PID + Fuzzy Logic

Process Controller

Quick User Manual

ZEL-C22
ZEL-C62
ZEL-C82
ZEL-C83
ZEL-C72
ZEL-C42
ZEL-R22
 Warning Symbol
This document contains notices that you should observe to ensure your own personal safety, as
well as to protect the product and connected equipment. These notices are highlighted in the manual by a
warning triangle and are marked as follows.

The danger symbol indicates that death or severe personal injury may result if proper precautions are
not taken. Do not proceed beyond a warning symbol until the indicated conditions are fully understood and
met.

Preface
Original equipment manufacturer reserves the right to change information available in this
document without notice. Manufacturer is not liable for any damages incurred to equipment/personal during
installation or use of equipment as explained in this document. User must acquire sufficient knowledge&
skills prior to using equipment in the application and follow all the local standards & regulations to meet
safety requirements.

NOTE
It is strongly recommended that a process should incorporate a Limit Control like a Zesta ZEL-L91
which will shut down the equipment at a preset process condition in order to avoid possible damage to
products or systems.

Contact Information
Zesta Engineering Ltd.
212 Watline Avenue
Mississauga, ON L4Z 1P4
Canada
Tel: 905-568-3100
Website: http://www.zesta.com
Email: [email protected]

Page 2 of 38
 TABLE OF CONTENTS

1 INTRODUCTION ----------------------------------------------------------------------------------------------------------------------- 5
1.1 Introduction ------------------------------------------------------------------------------------------------------------------------------------------------------ 5
1.2 Features ----------------------------------------------------------------------------------------------------------------------------------------------------------- 5
1.3 Specifications --------------------------------------------------------------------------------------------------------------------------------------------------- 6
1.4 Keys and Displays --------------------------------------------------------------------------------------------------------------------------------------------- 8
1.5 Menu Flowchart ------------------------------------------------------------------------------------------------------------------------------------------------- 9
1.5.1 User Menu ------------------------------------------------------------------------------------------------------------------------------------------------ 9
1.5.2 Setup Menu --------------------------------------------------------------------------------------------------------------------------------------------- 10
1.5.2.1 Basic Menu (bASE) -------------------------------------------------------------------------------------------------------------------------- 10
1.5.2.2 Output Menu (oUT) -------------------------------------------------------------------------------------------------------------------------- 11
1.5.2.3 Event Input Menu (EI) ----------------------------------------------------------------------------------------------------------------------- 12
1.5.2.4 Alarm Menu (ALRM) ------------------------------------------------------------------------------------------------------------------------- 12
1.5.2.5 User Select Menu (SEL) -------------------------------------------------------------------------------------------------------------------- 13
1.5.2.6 Communication Menu (CoMM)------------------------------------------------------------------------------------------------------------ 14
1.5.2.7 Current Transformer Input Menu (Ct)---------------------------------------------------------------------------------------------------- 14
1.5.2.8 Profile Menu (PRoF) ------------------------------------------------------------------------------------------------------------------------- 14
1.5.3 Manual Mode Menu ---------------------------------------------------------------------------------------------------------------------------------- 15
1.5.4 Auto-Tuning Mode ------------------------------------------------------------------------------------------------------------------------------------ 16
1.5.5 Calibration Mode -------------------------------------------------------------------------------------------------------------------------------------- 16

2 INSTALLATION AND WIRING -------------------------------------------------------------------------------------------------- 16

2.1 Unpacking ------------------------------------------------------------------------------------------------------------------------------------------------------ 17
2.2 Mounting -------------------------------------------------------------------------------------------------------------------------------------------------------- 17
2.3 Wiring ------------------------------------------------------------------------------------------------------------------------------------------------------------ 17
2.3.1 C22 Terminal Connection --------------------------------------------------------------------------------------------------------------------------- 18
2.3.2 C62 Terminal Connection --------------------------------------------------------------------------------------------------------------------------- 18
2.3.3 C82 & C42 Terminal Connection ------------------------------------------------------------------------------------------------------------------ 18
2.3.4 C83 Terminal Connection --------------------------------------------------------------------------------------------------------------------------- 19
2.3.5 C72 Terminal Connection --------------------------------------------------------------------------------------------------------------------------- 20
2.3.6 R22 Terminal Connection --------------------------------------------------------------------------------------------------------------------------- 20

3 PROGRAMMING -------------------------------------------------------------------------------------------------------------------- 21
3.1 User Security -------------------------------------------------------------------------------------------------------------------------------------------------- 21
3.2 Signal Input ---------------------------------------------------------------------------------------------------------------------------------------------------- 21
3.3 Control Output ------------------------------------------------------------------------------------------------------------------------------------------------ 21
3.3.1 Heat Only ON-OFF Control ------------------------------------------------------------------------------------------------------------------------- 22
3.3.2 Heat only P or PD Control -------------------------------------------------------------------------------------------------------------------------- 22
3.3.3 Heat only PID Control -------------------------------------------------------------------------------------------------------------------------------- 22
3.3.4 Cool only Control -------------------------------------------------------------------------------------------------------------------------------------- 22
3.3.5 Other Setup Required -------------------------------------------------------------------------------------------------------------------------------- 23
3.3.6 CPB Programming ------------------------------------------------------------------------------------------------------------------------------------ 23
3.3.7 DB Programming -------------------------------------------------------------------------------------------------------------------------------------- 23
3.3.8 Output 2 ON-OFF Control (Alarm function) ----------------------------------------------------------------------------------------------------- 23

3.4 Soft-Start -------------------------------------------------------------------------------------------------------------------------------------------------------- 24

3.5 Alarm ------------------------------------------------------------------------------------------------------------------------------------------------------------- 24
3.5.1 Alarm Types -------------------------------------------------------------------------------------------------------------------------------------------- 24
3.5.2 Alarm Modes ------------------------------------------------------------------------------------------------------------------------------------------- 26
3.5.2.1 Normal Alarm: ALMD = NORM ----------------------------------------------------------------------------------------------------------- 26
3.5.2.2 Latching Alarm: ALMD = LTCH ----------------------------------------------------------------------------------------------------------- 26
3.5.2.3 Holding Alarm: ALMD = HOLD ------------------------------------------------------------------------------------------------------------ 26
3.5.2.4 Latching / Holding Alarm: ALMD = LT.HO---------------------------------------------------------------------------------------------- 26
3.5.2.5 Set Point Holding Alarm: ALMD = SP.HO ---------------------------------------------------------------------------------------------- 26
Page 3 of 38
 3.5.3 Alarm Delay -------------------------------------------------------------------------------------------------------------------------------------------- 26
3.5.4 Alarm Failure Transfer ------------------------------------------------------------------------------------------------------------------------------- 26

3.6 User Select Menu Configuration ------------------------------------------------------------------------------------------------------------------------ 27

3.7 Ramp ------------------------------------------------------------------------------------------------------------------------------------------------------------- 28
3.7.1 Example without Dwell Timer ---------------------------------------------------------------------------------------------------------------------- 28

3.8 Dwell Timer ----------------------------------------------------------------------------------------------------------------------------------------------------- 28

3.9 User Calibration ---------------------------------------------------------------------------------------------------------------------------------------------- 29
3.10 Digital Filter ------------------------------------------------------------------------------------------------------------------------------------------------ 29
3.11 Failure Transfer------------------------------------------------------------------------------------------------------------------------------------------- 30
3.11.1 Output 1 Failure Transfer ----------------------------------------------------------------------------------------------------------------------- 30
3.11.2 Output 2 Failure Transfer ----------------------------------------------------------------------------------------------------------------------- 30
3.11.3 Alarm Failure Transfer --------------------------------------------------------------------------------------------------------------------------- 30

3.12 Auto-Tuning ----------------------------------------------------------------------------------------------------------------------------------------------- 30

3.12.1 Auto-Tuning Operation Steps ------------------------------------------------------------------------------------------------------------------ 31
3.12.2 Auto-Tuning Error --------------------------------------------------------------------------------------------------------------------------------- 31
3.12.3 Solution for Auto Tuning Error ----------------------------------------------------------------------------------------------------------------- 31

3.13 Manual Tuning -------------------------------------------------------------------------------------------------------------------------------------------- 31

3.14 Manual Control ------------------------------------------------------------------------------------------------------------------------------------------- 32
3.14.1 Exit Manual Control ------------------------------------------------------------------------------------------------------------------------------ 32

3.15 Factory Default ------------------------------------------------------------------------------------------------------------------------------------------- 32

3.16 Data Communication ----------------------------------------------------------------------------------------------------------------------------------- 33
3.16.1 RS-485 Setup -------------------------------------------------------------------------------------------------------------------------------------- 33

3.17 Retransmission ------------------------------------------------------------------------------------------------------------------------------------------- 33

3.18 Heater Current Monitoring ---------------------------------------------------------------------------------------------------------------------------- 33
3.19 Event Input ------------------------------------------------------------------------------------------------------------------------------------------------- 34
3.19.1 Event Input Functions ---------------------------------------------------------------------------------------------------------------------------- 34

3.20 Remote Set Point ---------------------------------------------------------------------------------------------------------------------------------------- 35

3.21 Ramp and Soak Program ------------------------------------------------------------------------------------------------------------------------------ 35
3.21.1 PROF ------------------------------------------------------------------------------------------------------------------------------------------------ 35
3.21.2 RUN -------------------------------------------------------------------------------------------------------------------------------------------------- 36
3.21.2.1 StAR --------------------------------------------------------------------------------------------------------------------------------------------- 36
3.21.2.2 CoNt --------------------------------------------------------------------------------------------------------------------------------------------- 36
3.21.2.3 PV ------------------------------------------------------------------------------------------------------------------------------------------------ 36
3.21.2.4 Hold ---------------------------------------------------------------------------------------------------------------------------------------------- 36
3.21.2.5 StoP---------------------------------------------------------------------------------------------------------------------------------------------- 36
3.21.3 RMPU------------------------------------------------------------------------------------------------------------------------------------------------ 36
3.21.4 STAR ------------------------------------------------------------------------------------------------------------------------------------------------ 36
3.21.5 END -------------------------------------------------------------------------------------------------------------------------------------------------- 36
3.21.5.1 SP1 ---------------------------------------------------------------------------------------------------------------------------------------------- 36
3.21.6 PFR -------------------------------------------------------------------------------------------------------------------------------------------------- 36
3.21.6.1 CONT-------------------------------------------------------------------------------------------------------------------------------------------- 37
3.21.6.2 PV ------------------------------------------------------------------------------------------------------------------------------------------------ 37
3.21.6.3 SP1 ---------------------------------------------------------------------------------------------------------------------------------------------- 37
3.21.6.4 OFF ---------------------------------------------------------------------------------------------------------------------------------------------- 37
3.21.7 Holdback -------------------------------------------------------------------------------------------------------------------------------------------- 37
3.21.8 CYC -------------------------------------------------------------------------------------------------------------------------------------------------- 38
3.21.9 Running, Holding and Stopping a Profile --------------------------------------------------------------------------------------------------- 38
3.21.10 Viewing and Modifying the Profile Progress ------------------------------------------------------------------------------------------------ 38
3.21.11 Configuring the Profile --------------------------------------------------------------------------------------------------------------------------- 38
3.21.11.1 Profile Segment Parameters ---------------------------------------------------------------------------------------------------------- 38
3.21.11.1.1 Target Set point ----------------------------------------------------------------------------------------------------------------------- 38
3.21.11.1.2 Ramp Time ----------------------------------------------------------------------------------------------------------------------------- 38
3.21.11.1.3 Soak Time ------------------------------------------------------------------------------------------------------------------------------ 38

Page 4 of 38
1 Introduction
1.1 Introduction
The new generation low-cost PID microprocessor-based Fuzzy logic controller series
incorporate two bright easy to read LCD Displays which indicate Process Value (PV) and Set point (SP).
The Fuzzy Logic technology incorporated on these series controllers enables a process to reach a
predetermined set point in the shortest time with minimum of overshoot during start up (Power ON) or
external load disturbances (example: an oven door being opened).

The below are the different controller models of this series.

Dimensions
Model No Mounting Type DIN Size Depth Behind Panel (mm)
LxWxD (mm)
C22 Panel Mount 1/32 DIN 24x48x85 76
C62 Panel Mount 1/16DIN 48x48x59 50
C82/C83 Panel Mount 1/8 DIN 48x96x59 50
C72 Panel Mount 1/7 DIN 72x72x59 50
C42 Panel Mount 1/4 DIN 96x96x59 50
R22 DIN RAIL 22.5x96x80

These controllers are powered by an 11-26 or 90-250 VDC /VAC supply, incorporating a 2
Amp control relay output as a standard. The second output can be used as a cooling control or an alarm.
Both outputs can be selected as a5VDC or 14VDC logic output, linear current or linear voltage to drive an
external device. There are six types of alarms and a dwell timer that can be configured for the third output.
The controllers are fully programmable for Linear current, Linear Voltage, PT100 and thermocouple
types J, K, T, E, B, R, S, N, L, U, P, C, and D. The input signal is digitized by using an 18-bit A to D
converter. Its fast sampling rate allows the controller to control fast processes.
1.2 Features
The new generation of low cost PID controllers has a lot of unique features.
The unique features are listed below.
❖ LCD Display
❖ High Accuracy 18 Bit A-D Conversion and 15 Bit D-A Conversion
❖ Fastest Sampling Rate 200msec
❖ Universal Input
❖ Fuzzy Logic +PID Technology
❖ Possibility of both RS-485 and analog retransmission
❖ 16 Segments of Ramp & Soak
❖ Current Transformer (CT) Inputs for heater break detection
❖ Up to 6 Event Inputs
❖ Remote Set point
❖ Auto-Tuning
❖ Bumpless Transfer
❖ Lockout Protection
❖ Bidirectional Menu Navigation
❖ Soft Start function

Page 5 of 38
 1.3 Specifications
Specification C22 C62 C82 C83 C72 C42 R22
Power Supply 90 to 250VAC, 47 to 63Hz, 20 to 28VAC, 47-63Hz / 11 to 40VDC
Power Consumption C22/R22: 8VA, 4W Maximum., C62: 10VA, 5W Maximum., C72/C82/C83/C42: 12VA, 6W Maximum
Signal Input
Type Thermocouple (J,K,T,E,B,R,S,N,L,U,P,C,D), RTD (PT100(DIN), PT100(JIS)), Current (mA), Voltage (Volts)
Resolution 18 Bits
Sampling Rate 5 Times / Second (200msec)
Maximum Rating -2VDC minimum, 12VDC maximum
Type Range Accuracy @ 25°C Input Impedance
J -120°C to 1000°C (-184°F to 1832°F) ±2°C 2.2 MΩ
K -200°C to 1370°C (-328°F to 2498°F) ±2°C 2.2 MΩ
T -250°C to 400°C (-418°F to 752°F) ±2°C 2.2 MΩ
E -100°C to 900°C (-148°F to 1652°F) ±2°C 2.2 MΩ
B 0°C to 1820°C (32°F to 3308°F) ±2°C (200°C to 1800°C) 2.2 MΩ
R 0°C to 1767.8°C (32°F to 3214°F) ±2°C 2.2 MΩ
S 0°C to 1767.8°C (32°F to 3214°F) ±2°C 2.2 MΩ
N -250°C to 1300°C (-418°F to 2372°F) ±2°C 2.2 MΩ
Input Characteristics
L -200°C to 900°C (-328°F to 1652°F) ±2°C 2.2 MΩ
U -200°C to 600°C (-328°F to 1112°F) ±2°C 2.2 MΩ
P 0°C to 1395°C (32°F to 2543°F) ±2°C 2.2 MΩ
C 0°C to 2300°C (32°F to 4172°F) ±2°C 2.2 MΩ
D 0°C to 2300°C (32°F to 4172°F) ±2°C 2.2 MΩ
PT100(DIN) -200°C to 850°C (-328°F to 1562°F) ±0.4°C 1.3KΩ
PT100(JIS) -200°C to 600°C (-328°F to 1112°F) ±0.4°C 1.3KΩ
mA -3mA to 27mA ±0.05% 2.5Ω
VDC -1.3VDC to 11.5VDC ±0.05% 1.5MΩ
Temperature Effect 1.5µV/°C for all inputs except mA input, 3.0µV/°C for mA
Thermocouple: 0.2 µV/°Ω; 3-wire RTD: 2.6°C/Ω of Difference of Resistance of two leads
Sensor Lead Resistance Effect
2-wire RTD: 2.6°C/Ω of Sum of Resistance of two leads
Burn-out Current 200nA
Common Mode Rejection Ratio (CMRR) 120 dB
Normal Mode Rejection Ratio (NMRR) 55dB
Sensor open for Thermocouple, RTD and mV inputs, Sensor short for RTD input,
Sensor Break Detection
Below 1mA for 4-20mA input, Below 0.25VDC for 1 - 5VDC input, Not available for other inputs.
Sensor Break Response Time Within 4 seconds for Thermocouple, RTD and mV inputs, 0.1 second for 4-20mA and 1 - 5VDC inputs.
Remote Set Point Input
Type Linear Current, Linear Voltage
Range -3mA to 27mA, -1.3VDC to 11.5VDC
Accuracy ±0.05 %
Remote Set Point Option Not Available Not Available Available Available Available Available Not Available
Input Impedance Current: 2.5Ω, Voltage:1.5MΩ
Resolution 18 Bits
Sampling Rate 1.66 Times/Second
Maximum Rating 280mA maximum for Current Input, 12VDC Maximum for Voltage Input
Temperature Effect ±1.5µV/°C for Voltage Input, ±3.0µV/°C for Current Input
Sensor Break Detection Below 1mA for 4-20mA input, Below 0.25VDC for 1 - 5VDC input, Not available for other inputs.
Sensor Break Responding Time 0.1 Second
Event Input
Number of Event Inputs 1 2 6 6 2 6 1
Logic Low -10VDC minimum, 0.8VDC maximum.
Logic High 2VDC minimum, 10VDC maximum
Functions See availability table
CT Input
CT Type CT98-1
Accuracy ±2%of Full scale Reading, ±0.2A
Input Impedance 294Ω
Measurement Range 0 to 50AAC
Output of CT 0 to 5VDC
CT Mounting Wall (Screw) Mount
Sampling Rate 1 Time/Second
Output 1 /Output 2
Type Relay, Pulsed Voltage, Linear Voltage or Linear Current
Relay Rating 2A,240V AC,200000 Life Cycles for Resistive Load
Page 6 of 38
Specification C22 C62 C82 C83 C72 C42 R22
Pulsed Voltage Source Voltage 5VDC, Current Limiting Resistance 66Ω
Linear Output Resolution 15 Bits
Linear Output Regulation 0.02% for full load change
Linear Output Settling Time 0.1 Sec (Stable to 99.9%)
Isolation Breakdown Voltage 1000 VAC
Temperature Effect ±0.01% of Span/ °C
Load Capacity of Linear Output Linear Current: 500Ω max., Linear Voltage: 10KΩ min
Alarm
Relay Type Form A
Maximum Rating 2A,240VAC,200000 Life Cycles for Resistive Load
Alarm Functions Dwell Timer, Deviation Low, Deviation High, Deviation Band Low, Deviation Band High, Process High, Process Low
Alarm Mode Latching, Hold, Normal, Latching/Hold
Dwell Timer 0.1 to 4553.6 Minutes
Data Communication
Interface RS-485
Protocol Modbus RTU (Slave Mode)
Address 1 to 247
Baud Rate 2.8KBPS to 115.2KBPS
Parity Bit None, Even or Odd
Stop Bit 1 or 2 Bits
Data Length 7 or 8 Bits
Communication Buffer 160 Bytes
Analog Retransmission
Output Signal 4-20mA, 0-20 mA,0 - 10VDC
Resolution 15 Bits
Accuracy ±0.05% of Span ± 0.0025% / °C
Load Resistance 0 to 500Ω for current output, 10KΩ minimum for Voltage Output
Output Regulation 0.01% for full load change
Output Setting Time 0.1Second (stable to 99.9%)
Isolation Breakdown 1000VAC min
Integral Linearity Error ±0.005% of span
Temperature Effect ±0.0025% of span /°C
Saturation Low 0mA or 0VDC
Saturation High 22.2mA or 5.55V,11.1V min
Linear Output Ranges 0 - 22.2mA (0 - 20mA/4 - 20mA), 0 - 5.55VDC (0 - 5VDC, 1 - 5VDC),0 - 11.1VDC (0 - 10VDC)
User Interface
Keypad 4 Keys
Display Type 4 Digit LCD Display
No of Display 2 2 3 3 3 3 2
Upper Display Size 0.4” (10mm) 0.58” (15mm) 0.7” (17.7mm) 0.7” (17.7mm) 0.58” (15mm) 0.98” (25mm) 0.31” (8mm)
Lower Display Size 0.19” (4.8mm) 0.3” (7.8mm) 0.4” (11.2mm) 0.4” (11.2mm) 0.32” (8.3mm) 0.55” (14mm) 0.25” (6.5mm)
Programming Port
Interface Micro USB
PC Communication Function Automatic Setup, Calibration and Firmware upgrade
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 0.1~50.0°C (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 ~ 500.0°C(0.1~900.0°F), Integral time 0 – 3600 Secs, Derivative Time 0 - 360.0 Secs
Cycle Time 0.1 to 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 to 500.0°C (0 to 900.0°F)/Minute or 0 to 500.0°C (0 to 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
Profiler
Availability No No Option Option Option Option No
1Program with 16 Segments or 2Programs with each 8 Segments or
No of Programs NA NA NA
4Programs with each 4 Segments
Environmental and Physical Specifications

Page 7 of 38
Specification C22 C62 C82 C83 C72 C42 R22
Operating Temperature -10°C to 50°C
Storage Temperature -40°C to 60°C
Humidity 0 to 90 % RH (Non-Condensing)
Altitude 2000 Meters Maximum
Pollution Degree II
Insulation Resistance 20MΩ Minimum (@500V DC)
Dielectric Strength 2000VAC,50/60 Hz for 1 Minute
Vibration Resistance 10 to 55 Hz, 10m/s2 for 2 Hours
Shock Resistance 200 m/s2(20g)
Housing Flame Retardant Polycarbonate
Mounting Panel Panel Panel Panel Panel Panel DIN Rail
Dimensions (W*H*D) (mm) 48*24*92 48*48*59 48*96*59 96*48*59 72*72*59 96*96*59 22.5*96*83
Depth Behind Panel (mm) 84 50 50 50 50 50
Cut Out Dimensions (mm) 45*22.2 45*45 45*92 92*45 68*68 92*92
Weight (grams) 120 160 220 220 190 290 160
Approval Standards
Safety UL61010-1, CSA 22.2 No.61010-1-12, EN61010-1 (IEC1010-1)
Protective Class IP66 for Panel (In process), IP20 for terminals and housing. All indoor use.
EMC EN61326

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 the selected parameter.
DOWN KEY:
This key is used to decrease the value of the selected parameter.
RESET KEY:
This key is used to:
1. Revert the display to the home screen.
2. Reset a latching alarm once the alarm condition is removed.
3. Stop manual control mode, Auto-Tuning mode or calibration mode.
4. Clear an Auto-Tuning or communication error message.
5. Restart the dwell timer when the dwell timer has timed out.
6. Enter the manual control menu if failure mode occurs.
ENTER KEY: Press and hold for 5 seconds or longer to:
1. Enter the setup menu. The display will show .
2. Enter manual control mode. The display will show .
3. Enter Auto-Tuning mode. The display will show .
4. Perform calibration of a selected parameter during the calibration procedure.

Press and hold for 6.2 seconds, then let go, to select manual control mode.
Press and hold for 7.4 seconds, then let go to select Auto-Tuning mode.
Press and hold for 8.6 seconds, then let go to select calibration mode.

During power-up, the upper display will show PROG and the lower display will show the
Firmware version for 6 seconds.

Page 8 of 38
 1.5 Menu Flowchart
The Menu has been divided in to 5 groups. They are as follows:
1. User Menu
2. Setup Menu
3. Manual Mode Menu
4. Auto-Tuning Mode Menu
5. Calibration Mode Menu
Setup Manual Mode Auto-Tuning Mode Calibration Mode
User Menu
Menu

5 Sec 6.2 Sec 7.4 Sec 8.6 Sec 9.8 Sec

5 Sec 5 Sec 2 Sec Min

3 Sec Max
To access To access To start To start To access
parameter parameter in Manual Control Auto-Tuning Calibration Mode,
In the User Menu, the Setup Menu, Mode, Refer to Mode, Refer to Refer to
Refer to Refer to Section 1.5.3 Section 1.5.4 Section 1.5.5
Section 1.5.1 Section 1.5.2

Press for the next parameter

Press and key to return to the previous parameter.

1.5.1 User Menu

The below user menu parameters are available depends on the user selection.

Page 9 of 38
 PV,SV

SP1
SP2
SP3
SP4
SP5
SP6
SP7
SFtR
CT1R
CT2R
DTMR
PASS
RUN
CYCR
STEP
TIMR
SEL1
SEL2
SEL3
SEL4
SEL5
SEL6
SEL7
SEL8

1.5.2 Setup Menu

The setup menu has been categorized in to eight categories. They are listed as below.
1. Basic Menu
2. Output Menu
3. Alarm Menu
4. Event Input Menu
5. User Select Menu
6. Communication Menu
7. Current Transformer Input Menu
8. Profile Menu

1.5.2.1 Basic Menu (bASE)

Use or key to get bASE in the lower display then use key to enter to basic menu
parameters.

Page 10 of 38
 or

SET bASE

OFS1
OFS2
OFS3
INPT
UNIT
DP
INLO
INHI
SP1L
SP1H
FILT
DISP
PB
TI
TD
RAMP
RR
RETY
RELO
REHI
RMSP
RINL
RINH
CODE
OFTL
OFTH
CALO
CAHI
SFT
SFL1
SFL2
SFtH

1.5.2.2 Output Menu (oUT)

Use or key to get oUT in the lower display then use key to enter to output menu
parameters.

Page 11 of 38
 or
SET OUT

OUT1
O1TY
O1FT
O1HY
CYC1
OFST
OUT2
O2TY
O2FT
CYC2
CPB
DB
PL1L
PL1H
PL2L
PL2H

1.5.2.3 Event Input Menu (EI)

Use or key to get EI in the lower display then use key to enter to event input
menu parameters.
or
SET EI

E1FN
SP2
E2FN
SP3
E3FN
SP4
E4FN
SP5
E5FN
SP6
E6FN
SP7

1.5.2.4 Alarm Menu (ALRM)

Use or key to get ALRM in the lower display then use key to enter to alarm
menu parameters.
Page 12 of 38
 or

SET ALRM

A1FN
A1MD
A1HY
A1FT
A1SP
A1DV
A1DL
A2OT
A2FN
A2MD
A2HY
A2FT
A2SP
A2DV
A2DL
A3OT
A3FN
A3MD
A3HY
A3FT
A3SP
A3DV
A3DL
A4OT
A4FN
A4MD
A4HY
A4FT
A4SP
A4DV
A4DL

1.5.2.5 User Select Menu (SEL)

Use or key to get SEL in the lower display then use key to enter to select the
user menu parameters.

Page 13 of 38
 or
SET SEL

SEL1
SEL2
SEL3
SEL4
SEL5
SEL6
SEL7
SEL8

1.5.2.6 Communication Menu (CoMM)

Use or key to get CoMM in the lower display then use key to enter in to
communication menu parameters.
or

SET CoMM

ADDR
BAUD
DATA
PARI
STOP

1.5.2.7 Current Transformer Input Menu (Ct)

Use or key to get Ct in the lower display then use key to enter in to Current
transformer (CT) input menu parameters.
or

SET Ct

HBEN
HBHY
HB1T
HB2T
HSEN
HSHY
HS1T
HS2T

1.5.2.8 Profile Menu (PRoF)

Page 14 of 38
 Use or key to get PRoF in the lower display then use key to enter in to Profile
menu parameters.

or

SET PRoF

PROF TSP7
RMPU RPT7
STAR SKT7
END TSP8
PFR RPT8
HBLO SKT8
HBHI TSP9
HBT RPT9
CYCL SKT9
CYCR TSPA
STEP RPTA
TIMR SKTA
STAT TSPB
TSP1 RPTB
RPT1 SKTB
SKT1 TSPC
TSP2 RPTC
RPT2 SKTC
SKT2 TSPD
TSP3 RPTD
RPT3 SKTD
SKT3 TSPE
TSP4 RPTE
RPT4 SKTE
SKT4 TSPF
TSP5 RPTF
RPT5 SKTF
SKT5 TSPG
TSP6 RPTG
RPT6 SKTG
SKT6

1.5.3 Manual Mode Menu

Page 15 of 38
 HANd

5 Sec

MV1
MV2
FILE

Press key 5 Sec To execute the selected default program

1.5.4 Auto-Tuning Mode

Press key 5 seconds to activate Auto-Tuning Mode

1.5.5 Calibration Mode

CALI

2 sec minimum,3 sec maximum

ADLO
ADHI
RTDL
RTDH
CJLO
CJHI
V1L
V1G
MA1L
MA1G
V2L
V2G
MA2L
MA2G

Press key for 2 seconds or longer (not more than 3 seconds) then release it to enter calibration Mode.
Press Key for 5 seconds to perform calibration.

Note:
▪ Using Manual, Auto-Tuning, Calibration modes will break the control loop and change
some of the previous setting data. Make sure that the system is allowable to apply these modes.
▪ The flow chart shows a complete list of all parameters. For actual application, the number
of available parameters will vary depending on the setup and model of controller, and will be
less than that shown in the flow chart.
▪ The user can select up to 8 parameters to put in the user select menu by using the
SEL1~SEL8 parameters in the setup menu
2 \Installation and Wiring

Page 16 of 38
 Sometimes dangerous voltages capable of causing death are present in this instrument. Before doing
installation or any troubleshooting procedures, the power to the equipment must be switched off and
isolated. Units suspected of being faulty must be disconnected and removed toa 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 area should not exceed the maximum
rating specified in the specification
Remove stains from this equipment using a soft, dry cloth. Do not use harsh chemicals, volatile
solvents such as thinner or strong detergents to clean the equipment in order to avoid deformation.
2.1 Unpacking
Upon receipt of the shipment, remove the controller from the carton and inspect the unit for
shipping damage. If any damage is found, contact your local representative immediately. Note the model
number and serial number for future reference when corresponding with our service center. The serial
number (S/N) is labeled on the box and the housing of the controller.
The controller is designed for indoor use only, and is not intended for use in any hazardous area. It should
be kept away from shock, vibration, and electromagnetic fields (such as variable frequency drives), motors
and transformers. It is intended to operate under the following environmental conditions.

Environmental Parameter Specification

Operating Temperature -10°C to 50 °C

Humidity 0% to 90% RH (Non-condensing)

Altitude 2000 M Maximum

2-1. Environmental Specification

2.2 Mounting
Make the panel cut out as per the dimensions required by the controller. The dimensions of the different
sizes of this series controller series are given in the following section. Remove the mounting clamps from
the controller and insert the controller into the panel cut out. After inserting the controller into the panel cut
out, re-install the mounting clamps. Gently tighten the clamp screws until the controller is properly secured
into the cutout.
2.3 Wiring
Sometimes dangerous voltages capable of causing death are present in this instrument. Before doing
installation or any troubleshooting procedures, the power to the equipment must be switched off and
isolated. Units suspected of being faulty must be disconnected and removed toa properly equipped
workshop for testing and repair. Component replacement and internal adjustments must be made by a
qualified maintenance person only.
The utmost care must be taken to ensure that the maximum voltage rating specified on the label is not
exceeded.
It is recommended that the supply power of these units be protected by fuses or circuit breakers rated at
the lowest value possible
Page 17 of 38
 All units should be installed inside a suitably grounded metal enclosure to prevent live parts being
accessible to human hands and metal tools.
All wiring must conform to appropriate standards of good practice and local codes and regulations. Wiring
must be suitable for the voltage, current, and temperature rating of the system.
The tightening torque on the Screw terminals should not exceed 1 N-m (8.9 Lb-in or 10.2 Kg F-cm).
Except Thermocouple Wiring, all other wires used are to be standard copper conductors with the maximum
Gauge not exceeding 18AWG.Before power on the controller, the equipment ground must be connected
with minimum of 1.6mm diameter conductor for protective grounding.
2.3.1 C22 Terminal Connection

2.3.2 C62 Terminal Connection

2.3.3 C82 & C42 Terminal Connection

Page 18 of 38
2.3.4 C83 Terminal Connection

Page 19 of 38
2.3.5 C72 Terminal Connection

2.3.6 R22 Terminal Connection

Page 20 of 38
3 Programming
Press for 5 seconds and release to enter the setup menu. Press and release to
select the desired parameter. The upper display indicates the parameter symbol, and the lower display
indicates the value of the selected parameter.
3.1 User Security
There are two parameters PASS (password) and CODE (security code) which will control
the data security function.
CODE Value PASS Value Access Rights
0 Any Value All parameters are changeable
=1000 All parameters are changeable
1000
≠1000 Only user menu parameters changeable
=9999 All parameters are changeable
9999
≠9999 Only SP1 to SP7 are changeable
=CODE All parameters are changeable
Others
≠CODE No parameters can be changed
3.2 Signal Input
INPT: Select the sensor type or signal type for signal input
Range: (Thermocouple) J_TC, K_TC, T_TC, E_TC, B_TC, R_TC, S_TC, N_TC, L_TC
(RTD) PT.DN, PT.JS
(Linear) 4-20, 0-20, 0-60, 0-1V, 0-5V, 1-5V, 0-10
UNIT: Select the process unit
Range: °C, °F, PU (Process unit). If the unit is neither °C nor °F, then selects PU.
DP: Select the resolution of process value.
Range: For Thermocouple and RTD Signal NO.DP, 1-DP and For Linear Signal NO.DP, 1-DP, 2-DP, 3-DP
INLO: Select the low scale value for the linear type input.
INHI: Select the high scale value for the linear type input.
How to use INLO and INHI:
If 4-20mA is selected for INPT, let SL represent the low scale of the input signal (i.e. 4 mA),
let SH represent the high scale of the input signal (i.e. 20 mA). S represents the current input signal value;
the conversion curve of the process value is shown as follows:

Formula: PV = INLO + (INHI-INLO) ((S – SL)/ (SH-SL))

Example: A 4-20mA current loop pressure transducer with range of 0-15 kg/cm is connected to the input.
The following parameters should be set as follows:
INPT = 4–20, INLO= 0.00, INHI = 15.00, DP = 2-DP
Of course, the user may select a different value for DP to alter the resolution.

3.3 Control Output

Page 21 of 38
 There are 4 kinds of control modes can be configured as shown below.

Control Mode OUT 1 OUT 2 O1HY O2HY CPB DB

Heat Only REVR X ∆ X X X
Cool Only DIRT X ∆ X X X
Heat PID
REVR DE.HI X O X X
Cool ON-OFF
Heat PID
REVR COOL X X O O
Cool PID
X: Not applicable
O: Adjust to meet process Requirements
∆: Required if ON-OFF Control is configured
3.3.1 Heat Only ON-OFF Control
Select REVR for OUT1, Set PB to 0. O1HY is used to adjust the dead band for ON-OFF
control. The output 1hysteresis (O1HY)setting becomes available when PB = 0. The heat only ON-OFF
control function is shown below.

ON-OFF control may cause excessive process oscillations even if the hysteresis is set to the smallest value.
If ON-OFF control is set (i.e. PB = 0), TI, TD, CYC1, OFST, CYC2, CPB, DB will no longer be applicable
and will be hidden. Auto-Tuning mode and Bumpless transfer will also be unavailable.
3.3.2 Heat only P or PD Control
Select REVR for OUT1, set TI = 0, OFST is used to adjust the control offset (manual reset).
If PB ≠0 then O1HY will be hidden.
OFST Function: OFST is measured in % with a range of 0 - 100.0 %. When the process is stable, let’s say
the process value is lower than the set point by 5°C.Let’s also say that 20 is used for the PB setting. In this
example, 5°C is 25% of the proportional band (PB).
By increasing the OFST value by 25%, the control output will adjust itself, and the process value will
eventually coincide with the set point.
When using Proportional (P) control (TI = 0), Auto-Tuning will be unavailable. Refer to “manual tuning "
section for the adjustment of PB and TD. Manual reset (OFST) is usually not practical because the load
may change from time to time; meaning the OFST setting would need to be constantly adjusted. PID
control can avoid this problem.
3.3.3 Heat only PID Control
Select REVR for OUT1. PB and TI should not be zero. Perform Auto-Tuning for initial
startup, or set PB, TI and TD using historical values. If the control result is not satisfactory, use manual or
Auto-Tuning to improve the control performance. The unit contains a very clever PID and Fuzzy algorithm
to achieve the set point with a very small overshoot and very quick response to the process if it is properly
tuned.
3.3.4 Cool only Control
Page 22 of 38
 ON-OFF control, P (PD) control and PID control can be used for cooling control. Set
OUT1 to DIRT (direct action). The other functions for cooling only are ON-OFF control, cool only P (PD)
control and cool only PID control are same as for heating, except that the output variable (and action) is
reversed.
NOTE: ON-OFF control may result in excessive overshoot and undershoot problems in the process. P (or
PD) control will result in a deviation of the process value from the set point. It is recommended to use PID
control for Heat-Cool control to produce a stable and zero offset process value.
3.3.5 Other Setup Required
O1TY, CYC1, O2TY, CYC2, O1FT, O2FT O1TY & O2TY are set in accordance with the
type of outputs installed (OUT1 & OUT2) installed. CYC1 & CYC2 are set according to the output 1 type
(O1TY) & output 2 type (O2TY). Generally, if SSRD or SSR is used for O1TY, CYC1 is set to a value of 0.5
- 2 seconds. If a Relay is used for O1TY, CYC1 is set to a value of 10 - 20 seconds. If a linear output is
used, CYC1 is not applicable. The similar conditions are applied for CYC2 selection.
The user can use Auto-Tuning program for initial start-up, or they can directly set the
appropriate values for PB, TI & TD using the historical records for repeat systems. If the control behavior is
still inadequate, then manual tuning may be required to improve control.
3.3.6 CPB Programming
The cooling proportional band is measured by % of PB with a range of 50~300. Initially,
set 100% for CPB and examine the cooling effect. If the cooling action should be enhanced, decrease the
CPB value. If the cooling action is too strong, increase the CPB value. The value of CPB is directly
proportional to the PB setting. Its value remains unchanged throughout the Auto-Tuning process.
Adjustment of CPB is related to the cooling media used. If air is used as a cooling media,
set the CPB to 100(%). If oil is used as the cooling media, set the CPB to 125(%). If water is used as the
cooling media, set the CPB to 250(%).
3.3.7 DB Programming
Adjustment of DB (Dead band) is dependent on system requirements. If greater dead band
is used, then an unwanted cooling action can be avoided, but an excessive overshoot of the set point will
occur. If a smaller dead band (DB) is used, then an excessive overshoot can be minimized, but an
overlapping of the heating and cooling action will occur. The DB setting is adjustable in the range of -36.0%
to 36.0 % of PB.
A negative DB value will have an overlap where both outputs are active. A positive DB
value has a dead band area where neither output is active.
3.3.8 Output 2 ON-OFF Control (Alarm function)
Output 2 can also be configured as an alarm output. There are 8 kinds of alarm functions
and a Dwell timer (dtMR) that can be selected for output 2.They are dtMR (Dwell Timer), dE.HI (deviation
high alarm), dE.Lo (deviation low alarm), dB.Hi (Out of band alarm), dB.Lo (In band Alarm), PV.HI (process
value high alarm) and PV.LO (process value low alarm), H.bK (Heater Break Alarm), H.St (Heater Short
Alarm).

Page 23 of 38
Output 2 Deviation High Alarm Output 2 Process Low Alarm
3.4 Soft-Start
The controller has soft start function to limit the control output on out1 and out2 for a
programmable time SFT or up to a programmed threshold value SFTH. The first of two will terminate soft
start function and the normal PID control begins. This function is useful for effects such as suppressing the
heater output during equipment startup, or lightening the load.
Note: In Profile Version controllers If PFR is set to other than SP1 then the profile function will continue
with the set parameter during power recovery. If PFR is set to SP1 then the profile will continue to run with
soft start parameters during power recovery.
There are 5 parameters available for soft start function. They are as below.
1. SFt: Soft start time. If the SFt ≠0 then the Soft start function will be enabled. The SFt can
be set in the form of Hour: Minute. The range can be set is 00.00 to 99:59.
2. SFL1: Soft Start output limit for output 1. It can be set from PL1L to PL1H.
3. SFL2: Soft Start output limit for output 2. It can be set from PL2L to PL2H.
4. SFtH: Soft start threshold value. The Soft start will be aborted when the process value is
greater than or equal to SFtH.
5. SFtR: Soft start time. It will show the remaining time of soft start when it is running.

3.5 Alarm
The controller has up to four alarm outputs depending on the controller model. There are
11 types of alarm functions and one dwell timer that can be selected. There are 4 kinds of alarm modes
(A1MD, A2MD, A3MD, and A4MD) available for each alarm function (A1FN, A2FN, A3FN, and A4FN). In
addition to the alarm output, output 2 can also be configured as an alarm. But output 2 has only provides
8different alarm functions or dwell timer available.
3.5.1 Alarm Types
There are 11 different types of alarms as listed below that the user can assign to different
alarm outputs.
Page 24 of 38
 1. dtMR: Dwell timer
2. dE.HI: Deviation high alarm
3. dE.Lo: Deviation low alarm
4. dB.Hi: Deviation band out of band alarm
5. dB.Lo: Deviation band in band alarm
6. PV.HI: Process value high alarm
7. PV.Lo: Process value low alarm
8. H.bK: Heater break alarm
9. H.St: Heater short alarm
10. E1.C.o: Event Input 1 Control Alarm Output
11. E2.C.o: Event Input 2 Control Alarm Output

The Dwell timer can be used separately or accompanied with a Ramp. Alarm outputs can
be configured as dwell timers by selecting dtMR for A1FN. If A1FN is set to DTMR, Alarm 1 will act as a
dwell timer. Similarly, Alarm 2, Alarm3 or Alarm4 will act as dwell timers if A2FN, A3FN, or A4FN is set to
dtMR. When the dwell timer is configured, the parameter DTMR is used for dwell time adjustment.

A deviation alarm alerts the user when the process value deviates too far from the set
point. When the process value is higher than SV+A1DV, a deviation high alarm (dE.HI) occurs. The alarm
is off when the process value is lower than SV+A1DV-A1HY. When the process value is lower
thanSV+A1DV, a deviation low alarm (dE.Lo) occurs. The alarm is off when the process value is higher
than SV+A1DV+A1HY. The trigger level of a deviation alarm is moves with the set point.

A deviation band alarm presets two trigger levels centered on the set point. The two trigger
levels are SV+A1DV and SV–A1DV. When the process value is higher than (SV+A1DV) or lower than
(SV – A1DV), a deviation band high alarm (dB.HI) occurs. When the process value 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. This is
different from SP1 when the ramp function is used.

A process alarm canset two absolute trigger levels. When the process value is higher than
A1SP, a process high alarm (PV.HI) occurs. The alarm is off when the process value is lower than A1SP-
A1HY. When the process value is lower than A1SP, a process low alarm (PV.Lo) occurs. The alarm is off
when the process is higher than A1SP+A1HY. A process alarm is independent of the set point.
In the above description A1SP andA1HY denote Alarm1 Set point and Alarm1 Hysteresis.
The respective Set point and Hysteresis parameters need to be set for other Alarm outputs.
Heater break detection is enabled by setting A1FNto HBEN. A Heater break alarm (H.bK)
alerts the user when the current measured by CT1 in CT1R is lower than HB1T-HBHY, or CT2in CT2R is
lower than HB2T-HBHY.When the current measured by CT1 in CT1R is higher than HB1T-HBHY and CT2
in CT2R is lower than HB2T-HBHY, the heater break alarm will be off. The Heater break alarm will be off
when both CT values are in normal range. This Alarm will function when output1 is in ON condition only.
The Heater short detection is enabled by setting A1FN to HSEN. A Heater short alarm
(H.St) alerts the user when the current measured by CT1 in CT1R is higher than HS1T+HSHY, or CT2in
CT2R is higher than HS2T+HSHY.When the current measured by CT1 in CT1R is lower than HS1T+HSHY
and CT2 in CT2R is lower than HS2T+HSHY, the heater short alarm will be off. The Heater short alarm will
be off when both CT values are in normal range. This Alarm will function when output1 is in OFF condition
only.
The Heater break and Heater short alarms will work only with Relay and SSR outputs in
output1.
Page 25 of 38
 The Alarm outputs can be controlled by Event input1 and Event input 2 by selecting Event
Input 1 Control Alarm Output (E1.C.o.) and Event Input 2 Control Alarm Output (E2.C.o.)for alarm
function A2FN and A3FN .The output will be ON as long as the event input is ON. The output will goes OFF
when the input is OFF.
3.5.2 Alarm Modes
There are four types of alarm modes available for each alarm function.
1. Normal alarm
2. Latching alarm
3. Holding alarm
4. Latching/ Holding alarm
5. Set point Holding Alarm
3.5.2.1 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.
3.5.2.2 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 can be reset by pressing the RESET key once the
alarm condition is removed.
3.5.2.3 Holding Alarm: ALMD = HOLD
A holding alarm prevents an alarm condition during power up. This will ignore the alarm
condition at first time after power on. Afterwards, the alarm performs the same function as normal alarm.
3.5.2.4 Latching / Holding Alarm: ALMD = LT.HO
A latching / holding alarm performs both holding and latching functions. The latching alarm
is reset when the RESET key is pressed after the alarm condition is removed.

3.5.2.5 Set Point Holding Alarm: ALMD = SP.HO

A set point holding alarm prevents an alarm from power up and / or changing set point.
The alarm output is de-energized whenever the set point is changed even if it is in an alarm condition. The
alarm reverts to a normal alarm once the alarm condition is removed.
3.5.3 Alarm Delay
In certain applications during startup, nuisance alarms will be generated before the
process value reaches the set point. To avoid these kinds of nuisance alarms, a time delay for alarms is
available. To enable the time delay for alarms, set the delay time using the A1DL, A2DL, A3DL, and
A4DLparameters. These parameters will avoid the nuisance alarm during the process value reaches set
point.
For example the process set point set to 100. When the process approaching 100 it will go
to 103 and 97. During this time the Hi Alarm will be activated and deactivated continuously. To avoid these
kind of nuisance alarms the alarm delay function can be used. It will generate the alarm after the PV is in
alarm condition continuously at least for the period of time configured in alarm delay parameters. The alarm
delay can be configured in minutes and seconds.

3.5.4 Alarm Failure Transfer

Page 26 of 38
 Alarm Failure transfer is activated as the unit enters failure mode. The respective Alarm
will go on if ON is set for A1FT, A2FT, A3FT or A4FT and will go off if OFF is set for A1FT, A2FT, A3FT, or
A4FT. The unit will enter failure mode if a sensor break occurs or if the A-D converter fails.
3.6 User Select Menu Configuration
Conventional controllers are designed with parameters in a fixed order.
If the user needs a friendlier menu operation to suit their application, most conventional controllers do not
offer a solution. The C series controllers have the flexibility for the user to select those parameters which
are most significant, and put these parameters in an easy access USER menu.
There are eight user friendly parameters from the below list that can be set for user select
menu configuration using the SEL1-SEL8 parameters.
1. SP2
2. DTMR
3. DISP
4. Pb
5. Td
6. TI
7. o1HY
8. CPb
9. dB
10. A1HY
11. A1SP
12. A1dV
13. A2HY
14. A2SP
15. A2dV
16. A3HY
17. A3SP
18. A3dV
19. A4HY
20. A4SP
21. A4dV
22. PL1L
23. PL1H
24. PL2L
25. PL2H
26. OFTL
27. OFTH
28. CALO
29. CAHI
30. A1DL
31. A2DL
32. A3DL
33. A4DL
When using the up-down key to select parameters, all of the above parameters may not be
available. The number of visible parameters is dependent on the setup configuration.
Example:
OUT2 is set to DE.LO, PB= 100.0, SEL1is set to INPT, SEL2is set to UNIT, SEL3is set to PB ,
SEL4is set to TI, SEL5~SEL8 is set to NONE. Now, the USER menu display appears as below.

Page 27 of 38
 3.7 Ramp
The ramping function is performed during power up as well as any time the set point is
changed. Choose MINR or HRR for the RAMP setting, and the controller will perform the ramping function.
The ramp rate is programmed by adjusting the RR setting. The ramping function is disabled as soon as the
Failure mode, the Manual control mode, the Auto-Tuning mode or the Calibration mode occur.
3.7.1 Example without Dwell Timer
Select MINR for RAMP, set °C for UNIT, set1-DP for DP, Set RR= 10.0, SV is set to
200°C initially, and changed to 100°C after 30 minutes from power up. The starting temperature is 30°C.
After power up the process is running like the curve shown below.

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 ramp
rate is initiated at power on and/or when the Set point is changed. Setting the RR setting to zero means no
ramping function at all.
3.8 Dwell Timer
The Dwell timer can be with or without a Ramp. Alarm outputs can be configured as dwell
timers by selecting dtMR for A1FN. If A1FN is set to dtMR, Alarm 1 will act as a dwell timer. Similarly,
Alarm 2, Alarm3 and Alarm4 will act as dwell timers if A2FN, A3FN, or A4FN is set to dtMR. When the dwell
timer is configured, the parameter DTMR is used for dwell time adjustment. The dwell time is measured in
minutes ranging from 0.0 to 4553.6 minutes. The Timer starts to count as soon as the Process Value (PV)
reaches its set point (SV), and triggers an alarm output once the time has elapsed. The dwell timer
operation is shown in the following diagram.

After the timer has finished, the dwell timer can be restarted by pressing the RESET key.
The timer stops counting during manual control mode, failure mode, calibration and Auto-
Tuning.

Page 28 of 38
 If alarm1is configured as a dwell timer, A1HY and A1MD are hidden. It is similar for other
alarms as well.
3.9 User Calibration
Each unit is calibrated in the factory before shipment. The user can still modify the
calibration in the field.
The basic calibration of the controller is highly stable and set for life. User calibration
allows the user to offset the permanent factory calibration in order to:
❖ Calibrate the controller to meet a user reference standard.
❖ Match the calibration of the controller to that of a particular transducer or sensor input.
❖ Calibrate the controller to suit the characteristics of a particular installation.
❖ Remove long term drift in the factory set calibration.
There are two parameters: Offset Low (OFTL)and Offset High (OFTH) for adjustment to
correct an error in the process value.
There are two parameters for the sensor input. These two signal values are CALO and
CAHI. The input signal low and high values are to be entered in the CALO and CAHI parameters
respectively.
Refer to section 1.6 for key operation and section 1.7f or the operation flowchart. Press
and hold the key until the setup Menu page is obtained. Then, press and release the key to navigate
to the calibration low parameter OFTL. Send your low signal to the sensor input of the controller, then press
and release the key. If the process value (the upper display) is different from the input signal, the user
can use and keys to change the OFTL value (the lower display) until the process value is equal to the
value the user needs. Press and hold the key for 5 seconds to complete the low point calibration. A
similar procedure is applied for high scale calibration.
As shown below, the two points OFTL and OFTH construct a straight line. For the purpose
of accuracy, it is best to calibrate with the two points as far apart as possible. After the user calibration is
complete, the input type will be stored in the memory. If the input type is changed, a calibration error will
occur and an error code is displayed.

3.10 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 a time
constant specified by the FILT parameter. A value of 0.5 seconds is used as a factory default. Adjust FILT
to change the time constant from 0 to 60 seconds. 0 seconds represents no filter applied to the input signal.
The filter is characterized by the following diagram.
Note
The Filter is available only for the process value (PV), and is performed for the displayed
value only. The controller is designed to use an unfiltered signal for control even when a filter is applied. If a
lagged (filtered) signal is used for control; it may produce an unstable process.

Page 29 of 38
 3.11 Failure Transfer
The controller will enter failure mode if one of the following conditions occurs.

1. An SBER error occurs due to an input sensor break, an input current below 1mA for 4-
20mA, or an input voltage below 0.25V for 1-5 V.
2. An ADER error occurs due to the A-D converter of the controller fails.
Output 1 and Output 2 will perform the failure transfer (O1.ft & O2.ft) function as the
controller enters failure mode.
3.11.1 Output 1 Failure Transfer
If Output 1 Failure Transfer is activated, it will perform as follows:
1. If output 1 is configured as proportional control (PB≠0), and BPLS is selected for O1FT,
then output 1 will perform a Bumpless transfer. After that, the previous average 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. After that 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 an off
state if OFF is set for O1FT, and transfer to on state if ON is set for O1FT.
3.11.2 Output 2 Failure Transfer
If Output 2 Failure Transfer is activated, it will perform as follows:
1. If OUT2 is configured as COOL, and BPLS is selected for O2FT, then output 2 will perform
a Bumpless transfer. After that, the previous average 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 a failure transfer. After that the value of O2FT will be used for controlling output 2.
3. If OUT2 is configured as an alarm function, and OFF is set for O2FT, then output 2 will
transfer to an off state, otherwise, output 2 will transfer to an on state if ON is set for O2FT.
3.11.3 Alarm Failure Transfer
An alarm failure transfer is activated as the controller enters failure mode. After that, the
alarm output will transfer to the ON or OFF state which is determined by the set value of A1FT, A2FT,
A3FT, and A4FT.
3.12 Auto-Tuning
The Auto-Tuning process will be performed at the set point (SP1). The process will oscillate around
the set point during the tuning process. Set a set point to a lower value if overshooting beyond the normal
process value will cause damage. It is usually best to perform Auto-Tuning at the Set point the machine is
expected to be operated at, with the process running normally (i.e. material in the oven, etc.)
Auto-Tuning is generally applied in the following cases:
❖ Initial setup for a new process
Page 30 of 38
 ❖ The set point is changed substantially from the previous Set point when Auto-Tuning was
performed.
❖ The control result is unsatisfactory
3.12.1 Auto-Tuning Operation Steps
1. The system has been installed normally.
2. Do not use a zero value for PB or TI; otherwise, the Auto-Tuning program will be disabled.
The LOCK parameter should be set to NONE.
3. Set the set point to a normal operating value or a lower value if overshooting beyond the
normal process value will cause damage.
4. Press and hold the key until appears on the upper display, then let go.
5. Press and hold the key for at least 5 seconds. The TUNE indicator will begin to flash,
and the Auto-Tuning process has begun.
NOTE:
If the ramping function is used, it will be disabled once Auto-Tuning is started. The Auto-
Tuning mode is disabled if either a failure mode or manual control mode occurs.
Procedures:
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 process is completed, the TUNE
indicator will stop flashing and the unit will revert to PID control by using its new PID values. The PID
values obtained are stored in nonvolatile memory.
3.12.2 Auto-Tuning Error

If Auto-Tuning fails, an ATER message will appear on the upper display in any of
the following cases.
❖ If PB exceeds 9000 (9000 PU, 900.0°F or 500.0°C)
❖ If TI exceeds 1000 seconds
❖ If the set point is changed during the Auto-Tuning process
3.12.3 Solution for Auto Tuning Error
1. Try Auto-Tuning once again.
2. Do not change the set point value during the Auto-Tuning process.
3. Do not set zero value for PB and TI.
4. Use manual tuning
5. Touch RESET key to reset the message.
3.13 Manual Tuning
In certain applications (very few), using Auto-Tuning to tune a process may be inadequate
for the control requirement. In this case, the user can try manual tuning.
If the control performance by using Auto- Tuning is still unsatisfactory, the following
guidelines can be applied for further adjustment of PID values.

ADJUSTMENT SEQUENCE SYMPTOM SOLUTION

Slow Response Decrease PB
Proportional Band (PB)
High overshoot or Oscillations Increase PB
Slow Response Decrease TI
Integral Time (TI)
Instability or Oscillations Increase TI
Slow Response or Oscillations Decrease TD
Derivative Time (TD)
High Overshoot Increase TD

Page 31 of 38
 3.14 Manual Control
To enable manual control, ensure the LOCK parameter is set to NONE. Press and hold
for 6.2 seconds or until (Hand Control) appears on the display. Press and hold for 5
seconds or until the MANU indicator begins to flash. The lower display will show . The controller
has now entered manual control mode. Indicates the output control variable for output 1, and
indicates the control variable for output 2. The user can use the up-down keys to adjust the
percentage values for the heating or cooling output. This % value is based on the CYC1 and CYC2
settings, where the associated output will stay on for the % of time the CYC1 & CYC2 values are set for.
The controller performs open loop control as long as it stays in manual control mode
The manual mode menu can be reached by pressing keys also
3.14.1 Exit Manual Control

Pressing the key will revert the controller to its normal display mode.

Effects of PID Adjustment

3.15 Factory Default
The controller parameters can be loaded with default values listed in the parameter
description table. In certain situation it is desirable to retain these values after the parameters values has
been changed. The below procedure to be followed to reload the default values.
1. Ensure the LOCK parameter is set to NONE.
2. Press and hold for 6.2 seconds or until (Hand Control) appears on
the display.
Page 32 of 38
 3. Press key to navigate the manual mode menu to reach FILE.
4. Press and hold for 5 seconds or until the upper display FILE flash for a moment.
The default values of all parameters are loaded now.

3.16 Data Communication

The controllers support RS-485 Modbus RTU protocol for data communication. Using a
PC for data communication is the most economical way. The signal is transmitted and received through the
PC communication Port .Since a standard PC can't support an RS-485 port, a network adaptor such as an
RS232 to RS485 Converter or USB to Serial Converter must be used to convert RS-485 to RS-232 or USB
for a PC.. Many RS-485 units (up to 247 units) can be connected to one RS-232 port or USB Port.
Therefore a PC with 4 comm. ports can communicate with up to 988 units. It is quite economical.
3.16.1 RS-485 Setup
❖ Enters the setup menu.
❖ Set individual addresses for units 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.
3.17 Retransmission
The controller can output (retransmit) PV or SP via its retransmission terminals RE+ and
RE- provided that the retransmission option is ordered. A correct signal type should be selected for option
board to meet the retransmission option installed. RELO and REHI are adjusted to specify the low scale
and high scale values of retransmission.
3.18 Heater Current Monitoring
A current transformer (CT98-1) is required to measure the heater current. The CT input
signal conditioner measures the heater current when the heater is powered (output 1 is on), and the current
value will remain unchanged the heater is unpowered (output 1 is off). There are 1 or 2 CT inputs that can
be connected to the controllers depending on the model. The CT1R &CT2R will indicate the heater current.
Heater break detection is enabled by enabling heater break detection setting HBEN. A
Heater break alarm (H.bK) alerts the user when the current measured by CT1 in CT1R is lower than
HB1T or CT2in CT2R is lower than HB2T.When the current measured by CT1 in CT1R is higher than
HB1T+HBHY and CT2 in CT2R is higher than HB2T+HBHY, the heater break alarm will be off. The Heater
break alarm will be off when both CT values are in normal range. The Heater break alarm function will be
enabled when OUT1 is in on condition.
Heater short detection is enabled by enabling heater short detection setting HSEN. A
Heater short alarm (H.St) alerts the user when the current measured by CT1 in CT1R is higher than
HS1T or CT2in CT2R is higher than HS2T.When the current measured by CT1 in CT1R is lower than
HS1T-HSHY and CT2 in CT2R is lower than HS2T-HSHY, the heater short alarm will be off. The Heater
short alarm will be off when both CT values are in normal range. The Heater short alarm function will be
enabled when OUT1 is in off condition.
Accessory Installed
CT98-1
Required Setup Parameters
Heater Break
1. HBEN
2. HBHY
3. HB1T
4. HB2T

Page 33 of 38
 Heater Short
1. HSEN
2. HSHY
3. HS1T
4. HS2T
3.19 Event Input
There are 6 or 2 or 1 Event Inputs that are available in this series of controllers depending
on the size of the controller. Refer section 2.8 for wiring an event input. The Event input accepts a digital
(on/off) type signal. Types of signals that can be used to switch the event input as below.
❖ Relay
❖ Switch contacts
❖ Open collector Pull Low
❖ TTL logic level
One of the below functions can be chosen by using EIFN1 through EIFN6 contained in the setup menu.
The same function cannot be set to more than one event input.
3.19.1 Event Input Functions
1. NONE
2. SP2
3. RS.A1
4. RS.A2
5. RS.A3
6. RS.AO
7. CA.LH
8. D.O1
9. D.O2
10. D.O1.2
11. LOCK
12. AU.MA
13. F.tra
14. AL.oN
15. StAR: Run profile as RUN=STAR
16. CoNt: Run profile as RUN=CONT
17. PV: Run profile as RUN=PV
18. Hold: Run profile as RUN=HOLD
19. StoP: Run profile as RUN=STOP
NONE: No Event input function. If chosen, the event input function is disabled. The controller will use PB1,
TI1 and TD1 for PID control and SP1 (or other values determined by SPMD) for the set point.
SP2: If chosen, the SP2 will replace the role of SP1 for control.
RS.A1: Reset Alarm 1 as the event input is activated. However, if the alarm 1 condition still exists, alarm 1
will be triggered again when the event input is released.
RS.A2: Reset Alarm 2 as the event input is activated. However, if the alarm 2 condition still exists, alarm 2
will be triggered again when the event input is released.
RS.A3: Reset Alarm 3 as the event input is activated. However, if the alarm 3 condition still exists, alarm 3
will be triggered again when the event input is released.
RS.AO: Reset all Alarms as the event input is activated. However, if the alarm condition still exists, the
alarm will be triggered again when the event input is released.
CA.LH: Cancel the latched alarm as the event input is activated.
D.O1: Disable Output 1 as the event input is activated.
Page 34 of 38
 D.O2: Disable Output 2 as the event input is activated.
D.O1.2: Disable both Output 1 and Output 2.
Note: When any of D.O1, D.O2 or D.O1.2 is selected for EIFN, output 1 and/or
Output 2 will revert to their normal conditions as soon as the event input is
Released.
LOCK: All parameters are locked and unable to be changed (Read only) in communication.
AU.MA: Switch between Auto-Tuning and manual tuning control mode.
F.tra: Switch to Failure Transfer Mode
AL.oN: If Alarm 2 or Alarm 3 set to E1.c.o or E2.c.o then EI1 or EI2will activate Alarm Output Alarm 2 or
Alarm 3.
StAR: Run profile as RUN=STAR
CoNt: Run profile as RUN=CONT
PV: Run profile as RUN=PV
Hold: Run profile as RUN=HOLD
StoP: Run profile as RUN=STOP
3.20 Remote Set Point
The Set point will change proportionally with respect to the input given in the remote Set
point input terminals. The remote Set point function needs the below parameters to be set properly.
1. RMSP
2. RINL
3. RINH
3.21 Ramp and Soak Program
The new C Series controller with profile option can be used in the application where the
set point should be changed automatically with the time. It provides 1 program with 16 segment or 2
programs with each 8 segments or 4 programs with each 4 segments. Each segment has both ramp and
soak function.
The following parameters are used to configure the controller for ramp and soak programs.
1. PROF
2. RUN
3. RMPU
4. STAR
5. END
6. PFR
7. HBLO
8. HBHI
9. HBT
10. CYC
3.21.1 PROF
Select the required segments to run. There are 8 options available for the user to select
the profile segments.
1. NoNE: Not used
2. 1--4: Uses steps 1 to 4
3. 5--8: Uses steps 5 to 8
4. 1--8: Uses steps 1 to 8
5. 9-12: Uses steps 9 to 12
6. 1316: Uses steps 13 to 16
7. 9-16: Uses steps 9 to 16

Page 35 of 38
 8. 1-16: Uses steps 1 to 16
3.21.2 RUN
Select the profile rune mode. There are 5 modes available in the controller.
1. StAR: Start to run profile
2. CoNt: Continue run profile
3. PV: Continue run profile from current PV
4. Hold: Hold profile
5. SToP: Stop profile
3.21.2.1 StAR
The Profile starts to run from the first segment in the selected profile. In run mode,
the profiler varies the set point according to the stored profile values.
3.21.2.2 CoNt
The Profile starts to run from the segment where it stopped.
3.21.2.3 PV
The Profile starts to run from the segment where it stopped with current process
value.
3.21.2.4 Hold
In hold mode, the profile is frozen at its current point. In this state the user can
make temporary changes to any profile parameter (for example, a target set point, a dwell time or the time
remaining in the current segment). Such changes will only remain effective until the profile is reset and run
again and when they will be overwritten by the stored profile values.
3.21.2.5 StoP
In stop mode the Profile is stopped.
3.21.3 RMPU
Select the Ramp and Soak time units to be used. The options available for selection are
Hour Minutes (HH:MM) and Minute Seconds (MM:SS)
3.21.4 STAR
The Set point value of the profile start. The options available for selection is
Process value (PV) and controller Set point (SP1).
The normal method is to start the profile from the process value, because this will produce
a smooth and Bumpless start to the process. However, to guarantee the time period of the first segment,
the STAR set to SP1 for the start point
3.21.5 END
The Set point value at the end of profile. The options available for end Set point is
Controller Set point (SP1).
3.21.5.1 SP1
The Profile ends with controller Set point SP1.

3.21.6 PFR

Page 36 of 38
 If power is lost and then restored, while a profile is running, the behaviour of the profile is
determined by the setting of the parameter “PFR“ power fail recovery in profile configuration. The options
available for PFR are CONT, PV, SP1 and OFF.
3.21.6.1 CONT
If CONT is selected, then when power is restored the profile continues from where it was
interrupted when power was lost. The parameters such as set point value (SV), time remaining (DTMR)
and cycle remaining (CYCR) will be restored to their power-down values. For applications that need to
bring the process value to the set point value as soon as possible, this is the best choice. The two diagrams
below illustrate the respective responses.

Power failure recovery from profile at Dwell segmentPower failure recovery fromprofile at Ramp segment
3.21.6.2 PV
If PV is selected then when power is restored the set point starts at the current process
value, and then runs to the target set point of the active segment. This choice provides a smoother
recovery. The two diagrams below illustrate the respective responses

Power failure recovery from PV at Dwell segmentPower failure recovery from PV at Ramp Segment
3.21.6.3 SP1
If SP1 If is selected, then when power is restored the profiler is disabled and it enters static
mode, and SP1 is selected for control set point.
3.21.6.4 OFF
If OFF is selected, then when power is restored the profiler is disabled and it enters OFF
mode, all the control outputs as well as alarms and events are off.
3.21.7 Holdback
As the set point ramps up or down (or dwells), the measured value may lag behind or
deviate from the set point by an undesirable amount. "Holdback" is available to freeze the profile at its
current state. The action of Holdback is the same as a deviation alarm. Holdback has three parameters.
1. HBLO: Holdback low band
2. HBHI: Holdback high band
3. HBT: Holdback wait time
Page 37 of 38
 If the error from the set point exceeds the set holdback high band (HBHI) or lags than
the set holdback low band (HBLO), then the holdback will automatically freeze the profile at its current
point and the holdback timer begins to count. When the value of holdback timer exceeds the value of
holdback wait time (HBT), Holdback indicator HdbK will flash and an error code HBER will be displayed.
3.21.8 CYC
The number of cycles to be repeated for the selected profile to be configured by this
parameter
3.21.9 Running, Holding and Stopping a Profile
The profile has been start by selecting STAR in the lower display by using keys.
After selecting STAR press keys simultaneously for 1 second to start the profile. The same
procedure is applied for Holding and stopping profile. To holding the profile select HOLD and stop the
profile select STOP in the lower display
3.21.10 \Viewing and Modifying the Profile Progress
The Profile in progress can be monitored and modified by using the four parameters as
below.
1. CYCR: The remaining cycles of the profile
2. STEP: The running step of the profile
3. TIMR: The time remaining to complete the current step of the profile
4. STAT: The current state of the profile.
3.21.11 \Configuring the Profile
The profile has been configured by using the following parameters. There are 16 segments
available for the user for the configuration. The 16 segments can be used as a single profile or two profiles
with each 8 segments or four profiles with each 4 profiles. This selection can be done by PROF parameter
selection.
3.21.11.1 Profile Segment Parameters
Each profile segments have the following parameters.
1. Target Set Point(TSP)
2. Ramp Time (RPT)
3. Soak Time (SKT)
3.21.11.1.1 Target Set point
The target Set point of the segment can be configured by the parameters TSP1, TSP2,
TSP3, TSP4, TSP5, TSP6, TSP7, TSP8, TSP9, TSP10, TSP11, TSP12, TSP13, TSP14, TSP15, and
TSP16.
3.21.11.1.2 Ramp Time
The Ramp time of the segment can be configured by the parameters RPT1, RPT2, RPT3,
RPT4, RPT5, RPT6, RPT7, RPT8, RPT9, RPT10, RPT11, RPT12, RPT13, RPT14, RPT15, and RPT16.
3.21.11.1.3 Soak Time
The Soak time of the segment can be configured by the parameters SKT1, SKT2, SKT3,
SKT4, SKT5, SKT6, SKT7, SKT8, SKT9, SKT10, SKT11, SKT12, SKT13, SKT14, SKT15, and SKT16.

Page 38 of 38