User's Manual

8000series

4000 Series 1/4 DIN

6000 Series 1/16 DIN
8000 Series 1/8 DIN
Auto-Tune Fuzzy / PID
Process / Temperature Controller

117 East Adam Street LaGrange, KY 40031

502 222-1402 Fax: 502 222-0714
www.proheatinc.com
Warning Symbol
This Symbol calls attention to an operating procedure, practice, or the
like, which, if not correctly performed or adhered to, could result in
personal injury or damage to or destruction of part or all of the
product and system. Do not proceed beyond a warning symbol until
the indicated conditions are fully understood and met.

Use the Manual

Installers Read Chapter 1, 2
System Designer Read All Chapters
User Read Page 12

NOTE:
It is strongly recommended that a process should incorporate a
LIMIT CONTROL which will shut down the equipment at a
preset process condition in order to preclude possible damage
to products or system.

Information in this user's manual is subject to change without notice.

Copyright January 2018, Proheat Inc., all rights reserved. No part of

this publication may be reproduced, transmitted, transcribed or stored
in a retrieval system, or translated into any language in any form by
any means without the written permission of Proheat Inc.
Quick Reference Guide

PID Adjustment Guide

iv
 Parameter Parameter Default
Notation Description Value
SP1 Set point for output 1 77.0°F
Set-up Menu SP2 Set point for output 2 18.0°F
SP3 Set point for alarm 18.0°F
LOCK Select parameters to be locked None
Press key for INPT Input sensor selection Type J
3 seconds to enter UNIT Input unit selection °F
DP Decimal point selection 1 digit
the set-up menu. INLO Input low scale value 0°F
INHI Input high scale value 200.0°F
The flow chart SP1L Low limit of set point value 0°F
SP1H High limit of set point value 1000°F
shows a complete SHIF PV shift value 0.0
listing of all FILT Filter damping time .5 sec
parameters. The PB Proportional band value 18.0°F
TI Integral time value 100
number of TD Derivative time value 25.0
available OUT1 Output 1 function Heating
parameters O1TY Output 1 signal type Relay
O1FT Output 1 failure transfer mode Off
depends on setup O1HY Output 1 hysteresis 0.2°F
conditions, and CYC1 Output 1 cycle time 18.0
should be less OFST Offset value for P control 25.0
RAMP Ramp function selection None
than that shown RR Ramp rate 0.0
in the flow chart. OUT2 Output 2 function Dev Hi
alarm
O2TY Output 2 signal type Relay
O2FT Output 2 failure transfer mode Off
O2HY Output 2 hysteresis 0.2°F
CYC2 Output 2 cycle time 18.0
CPB Cooling prop band value 100
DB Heating-cooling dead band 0
ALFN Alarm function Dev hi
alarm
ALMD Alarm operation mode Normal
ALHY Hysteresis control of alarm Normal
ALFT Alarm failure transfer mode On
COMM Communication function Modbus
ADDR Address assignment --
BAUD Baud rate 9.6
DATA Data bit count 8
PARI Parity bit Even
STOP Stop bit count 1
RELO PV retransmission low value 0°F
REHI PV retransmission high value 200.0°F
SEL1 1st parameter for user menu INPT
SEL2 2nd parameter for user menu UNIT
SEL3 3rd parameter for user menu DP
User Menu SEL4 4th parameter for user menu PB
SEL5 5th parameter for user menu TI
SEL6 6th parameter for user menu TD
This series control SEL7 7th parameter for user menu CYC1
has the flexibility SEL8 8th parameter for user menu ADDR
for you to select
those parameters
which are most
significant to your
application. These
parameters are
able to be put in
the front of the
display sequence
for ease of access.

Select the
parameters for
view in the user
menu by using

Quick Reference Guide

SEL1 – SEL8
contained at the
bottom of the set-
up menu.

v
 L1
120V
L2

Fuse
High Limit
Contactor

Coil

Solid state
Relay

6000-201-00 L91-4110
Proheat Control Limit Control
Alarm

1 7 Heater 1 6
2 8
2 7
3 9
4 10 3 8
4 9
Quick Reference Guide

5 11 Process Limit
Sensor Sensor 5 10
6 12

Example System Wiring Diagram

Solid State Relay

vi
vii
L1
120V
L2

Fuse
High Limit
Contactor

Coil

Mercury
6000-101-00 Relay L91-4110
Proheat Control Limit Control
Alar

1 7 Heater 1 6
2 8
2 7
3 9
4 10 3 8
5 11 Process Limit 4 9
Quick Reference Guide

Sensor Sensor 5 10
6 12

Example System Wiring Diagram

Mercury Relay
Contents
Page No Page No
Chapter 1 Overview Chapter 4 Calibration --------48
1-1 General -------------------------4
1-2 Ordering Code ---------------7 Chapter 5 Specifications - --53
1-3 Programming Port ------------8
1-4 Keys and Displays ----------9
1-5 Menu Overview -------------11 Appendix
1-6 Parameter Descriptions ---12
A-1 Error Codes -------------------59
A-2 Warranty ------------------------60
Chapter 2 Installation
2-1 Unpacking -----------------------19
2-2 Mounting -----------------------19
2-3 Wiring precautions -------------21
2-4 Power Wiring --------------------24
2-5 Sensor Installation
Guidelines -----------------------24
2-6 Sensor Input Wiring------------25
2-7 Control Output Wiring ---------25
2-8 Alarm Wiring---------------------28
2-9 Process Retransmission ----28
2-10 Data Communications-------29

Chapter 3 Programming
3-1 Lockout -----------------------31
3-2 Signal Input ------------------31
3-3 Control Outputs --------------32
3-4 Alarm ---------------------------37
3-5 Configure User Menu -----38
3-6 Ramp -------------------------39
3-7 Dwell Timer ------------------40
3-8 PV Shift -----------------------41
3-9 Digital Filter -------------------41
3-10 Failure Transfer -------------42
3-11 Auto-tuning ------------------43
3-12 Manual tuning -------------44
3-13 Manual Control -------------45
3-14 Data communication -----47
3-15 PV Retransmission----- -----47

3
Chapter 1 Overview
1-1 General
The Fuzzy Logic plus PID microprocessor-based controller series,
incorporate two bright, easy to read 4-digit LED displays, indicating
process value and set point value. The Fuzzy Logic technology
enables a process to reach a predetermined set point in the
shortest time, with the minimum of overshoot during power-up or
external load disturbance.

SERIES 6000 is a 1/16 DIN size panel mount controller. SERIES 4000
is a 1/4 DIN size panel mount controller. SERIES 8000
is a 1/8 DIN size panel mount controller. These units are powered by
11-26VAC/VDC or 90-250 VAC supply, incorporating a 2 amp. control
relay output as standard. The second output can be used as cooling
control, or an alarm. Both outputs can select triac, 5V logic output,
linear current or linear voltage to drive external device. There are
six types of alarm plus a dwell timer can be configured for the third
output. The units are fully programmable for PT100 and thermocouple
types J,K, T, E, B, R, S, N, L with no need to modify the unit. The input
signal is digitized by using a 18-bit A to D converter. Its fast sampling
rate, 5 scans/second, allows the unit to control with greater accuracy
and response time.

Digital communications RS-485 or RS-232 are available as an

additional option. These options allow the units to be integrated with
supervisory control system and software.

A programming port is available for automatic configuration,

calibration and testing without the need to access the keys on front
panel.

By using proprietary Fuzzy modified PID technology, the control

loop will minimize the overshoot and undershoot in a shortest
time. The following diagram is a comparison of results with and
without Fuzzy technology.

4
 PID control with properly tuned
Temperature PID + Fuzzy control

Set
point

Figure 1.1
Fuzzy Control
Advantage

Warm Up Load Disturbance

Time
High Accuracy
This Series controllers are manufactured with custom designed
ASIC(Application Specific Integrated Circuit ) technology which
contains a 18-bit A to D converter for high resolution measurement
( true 0.1 F resolution for thermocouple and PT100 ) and a 15-bit
D to A converter for linear current or voltage control output. The
ASIC technology provides improved operating performance,
low cost, enhanced reliability.

Fast Sampling Rate

The sampling rate of the input A to D converter reaches 5 times/second.
The fast sampling rate allows this series to control fast processes.

Fuzzy Control
The function of Fuzzy control is to adjust PID parameters from time to
time in order to make manipulation output value more flexible and
adaptive to various processes. The results is to enable a process to
reach a predetermined set point in the shortest time, with the minimum
of overshoot and undershoot during power-up or external load
disturbance.

Digital Communication
The units are equipped with RS-485 or RS-232 interface card to
provide digital communication. By using the twisted pair wires there
are at most 247 units can be connected together via RS-485 interface
to a host computer.

5
Programming Port
A programming port is used to connect the unit to a hand-held
programmer or a PC for quick configuration, also can be connected
to an ATE system for automatic testing & calibration.

Auto-tune
The auto-tune function allows the user to simplify initial setup for a
new system. A sophisticated algorithm is provided to obtain an optimal
set of control parameters for the process, and it can be applied
either as the process is warming up (cold start) or as the process
has been in steady state (warm start).

Lockout Protection
According to your security requirements, one of four lockout levels
can be selected to prevent unauthorized changes.
Bumpless Transfer
Bumpless transfer allows the controller to continue to control by
using its previous values if a sensor fails.

Soft-start Ramp
The ramping function is performed during power up as well as any
time the set point is changed. It can be ramping up or ramping down.
The process value will reach the set point with a predetermined
constant rate.

Digital Filter
A first order low pass filter with a programmable time constant is used
to improve the stability of process value. This is particularly useful in
certain application where the process value is unstable.

SEL Function
The units have the flexibility to select parameters which are most
significant so as to put these parameters in the front of display
sequence. There are 8 parameters that can be selected to allow the
user to build a custom display sequence.

6
 1-2 Ordering Code
40 - -
60 Options
80
0: Panel mount IP50 standard
1: Panel mount IP65 water
Power Input resistant rubber installed
2: DIN Rail mount with IP50
0: 90 - 250 VAC, (for 9100 only)
50/60 HZ 3: DIN Rail mount with IP65
1: 11 - 26 VAC or (for 9100 only)
VDC
X: Special Order
Communications
Signal Input 0: None
1: RS-485 interface
0: Standard Input 2: RS-232 interface
Thermocouple: 3: Retransmit 4-20mA / 0-20mA
J, K, T, E, B, R, 4: Retransmit 1-5 V / 0-5V
S, N, L 5: Retransmit 0-10V
RTD: PT100 DIN, X: Special order
PT100 JIS
1: 0 - 60 mV
2: 0 -1 V Alarm
3: 0 - 5 V 0: None
4: 1 - 5 V 1: Form C relay 2A/240VAC
5: 4 - 20 mA 9: Special order
6: 0 - 20 mA Output 2
7: 0 - 10 V 0: None
X: Special Order 1: Form A relay 2A/240VAC
2: Pulsed voltage to
drive SSR, 5V / 30mA
3: Isolated 4 - 20mA / 0 - 20mA
Output 1 4: Isolated 1 - 5V / 0 - 5V
0: None 5: Isolated 0 - 10V
1: Relay rated 2A/240VAC 6: Triac output, 1A / 240VAC,
SSR
2: Pulsed voltage to drive SSR, 7: Isolated 20V/25mA
5V/30mA transducer power supply
3: Isolated 4 - 20mA / 0 - 20mA 8: Isolated 12V/40mA
4: Isolated 1 - 5V / 0 - 5V transducer power supply
5: Isolated 0 - 10V 9: Isolated 5V/80mA
6: Triac output 1A / 240VAC,SSR transducer power supply
C: Pulsed voltage to drive SSR, C: Pulsed voltage to drive SSR,
14V/40mA 14V/40mA
X: Special order X: Special order

7
1-3 Programming Port

Rear Front
Terminal Panel

Figure 1.2
Programming Port
6 4 2
Overview
5 31

Access Hole

6 4 2

5 31

A special connector can be used to touch the programming port

which is connected to a PC for automatic configuration, also can be
connected to an ATE system for automatic calibration and testing.

The programming port is used for off-line automatic setup and testing
procedures only. Do NOT attempt to make any connection to these
pins when the unit is in normal operation.

8
1- 4 Keys and Displays
KEYPAD OPERATION
SCROLL KEY :
This key is used to select a parameter to be viewed or adjusted.

UP KEY :
This key is used to increase the value of selected parameter.

DOWN KEY :
This key is used to decrease the value of selected parameter.

RESET KEY : R
This key is used to:
1. Revert the display to display the process value.
2. Reset the latching alarm, once the alarm condition is
removed.
3. Stop the manual control mode , auto-tuning mode and calibration
mode.
4. Clear the message of communication error and auto-tuning error.
5. Restart the dwell timer when the dwell timer has been time out.
6. Enter the manual control menu during failure mode occurs.

ENTER KEY : Press for 3 seconds or longer .

Press for 3 seconds to:
1. Ener setup menu. The display shows .
2. Enter manual control mode during manual control mode
is selected.
3. Enter auto-tuning mode during auto-tuning mode is
selected.
4. Perform calibration to a selected parameter during the
calibration procedure.
Press for 4.2 seconds to select manual control mode.
Press for 5.4 seconds to select auto-tuning mode.
Press for 6.6 seconds to select calibration mode.

9
Alarm Upper Display, to display process value,
Indicator menu symbol and error code etc.
Output 2 Process Unit Indicator
Indicator
Output 1 OP1 OP2 ALM
Indicator C F

Manual Lower Display,

Mode to display set point value,
Indicator MAN parameter value or
control output value etc.
Auto-tuning AT
Indicator
R 4 Buttons for ease of
control setup and
6000 set point adjustment.

Figure 1.3 Front Panel Description

Table 1.1 Display Form of Characters

A E I N S X
B F J O T Y
C G K P U Z
c H L Q V ?
D h M R W =
: Confused Character

OP1 OP2 ALM Display program code of the product

C F for 2.5 seconds.

The left diagram shows program no. 6

for 6000 Series with version 12.
MAN
The program no. for 4000 Series is 12 and
the number for the 8000 Series is 11.
AT

R Figure 1.4
6000 Display of Initial Stage

10
1- 5 Menu Overview
User Setup Manual Auto-tuning Calibration
menu menu Mode Mode Mode

3 sec. 4.2 sec. 5.4 sec. 6.6 sec. 7.8 sec.

PV, SV
Release then *3
*2 *1 press for 3
SP2 LOCK H_ _ _ ADLO
seconds to
SP3 INPT ADHI
INPT UNIT
start auto- RTDL
UNIT DP tuning mode. RTDH
C_ _ _
DP INLO CJLO
PB INHI Press CJHI
TI SP1L for 3 seconds
TD SP1H to start manual
CYC1 SHIF control. Press for
ADDR FILT
3 seconds to
PB
TI perform calibration.
TD
OUT1
Apply these modes will break the control
O1TY
O1FT
loop and change some of the previous
O1HY setting data.
CYC1
OFST *1: The flow chart shows a complete listing
RAMP of all parameters. For actual application
RR
OUT2
the number of available parameters
O2TY depends on setup conditions, and should
O2FT be less than that shown in the flow chart.
O2HY
CYC2 *2: You can select up to 8 parameters to
CPB
put place in the user menu by using
DB
ALFN
SEL1~SEL8 contained at the bottom of
ALMD setup menu.
ALHY
ALFT *3: Release , press again for 2 seconds
COMM then release to enter the calibration menu.
ADDR
BAUD
DATA The user menu shown in the flow chart is
PARI corresponding to the default setting for
STOP the SEL parameters SEL1 to SEL8. SP3
SEL1 will be hidden if NONE is selected for
SEL2
ALFN. SP2 will be hidden if alarm function
SEL3
SEL4
is not selected for OUT2. The unused
SEL5 parameter will be hidden even if it is
SEL6 selected by SEL parameters.
SEL7
SEL8

11
1-6 Parameter Descriptions
Parameter Parameter Description Range Default
Notation Value
25.0 C
SP1 Set point for output 1 Low: SP1L High :SP1H (77.0 F)
Set point for output 2
Low: -19999 High :45536 10.0 C
SP2 when output 2 performs (18.0 F)
alarm function
Set point for alarm or Low: -19999 High: 45536 10.0 C
SP3 dwell timer output (18.0 F)
0 : No parameter
is locked
1 : Setup data are
Select parameters to be locked
LOCK 0
locked 2 : Setup data and
User data except Set
point are locked
3 : All data are locked
0 : J type thermocouple
1 : K type thermocouple
2 : T type thermocouple
3 : E type thermocouple
4 : B type thermocouple
5 : R type thermocouple
6 : S type thermocouple
7 : N type thermocouple
8 : L type thermocouple
1
INPT Input sensor selection 9 : PT 100 ohms DIN (0)
curve
10 : PT 100 ohms JIS
curve
11 : 4 - 20 mA linear
NOTE; 12
current input
: 0 - 20 mA linear
Input Selection current input
11 - 17 13 : 0 - 60 mV linear
millivolt input
of Linear (ma/VDC) 14 : 0 - 1V linear voltage
Require input
special order 15 : 0 - 5V linear voltage
input
only See Matrix 16 : 1 - 5V linear voltage
Page 8. input
17 : 0 - 10V linear voltage
input

12
Parameter Parameter Description Range Default
Notation Value

0 : Degree C unit
0
UNIT Input unit selection 1 : Degree F unit
(1)
2 : Process unit

0 : No decimal
point

1 : 1 decimal digit
DP Decimal point selection 1
2 : 2 decimal digits

3 : 3 decimal digits

Input low sale value High: 45486 -17.8 C

INLO Low: -19999 ( 0F )
93.3 C
INHI Input high scale value Low: INLO+50 High: 45536 (200.0 F)
Low limit of set point -17.8 C
SP1L Low: -19999 High: 45536 (0 F)
value
High limit of set point 537.8 C
SP1H Low: SP1L High: 45536 (1000 F)
value
-200.0 C High: ( 200.0 C
SHIF PV shift (offset) value Low: (-360.0 F) 360.0 F) 0.0

0 : 0 second time
constant
1 High: : 0.2 second time
constant
2 : 0.5 second time
constant
3 : 1 second time
constant
4 : 2 seconds time
Filter damping time constant
FILT 5 2
constant of PV : 5 seconds time
constant
6 : 10 seconds time
constant
7 : 20 seconds time
constant
8 : 30 seconds time
constant
9 : 60 seconds time
constant

13
Parameter Parameter Description Range Default
Notation Value

Proportional band value 500.0 C

High: (900.0 10.0 C
PB Low: 0 F) (18.0 F)
TI Integral time value Low: 0 High: 1000 sec 100
TD Derivative time value Low: 0 High: 360.0 sec 25.0

0 : Reverse (heating )
control action
OUT1 Output 1 function 0
1 : Direct (cooling)
control action

0 : Relay output
1 : Solid state relay
drive output
2 : Solid state relay
output
3 : 4-20 mA current
module
O1TY Output 1 signal type 4 : 0 - 20 mA current 0
module
5 : 0 - 1V voltage
module
6 : 0 - 5V voltage
module
7 : 1 - 5V voltage
module
8 : 0 - 10V voltage
module
Select BPLS ( bumpless
transfer ) or 0.0 ~ 100.0 % to
Output 1 failure transfer continue output 1 control
O1FT mode function as the unit fails, or 0
select OFF (0) or ON (1)
for ON-OFF control.

Output 1 ON-OFF control 0.1C

O1HY hysteresis Low: 0.1 High: 50.0 C (90.0 F) (0.2 F)

CYC1 Output 1 cycle time Low: 0.1 High: 90.0 sec. 18.0
OFST Offset value for P control Low: 0 High: 100.0 % 25.0
0 : No Ramp Function
1 : Use unit/minute as
RAMP Ramp function selection Ramp Rate 0
2 : Use unit/hour as
Ramp Rate

14
Parameter Parameter Description Range Default
Notation Value

Ramp rate 500.0 C

High: (900.0
RR Low: 0 F) 0.0

0 : Output 2 No Function

2 : Deviation High Alarm

3 : Deviation Low Alarm

OUT2 Output 2 function 2
6 : Process High Alarm

7 : Process Low Alarm

8 : Cooling PID Function

0 : Relay output

1 : Solid state relay

drive output
2 : Solid state relay
output
3 : 4 - 20 mA current
module
O2TY Output 2 signal type 0
4 : 0 - 20 mA current
module
5 : 0 - 1V voltage
module
6 : 0 - 5V voltage
module
7 : 1 - 5V voltage
module
8 : 0 - 10V voltage
module
Select BPLS ( bumpless transfer )
or 0.0 ~ 100.0 % to continue
Output 2 failure 0
O2FT output 2 control function as the
transfer mode
unit fails, or select ON (0) or
OFF (1) for alarm function.

Output 2 hysteresis
value when output 2 50.0 C 0.1 C
O2HY performs alarm Low: 0.1 High: (90.0 F) (0.2 F)
function

CYC2 Output 2 cycle time Low: 0.1 High: 90.0 sec. 18.0

CPB Cooling proportional High: 300 % 100

band value Low: 50

15
Parameter Parameter Description Range Default
Notation Value

Heating-cooling dead
DB band (negative value= Low: -36.0 High: 36.0 % 0
overlap)

0 :No alarm function

1 :Dwell timer action
2 :Deviation high alarm
3 :Deviation low alarm

Alarm function for 4 :Deviation band out of

ALFN alarm output band alarm 2
5 :Deviation band in
band alarm
6 :Process value high
alarm
7 :Process value low
alarm

0 : Normal alarm
action
1 : Latching alarm
ALMD Alarm operation mode action 0
2 : Hold alarm action

3 : Latching & Hold

action

Hysteresis control of 50.0 C 0.1 C

ALHY Low: 0.1 High: (90.0 F)
alarm (0.2 F)

0 : Alarm output ON as
Alarm failure transfer unit fails
ALFT mode 0
1 : Alarm output OFF as
unit fails
0 : No communication
Communication
COMM function 1 : Modbus RTU mode 1
protocol
2 : 4 - 20 mA
PV Retransmission
3 : 0 - 20 mA
PV retransmission
4 : 0 - 5 VDC
PV Retransmission
5 : 1 - 5 VDC
PV Retransmission
6 : 0 - 10 VDC
PV Retransmission
16
Parameter Parameter Description Range Default
Notation Value
Address assignment of
ADDR digital communication Low: 1 High: 255

0 : 2.4 Kbits/s baud rate

1 : 4.8 Kbits/s baud rate

2 : 9.6 Kbits/s baud rate

Baud rate of digital 3 : 14.4 Kbits/s baud rate

BAUD 2
communication

4 : 19.2 Kbits/s baud rate

5 : 28.8 Kbits/s baud rate

6 : 38.4 Kbits/s baud rate

Data bit count of digital 0 : 7 data bits

DATA communication 1
1 : 8 data bits

0 : Even parity
Parity bit of digital 1 : Odd parity
PARI communication 0
2 : No parity bit

Stop bit count of digital 0 : One stop bit

STOP communication 0
1 : Two stop bits

PV Retranmission High: 45486 -17.8 C

RELO Low Value Low: -19999 ( 0F )

REHI PV Retranmission Low: -19999 High: 45486 93.3 C

High Value (200.0 F)

2
0 : No parameter selected

1 : LOCK is put ahead

2 : INPT is put ahead

SEL1 Select 1'st parameter for 3 : UNIT is put ahead

user menu : DP is put ahead
4
5 : SHIF is put ahead

6 : PB is put ahead

7 : TI is put ahead
17
Prameter Parameter Description Range Default
Notation Value

8 : TD is put ahead

9 : O1HY is put ahead

10 : CYC1 is put ahead

11 : OFST is put ahead

12 : RR is put ahead
Select 1'st parameter for
SEL1 user menu 13 : O2HY is put ahead 2

14 : CYC2 is put ahead

15 : CPB is put ahead

16 : DB is put ahead

17 : ADDR is put ahead

18 : ALHY is put ahead

Select 2'nd parameter

SEL2 for user menu Same as SEL1 3

Select 3'rd parameter

SEL3 for user menu Same as SEL1 4

Select 4'th parameter

SEL4 for user menu Same as SEL1 6

Select 5'th parameter

SEL5 for user menu Same as SEL1 7

Select 6'th parameter

SEL6 for user menu Same as SEL1 8

Select 7'th parameter

SEL7 for user menu Same as SEL1 10

Select 8'th parameter

SEL8 for user menu Same as SEL1 17

18
 Dangerous voltages capable of causing death are sometimes
present in this instrument. Before installation or beginning any
troubleshooting procedures the power to all equipment must be
switched off and isolated. Units suspected of being faulty must be
disconnected and removed to a properly equipped workshop for
testing and repair. Component replacement and internal adjustments
must be made by a qualified maintenance person only.

To minimize the possibility of fire or shock hazards, do not

expose this instrument to rain or excessive moisture.

Do not use this instrument in areas under hazardous

conditions such as excessive shock, vibration, dirt, moisture,
corrosive gases or oil. The ambient temperature of the areas should
not exceed the maximum rating specified in Chapter 5.

Upon receipt of the shipment remove the control from the carton
and inspect for any shipping damage. If any damage have
occured, report and claim with the shipping carrier. Write down
the model number, serial number, and date code for future
reference when corresponding with our service team. The serial
number (S/N) and date code (D/C) are labeled on the box and
the housing of control.

Make panel cutout to dimension shown in Figure 2.1.

Take both mounting clamps off and insert the control into
panel cutout. Re-install the mounting clamps. Gently tighten
the screws in the clamp till the controller front panels is fit s
snugly in the cutout.

19
 Figure 2.1 Mounting Dimensions
92 mm

3.62” Panel Cutout

4000 Series

Panel
92 mm
53 mm
3.62” 2.08”

Panel
92 mm

3.62”
Cutout 8000 Series

Panel
45 mm

1.77”
65 mm
2.55”

1.77” Panel
45 mm
1.77”

Panel
45 mm

Cutout 6000 Series

104.8mm
4.12”

20
2 - 3 Wiring Precautions
Before wiring, verify the label for correct model number and
options.

Care must be taken to ensure that maximum voltage rating

specified on the label are not exceeded.

It is recommended that power of these units to be protected by

fuses or circuit breakers rated at the minimum value possible.

All units should be installed inside a suitably grounded metal

enclosure to prevent electrical shock. Installation should be
performed under the supervision of a qualified electrician.

All wiring must conform to appropriate standards of good practice

and local codes and regulations. Wiring must be suitable for
voltage, current, and temperature rating of the system.
Beware not to over-tighten the terminal screws.

Unused control terminals should not be used as jumper points as

they may be internally connected, causing damage to the unit.

Verify that the ratings of the output devices and the inputs as
specified in Chapter 5 are not exceeded.

21
 3.2mm min. 7.0mm max.
Figure 2.2
Lead Termination for
4000 Series & 8000 Series

6.0mm max.
Figure 2.3
Lead Termination
3.0mm min. for 6000 Series

90-250VAC 1 L 11
47-63 Hz
12VA 2 N 12
3 C TX1 TXD 13 +
+

RE RS-485
OP1 /Retransmission Ma
_ 4 NO TX2 RXD 14 - RE
RS-232
5 C COM 15
+

OP2
_ 6 NO 16
7 C 17
A
ALM 8 NO PTA 18
RTD
TC+, V+
9 NC PTB, mA+ 19 B
+
+
+

TC-, V- _ _V _
10 PTB, mA-
20 B
TC V mA RTD

Figure 2.4
Rear Terminal Connection
for 4000 Series & 8000 Series

22
 PV Retrans + -
RS-232: TXD RXD COM
RS-485: TX1 TX2

13 14 15

1 NO L 7 90-250 VAC
47-63 Hz
12VA
ALM 2 NC
N 8
3 C C 9

+
OP1
A 4 PTA NO 10 _
RTD
TC+, V+
5 C 11
+

+
PTB, mA+
I V OP2
_ _ TC-, V-
B 6 PTB, mA- NO 12 _

Figure 2.6
Rear Terminal Connection for 6000 Series

23
 The controller is supplied to operate at 11-26 VAC / VDC or 90-250
VAC. Check that the installation voltage corresponds with the power
rating indicated on the product label before connecting power to
the controller.

4000 Series 6000 Series

8000 Series 90 - 250 VAC or 90 - 250 VAC or
11 - 26 VAC / VDC 11 - 26 VAC / VDC
L 1 L 7 ~
Fuse Fuse ~
N 2 N 8

Figure 2.7 Power Supply Connections

This equipment is designed for installation in an enclosure

which provides adequate protection against electric shock. The
enclosure must be connected to earth ground.

Local requirements regarding electrical installation should be rigidly

observed. Consideration should be given to prevent unauthorized
access to the power terminals.

Proper sensor installation can eliminate many problems in a

control system. The probe should be placed so that it can
detect any temperature change with minimal thermal lag. In a
process that requires fairly constant heat output, the probe
should be placed close to the heater. In a process where the
heat demand is variable, the probe should be close to the
work area. Some experiments with probe location are often
required to find this optimum position.

In a liquid process, the addition of a stiring devise will help

to eliminate thermal lag.

In many air heating applications, placing more than one

thermocouple in parallel will provide an average
temperature reading, producing greater overall accuracy.

24
Proper sensor type is also a very important factor to obtain precise
measurements. The sensor must have the correct temperature range
to meet the process requirements. In special processes the sensor
might need to have additional options such as leak-proof, anti-
vibration, be un-grounded or have special sheath materials.

Standard sensor limits of error are +/-4 degrees F (+/- 2 degrees C )

or 0.75% of sensed temperature (half that for special ) plus drift
caused by improper protection or an over-temperature occurrence.
This error is far greater than controller error and cannot be corrected
on the sensor except by proper selection and replacement.

2-6 Sensor Input Wiring

4000 Series 6000 Series

8000 Series
A
PTA 18 PTA 4 RTD
TC+, V+ 19 TC+, V+
PTB, mA+ 5 +
B

+
+
PTB, mA+ V
TC-, V- 20 TC-, V- 6 _ _ _ B
PTB, mA- PTB, mA-
TC V mA RTD

Figure 2.8 Sensor Input Wiring

2-7 Control Output 1 Wiring

4000 Series
8000 Series 6000 Series

3 9 LOAD

4 10
120V/240VAC
Mains Supply
Figure 2.9
Output 1 Relay or Triac (SSR) to Drive Load External Device

25
2-7 Control Output 1 Wiring (Cont’d)
External device

4000 Series 120V /240V

8000 Series 6000 Series Mains Supply
SSR
+

+
3 9 Output

+
Output
4 _ 10 _ _

30mA / 5V 5V
Pulsed
Voltage 33 +

33
0V

Figure 2.10 Output 1 Pulsed +5 VDC Voltage to Drive SSR

External device
4000 Series
8000 Series 6000 Series
+
+

3 0 - 20mA, 9 0 - 20mA, Load

4 - 20mA
4 _ 10 4 - 20mA _
Maximum
Load 500 ohms

Figure 2.11 Output 1 Linear Current

4000 Series
8000 Series 6000 Series External device
+
+

3 0 - 1V, 0 - 5V 9 0 - 1V, 0 - 5V Load

1 - 5V, 0 - 10V 1 - 5V, 0 - 10V
4 _ 10 _ Minimum
Load 10 K
ohms
Figure 2.12 Output 1 Linear Voltage

26
 Control Output 2 Wiring

4000 Series
8000 Series 6000 Series

5 11 LOAD

6 12
120V/240VAC
Mains Supply
Figure 2.13 External device
Output 2 Relay or Triac (SSR) to Drive Load

4000 Series External device

8000 Series 6000 Series
SSR
+

+
5 11
+
5 VDC @ 30 ma
Pulsed Voltage
_
6 _ 12 _

120V /240V
Mains Supply
30mA / 5V 5V
Pulsed
Voltage 33 +

33
0V

Figure 2.14 Output 2 Pulsed Voltage to Drive SSR

4000 Series External device

8000 Series 6000 Series
+

5 0 - 20mA, 11 0 - 20mA,
Load
4 - 20mA 4 - 20mA
6 _ 12 _
Maximum
Load
500 ohms
Figure 2.15 Output 2 Linear Current

27
 Control Output 2 Wiring (Cont’d)
4000 Series. External device
8000 Series 6000 Series

+
+

+
5 0 - 1V, 0 - 5V 11 0 - 1V, 0 - 5V
Load
1 - 5V, 0 - 10V 1 - 5V, 0 - 10V
6 _ 12 _
_
Minimum
Load
Figure 2.16 Output 2 Linear Voltage 10 K ohms

2-8 Alarm Wiring

4000 Series
8000 Series 6000 Series
7 3 LOAD

8 1
9 2
120V/240VAC
Figure 2.17 Alarm Output to Drive Load Mains Supply
External device

2-9 Process Retransmission

4000 Series 6000 Series 8000 Series

Output to
Re+ 13 +0-20/4-20ma, Recorder,
PLC, Etc.
0-5/1-5VDC, 0-10VDC
Re - 14
-
Load Resistance : 0 - 500 ohms ( for current output )
10 K ohms minimum ( for voltage output )

Figure 2.18
Retransmission Output Wiring

28
2-10 Data Communication
4000 Series
6000 Series RS-485 to RS-232
8000 Series network adaptor
TX1
TX113 SNA10A or
SNA10B
TX2 14 TX2
RS-232
Twisted-Pair Wire
4000 Series
6000 Series
8000 Series
TX1
TX1 13
TX2 14
TX2

Max. 247 units can be linked

4000 Series
6000 Series
8000 Series
TX1
TX1 13
TX2
TX2 14 Terminator
220 ohms / 0.5W

Figure 2.19 RS-485 Wiring

29
 RS-232
4000 Series
6000 Series
8000 Series
PC
TXD 13
RXD 14
COM 15 9-pin
RS-232
port

CC94-1

Figure 2.20
RS-232 Wiring

If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable
must be modified according to the following circuit diagram.

4000 Series To DTE ( PC ) RS-232 Port

6000 Series
8000 Series 1 1 DCD
TX1 RD 6 2 RD
TXD 13 2
7 3 TD
TX2 TD 4 DTR
RXD 14 3
8 5 GND
COM 15 COM 4 6 DSR
GND 9
5 7 RTS
8 CTS
9 RI
Female DB-9

Figure 2.21
Configuration of RS-232

30
Chapter 3 Programming
Press for 3 seconds and release to enter setup menu. Press
to select the desired parameter. The upper display indicates the
parameter symbol, and the lower display indicates the selected value
of parameter.

3-1 Lockout
There are four security levels that can be selected by using
the LOCK parameter.
If NONE is selected for LOCK, then no parameter is locked.
If SET is selected for LOCK, then all setup data are locked.
If USER is selected for LOCK, then all setup data as well as user data
(refer to section 1-5) except set point is locked to prevent from being
changed.
If ALL is selected for LOCK, then all parameters are locked to prevent
from being changed.

3-2 Signal Input

INPT: Selects the sensor type or signal type for signal input.
Range: ( thermocouple ) J, K, T, E, B, R, S, N, L
( RTD ) PT.DN, PT.JS
(linear ) 4-20, 0-20, 0-60, 0-1V, 0-5V, 1-5V, 0-10
UNIT: Selects the process unit
Range: C, F, PU( process unit ). If the unit is neither C nor F,
then selects PU.
DP: Selects the resolution of process value.
Range: ( for T/C and RTD ) NO.DP, 1-DP
(for linear ) NO.DP, 1-DP, 2-DP, 3-DP
INLO: Selects the low scale value for the linear type input.
INHI : Selects the high scale value for the linear type input.

How to use INLO and INHI :

IA unit ordered with 4 - 20 mA is setup as INPT=4-20,
then if SL specifies the input signal low (ie. 4 mA ), SH specifies the input
signal high ( ie. 20 mA ), S specifies the current input signal value,
the conversion curve of the process value is shown as follows :

31
 process value

INHI
Figure 3.1
PV Conversion Curve for
Linear Type Process Value
INLO
input signal
SL S SH

S SL
Formula : PV = INLO + ( INHI INLO )
SH SL
Example : A 4-20 mA current loop pressure transducer with range
0 - 15 kg/cm is connected to input, then perform the
following setup :
INPT = 4 - 20 INLO = 0.00
INHI = 15.00 DP = 2-DP
Of course, you may select other values for DP to alter
the resolution.

3-3 Control Outputs

There are 4 kinds of control modes can be configured as shown in
Table 3.1
Table 3.1 Heat-Cool Control Setup Value

Control
Modes OUT1 OUT2 O1HY O2HY CPB DB

Heat only REVR

Cool only DIRT
Heat: PID
Cool: ON-OFF REVR DE.HI

Heat: PID
Cool: PID REVR COOL

: Not Applicable :Required if ON-OFF control

:Adjust to met process is configured
requirements

32
Heat Only ON-OFF Control : Select REVR for OUT1, Set PB to 0,
O1HY is used to adjust dead band for ON-OFF control, The output 1
hysteresis ( O1HY ) is enabled in case of PB = 0 . The heat only
on-off control function is shown in the following diagram :

PV

SP1

Dead band = O1HY

SP1 O1HY

OUT1 Action Time

ON

OFF

Time
Figure 3.2 Heat Only
ON-OFF Control
The ON-OFF control may introduce excessive process oscillation even
if hysteresis is minimized to the smallest. If ON-OFF control is set ( ie.
PB = 0 ), TI, TD, CYC1, OFST, CYC2, CPB, DB will be hidden and have
no function to the system. The auto-tuning mode and bumpless
transfer will be disabled too.

Heat only P ( or PD ) control : Select REVR for OUT1, set TI to 0,

OFST is used to adjust the control offset ( manual reset ). O1HY is
hidden if PB is not equal to 0. OFST Function : OFST is measured by
% with range 0 - 100.0 %. In the steady state ( ie. process has been
stabilized ) if the process value is lower than the set point a definite
value, say 5 LC, while 20 LC is used for PB, that is lower 25 %,

33
then increase OFST 25 %, and vice versa. After adjusting OFST value,
the process value will be varied and eventually, coincide with set point.
Using the P control (TI set to 0), the auto-tuning is disabled.
Refer to section 3-12 "manual tuning" for the adjustment of PB and
TD. Manual reset (adjust OFST) is not practical because the load may
change from time to time and OFST would require repeated changes.
Selecting the PID option will prevent this issue.

Heat only PID control : Selecting REVR for OUT1, PB and TI should
not be zero. Operate auto-tuning for the new process, or set PB, TI
and TD with historical values. See section 3-11 for auto-tuning
operation. If the control result is still unsatisfactory, then use manual
tuning to improve the control . See section 3-12 for manual tuning. The
unit contains a sophisticated PID and Fuzzy algorithm to eliminate
overshoot when the control is properly tuned.

Cool only control:ON-OFF control, P ( PD ) control and PID

control can be used for cool control. Set OUT1 to DIRT ( direct
action ). The other functions for cool only ON-OFF control, cool
only P ( PD ) control and cool only PID control are same as
descriptions for heat only control except that the output variable
( and action ) for the cool control is inverse to the heat control.

NOTE : The ON-OFF control may result excessive overshoot and

undershoot problems in the process. The P ( or PD ) control will result
in a deviation process value from the set point. It is recommended to
use PID control for the Heat-Cool control to produce a stable and zero
offset process value.

Other Setup Required : O1TY, CYC1, O2TY, CYC2, O1FT, O2FT O1TY
& O2TY are set in accordance with the types of OUT1 & OUT2
installed. CYC1 & CYC2 are selected according to the output 1 type (
O1TY ) & output 2 type ( O2TY ). Generally, selects 0.5 ~ 2 sec. for
CYC1, if SSRD or SSR is used for O1TY; 10 ~ 20 sec. if relay is used
for O1TY, and CYC1 is ignored if linear output is used. Use similar
selections for CYC2.

34
You can use the auto-tuning program for new processes or directly
set the appropriate values for PB, TI & TD according to historical
data for the repeated systems. If the control behavior is still
inadequate, then use manual tuning to improve the control. See
section 3-12 for manual tuning.

CPB Programming : The cooling proportional band is measured by %

of PB with range 50~300. Initially set 100% for CPB and examine the
cooling effect. If cooling action should be enhanced then decrease
CPB, if cooling action is too strong then increase CPB. The value of
CPB is related to PB and its value remains unchanged throughout the
auto-tuning procedures.

Adjustment of CPB is related to the cooling media used. If air is used

as the cooling media, adjust CPB to 100%. If oil is used as cooling
media, adjust CPB to 125%. For water, adjust CPB to 250%.

DB Programming: Adjustment of DB is dependent on the system

requirements. If more positive value of DB ( greater dead band ) is
used, an unwanted cooling action can be avoided but an excessive
overshoot over the set point will occur. If more negative value of DB (
greater overlap ) is used, an excessive overshoot over the set point
can be minimized but an unwanted cooling action will occur. It is
adjustable in the range -36.0% to 36.0 % of PB. A negative DB value
shows an overlap area over which both outputs are active. A positive
DB value shows a dead band area over which neither output is active.

Output 2 ON-OFF Control (Alarm function): Output 2 can also be

configured as an alarm. There are 4 kinds of alarm functions that can
be selected for output 2; these are: DE.HI (deviation high alarm ),
DE.LO (deviation low alarm ), PV.HI (process high alarm ) and PV.LO
( process low alarm ). Refer to Figure 3.3 and Figure 3.4 for the
description of deviation alarm and process alarm.

35
 PV OUT2=DE.HI

SV+SP2

SV+SP2-O2HY

OUT2 Action Time

ON
OFF

Figure 3.3 Output 2 Deviation Time

High Alarm

PV

SP2+O2HY

SP2

OUT2 Action Time

ON
OFF

Figure 3.4 Output 2 Process Time

Low Alarm

36
3-4 Alarm
The controller has one alarm output. There are 6 types of alarm
functions and one dwell timer that can be selected, and four kinds of
alarm modes (ALMD) that are available for each alarm function
(ALFN). Besides the basic alarm output, output 2 can also be
configured as an alarm. But output 2 only provides 4 kinds of alarm
functions and only the normal alarm mode is available for this alarm.

A process alarm sets two absolute trigger levels. When the process is
higher than SP3, a process high alarm ( PV.HI ) occurs, and the alarm
is off as the process is lower than SP3-ALHY. When the process is
lower than SP3, a process low alarm ( PV.LO ) occurs and the alarm is
off as the process is higher than SP3+ALHY. A process alarm is
independent of set point.

A deviation alarm alerts the user when the process deviates too far
from set point. When the process is higher than SV+SP3, a deviation
high alarm (DE.HI) occurs and the alarm is off as the process is lower
than SV+SP3-ALHY. When the process is lower than SV+SP3, a
deviation low alarm (DE.LO) occurs and the alarm is off as the process
is higher than SV+SP3+ALHY. Trigger level of deviation alarm is
moving with set point.

A deviation band alarm presets two trigger levels relative to set point.
The two trigger levels are SV+SP3 and SV - SP3 for alarm. When the
process is higher than ( SV+SP3 ) or lower than ( SV - SP3 ), a
deviation band high alarm ( DB.HI ) occurs. When the process is within
the trigger levels, a deviation band low alarm (DB.LO) occurs.

In the above descriptions SV denotes the current set point value for
control which is different from SP1 as the ramp function is performed.

There are four types of alarm modes available for each alarm function,
these are: Normal alarm, Latching alarm, Holding alarm and Latching/
Holding alarm. They are described as follows:

37
Normal Alarm : ALMD = NORM
When a normal alarm is selected, the alarm output is de-energized
in the non-alarm condition and energized in an alarm condition.
Latching Alarm : ALMD = LTCH
If a latching alarm is selected, once the alarm output is energized, it
will remain unchanged even if the alarm condition is cleared. The
latching alarm is reset when the RESET key is pressed, once the alarm
condition is removed.
Holding Alarm : ALMD = HOLD
A holding alarm prevents an alarm from power up. The alarm is
enabled only when the process reaches the set point value. Afterwards
, the alarm performs same function as normal alarm.
Latching / Holding Alarm : ALMD = LT.HO
A latching / holding alarm performs both holding and latching function.
The latching alarm is reset when the RESET key is pressed, once the
alarm condition is removed.

Alarm Failure Transfer is activated as the unit enters failure mode.

Alarm will go on if ON is set for ALFT and go off if OFF is
set for ALFT. The unit will enter failure mode when sensor break
occurs or if the A-D converter of the unit fails.

3-5 Configure User Menu

This series has the flexibility for you to select those
parameters which are most significant to your application.
These parameters are able to be put in the front of display sequence
for ease of access.

SEL1~SEL8 : Selects the parameter for view and change in the user menu.

Range : LOCK, INPT, UNIT, DP, SHIF, PB, TI, TD, O1HY, CYC1, OFST,
RR, O2HY, CYC2, CPB, DB, ADDR, ALHY
When using the up-down key to select the parameters, you may not obtain
all of the above parameters. The number of visible parameters is dependent
on the setup condition. The hidden parameters for the specific application
are also deleted from the SEL selection.

38
Example :
OUT2 selects DE.LO PB= 100.0 SEL1 selects INPT
SEL2 selects UNIT SEL3 selects PB SEL4 selects TI
SEL5~SEL8 selects NONE Now, the upper display scrolling becomes :

3 - 6 Ramp
The ramping function is performed during power up as well as any
time the set point is changed. Choose MINR or HRR for RAMP, the
unit will perform the ramping function. The ramp rate is programmed
by adjusting RR. The ramping function is disabled as soon as the
failure mode, the manual control mode, the auto-tuning mode or the
calibration mode occurs.

Example without Dwell Timer

Select MINR for RAMP, selects C for UNIT, selects 1-DP for DP, Set
RR= 10.0. SV is set to 200 C initially, and changed to 100 C after 30
minutes since power up. The starting temperature is 30 C. After power
up the process is running like the curve shown below:

PV
200
C

100
C Figure 3.5 RAMP Function
30
C
Time
(minutes)

Note: When the ramp function is used, the lower display will show the
current ramping value. However it will revert to show the set point
value as soon as the up or down key is touched for adjustment. The
ramping value is initiated to process value either as power up or RR
and /or set point are changed. Setting RR to zero means no ramp
function at all.

39
3-7 Dwell Timer
The alarm output can be configured as dwell timer by selecting TIMR
for ALFN . As the dwell timer is configured, the parameter SP3 is used
for dwell time adjustment. The dwell time is measured in minutes
ranging from 0.1 to 4553.6 minutes. Once the process reaches the set
point the dwell timer starts to count down until zero ( time out ). The
timer relay will remain unchanged until time out. The dwell timer
operation is shown in the following diagram.

After time out the dwell timer will be restarted by pressing the RESET
key.

The timer stops to count during the manual control mode, failure mode,
calibration period and auto-tuning period.

PV

SP

Time
ALM power off or
SP3
touch RESET key

ON

OFF

Time
Timer starts

Figure 3.6 Dwell Timer Function

If alarm is configured as dwell timer, ALHY and ALMD are
hidden.

40
3 - 8 PV Shift
In certain applications it is desirable to shift the controller display value
from its actual value. This can be easily accomplished by using the PV
shift function.

The SHIF function will alter PV only.

Example: If process variable is reading a value of 195 degrees and
needs to match another indicator reading 200. The value of +5 can be
installed in the SHIFT parameter. This will now ADD a 5 degree value
to the current reading, allowing the controller to read 200 degrees. A
negative value can also be used to subtract from controller current
reading.

3- 9 Digital Filter
In certain applications the process value is too unstable to be read.
To improve this a programmable low pass filter incorporated in the
controller can be used. This is a first order filter with time constant
specified by FILT parameter . The default value of FILT is 0.5 sec.
before shipping. Adjust FILT to change the time constant from 0 to 60
seconds. 0 second represents no filter is applied to the input signal.
The filter is characterized by the following diagram.

Figure 3.8 Filter Characteristics

Note
The Filter is available only for PV, and is performed for the displayed
value only. The controller is designed to use unfiltered signal for control
even if Filter is applied. A lagged ( filtered ) signal, if used for control,
may produce an unstable process.
41
3 -10 Failure Transfer
The controller will enter failure mode as one of the following conditions
occurs:
1. SBER occurs due to the input sensor break or input current below
1mA if 4-20 mA is selected or input voltage below 0.25V if 1-5 V is
selected .
2. ADER occurs due to the A-D converter of the controller failing.

The output 1 and output 2 will perform the failure transfer functions
as the controller enters failure mode.

Output 1 Failure Transfer, if activated, will perform :

1. If output 1 is configured as proportional control ( PB=0 ), and BPLS
is selected for O1FT, then output 1 will perform bumpless transfer.
Thereafter the previous averaging value of MV1 will be used for
controlling output 1.
2. If output 1 is configured as proportional control ( PB=0 ), and a
value of 0 to 100.0 % is set for O1FT, then output 1 will perform
failure transfer. Thereafter the value of O1FT will be used for
controlling output 1.
3. If output 1 is configured as ON-OFF control ( PB=0 ), then output 1
will transfer to off state if OFF is set for O1FT and transfer to on
state if ON is set for O1FT.

Output 2 Failure Transfer, if activated, will perform :

1. If OUT2 is configured as COOL, and BPLS is selected for O2FT,
then output 2 will perform bumpless transfer. Thereafter the previous
averaging value of MV2 will be used for controlling output 2.
2. If OUT2 is configured as COOL, and a value of 0 to 100.0 % is set
for O2FT, then output 2 will perform failure transfer. Thereafter the
value of O2FT will be used for controlling output 2.
3. If OUT2 is configured as alarm function, and OFF is set for O2FT,
then output 2 will transfer to off state, otherwise, output 2 will transfer
to the on state if ON is set for O2FT.

Alarm Failure Transfer is activated as the controller enters failure mode.

Thereafter the alarm will transfer to the ON or OFF state which is
determined by the set value of ALFT.

42
3 -11 Auto-tuning
The auto-tuning process is performed at set point.
The process will oscillate around the set point during tuning
process. Set the set-point to a lower value if overshooting
beyond the normal process value is likely to cause damage.

The auto-tuning is applied in cases of :

Initial setup for a new process
* The set point is changed substantially from the previous auto-
tuning value
The control result is unsatisfactory *
*
Operation :
1. The unit has been installed normally.
2. Set the correct values for the setup menu of the unit.
But don't use a zero value for PB and TI , otherwise, the
auto-tuning program will be disabled. The LOCK parameter
should be set at NONE.
3. Set the set point to a normal operating value or a lower value if
overshooting beyond the normal process value is likely to
cause damage.
4. Press and hold until appears on the display.
5. Press for at least 3 seconds. The AT indicator will begin to
flash and the auto-tuning procedure is beginning.

NOTE :
The ramping function, if used, will be disabled once auto-tuning
is proceeding.
The auto-tuning mode is disabled as soon as either failure mode
or manual control mode occurs.

43
 Procedures:
The auto-tuning can be applied either as the process is warming
up ( Cold Start ) or as the process has been in steady state
( Warm Start ).
After the auto-tuning procedures are completed, the AT indicator
will cease to flash and the unit revert to PID control by using its
new PID values. The PID values obtained are stored in the
nonvolatile memory.

Auto-Tuning Error
If auto-tuning fails an ATER message will appear on the upper display
in cases of :

If PB exceeds 9000 ( 9000 PU, 900.0 F or 500.0 C ).

or if TI exceeds 1000 seconds.
or if set point is changed during auto-tuning procedure.

Solutions to
1. Try auto-tuning once again.
2. Don't change set point value during auto-tuning procedure.
3. Don't set zero value for PB and TI.
4. Use manual tuning instead of auto-tuning. ( See section 3-12 ).
5. Touch RESET key to reset message.

3 - 12 Manual Tuning
In some applications using auto-tuning to tune a process may be
inadequate for the control requirement. You should then try manual
tuning.

If the control performance using auto-tuning is still unsatisfactory,

apply additional PID values show on the next page.

44
 ADJUSTMENT SEQUENCE SYMPTOM SOLUTION
Slow Response Decrease PB
(1) Proportional Band ( PB )
High overshoot or
Increase PB
Oscillations

Slow Response Decrease TI

(2) Integral Time ( TI ) Instability or
Increase TI
Oscillations

Slow Response or
Decrease TD
(3) Derivative Time ( TD ) Oscillations
High Overshoot Increase TD

Table 3.2 PID Adjustment Guide

Figure 3.9 shows the effects of PID adjustment on process response.

3 -13 Manual Control

Operation:
To enable manual control the LOCK parameter should be set to
NONE, then press for 4.2 seconds ( Hand
Control ) will appear on the display.Release key and depress
Press for 3 seconds then the MAN indicator will begin to flash
and the lower display will show
The controller now enters the manual control mode.
indicates output control variable for output 1, and indicates
control variable for output 2. Now you can use up-down key to adjust
the percentage values for the heating or cooling output.

The controller performs open loop control as long as it stays in manual

control mode.

Exit Manual Control

press R key the controller will revert to its normal display mode.

45
 PV PB too low

Ideal

Set point
P action

PB too high

Time

TI too high
PV

Set point
I action

Ideal
TI too low

Time

TD too low
PV
Ideal

Set point

D action
TD too high

Time

Figure 3.9 Effects of PID Adjustment

46
3 - 14 Data Communication
The controllers support RTU mode of Modbus protocol for data
communication. Other protocols are not available for the series.

Two types of interface are available for Data Communication. These

are RS-485 and RS-232 interface. Since RS-485 uses a differential
architecture to drive and sense signal instead of a single ended
architecture which is used for RS-232, RS-485 is less sensitive to the
noise and thus suitable for a longer distance communication. RS-485
can communicate without error over 1 km distance while RS-232 is
not recommended for a distance over 20 meters.

Using a PC for data communication is convenient approach. The

signal is transmitted and received through the PC communication
Port ( generally RS-232 ). Since a standard PC may not support a
RS-485 port, a network adaptor (such as SNA10A) will need to be
used to convert RS-485 to RS-232 for a PC if RS-485 is required for
data communication. Multiple RS-485 units (up to 247 units) can be
connected to one RS-232 port.

Setup
Enters the setup menu.
Select RTU for COMM . Set individual address as for those units
which are connected to the same port.
Set the Baud Rate ( BAUD ), Data Bit ( DATA ), Parity Bit ( PARI ) and
Stop Bit ( STOP ) such that these values are accordant with PC setup
conditions.

3 - 15 Process Retransmission
The controllers support a optional ma/VDC output (retransmit) of the
process variable. The program parameters to scale the ma/VDC
signal are RELO and REHI, respectively for low and high scale.
For example, using a 4/20 ma retransmission option to represent a
temperature of 0/200 F unit would be setup as;
RELO = 0 for 4 ma equals 0 F
REHI = 200 for 20 ma equals 200 F
This output would typically go to a recorder, PLC, indicator etc.

47
Chapter 4 Calibration
Do not proceed through this section unless there is a definite
need to re-calibrate the controller. Otherwise, all previous
calibration data will be lost. Do not attempt recalibration unless
you have appropriate calibration equipment. If calibration data is
lost, you will need to return the controller to your supplier who
may charge you a service fee to re-calibrate the controller.

Entering calibration mode will break the control loop. Verify

that the system is acceptable to apply calibration mode.

Equipment needed before calibration:

(1) A high accuracy calibrator ( Fluke 5520A Calibrator
recommended ) with following functions:
0 - 100 mV millivolt source with +/-0.005 % accuracy
0 - 10 V voltage source with +/-0.005 % accuracy
0 - 20 mA current source with +/-0.005 % accuracy
0 - 300 ohm resistant source with +/-0.005 % accuracy
(2) A test chamber providing 25 C - 50 C temperature range
(3) A switching network ( SWU16K, optional for automatic
calibration )
(4) A calibration fixture equipped with programming units
(optional for automatic calibration )
(5) A PC installed with calibration software FDC-Net and Smart
Network Adaptor SNA10B ( optional for automatic calibration )

The calibration procedures described in the following section are a

step by step manual procedures.

Since it needs 30 minutes to warm up an unit before calibration,

calibrating the unit one by one is quite inefficient. An automatic
calibration system for small quantity as well as for unlimited quantity is
available. Consult factory.

48
 Manual Calibration Procedures
Perform step 1 to enter calibration mode.
Step 1. Set the Lock parameter to the unlocked condition
( LOCK=NONE).
Press and hold the scroll key until appears on the
display, then release the scroll key.
Press the scroll key for 2 seconds then release,the display
will show and the unit enters calibration mode .

Perform step 2 to calibrate Zero of A to D converter and

step 3 to calibrate gain of A to D converter.

Step 2. Short the thermocouple input terminals, then press the

scroll key for at least 3 seconds. The display will blink a
moment and a new value is obtained. Otherwise, if the
display didn't blink or if the obtained value is equal to -199.9
or 199.9, then the calibration failed.

Step 3. Press scroll key until the display shows . Send a 60

mV signal to the thermocouple input terminals in correct
polarity . Press scroll key for at least 3 seconds . The display
will blink a moment and a new value is obtained . Otherwise ,
if the display didn't blink or if the obtained value is equal to
-199.9 or 199.9, then the calibration failed.

Perform both steps 4 and 5 to calibrate RTD function ( if

required ) for input .

49
Step 4. Press scroll key until the display shows . Send a 100
ohms signal to the RTD input terminals according to the
connection shown below:

4000 Series
8000 Series 6000 Series

100 ohms 100 ohms

Figure 4.1 RTD Calibration

Press scroll key for at least 3 seconds . The display will
blink a moment, otherwise the calibration failed.

Step 5. Press scroll key and the display will show . Change
the ohm's value to 300 ohms .Press scroll key for at least 3
seconds. The display will blink a moment and two values are
obtained for RTDH and RTDL ( step 4 ). Otherwise, if the
display didn't blink or if any value obtained for RTDH and
RTDL is equal to -199.9 or 199.9 , then the calibration
failed.

* Perform step 6 to calibrate offset of cold junction

compensation, if required.
Step 6. Setup the equipments according to the following diagram
for calibrating the cold junction compensation.
Note that a “K” type thermocouple must be used.

50
 Temperature
Calibrator 4000 Series
8000 Series 6000 Series
K-TC

Stay at least 20 minutes in still-

air room
room temperature 25 +/- 3 C
Figure 4.2
Cold Junction Calibration Setup

The temperature calibrator is configured as K type thermocouple

output with internal compensation. Send a 0.00 C signal to the unit
under calibration.

The unit under calibration is powered in a still-air room with

temperature 25 +/-3 C. Stay at least 20 minutes for warming
up. Perform step 1 stated above, then press scroll key until
the display shows . Press up/down key to obtain
40.00.
Press scroll key for at least 3 seconds. The display will blink a
moment and a new value is obtained . Otherwise , if the
display didn't blink or if the obtained value is equal to -5.00 or
40.00, then the calibration failed.

Perform step 7 to calibrate gain of cold junction compensation

if required.
Step 7. Setup the equipments same as step 6. The unit under
calibration is powered in a still-air room with temperature 50
+/-3 C. Stay at least 20 minutes for warming up . The
calibrator source is set at 0.00 C with internal compensation
mode.

51
 Perform step 1 stated above , then press scroll key until the
display shows . Press the scroll key for at least 3
seconds. The display will blink a moment and a new value is
obtained. Otherwise , if the display didn't blink or if the
obtained value is equal to -199.9 or 199.9, then the calibration
failed.

This setup is performed in a high temperature chamber, hence

it is recommended to use a computer to perform the
procedures.
Input modification and recalibration procedures for a linear
voltage or a linear current input:

1. Remove R60(3.3K) and install two 1/4 W resistors RA and RB

on the control board with the recommended values specified
in the following table.
The low temperature coefficient resistors should be used for
RA and RB.

Input Function RA RB R60

T/C, RTD, 0~60mV X X 3.3K
0~1V 61.9K 3.92K X
0 ~ 5V, 1 ~ 5V 324K 3.92K X
0 ~ 10 V 649K 3.92K X
0~20mA, 4~20mA 39ohm 3.01ohm X

2. Perform Step 1 and Step 2 to calibrate the linear input zero.

3. Perform Step 3 but send a span signal to the input terminals

instead of 60mV. The span signal is 1V for 0~1V input, 5V for
0~5V or 1~5V input, 10V for 0~10V input and 20mA for
0~20mA or 4~20mA input.

Final step
Step 8. Set the LOCK value to your desired function.

52
Chapter 5 Specifications
Power
90 - 250 VAC, 47 63 Hz, 12VA, 5W maximum
11 - 26 VAC / VDC, 12VA, 5W maximum

Input

Resolution: 18 bits
Sampling Rate: 5 times / second
Maximum Rating: -2 VDC minimum, 12 VDC
maximum.
( 1 minute for mA input )
Temperature Effect: +/-1.5uV/ C for all inputs
except
mA input.
+/-3.0uV/ C for mA input
Lead Resistance Effect:
T/C: 0.2uV/ohm
3-wire RTD: 2.6 C/ohm of
resistance difference of two
leads.
2-wire RTD: 2.6 C/ohm of
resistance sum of two leads
Burn-out Current: 200 mA
Common Mode Rej: 120dB
Normal Mode Rej: 55dB

Sensor Break Detection:

Sensor open for TC, RTD and mV inputs,
Sensor short for RTD input
below 1 mA for 4-20 mA input,
below 0.25V for 1 - 5 V input, unavailable for
other inputs.
Sensor Break Responding Time:
Within 4 seconds for TC, RTD and mV inputs. 0.1 second for
4-20 mA and 1 - 5 V inputs.

53
Characteristics:

Accuracy Input
Type Range
@ 25 C Impedance
-120 C 1000 C
J +/-2 C 2.2 M
( -184 F 1832 F )
-200 C 1370 C
K ( -328 F 2498 F ) +/- 2C 2.2 M
-250 C 400 C
T ( -418 F 752 F ) +/- 2C 2.2 M

E -100 C 900 C
( -148 F 1652 F ) +/- 2C 2.2 M

0 C 1800 C +/- 2C 2.2 M

B
( 32 F 3272 F )
0 C 1767.8 C
R +/- 2C 2.2 M
( 32 BF 3214 F )
0 C 1767.8 C
S +/- 2C 2.2 M
( 32 BF 3214 F )
-250 C 1300 C
N ( -418 F 2372 F ) +/- 2C 2.2 M
-200 C 900 C
L ( -328 F 1652 F ) +/- 2C 2.2 M
PT100 -210 C 700 C
+/-0.4 C 1.3 K
( DIN ) ( -346 F 1292 F )
PT100 -200 C 600 C
( JIS ) +/-0.4 C 1.3 K
( -328 F 1112 F )
mV -8mV 70mV +/-0.05 % 2.2 M
mA -3mA 27mA +/-0.05 % 70.5
V -1.3V 11.5V +/-0.05 % 650 K

54
Output 1 / Output 2
Relay Rating : 2A/240 VAC, life cycles 200,000
for resistive load.

Pulsed Voltage : Source Voltage 5V,

current limiting resistance 66.

Linear Output Characteristics

Type Zero Span Load

Tolerance Tolerance Capacity
4-20 mA 3.8-4 mA 20-21 mA 500W max.
0-20 mA 0 mA 20-21 mA 500W max.
0~5V 0V 5 ~ 5.25 V 10 KW min.
1~5V 0.95 ~ 1 V 5 ~ 5.25 V 10 KW min.
0 ~ 10 V 0V 10 ~10.5 V 10 KW min.

Linear Output
Resolution: 15Bits
Output Regulation : 0.02 % for full load change
Output Settling Time : 0.1 sec. ( stable to 99.9 % )
Isolation Breakdown Voltage : 1000 VAC
Temperature Effect: +/-0.01 % of SPAN / LC

Triac ( SSR ) Output

Rating: 1A / 240 VAC
Inrush Current: 20A for 1 cycle
Min. Load Current: 50 mA rms
Max. Off-state Leakage: 3 mA rms
Max. On-state Voltage: 1.5 V rms
Insulation Resistance: 1000 Mohms min. at 500 VDC
Dielectric Strength: 2500 VAC for 1 minute

55
DC Voltage Supply Characteristics ( Installed at Output 2 )
Type Tolerance Max. Output Ripple Isolation
Current Voltage Barrier
20 V +/-0.5 V 25 mA 0.2 Vp-p 500 VAC
12 V +/-0.3 V 40 mA 0.1 Vp-p 500 VAC
5 V +/-0.15 V 80 mA 0.05 Vp-p 500 VAC

Alarm
Alarm Relay : Form C Rating
2A/240VAC, 200,000 cycles for resistive load.
Alarm Functions : Dwell timer, PV High / Low Alarm,
Deviation High / Low Alarm,
Deviation Band High / Low Alarm
Alarm Mode : Normal, Latching, Hold, Latching / Hold.
Dwell Timer : 0.1 - 4553.6 minutes
Data Communications
Interface: RS-232 ( 1 unit ), RS-485 ( up to 247 units )
Protocol: Modbus Protocol RTU mode
Address: 1 - 247
Baud Rate: 2.4 ~ 38.4 Kbits/sec
Data Bits: 7 or 8 bits
Parity Bit: None, Even or Odd
Stop Bit: 1 or 2 bits
Comm Buffer: 160 bytes
Analog Retransmission
Functions: Process Variable
Output Signal: 4-20 mA, 0-20 mA, 0 - 5V, 1 - 5V, 0 - 10V
Resolution : 15 bits
Accuracy : +/-0.05 % of span +/-0.0025 %/ C
Load Resistance : 0 - 500 ohms ( for current output )
10 K ohms minimum ( for voltage output )
Regulation: 0.01 % for full load change
Settling Time: 0.1 sec. (stable to 99.9 % )
Breakdown Volts: 1000 VAC min.
Linearity Error : +/-0.005 % of span
Temp Effect: +/-0.0025 % of span / C
Saturation Low : 0 mA ( or 0V )
Saturation High : 22.2 mA ( or 5.55V, 11.1V min. )
Output Range : 0-22.2mA(0-20mA or 4-20mA)
0-5.55V ( 0 - 5V, 1 - 5V )
0 - 11.1 V ( 0 - 10V )

56
User Interface
Display: Dual 4-digit LED Displays
Keypad: 4 keys
Programming Port: For automatic setup, calibration
and testing
Communication Port : Connection to PC for
supervisory control

Control Mode
Output 1: Reverse ( heating ) or direct ( cooling )
action
Output 2: PID cooling control, cooling P band
50~300% of PB, dead band -36.0 ~
36.0 % of PB
ON-OFF: 0.1 - 90.0 ( F ) hysteresis control
( P band = 0 )
P or PD: 0 - 100.0 % offset adjustment
PID: Fuzzy logic modified
Proportional band 0.1 ~ 900.0 F.
Integral time 0 - 1000 seconds
Derivative time 0 - 360.0 seconds
Cycle Time: 0.1 - 90.0 seconds
Manual Control: Heat (MV1) and Cool (MV2)
Auto-tuning: Cold start and warm start
Failure Mode: Auto-transfer to manual mode
while
sensor break or A-D converter damage
Ramping Control: 0 - 900.0 F/minute or
0 - 900.0 F/hour ramp rate

Digital Filter
Function: First order
Time Constant: 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60
seconds programmable

57
Environmental & Physical
Operating Temperature: -10 C to 50 C
Storage Temperature: -40 C to 60 C
Humidity: 0 to 90 % RH ( non-condensing )
Insulation Resistance: 20 Mohms min. ( at 500 VDC )
Dielectric Strengt : 2000 VAC, 50/60 Hz for 1 minute
Vibration Resistance: 10 - 55 Hz, 10 m/s for 2 hours
Shock Resistance: 200 m/s ( 20 g )
Moldings: Flame retardant polycarbonate
Dimensions:
4000 Series: 96mm(W) X 96mm(H) X 65mm(D),
53 mm depth behind panel

6000 Series: 48mm(W) X 48mm(H) X 116mm(D),

105 mm depth behind panel

8000 Series: 48mm(W) X 96mm(H) X 80mm(D),

65 mm depth behind panel

Weight : 4000 Series: 250 grams

6000 Series: 150 grams
8000 Series: 210 grams

Agency Approvals
UL Pending
CSA Pending

Protective Class:
IP65 for panel with additional option
IP50 for panel without additional option
Ip20 for terminals and housing with protective cover.

EMC: EN61326

58
Table A.1 Error Codes and Corrective Actions
Error Display Error Description
Code Symbol Corrective Action

Illegal setup values have been Check and correct setup values of
used: Before COOL is used for OUT2, PB, TI and OUT1. IF OUT2
OUT2, DIRT ( cooling action ) has is required for cooling control, the
already been used for OUT1, control should use PID mode ( PB
or PID mode is not used for OUT1 = 0, TI = 0 ) and OUT1 should
4 ( that is PB = 0, and / or TI = 0 ) use reverse mode (heating action)
, otherwise, don't use OUT2 for
cooling control.

Communication error: bad Correct the communication

10 function code software to meet the protocol
requirements.
Communication error: register Don't issue an over-range
11 address out of range register address to the slave.
Communication error: attempt Don't write a read-only data or a
14 to write a read-only data or a protected data to the slave.
protected data
Communication error: write a Don't write an over-range data
15 value which is out of range to a to the slave register.
register
1.The PID values obtained after
auto-tuning procedure are out
of range. Retry auto-tuning.
2.Don't change set point value
during auto-tuning procedure.
Fail to perform auto-tuning
26 3.Use manual tuning instead of
function
auto-tuning.
4. Don't set a zero value for PB.
5. Don't set a zero value for TI.
6. Touch RESET key
29 EEPROM can't be written correctly Return to factory for repair.

30 Cold junction compensation for

Return to factory for repair.
thermocouple malfunction
Input sensor break, or input
current below 1 mA if 4-20 mA is
39 selected, or input voltage below Replace input sensor.
0.25V if 1 - 5V is selected
A to D converter or related
40 component(s) malfunction Return to factory for repair.

59
 Warranty
Proheat Inc. makes no warranty or representations of any sort regarding the fitness for
use, merchantability, fitness for a particular purpose or the application of its products by
the purchaser. The selection, application or use of Proheat Inc. products is the
purchaser's responsibility.

Proheat Inc. controls are warranted to be free from functional defects in material and
workmanship for TWO YEARS after delivery to the first purchaser.

Proheat Inc.'s sole responsibility under the warranty, at Proheat Inc.'s option, is limited to
replacement or repair, free of charge, or refund of purchase price within the warranty
period specified. This warranty does not apply to damage resulting from transportation,
alteration, misuse or abuse.

No claims will be allowed for any damages or losses, whether direct, indirect, incidental,
special or consequential. Specifications are subject to change without notice. In addition,
Proheat Inc. reserves the right to make changes without notification to purchaser to
materials or processing that do not affect compliance with any applicable specifications.

There are no expressed or implied warranties extending beyond the warranty herein.

RETURN MATERIAL AUTHORIZATION:

Please contact Proheat Inc. for Return Material Authorization number prior to any returns.

Proheat Inc.
117 East Adam Street
LaGrange, KY 40031
Main Office Phone: 502-222-1402
Fax: 502-222-0714
Technical Support
Phone: 502-222-1402
www.proheatinc.com
E-mail: [email protected]

60