital Input or the

AUX pushbutton, but you cannot use both.

Digital Input

The Digital Input allows you to use a remote switch, pushbutton or contact to perform any one of seven possible functions:

• PID1/PID2 Switch • Output Disable/Enable

• SP/AUX Setpoint Switch • Ramp/Soak

• Local/Remote Setpoint • Alarm Reset

Switch

• Auto/Manual Control Switch

The external switching device is connected to the controller Digital Input at terminals 1 and 2 (see page

10 for wiring instructions). The Digital Input function is selected in the CTRL PAGE programming.

C

TRL

P

A

GE

▲

RESET AUX

▼

➮

RESET AUX

▲ ▼

When the Digital Input is used, the AUX (Auxiliary)

LED on the controller front panel is used for indication of the Digital Input function.

RESET AUX

▲

AUX

▼

LED Indicates

Auxiliary Function

ON or Enabled

( rSP

= Remote Setpoint)


60

AUX Pushbutton

The AUX front panel pushbutton can be assigned to perform any one of six possible functions and the

AUX LED is used for indication of that function.

Like the Digital Input, its function is selected in the

CTRL PAGE programming. No wiring or hardware adjustments are required to use the AUX pushbutton as a function key.

RESET AUX

▲

AUX

▼

LED Indicates

Auxiliary Function

ON or Enabled

(AUTO = Auto/Manual Control)

Programmable Pushbutton

• PID1/PID2 Toggle Switch

• SP/Auxiliary Setpoint Switch

• Local/Remote Setpoint Switch

• Output Disable/Enable

• Auto/Manual Selector

☛

Remember:

• The Digital Input and AUX function pushbutton cannot be used at the same time.

• If the AUX pushbutton is set to NONE, it will display the Ramp/Soak Program Status when pressed.

45

• When the AUX function = NONE, the Digital

Input can be used.


Digital

Input

P

I D

2

▲

RESET AUX

▼

When disabled, the Digital Input has no effect on controller operation. If the AUX key is also disabled, the AUX light is used to indicate the output state

(ON or OFF) of Output #5, if the controller has

Output #5.

This function can be used in single output control applications only (CTRL PAGE, CONT = HEAT or COOL).

When this function is selected, the controller uses

PID1 parameters (CTRL PAGE) when the Digital Input switch is open. The PID2 parameters will be used when the switch is closed. The AUX indicator is ON when PID2 parameters are selected and OFF when

PID1 parameters are selected.

A

USP

When this function is selected, the controller uses the

Local Setpoint (CTRL PAGE

, SP) when the Digital

Input switch is open. The Auxiliary Setpoint (CTRL

PAGE , AUSP) is used when the switch is closed. The

AUX indicator is ON when the Auxiliary SP is selected and OFF when the Local Setpoint is selected.

The setpoints are adjustable in the Operator Mode according to security. This function cannot be used when Ramp/Soak is enabled.

When this function is selected, the controller uses the

Local Setpoint (CTRL PAGE

,

SP) when the Digital

Input switch is open. The Remote Setpoint is used when the switch is closed. Remote Setpoint must be enabled (CTRL PAGE

,

RSP = ON) for this function to operate. The AUX indicator is ON when the Remote

Setpoint is selected and OFF when the Local Setpoint is selected. This function cannot be used when Ramp/

Soak is enabled.


62

Digital

Input

(continued)

RESET AUX

▲ ▼

☛

O

UTD

When this function is selected, the control output(s) are enabled when the Digital Input switch is open, and disabled, when the switch is closed. The

AUX indicator is ON, when the control output(s) are disabled and OFF, when enabled.

Note: Disabling the outputs allows all control parameters to be set up without starting the process.

This setting is NOT intended for process shutdown. An external disconnect should be used for process shutdown.

41

This function allows the Digital Input to act as a

Start/Stop and Hold button for controlling Ramp/

Soak operation:

• Ramp/Soak operation is started when the Digital

Input switch is closed (100 milliseconds), then opened (momentary action) while in Standby

Mode.

• In Run Mode, this action will skip to the next interval.

• Hold Mode is entered by closing the Digital

Input switch for 2 seconds while the program is running.

• Momentarily closing (100 milliseconds) the input switch while in HOLD will continue the program.

• Closing the Digital Input Switch for 2 seconds while in Hold Mode will stop the program and return to Standby.


Digital

Input

(continued)

31

RESET

A

UTO

▲

AUX

▼

A

UTO

This function allows the Digital Input to act as an

Auto/Manual Control selector. Manual operation is selected when the Digital Input switch is closed.

Automatic operation is selected when the switch is open. The AUX light is ON in Manual, and OFF in

Automatic Mode.

A

LR

This function allows the Digital Input switch to be used as a remote Alarm Reset button for use with latching type alarms. The AUX light is used to indicate the state (ON or OFF) of Output #5, if the

Output #5 option is installed in the controller.

AUX Key

A

U

A

USP

▲

RESET AUX

▼

The AUX Key can be setup for any of the functions listed below:

When disabled, the AUX Key has no effect on controller operation. AUX can be used to display the

Ramp/Soak status, if Ramp/Soak is enabled. If the

Digital Input is also disabled, the AUX light is used to indicate the state (ON or OFF) of Output #5, if installed.


64

AUX Key

(continued)

RESET AUX

I D

2

▲ ▼

This function can be used in single output control applications only (CTRL PAGE CONT = HEAT or

COOL). When this function is selected, pressing the

AUX Key will toggle between PID1 (CTRL PAGE, menus PB1, AR1, RAT1) and PID2 (CTRL PAGE, menus

PB2, AR2, RAT2) parameters. If the power is interrupted, the last active PID parameters will be used when power is restored. The AUX indicator is

ON when PID2 parameters are selected and OFF when PID1 parameters are selected.

A

USP

When this function is selected, pressing the AUX

Key will toggle between the Auxiliary and Local setpoints. If the power is interrupted, the last active setpoint will be used when power is restored. The

AUX indicator is ON when the Auxiliary Setpoint is selected and OFF when the Local Setpoint is selected. The setpoints are adjustable in Operator

Mode according to security. This function cannot be used when Ramp/Soak is enabled.

When this function is selected, pressing the AUX

Key will toggle between the Remote and Local

Setpoints. If the power is interrupted, the last active setpoint will be used when power is restored.

Remote setpoint must be enabled (CTRL

PAGE,

RSP = ON) for this function to operate. The AUX indicator is ON when the Remote Setpoint is selected and OFF when the Local Setpoint is selected. This function cannot be used when

Ramp/Soak is enabled.


AUX Key

(continued)

A

U

O

UTD

▲

RESET AUX

▼

☛

31

O

UTD

When this function is selected, pressing the AUX Key will toggle between outputs enabled and outputs disabled. The AUX indicator is ON when the control output(s) are disabled and OFF when enabled.

Note: Disabling the outputs allows for all the parameters to be set without starting the process.

This setting is not intended for shutdown of the process. An external disconnect should be used.

A

UTO

When this function is selected, pressing the AUX Key toggles between Manual and Automatic operation with Automatic as default at powerup. The AUX light is ON in Manual Mode, and OFF in Automatic Mode.



Section 8

Remote Setpoint &

Analog Output Option

Remote

Setpoint

The Remote Setpoint standard feature allows an external device to control the setpoint of the controller. The Remote Setpoint input accepts either

4-20mA or 1-5 Vdc input signals, selectable by a switch on the bottom of the controller. The Digital

Input or AUX pushbutton can be set up to switch between the Local Setpoint and the Remote Setpoint.

To Select the Remote Setpoint Input Signal

Locate switch #4 on the bottom of the controller, as shown in Figure 8.1. Place the switch in the desired position.

Figure 8.1

Remote

Setpoint

Input Signal

Controller

Bottom Surface

Sensor Selection Switch #4

• 4-20mA ...... Down

• 1-5 Vdc ....... Up

To Enable the Remote Setpoint

Go to MENU RSP on the CTRL PAGE and select ON.

C

TRL

P

A

GE

▲

RESET

AUX

▼

➮

O

N

▲

RESET

AUX

▼

Note: The Digital Input or AUX pushbutton can be used to switch between Remote Setpoint and Local

Setpoint (see page 57 for setup).


To Scale the Input Signal

Go to the SCAL PAGE, MENUs RSPL (remote setpoint low) and RSPH (remote setpoint high).

Enter the sensor span low and high ranges. For example, for a 100 to 500

°

F range, 4mA would equal 100

°

F setpoint, and 20mA would equal

500

°

F setpoint.

S C

A

L

RESET

AUX

▲ ▼ This page appears only if Remote Setpoint and/or Analog Process Output are Enabled.


MENU Description

RSP

RSP

L

H

Remote Setpoint-Low

Remote Setpoint-High

Available Settings



Remote Setpoint Wiring

Figure 8.2

2-Wire 4-20mA

Transmitter

(Loop-Powered)

2104

+24 Vdc

3

Remote SP Input

5

Common 6

+

-

Security

C

C

Figure 8.3

2-wire 4-20mA,

1-5 Vdc Transmitter

(Self-Powered)

2104

+24 Vdc

3

Remote SP Input

5

Common

6

+

Output

-

Common

Figure 8.4

3-wire 4-20mA,

1-5 Vdc Transmitter

68

2104

+24 Vdc

3

Remote SP Input

5

Common

6

Power

+

Output

-

Common


Analog

Output

Option

The Analog Output Option is provided on controllers with model number

• 2104 - ***3*

• 2104 - ***4*

• 2104 - ***5*

This option can be used to transmit any one of four process parameters:

• PROC ............ Process Variable

• ASP .............. Active Setpoint

• OUT1 ............. Output #1 Command (%ON)

• OUT2 ............ Output #2 Command (%ON)

The variable can be transmitted to a remote recorder, computer or other device via a 4-20mA or 1-5 Vdc signal, selectable by a switch on the bottom of the controller.

To Select the Analog Process Output Signal

Locate switch #5 on the bottom of the controller, as shown in Figure 8.2. Place the switch in the desired position.

Figure 8.5

Analog Output

Signal

Controller

Bottom Surface

Sensor Selection Switch #5

• 4-20mA ...... Up

• 1-5 Vdc ....... Down


To Enable the Analog Output Option:

Go to MENU AOut on the CTRL PAGE and select one of the 4 parameters.

C

TRL

P

A

GE

▲

RESET

AUX

▼

➮

A O

UT

RESET

AUX

▲ ▼

Figure 8.6

Process

Output Wiring

2104

Analog Output

4

Common 6

+

-

4-20mA,

1-5 Vdc

Input

Common

To Scale the Output Signal

When the Process Variable or Active Setpoint is selected for transmission, the output signal is scaled using the Analog Output scaling MENUs. Go to the

SCAL PAGE, MENUs AOTL (analog output low) and

AOTH (analog output high). Enter the output signal range to be sent to your recorder or computer (i.e.,

100 = 4mA and 500

°

F = 20mA).

S C

AL

RESET AUX

▲ ▼

70


MENU Description

A O

A O

T

T

Analog Process

Output - Low

Analog Process

Output - High

Available Settings



Security

C

C

When Output #1 or Output #2 are selected for transmission, the low end of span (4mA or 1 Vdc) represents 0.0% output, and the high end of span

(20mA or 5 Vdc) represents 100.0% output.


Section 9

Digital Communications

The Digital Communications option is provided on the following controllers:

Model Communications

2104 - ***2* RS232

2104 - ***5* RS232

2104 - ***1* RS485/422

2104 - ***4* RS485/422

The Digital Communications option gives the 2104 the ability to interface with computers using either

Chromalox’s Computer Interface mode or ASCII Line mode. These modes implement communications that can address up to 255 Chromalox controllers on an

RS422A/RS485 multidrop line. The protocols for these two modes are described in the Digital

Communications User’s Manual (P/N 0037-75129) that is supplied with controllers containing the Digital

Communication option.

ChromaSoft™

If a prepackaged software program is preferred for multidrop digital communication with up to 255

Chromalox controllers, Chromalox offers ChromaSoft remote operator interface software. ChromaSoft is

DOS-based and communicates with the controllers via a serial interface port. Instructions for using

ChromaSoft are given in the User’s Manual provided with the software.

Hardware Setup

RS232 can be used to connect a computer or modem to a single 2104 controller. RS232 lines can be run over distances up to 50 feet.

RS422 and RS485 provide multidrop network communications where up to 255 controllers can communicate with a single computer at a distance of up to 4000 feet.


72

Figure 9.1

RS422/RS485

Communications

Switches

Hardware Setup (continued)

When shipped from the factory, the multidrop communications interface is set for RS422. If you are using RS485, two switches in the controller hardware must be positioned for the communications interface. Locate the switches on the bottom of the controller and position them as shown in Figure 9.1.

Controller

Bottom Surface

..................

#1

Switch

#2

RS-422 ..... Down Up

RS-485 ..... Up Down

Figure 9.2

RS232 Wiring

Connections

Digital Communications Wiring

Wiring connections for the digital communications interface are made on terminals 9-13 using shielded serial interface cable.

2104 Computer

XMT 21

RCV 19

DTR 22

GND 23

XMT

RCV

GND

Note: The DTR output is always enabled when the 2104 power is on.


Figure 9.3

RS422A Wiring Connections (4-wire)

2104

GND

23

RCV-

20

RCV+

19

XMT-

22

XMT+

21

2104

GND

23

RCV-

20

RCV+

19

XMT-

22

XMT+

21

270

Ω

270

Ω

Computer with RS422

Interface Card

RCV+

RCV-

XMT+

XMT-

GND

Note: 270

Ω

resistors recommended across receive line on computer and last controller.

Figure 9.4

RS485 Wiring Connections (2-wire)

2104

GND

23

R/T-

22

R/T+

21

GND

23

2104

R/T-

22

R/T+

21

270

Ω

270

Ω

Computer with RS485

Interface Card

R/T+

R/T-

GND

Note: 270

Ω

resistors recommended across receive line on computer and last controller.


Digital Communications

Programming and Setup

All programmed selections are made on the DIG PAGE of the controller.

RESET AUX

▲ ▼

This setup PAGE appears only if the controller is equipped the digital

Communications option.

Digital Communications Page: DIG PAGE

MENU Description

Mode Selection

B

A

A

UD

DDR

Baud Rate

Address

Available Settings

OFF

= Disabled

CPIF

= Computer Interface

LINE

= ASCII Line

1200

2400

4800

9600

19.2K

1 to 255

Security

C


Section 10

Calibration

In this section you will find calibration instructions for calibrating:

• Sensor Input

• Remote Setpoint Input

• Analog Output

Instructions are also given for:

• Factory Calibration Recovery

• Calibration Offset

When is

Calibration

Required?

The 2104 controller is factory calibrated before shipment to you, therefore, it is not necessary to calibrate the controller when you receive and install it. Periodic calibration checks or adjustments of the unit should not be required under normal operating conditions. Chromalox recommends that you recalibrate the controller in the following instances:

• all instruments in your facility are periodically calibrated to one device (metrology)


76

Important

Calibration

Notes

1. Disconnect load power when calibrating or

disable the control output using the

AUX pushbutton.

2. RTD inputs should be calibrated using copper

(Cu) wire, and thermocouple inputs should be calibrated using thermocouple extension wire of the same type as the thermocouple you are calibrating.

3. Substitute a precision sensor simulator

(thermocouple simulator or resistance decade box) for the sensor inputs. The controller should be allowed to warm-up with the appropriate sensor simulator connected for at least one hour prior to calibration.

4. To access the calibration, you will need to be at

LEVEL D security. Enter Security Code “736” at menu LOCH on the CTRL PAGE.

Sensor

Input

Calibration

The sensor input of the 2104 can be calibrated using an appropriate sensor simulator and the Sensor

Calibration menu on the Input Page.

P

A

GE

▲

RESET AUX

▼

1. Connect the sensor simulator to the sensor input terminals.

2. Go to menu CALS. The lower display will show

INLO, indicating that you should first calibrate the sensor low end.

I N

L

O

▲

RESET

AUX

▼


Sensor

Input

Calibration

(continued)

3. Adjust the simulator to output the low end of the selected sensor range. Sensor minimum ranges are:

°

C

-73

-184

-212

-73

-18

-18

10

4. Wait 30 seconds for the electronics to fully stabilize.

Press ▲. Dashes will appear in the lower display while the controller calibrates the low end of span.

I N

L

O

▲

RESET

AUX

▼

➮

RESET

AUX

▲ ▼

➮

RESET

I N

H

▲

AUX

▼

5. When the controller prompts INHI in the lower display, adjust the sensor simulator to output the high end of the currently selected sensor span.

Sensor maximum ranges are:

°

C

760

1316

399

593

1760

1760

1816


78

Sensor

Input

Calibration

(continued)

6. Wait 30 seconds for the electronics to stabilize.

Press ▲. Dashes will appear in the lower display while the controller calibrates the high end of span. When finished, the controller will display

DONE.

I N

H

RESET

AUX

▲ ▼

➮

RESET

AUX

▲ ▼

➮

RESET

AUX

▲ ▼

7. Press RESET to exit calibration.

Remote

Setpoint

Input

Calibration

The Remote Setpoint Input is calibrated using an appropriate 4-20mA or 1-5 Vdc simulator.

Calibration is performed in the menu CALR on the

Input Page.

1. Connect the simulator to the remote setpoint input terminals.

2. Go to menu CALR. The lower display will show

INLO, indicating that you should first calibrate the input low end (4mA or 1 Vdc).

CAL

R

I N

L

O

▲

RESET AUX

▼


Remote

Setpoint

Input

Calibration

(continued)

3. Adjust the simulator to output the low end of the selected range. Wait 30 seconds for the electronics to fully stabilize. Press ▲. Dashes will appear in the lower display while the controller calibrates the low end of span.

CAL

R

I N

L

O

▲

RESET AUX

▼

➮

CAL

R

RESET AUX

▲ ▼

CAL

R

➮

I N

H

▲

RESET AUX

▼

4. When the controller prompts INHI in the lower display, adjust the simulator to output the high end of the currently selected input span (20mA or 5 Vdc).

5. Wait 30 seconds for the electronics to stabilize. Press ▲.

Dashes will appear in the lower display while the controller calibrates the high end of span. When finished, the controller will display DONE.

CAL

R

I N

H

▲

RESET AUX

▼

➮

CAL

R

RESET AUX

▲ ▼

➮

CAL

R

RESET AUX

▲ ▼

6. Press RESET to exit calibration.


80

Analog

Output

Option

Calibration

The Analog Output signal is calibrated using an appropriate current or voltage meter. Calibration is performed in the two analog output calibration menus (Ao O and Ao S) on the Input Page.

1. Connect the meter to the analog process output terminals. To calibrate the analog output, the output must be forced to the low end of span. If the setpoint is selected for transmission

(CTRL PAGE, AOUT = ASP) this can be done by adjusting the setpoint to the low end of span

(i.e. J T/C = -100

°

F).

2. Go to menu AO O. Adjust the Analog Output

(using ▲ and ▼) until the meter reads 4mA or

1.000 Vdc.

Note: The number displayed in the lower display page is for reference only.

RESET AUX

▲ ▼

3. Go to menu AO O = ASP and adjust the setpoint to the high end of span (i.e., for J T/C = 1400

°

F).

4. Go to menu AO S. Adjust Analog Output

(using ▲ and ▼) until the meter reads 20mA or

5.000 Vdc.

RESET AUX

▲ ▼

5. Press and hold

RESET calibration mode.

for 3 seconds to exit


Factory

Calibration

Recovery

This option allows you to return the controller to its factory calibration settings in the event that it is severely out of calibration due to poor technique or unauthorized calibration. Although the factory calibration settings are recovered, this does not guarantee original calibration accuracy. The Factory

Calibration Recovery should be used as a “starting point” for recalibration, should the unit become severely out of calibration.

Factory Calibration Recovery is performed on the INPT

PAGE, menu RECC.

R

E C

C

RESET

AUX

▲ ▼

To reestablish the factory calibration constants:

1. Disconnect load power.

2. Go to menu RECC and press ▲. The controller will automatically recalibrate.

R E

C

C

RESET

AUX

▲ ▼

R E

C

➮

RESET

AUX

▲ ▼

➮

R E

C

C

RESET

AUX

▲ ▼

3. The lower display cycles from “----” to “DONE”.

Press RESET to exit the calibration mode.


Display

Calibration

Offset

If an offset on the temperature reading is desired, the

Display/Calibration Offset menu may be used. In some applications, this offset may be desired to match another instrument or an inferred temperature in another part of the system.

To establish the calibration offset:

1. Go to menu COFF on the Input Page.

RESET AUX

▲ ▼

2. Use ▲ and ▼ to set the calibration offset, adjustable from -100 to 100

°

F.

RESET AUX

▲ ▼


Section 11

Specifications

Control Modes

Automatic

Control Adjustments

Control Setpoint

Setpoint Limits

Deadband

Proportional Band

Manual Reset

Automatic Reset

Rate

Output Cycle Time

Output Limit

Open Sensor

& Out of Range

Output Command

Display Offset

Heat/Cool Adjustments

Output Offsets

Cooling Medium

Alarm Adjustments

Setpoints

Alarm Types

Relay Action

Alarm Deadband

Alarm Inhibit

Control/Alarm Outputs

Relay

Solid State Relay Drive

Triac

Current/Voltage

Output #5 (Optional)

Sensor Input

Input Update Rate

On/Off

Proportional (P)

PID-Proportional with Integral and/or Derivative (PID, PI, PD)

PID + Fuzzy Logic

Heat/Cool (Dual PID)

Sensor Range

Sensor Range

1 to 100

°

F

Sensor Range

-99.9 to 99.9

0.00 to 99.99 repeats per minute

0 to 500 seconds

0.1 to 60.0 seconds

0.0 to 100.0%

0.0 to 100.0%

-100 to 100

°

F

0 to 100% of Proportional Band

Air, Water or Oil

High and Low Settings for each Alarm Output

Absolute: High, Low and High/Low

Tracking: + Deviation, - Deviation and +/- Deviation

Latching or Non-Latching, Energized or De-Energized

Adjustable, 0 to 100

°

F

On Power-Up, Enabled or Disabled

Total of five (5) Control/Alarm outputs possible

Relay—Form A contacts, 1.0 Amps at 120/230 Vac (resistive)

24 Vdc nominal at 40mA

1 Amp continuous, 10 Amp in-rush, at 120 or 230 Vac

4 to 20mA into 0 to 800

Ω

, field changeable to 1-5 Vdc

Relay—N.O. Form C contact, 5A at 120 or 2.5A at 230 Vac

(resistive)

Field selectable Thermocouple, RTD, Current or Voltage

2 Samples per Second


84

Input Specifications

J T/C

K T/C

T T/C

E T/C

Range

°

F Range

°

C

-100 to 1400 -73 to 760

Accuracy @ 77

°

F ambient

±

0.2% of sensor span

-300 to 2400 -184 to 1316

±

0.2% of sensor span

-350 to 750

-100 to 1100

-212 to 399

±

0.2% of sensor span for

PV > -80

°

C

-73 to 593

±


PV < -80

°

C

±

0.2% of sensor span

R T/C

S T/C

B T/C

0 to 3200

0 to 3200

50 to 3300

-18 to 1760

±

0.4% of sensor span

-18 to 1760

±

0.4% of sensor span

10 to 1816

±


PV > 538

°

C

100

Ω

Pt RTD (

RTDT (0.1

α

°

res.)

= .00385) -200 to 1000 -128 to 538

±

0.2% of sensor span

-99.9 to 899.9

-73.3 to 432.1

±

0.2% of sensor span

4-20mA

0-5 Vdc

1-5 Vdc

-500 to 5000 (programmable)

±

0.2% of sensor span


±

0.2% of sensor span


±

0.2% of sensor span

Transmitter Power

+24 Vdc Output

Ramp/Soak Programming

Intervals

Loops

Event Outputs

Guaranteed Soak

Differential

Time Units

+24 Vdc

16 intervals

1 loop, 0-255 times or continuous

Up to 3

Off, 1

°

±

20% at 50mA maximum

F to sensor span

Seconds, Minutes, Hours (1 second to 99.99 hours/segment)

Readout Stability

J, K, E Thermocouple

T Thermocouple

R, S, B Thermocouple

RTD

4-20mA, 1-5Vdc

±

1

°

F/10

°

F change in ambient temperature

±

2

°

F/10

°

F change in ambient temperature for sensor temperature > -80

°

C

±

5

°

F/10

°

F change in ambient temperature for sensor temperature < -80

°

C

±

2

°

F/10

°


±

0.5

°

F/10

°


±

0.05% of span / 10

°


Open Sensor and

Programmable control action with display indicating

Out-of-Range Conditions

condition “OPEN SENS”

Remote Setpoint Input

Input Signal 4-20mA, 250

Ω

Input Impedance

1-5 Vdc, 110k

Ω

Input Impedance

Voltage or Current Field Selectable via switch

Range

Accuracy

Programmable over selected Sensor Span

±

0.3% of Sensor Span (initial accuracy) at 75

°

F ambient temperature and rated line voltage. field calibrate to

±

0.2% of Sensor Span


Digital Input

Analog Output Option

Assignable Functions

Accepts dry-contact closure

Output Signal

Process Variable

Active Setpoint

Output #1 Command

Output #2 Command

4-20mA into 0-800

Ω

load

1-5 Vdc into 100K

Ω

or greater load

Selectable via DIP switch

Range

Accuracy

Programmable over selected sensor span for retransmission of Process Variable and Active Setpoint, fixed to 0 to 100% for transmission of output commands

±

0.2% of programmed span,

±

1 LSD

Digital Communications (Optional)

RS-232 Single-drop, isolated

RS-422/485 Multi-drop, isolated, field selectable by switch

Baud rates

Protocols

Instrument Power

Operating Environment

1200, 2400, 4800, 9600, 19.2K

ASCII Line, Computer Interface

100 to 240 Vac, +10%, -15%;

12 to 24 Vac/Vdc,

±

10%; 50 to 60 Hz

32 to 150

°

F (0 to 65

°

C) ambient temperature, relative humidity less than 95%, non-condensing

Dimensions

Overall 3.8 x 3.8 x 4.75 inches (96 x 96 x 121mm)

Depth Behind Projection 4.0 inches (102 mm)

Front Panel Projection

Panel Cutout

Case Material

0.75 inches (19 mm)

3.6 x 3.6 inches (92 mm x 92 mm)

High Impact, Black ABS Plastic

NEMA 4X Construction

Front Panel

Influence of Line Voltage

Variation

±

0.1% of Sensor Span/10% change in nominal line voltage

Noise Rejection

Common Mode Noise

Series Mode Noise

RFI

140dB at 60 Hz

±

0.1% of Sensor Span with 300mV peak to peak, 50 or

60Hz series mode noise

Typically less than 0.5% of Sensor Span at a distance of 1 meter (3.1 feet) from transmitter (4W, 464Mhz)


Sensor Leadwire Effect

J Thermocouple

K Thermocouple

E Thermocouple

R Thermocouple

S Thermocouple

B Thermocouple

T Thermocouple

RTD, 4-20mA, 1-5 Vdc

+1

°

F for 1000 Ft. of 18 AWG extension wire

+5

°


+4

°


+3

°


+3

°


+6

°


+1

°

F (temperatures > -80

°

C)

+2

°

F (temperatures < -80

°

C)

±

0.1% of Sensor Span/20

Ω

balanced leadwire resistance


Section 12

Troubleshooting

The following Troubleshooting Guide gives simple solutions to common problems, and explains the

2104’s Error Messages. Should you have a problem with your controller, it is a good idea to check this

Guide for possible corrections before contacting the factory. The corrections are listed in the order in which they should be performed.

Note: A specific List of Loop Alarms and probable causes are given on pages 55-57.

Troubleshooting Guide

Symptom Probable Cause

Power applied, display does 1. No power applied not light and controller does not function

Display reads OPEN SENS 1. Open sensor

2. Out of calibration

Process does not heat up

Erratic operation

1. No power being applied to the load

1. Intermittent sensor connections

2. Controller failure

(internal electronics)

Correction

1. Check power wiring and fusing

2. Power down and repower up

1. Check sensor wiring (page 7)

2. Check sensor type selected at

INPT PAGE, SENS

3. Recover Factory Calibration

(page 81)

4. Attach sensor simulator and verify calibration (page 76)

5. Check “Control Loop

Protection” Alarm

1. Verify output wiring (page 11)

2. Verify that load is not open and output jumpers are properly installed

3. Check “control type” entered at CTRL PAGE, CONT (Heat,

Cool or Heat Cool)

4. Check “output limit” entered on OUT1/OUT2 PAGE, OL1/OL2

1. Check sensor wiring or substitute sensor simulator

2. Power down and repower up

3. Contact factory

Chromalox 2104 Technical Manual continued on next page

87

88

Troubleshooting Guide

Symptom

Process not in control

Probable Cause Correction

1. Incorrect “control action” 1. Check “control type” entered selected

2. Not tuned correctly

CTRL PAGE, CONT

2. See Self-Tuning and PID settings, CTRL PAGE

Instrument continually goes 1. Internal electronic failure 1. Contact factory through power-up reset 2. Drastic power line anomalies

ERR3 displayed with

PAGE in lower display

1. EEPROM failed redundancy check

1. Power down and back up to retest EEPROM

2. Set controller to Level D (736)

Security Code.

3. Go to PAGE shown. Use RESET pushbutton to scroll through all menus. Readjust any settings that appear incorrect.

After scrolling through all menus, error will clear.

ERR4 displayed

TERR flashing on upper or lower display

LOOP error

1. A to D electronics failure 1. Power down and up to reset

2. Consult factory

1. Self-tune was enabled, 1. Press RESET to clear error.

but unable to Previous PID parameters successfully tune because: are retained

2. Consult factory a. process could not get

50

°

F below setpoint

(for heating) or 50

° above setpoint (for cooling) in 30 minutes b. over a 10 hour period, the process has not changed enough to initiate turning c. process went in and out of sensor range during tune.

d. 2104 is unable to calculate PID parameters

See pages 55-57 1. Press RESET to clear error

2. Verify wiring and external devices


Section 13

Warranty & Return

Warranty

Limitations

Chromalox warrants only that the Products and parts manufactured by Chromalox, when shipped, and the work performed by Chromalox when performed, will meet all applicable specification and other specific product and work requirements (including those of performance), if any, and will be free from defects in material and workmanship under normal conditions of use. All claims for defective or nonconforming (both hereinafter called defective) Products, parts or work under this warranty must be made in writing immediately upon discovery, and in any event, within three (3) years from delivery, provided, however all claims for defective Products and parts must be made in writing no later than thirty-six (36) months after shipment by Chromalox. Defective and nonconforming items must be held by Chromalox’s inspections and returned to the original f.o.b. point upon request. THE FOREGOING IS EXPRESSLY IN

LIEU OF ALL OTHER WARRANTIES

WHATSOEVER, EXPRESSED, IMPLIED AND

STATUTORY, INCLUDING, WITHOUT

LIMITATION, THE IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE.

Notwithstanding the provisions of this WARRANTY

AND LIMITATIONS Clause, it is specifically understood that Products and parts not manufactured and work not performed by Chromalox are warranted only to the extent and in the manner that the same are warranted to Chromalox by Chromalox’s vendors, and then only to the extent that Chromalox is reasonably able to enforce such a warranty, it being understood Chromalox shall have no obligation to initiate litigation unless buyer undertakes to pay all cost and expenses therefore including but not limited to attorney’s fees, and indemnifies Chromalox against any liability to Chromalox’s vendors arising out of such litigation.


90

Upon buyer’s submission of a claim as provided above and in its substantiation, Chromalox shall at its option either (i) repair or replace its Products, parts or work at the original f.o.b. point of delivery or (ii) refund an equitable portion of the purchase price.

The foregoing is Chromalox’s only obligation and buyer’s exclusive remedy for breach of warranty, and is buyer’s exclusive remedy against Chromalox for all claims arising hereunder or relating hereto whether such claims are based on breach of contract, tort

(including negligence and strict liability) or other theories, buyer’s failure to submit a claim as provided above shall specifically waive all claims for damages or other relief, including but not limited to claims based on latent defects. In no event shall buyer be entitled to incidental or consequential damages and buyer should hold Chromalox harmless therefrom.

Any action by buyer arising hereunder or relating hereto, whether based on breach of contract, tort

(including negligence and strict liability) or other theories, must be commenced within one (1) year after the date of shipment or it shall be barred.

Returns

Items returned to Chromalox Instruments and

Controls must be accompanied by a Return

Authorization Number. This number may be obtained from Chromalox Instruments and

Controls, Customer Service Department, Telephone

Number (615) 793-3900. It should appear on the exterior of the shipping carton and on the shipping documents. Defective items will be repaired or replaced at our option, at no charge.

Return the defective part or product, freight prepaid, to:

Chromalox Instruments and Controls

1382 Heil-Quaker Blvd.

LaVergne, TN 37086-3536


Appendix 1

PAGE/MENU Tables

Setup Page

C

TRL

SC

O

O

AL

UT1

UT2

PAGE Name

Display

Control

Input

PAGE Contents

Allows you to monitor any of 11 real time variables in the lower digital display: process variable; setpoint; outputs; timers and alarm status. This is useful during troubleshooting or brief trending periods. Values on this page are for display only and cannot be changed on this

PAGE.

Security Lock

Setpoints

Self Tune

PID1 and PID2 Control Parameters

Manual Reset

Fuzzy Logic

Output Commands

Control Loop Protection (CLP)

Auto/Manual Disintegration Timer

Ramp Rate

Controller Type

Cooling Medium

Event/Digital Function

Auxiliary Pushbutton Function

Analog Output assignment

Ramp/Soak

User Selected Security Code

Sensor Type

Display Units

Display/Calibration Offset

Setpoint Low Limit

Setpoint Upper Limit

Custom Scaling Analog Input Decimal Points

Analog Input Low

Analog Input High

Analog Output High

Remote Setpoint Input Low

Remote Setpoint Input High

Output #1 Output #1 Cycle Time

Output #1 Limit

Heat Offset

Output #2 Output #2 Cycle Time

Output #2 Limit

Heat Offset


Security Levels

See pages 26-27 for details.

Security Levels and PAGE/MENU Contents

Level Code Description

A

--Display Page and Security Lock

B

C

D

123

458

736

Setpoint and Auxiliary Setpoint

Settings for:

Control

Input

Ramp/Soak


Calibration Security Codes

Security Codes

Security Codes

Security

Level

A

B

C

D

Security

Code

- - -

123

458

736

View

Level

A

A, B

A, B, C

A, B, C, D

Adjust

Level

A

A, B

A, B, C

A, B, C, D


Control Page


Control Page

Menu

A

USP

TUNE

Description

LL

OC

H

Security Lock

Setpoint

Auxiliary SP

Self Tune

Available Settings

0 to 9999



OFF

= Self tuning disabled

PRUP = Powerup tuning

BEGN = Begin tuning

0

°

F to sensor range

A

R1

R

A

T1

Proportional

Band 1

Automatic

Reset 1

Rate 1

Dead Band 1


0 to 500 seconds

1 to 100

°

F


0

°

F to sensor range

A

R2

Proportional

Band 2

Automatic

Reset 2


R

A

T2

Rate 2

Dead Band 2

0 to 500 seconds

1 to 100

°

F


O

FST

Manual Reset -99.9 to 99.9

Fuzzy Logic

OFF

= Disabled

ON

= Enabled

O

RNG

Open Sensor For Heat/Cool Control, adjustable:

Output Command -100.0 to 100.0%:

-100.0 to -0.1 for cooling

0.1 to 100.0 for heating

LL

OOP

Control Loop

Protection

OFF, 0.1 to 999.9 minutes

A

UTO

Auto/Manual 0 to 100 seconds

Disintegration Timer

RR

A

T

Ramp Rate

OFF

Factory Settings Security

A

458

Span Low B

Span Low

OFF

C

25

°

0.10

10

5

°

25

°

0.10

10

5

°

0.0

ON

F

F

F

F

0.0%

OFF

10

OFF


Control Page


Control Page (continued)

Menu Description Available Settings

C

ONT

Controller Type

HEAT = Reverse Acting

Output Controller

COOL = Direct Acting Single

Output Controller

HTCL = Heat/Cool Controller

C

OO

LL

Cooling

Medium

PID2 = Uses PID2 settings for cooling

AIR

= Air Cooling

OIL

= Oil Cooling

H2O

= Water Cooling

Remote

Setpoint

Enable

ENTI

Event/Digital

Function

OFF

ON

A

A

U

OUT

Auxiliary

Pushbutton

Function

Analog

Output

Assignment

NONE = Disabled

PID2 = PID2 enable

AUSP = Auxiliary SP enable

RSP

= Remote SP enable

OUTD = Output disable

RS

= Ramp/Soak

AUTO = Auto/Manual

AIR

= Alarm Reset

NONE = Disabled

PID2 = PID2 enable

AUSP = Auxiliary SP enable

RSP

= Remote SP enable

OUTD = Output disable

AUTO = Auto/Manual

NONE = Disabled

PROC = Process Variable

ASP

= Active Setpoint

OUT1 = Control Output !

OUT2 = Control Output 2

RSEN

Ramp/Soak

OFF

ON

C

ODE

User Selected 0-122 = Level A

Security Code 123-457 = Level B

458-735 = Level C

736-999 = Level D


HEAT

C

PID2

OFF

NONE

NONE

ASP

OFF

0

D


Ramp/Soak Page


Ramp/Soak Page

MENU Description

UNIT

Time Units

Available Settings

SEC

= seconds (1 to 9999)

MIN

= minutes (0.1 to 999.9)

HR

= hours (0.01 to 99.99)


STBY

Standby

Setpoint

Interval 1 Time see Time Units Menu (above)

•

Setpoint 1 Instrument Sensor Span

• Intervals 2-15

• Time and Setpoint

Interval 16 Time see Time Units Menu (above)

SP16

Setpoint 16

C

ONT

Continuous

Program


OFF

ON

Loop from the

1 TO 16 end of interval

To the beginning 1 TO 16 of interval

Number of times 0 TO 9999

SBET

Standby

Events

OFF = All off

E3

= Event Output 3 On

E4

= Event Output 4 On

E43


E5

= Event Output 5 On

E53


E54


E543 = Event Outputs 5, 4, 3 On

Interval 1

Events

OFF = All off

E3

= Event Output 3 On

E4

= Event Output 4 On

E43


E5

= Event Output 5 On

E53


E54


E543 = Event Outputs 5, 4, 3 On

IL6E

Interval 16

Events same as above

G

SDB

Guaranteed

Soak differential

OFF, 1

°

F to sensor range


SEc

C

Span Low

0

Span Low

0

Span Low

OFF

0

OFF

OFF

OFF

0

1

1

°

F


Input Page

See page 38 for details.

Input Page

MENU Description Available Settings

SENS

UNIT

Sensor Type

Display Units

Sensor Type selected here must agree with dip switch settings.

J

= J Thermocouple

K

= K Thermocouple

T

= T Thermocouple

E

= E Thermocouple

R

= R Thermocouple

S

= S Thermocouple

B

= B Thermocouple

RTD

= 100

Ω

Pt RTD (a = .00385)

4-20 = 4 to 20mA

0-5

= 0 to 5 Vdc

1-5

= 1 to 5 Vdc rtdt = 100

Ω

Pt RTD

(0.1

°

resolution)

NONE = no units

°

°

F

= Degrees Fahrenheit

C

= Degrees Celsius

-100

°

F to 100

°

F

C

OFF

Display/ Cal.

Offset

SP

LL

Setpoint

Low Limit

SP

UL

Setpoint

Upper Limit



CALS

Sensor

Calibration

INLO

INHI

DONE

CAL

A

O

0

R

Remote

Setopint

Calibration

INLO

INHI

DONE

Analog Output O to 4095

Zero Calibration

A

O

5

Analog Output 0 to 4095

Span Calibration


J

C

°

0

F

Span Low

Span High

INLO

INLO

D

RE

C

C

Factory

Calibration

Recovery

LL

T

Digital Filter

HPRC

High (max.)

Process Input

LL

PRC

Low (min.)

Process Input

HI

A

High (max.)

Ambient Temp.

LL

O

A

Low (min.)

Ambient Temp.

RDY = Ready

--- = Wait

DONE = Finished

0 to 60 seconds







MENU Description

Analog Input

Decimal Pts.

Available Settings

0 = none

1 = 123.4

2 = 12.34

3 = 1.234

-500 to 5000

A

IN

LL

Analog Input

Low

A

IN

H

Analog Input

High

-500 to 5000

A

OT

LL

Analog Output -500 to 5000

Low

A

OT

H

Analog Output -500 to 5000

High

-500 to 5000

RSPL

Remote SP

Input Low

RSPH

Remote SP

Input High

-500 to 5000

Custom Scaling

Page



1

C

0.0

100.0

Span Low

Span High

Span Low

Span High

Output #1 Page


Output #1 Page

MENU Description

C

YC1

Output #1

Cycle Time

H

OFF

Output #1

Limit

Heat Offset

Available Settings

0.0 to 60.0 seconds

0.0 to 100.0%

0

°

F to PB1 setting

Factory Settings

* For 2104-A (voltage or current output) cycle time must be set to 0.0.

1.0*

100.0%

0

Security

C


Output # 2 Page


Output #2 Page

MENU Description

C

YC2

Output #2

Available Settings

0.0 to 60.0 seconds



1.0

C

0.0 to 100.0%

100.0%

Output #2

Limit

H

OFF

Heat Offset 0

°

F to PB1 setting

0

Output # 3 Page


Output #3 Page

MENU Description Available Settings Factory Settings Security

TYP3

Output #3 Type

OFF

= Disabled

ALR

= Alarm Output

ENT

= Event Output


A

LR3

Alarm #3 Type

NONE = Disabled (off)

HI

= High Alarm

LO

= Low Alarm

HILO = High-Low Alarm

PDE


-DE


DE


LOOP = Control Loop Protection Alarm

R

LL

Y 3

Alarm #3

Relay Action

NDE


NE


NDEL = Normally de-energized latching

NEL


OFF

NONE

NDE

C


Output #3 Page (continued)


A

OL3

Alarm #3

Low Setpoint

INH3

Alarm #3

Inhibit


A

HI3

Alarm #3

High Setpoint


Output #3

Dead Band

(Alarm Hysteresis)

0 to 100

°

F

OFF

ON

Output # 3 Page



Span Low C

Span High

1

°

F

OFF

Output # 4 Page


Output #4 Page


TYP4

Output #4 Type

OFF

= Disabled

ALR

= Alarm Output

ENT

= Event Output



C

A

LR4

Alarm #4 Type


HI

= High Alarm

LO

= Low Alarm


PDE


-DE


DE



OFF

NONE


Output # 4 Page




R

LL

Alarm #4

Relay Action

NDE


NE



NEL


A

OL4

Alarm #4

Low Setpoint


A

HI4

Alarm #4

High Setpoint


Output #4

Dead Band

(Alarm Hysteresis)

0 to 100

°

F

INH4

Alarm #4

Inhibit

OFF

ON


NDE

C

Span Low

Span High

1

°

F

OFF

Output # 5 Page


Output #5 Page


TYP5

Output #5 Type

OFF

= Disabled

ALR

= Alarm Output

ENT

= Event Output



C

A

LR5

Alarm #5 Type


HI

= High Alarm

LO

= Low Alarm


PDE


-DE


DE



OFF

NONE


Output # 5 Page




R

LL

Alarm #5

Relay Action

NDE


NE



NEL


A

OL5

Alarm #5

Low Setpoint


A

HI5

Alarm #5

High Setpoint


Output #5

Dead Band

(Alarm Hysteresis)

0 to 100

°

F

0.00 to 6.25% for analog input

INH5

Alarm #5

Inhibit

OFF

ON


NDE

C

Span Low

Span High

1

°

F

OFF

Digital

Communications

Page


Digital Communications Page: DIG PAGE


DIGT

Mode

Selection

B

A

UD

Baud Rate

OFF

LINE = ASCII Line

1200

2400

4800

9600

19.2K

= Disabled

CPIF = Computer Interface

A

DDR

Address 1 to 255


CPIF

C

19.2K

1


Display Page

The Display Page is for status only.

None of the settings can be changed.


Display Page

MENU Description

Process Variable

A

O

SP

UT1

O

UT2

Active Setpoint

Output #1 Command

Output #2 Command


Ramp/Soak Status

Displays

Sensor Span

Sensor Span

Sensor Span

OFF

= Program not running

RUN

= Program running

HOLD

Program in hold

STB Y

Program in standby

= Guaranteed soak

Security

A

L

EFT

L

OOP

A

LR

E

NT

Ramp/Soak Interval Number

Ramp/Soak Time Left in Interval

Ramp/Soak Loops Remaining

Alarm Output Status

Event Output Status

NONE

No alarms

= Alarm Output #3

= Alarm Output #4

A 4

3


= Alarm Output #5

A 5

3


A 5

4


A54

3

Alarms 5, 4 and 3

NONE

All off

E

3

= Event Output #3

E

4

E

5

= Event Output #4

E 4

3


= Event Output #5

E 5

3


E 5

4


E54

3

Events 5, 4 and 3


Index

A

ccuracy 7, 8, 81, 85

Alarm Inhibit 48, 50, 51, 52, 83

Alarm Operation 49

Alarm Outputs 34, 47, 51, 83

Alarms

Control Loop Protection (see Control Loop Protection Alarm)

Latch/Non-Latching 49-52, 63, 83

Low Alarm 1, 41, 50-52

Reset 22, 49

Wiring 19-20

Analog Output Option 2, 67-70, 80, 85

Applications 1, 29, 61, 82

Auto/Manual 10, 22, 36, 37, 59, 60, 63, 65

Auto Tuning, see Self-Tuning

C

alibration 75-82

Calibration

Analog Output 80

Factory Recovery 81

Offset 38, 82

Remote Setpoint Input 78

Security Codes 26

Sensor Input 76

ChromaSoft 1, 45, 71

Control Loop Protection Alarm (CLP) 50-57

Control Parameters 23, 26, 28

Control Programming 21-22, 24-25

Cycle Time 39, 83

D

igital Communications 1, 2, 71-74

Hardware Setup 71-72

Programming 74

Wiring 72-73

Digital Input 1, 7, 30, 31, 35, 36, 45, 49, 59-63, 67, 85

Dimensions 5, 85

Dip Switches 3

Analog Output 69

Digital Communications 72

Remote Setpoint 67

Sensor Input 4

Displays 21-25, 34, 35, 56, 57, 87-88

Display Mode, Normal 21, 22, 44-46

E

rror Messages 87-88


F

uzzy Logic 30, 36

I

ndications 21

Input Type 4, 36

Inputs, Sensor 1, 8-10, 76

Installation 3

J

umpers, Output 11-14, 17

M

anual Operation 31, 63, 65

Menu Selection 24

Model Identification 2

Mounting 4-5

O

peration 21-31

Alarm 49

Auto/Manual 63, 65

Control 28-31

Erratic 87

Manual 31

Ramp/Soak 10, 41-45, 62

O

utput #1 1, 11-14, 16-18, 22, 28, 33-35, 39, 69, 70, 85

Output #2 1, 11, 14, 16-18, 22, 28, 33-35, 39, 69, 70, 85

Output #3 7, 19, 23, 34, 41, 43, 47-50, 54-57

Output #4 1, 7, 19, 23, 34, 41, 43, 48, 49, 55-57

Output #5 7, 20, 23, 34, 41, 43, 47-49, 52, 55-57, 61, 63, 83

Output, Analog 69-70

Output, Alarm Relays 49-52

Output Wiring 6, 11, 13, 15-18, 70, 87

P

AGE

Control 26, 28, 35-37

Custom Scaling 39, 68

Digital Communications 74 (see Digital Communications in this index)

Display 26, 34 (see Display and Displays in this index)

Input 38

Output #1 39 (see Output #1 in this index)





Ramp/Soak 43 (see Ramp/Soak in this index)

PID1 22, 28, 29, 35, 59-61

PID2 22, 28, 29, 35-37, 59-61

Pushbuttons 21-31


R

amp/Soak 10, 26, 28, 31, 33, 34, 36, 37, 50-52, 59-64

Operation 22, 41-45

Programming 41-42, 44-45, 84

Ramp to Setpoint 28, 30

Remote Setpoint 3, 22, 30, 36, 59-61, 64, 78-79, 84

Repair 89-90

Reset Pushbutton 22, 24, 49

RTD Inputs 76

Calibration 76

Wiring 8-9

S

ecurity Codes 26, 27, 35

Security Levels 26, 27

Self-Tuning 29, 88

Sensor

Setup, Menu 38

Wiring 7-10, 56, 87

Setpoint

Ramp 28, 30

Remote (see Remote Setpoint in this index)

Setup Mode 22, 24, 27

Specifications 83-86

T

hermocouple Inputs 8, 76

Timer

Loop 36, 53, 55-57

Troubleshooting 87-88

Tuning

Self (see Self-Tuning in this index)


W

arranty 89-90

Wiring

Alarm 19-20

Current Input Wiring (Loop Powered by Controller) 10

Current Input Wiring (Self powered) 9

Digital Communications 72-73

Digital Input 10

Dual Analog Output Wiring 16

Dual Output Analog/Relay Wiring 18

Dual Output Analog/Triac Wiring 18

Dual Output SSR/Relay Wiring 17

Dual Output SSR Triac Wiring 17

Dual Relay Output Wiring 16

Dual SSR Drive Output Wiring 16

Dual Triac Output Wiring 16

Dual 1-5 Vdc Output Wiring 17

Good Wiring Practices 6

Heat/Cool Output 16-18

Instrument Power 19

Output 16-17, 48

Remote Setpoint 68

RS232 Wiring Connections 72

RS422A Wiring Connections (4-wire) 73

RS485 Wiring Connections (2-wire) 73

Sensor (see Sensor Wiring in this index)

Terminal Identification 7

Voltage Input Wiring (Self-powered) 10


Chromalox

®

INSTRUMENTS AND CONTROLS

1382 HEIL QUAKER BOULEVARD

LAVERGNE, TN 37086-3536

PHONE (615) 793-3900

FAX (615) 793-3563

WIEGAND INDUSTRIAL DIVISION

EMERSON ELECTRIC CO.

®

Chromalox

Chromalox

®

Issue Date

May 1996

Technical Manual

0037-75276

Table of Contents

Sections

Section

Topic Page

Menu Index

Illustrations

Figure Topic

Page

Illustrations

Figure Topic

Page

Section 1

Getting Started

Section 2

Installation

Section 3

Operation

Section 4

Controller Setup PAGEs

Section 5

Ramp/Soak Operation

Section 6

Alarms

Warning

Section 7

Digital Input and AUX Function

Section 8

Remote Setpoint &

Analog Output Option

Section 9

Digital Communications

Section 10

Calibration

Section 11

Specifications

Section 12

Troubleshooting

Section 13

Warranty & Return

Appendix 1

PAGE/MENU Tables

Index

A

C

D

E

F

I

J

M

O

O

P

R

S

T

W

Chromalox

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