AI-SERIES MULTI-CHANNEL PID TEMPERATURE CONTROLLER

AI-7028 / AI-7048

Operation Instruction
Ver. 7.8

1. SUMMARY
Multi-channel temperature controller provides thermocouple inputs and solid-state SSR outputs.
Each channel can be set as different type of inputs and works independently. This controller can
either used independently or used with computer or PLC (Programmable Logic Controller). The
supply power can be ordered as 24VDC/AC or 100~240VAC. It complies with ISO9001 quality
assurance. It is highly reliable with EMC standard compatible. The power and all I/O terminals has
passed 4KV/5KHz EFT test. It is able to be stably working under strong interference. By adopting
YUDIAN’s new technology, the anti-interference power of multi-channel inputs is as strong as that of
single channel measurement.
● Providing up to 4 channels of programmable inputs, supporting multiple thermocouple inputs, K,
S, E, J, B, N, T, WRe5-WRe25 and etc, with automatic cold junction compensation and linear
voltage (mV) inputs with user defined scale. Individual digital filtering for each channel are
possible to be adjusted or disabled.
● High performance hardware design, which greatly decreased temperature drift and the
interference among the 4 channels. Therefore, this multi-channel controller obtains the same
measurement accuracy and anti-interference ability as that of single channel controller.
● Rail mounted panel with code D5/E5/D7/E7 are available. Those panels without display can be
programmed by connecting the external handset display E8.
● Apart from rail mounted panel D5, every channel has independent high/low limit alarm or
deviation alarm outputs. Those alarms can be assigned to different alarm output slot (AL1 or
AL2) by programming. Alarms from different channels can be assigned to the same alarm slot or
different alarm slots.
● There are 12 programmable Field Parameters. Users can tailor-made the parameter table.
● Advanced communication functions, compatible with the communication protocol of other AI
series instruments such as AI-708 high precision artificial intelligent regulator/temperature
controller. One unit of AI-7048 in communication works as if there are 4 individual units of AI-708
controllers working.
● Among this multi-channel controller series, AI-70482 provides 4 channels of individual inputs
with weak electronic signal isolation among channels. It is suitable for application of grounded
thermocouples of which the negative pole of thermocouple is connected to the probe shell.
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● AI-7048 is fully compatible to AI-7028. AI-7028 is a 2 channel individual controller. The wire
connection method is taken reference to the first 2 channel of AI-7048.

2. Technical Specification
 Input type:
Thermocouple: K, S, R, E, J, T, B, N, WRe5-WRe26
Linear voltage: 0～20mV, 0～60mV, 0～100mV, 0～1V, etc.
 Instrument Input range
K(-50~+1300°C), S(-50~+1700 °C), R(-50~+1700°C), T(-200~+350°C), E(0~+800°C),
J(0~+1000°C), B(+200~+1800°C), N(0~+1300°C), WRe3-WRe25(0~+2300°C),
WRe5-WRe26(0～+2300°C), Pt100(-200~+800°C)
Linear mV Input: Range defined by SCH and SCL parameters.
 Measurement accuracy : ± 0.2%FS ± 0.1°C
Note 1: For thermocouple input with internal compensation, cold junction compensation error up to 1°C
should be considered.
Note 2: Type-B thermocouple can reach the stated measurement accuracy only at the range of 600～
1800°C.
 Temperature shift : ≤0.01%FS /°C (typical value is 60ppm/°C)
 Electromagnetic compatibility (EMC) : ±4KV/5KHz according to IEC61000-4-4;
4KV according to IEC61000-4-5.
 Isolation withstanding voltage : Between power, relay contact or signal terminal ≥2300VDC;
Between SSR voltage output and thermocouple input
≥600VDC
 Control period : 0.48 sec / 4 channels
 Output : SSR driving voltage, 12VDC/20mA each channel with short-circuit protection
 Power Supply: 100～240VAC/ 50Hz or 24VAC/DC +10%, -15%; 5VA.
 Operating Ambient: Temperature -10～60°C; humidity ≤90%RH

3. Rear Terminal Layout and Wiring

Wiring diagram of AI-7028/7048 multi-channel
1 11 COMM
temperature controller 100-240VAC~

2 + 12 OP2

3 A + 13 OP1

COMM
4 B 14
IN4

5 15
+ N/O N/O AL1
IN3
This wiring diagram is valid for panel size code A, C, E, E5 6 + N/C N/O AL2 16
or etc.
COM COM
7 17
ALM
IN2
OP3 8 + 18
IN1
For instruments with dimension B and F, the diagram is OP4 9 + 19
clock-wisely rotated by 90°. The terminal numbers keep
COM 10 CJC 20
unchanged.

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 Wiring diagram of AI-70482 multi-channel
temperature controller

This wiring diagram is valid for panel size code A, C, E, E5

or etc.

For instruments with dimension B and F, the diagram is

clock-wisely rotated by 90°. The terminal numbers keep
unchanged.

Wiring diagram and explanation of indicating lights of D5 panel

MODE: Status of communication and alarm
OP1~OP4: Output of channel 1~4.
Terminal 1~2: Power 100~240VAC or 24VAC/DC
Terminal 9~12: Positive poles of 4 thermocouple inputs
Terminal 15~16: Negative poles of 4 thermocouple inputs in common.
Terminal 5~8: Positive poles of 4 SSR voltage outputs
Terminal 3~4: Negative poles of 4 SSR voltage outputs in common. The
specification of SSR outputs is 12~16VDC/20mA with short-circuit
protection.
Terminal 13~14: RS485 communication.
No alarm output is available in this D5 panel.

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D7 multi-channel temperature controller
Wiring diagram
Power Base Terminals
Terminal 1~2: Power 100~240VAC or 24VAC/DC
Terminal 4~5: RS485 communication.

Instrument Terminals
Terminal 5~8: Positive poles of 4 SSR voltage
outputs
Terminal 9~10: Positive poles of AL1 and AL2
SSR alarm outputs.
Terminal 11~12: Negative poles of AL1 and AL2
SSR alarm outputs.
The specification of SSR outputs is 12~16VDC/20mA
with short-circuit protection.
Terminal 13,14,17,18: Positive poles of 4
thermocouple inputs
Terminal 15,16,19,20: Negative poles of 4
thermocouple inputs

E7 multi-channel temperature controller

Wiring diagram
Terminal 3~4: Power 100~240VAC or 24VAC/DC
Terminal 5~8: Positive poles of 4 SSR voltage outputs
Terminal 9~10: Positive poles of AL1 and AL2 SSR alarm outputs.
Terminal 11~12: Negative poles of AL1 and AL2 SSR alarm
outputs.
The specification of SSR outputs is 12~16VDC/20mA with
short-circuit protection.
Terminal 13,14,17,18: Positive poles of 4 thermocouple inputs
Terminal 15,16,19,20: Negative poles of 4 thermocouple inputs
Terminal 23~24: RS485 communication.

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4. DISPLAYS AND OPERATIONS

① Upper display window, displays PV,

parameter code, etc.
② Lower display window, displays SV,
parameter value, channel no. or alarm
code.
③ Setup key, for accessing parameter table
and conforming parameter modification.
④ Data shift key, or for switching the channel
display in manual/auto.
⑤ Data decrease key, and also for displaying
the previous channel.
⑥ Data increase key, and also for displaying
the next channel.

Operation Instructions:
1. Switch between channels:
Press to display to the previous channel
Press to display the next channel.
Press can switch between auto multi-channel circulating display status and normal display.
2. Set parameters:
Keep pressing about 2 seconds can access Full Parameter Table (When the parameter lock
“Loc” isn't locked. Loc=808.)
Pressing can go to the next parameter,and pressing 、 or can modify a parameter.
Setpoints (SV) can be set by pressing 、 or
Press key to decrease the value.
Press key to increase the value.
Press key to move to the digit expected to modify.
Keep pressing or , the speed of decreasing or inscreasing value gets quick. The range of
setpoint is between the parameter SPL and SPH.
Pressing and holding can return to the preceding parameter. Pressing (don't release) and

then press key simultaneously can escape from the parameter table.

When the parameter is locked, pressing can display Field Parameter Table which includes up to
12 parameters selected by user.
The instrument will escape auomatically from the parameter table if no key is pressed within 25
seconds, and the change of the last parameter will not be saved.
3. Alarm display:
The channel number is displayed in the lower display window.
When high or low limit alarm occurs, the first digital on the left side flickeringly displays H or L.
When an input singal is out of range, for example, the thermocouple circuit is break, the upper
window will display the upper limit or lower limit, and the lower window will flicker.

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4. MODE indication light:
When the instrument is communicating with the host computer, the light will keep flashing in
random speed.
When the instrument hasn’t received signal from the host computer more than 6 seconds, the
indication light should flicker with the same light on time and light off time.
It means:
The on-off period is as long as 1.6 second means no communication and no alarm (it can be
treated as normal);
The light flashing with period 0.6 second means no communication and some general error
occurs.
The light quickly flashing with period 0.3 second means no communication and severe error
such as input over range occurs.
The light keeping off means the instrument power off or damaged; the light keep on (longer
than 8 seconds) means the instrument power on but damaged.

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 5. Setting Parameters:
(Note: x means channel number. It can be 1~4.)
Parameter Name Remarks Setting range
When COMM module interface is used for communication, bAud defines the
bAud Baud rate 0 ~ 19.2K bit/S
baud rate range is 300~19200bit/s.
Every instrument in the same communication line should be assigned to
different communication address. The communication applies AIBUS
Communication
Addr protocol. Every input channel takes one address. For example, if channel 0 ~ 80
address
number Cn=3 and Addr=10, then the communication address 10~12 are
assigned to the instrument.
SPx Setpoint Setpoints of channel 1~4. -999~+ 3200℃
0: Auto tuning function is disable
1: Active auto turning function to calculate the values of parameters P, I, d
Atx Auto tuning 0~1
and CtI. After auto tuning is accomplished, “At” will be automatically
changed to 0.
Define the input specification of channel 1~ 4.
INP Input spec. INP Input spec.
0 K 1 S
2 R 3 T
4 E 5 J
Input 6 B 7 N
INPx 8 WRe3-WRe25 9 WRe5-WRe26 0 ~ 39
specification
10 Extended input spec. 11~24 Spare
25 0~75mV 26~27 Spare
28 0~20mV 29 0~100mV
30 0~60mV 31 0~1V
32 0.2~1V

dPtx is set to select display resolution for channel x

for linear inputs, the corresponding display resolution of dPt=0,1,2,3 are 0,
0.0, 0.00 and 0.000
dPtx Decimal point 0~3
For thermocouple inputs, when dPt=0, the display resolution is 1℃; when
dPt=1, the resolution is 0.1℃.
Note: dPt only affects the display, and has no effect on internal data.
SCLx Scale low limit -9999~+30000
SCL and SCH define the corresponding scale range of linear inputs as mV.
SCHx Scale high limit units
For thermocouple, the units of Scb is 0.1℃. For example, when Scb=-100,
-1999~+4000
Scbx Input offset the actual offset=-10℃, then the measured temperature will be 10℃ lower
units or 0.1℃
than that when Sc=0.
The value of FIL will determine the ability of filtering noise.
FIL=0, no filtering;
FIL=1, filtering with mean;
FIL=2~40, filtering with mean and integral.
When a large value is set, the measurement input is stabilized but the
FILx Digital filter 0~40
response speed is slow. Generally, it can be set to 1 to 3.
If strong interference exists, then you can increase parameter FIL gradually to
make momentary fluctuation of measured value less than 2 to 5.
When the instrument is being metrological verified, FIL can be set to 0 or 1 to
shorten the response time.
Proportional band in PID and APID control. Instead of percentage of the
Proportional measurement range, the unit is the same as PV.
Px 10～9999 units
band Generally, optimal P, I, D and CtI can be obtained by auto tuning. They can
also be manually inputted if you already know the correct values.
0～9999
Ix Time of Integral Time of Integral in PID. No integral effect when I=0
seconds
Time of 0～999.9
Dx Time of derivative in PID. No derivative effect when d=0
derivative seconds
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 x channel high alarm is triggered when PVx (the present value of x
H.ALx Alarm high limit
channel)>H.ALx; alarm releases when PVx<H.ALx - HYSx.
-999~+3200 ℃
x channel low alarm is triggered when PVx<L.ALx;
L.ALx Alarm low limit
alarm releases when PVx>L.ALx+HYSx.
HYS is set to avoid high frequent alarm on/off actions caused by process
HYSx Hysteresis 0~999.9℃
input fluctuation. It also works at auto-tuning.
Alarm Low limit alarm High limit alarm
Output to
Alarm output
None 0 0
allocation
AOPx AL1 3 3 0~44
(Valid only for
E5 size) AL2 4 4
For example, AOP1=43 that the low limit alarm of channel 1 is sent to AL2,
and high limit alarms sent to AL1
Define actual number of input channels. Setting range is 1~4.
Number of
Cn When Cn=2, the lower window display the present value of channel 2 instead 1~ 4
input channels
of the channel number.
If several of AI-7048 has used, this parameter can define the AI-7048 to
First display
Cno display assigned channel number on display. For example, when Cno=6, the
channel setting
controller will display channel number from 6~9. (6, 7, 8, 9)
Parameter “AF” was defined as below:
AF=A x 1 + B x 2 + C x 3 + D x 4
Addition
A=0; Normal speed in channel cycle display;
AF function setting
A=1; Faster speed in channel cycle display;
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B=0; C=0;
D=0; Normal application; D=1; Change all of the low alarm to be high alarm;
Parameter “AF2” was defined as below:
AF=A x 1 + B x 2
A=0; Normal application;
A=1; Change all of the high alarm to be high deviation alarm; when deviation
value (PV – SV) > H.ALx, it will trigger the alarm. When (PV – SV) < H.ALx –
Addition
HYSx, alarm off, set the H.ALx value to maximum will disable the alarm
AF2 function setting
function.
2
B=0; Normal application;
B=1; Change all of the low alarm to be low deviation alarm; when deviation
value (PV – SV) < L.ALx, it will trigger the alarm. When (PV – SV) > L.ALx –
HYSx, alarm off, set the L.ALx value to minimum will disable the alarm
function.
Single channel relay module provides both normal open and normal close
output, while dual relay output module L5 only provides normal open output.
NO/NC
nonc However, by parameter “nonc”, the NO output can be changed to NC output. 0, 127
selection
nonc = 0, AL1, AL2 (L5 is installed in ALM socket) are normal open output.
nonc = 127, AL1 and AL2 are normal close output
Loc=0, Allow to display and modify parameter “Loc” and the field parameters
which is defined in EP1~EP12 .
Loc=1, Allow to display and modify parameter “Loc”, and only display field
Loc Parameter lock parameters, can’t modify them. 0 ~9999
Loc=808, allow to display and set all parameters.
Note: This setting just effect on external display. Modify parameter by
communication was always allowed.
When configuration of the instrument is completed, most parameters will not
need to be set by field operators. Furthermore, field operators may not
understand many parameters, and may probably set parameters incorrectly
by mistake and make the instrument unable to work.
EP1~EP12 define 0~12 field parameters for operators’ use in parameter
Field table. Their parameter values are parameters except parameter EP itself, for
EP1-12 NonE~bAud
parameter example, H.AL1, L.AL1, .etc,
Parameters from EP1 to EP12 can define 12 field parameters at most, if the
number of field parameters is less than 12(sometimes even none), it is
necessary to define field parameters from EP1 to EP12 in order, the first
unused EP should be set to none.
For example, four parameters of SP1 to SP4 (all channels’ setpoints) are
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need to be modified by field operators, the parameter EP can be set as :
EP1=SP1, EP2=SP2, EP3=SP3, EP4=SP4, EP5=none, Loc=0
Then only parameter SP1~4 can be displayed and modified, but via
communication, on the host computer, all parameters can be displayed and
modified.