2104 Chromalox ® Temperature Controller C Issue Date September 2006 Technical Manual 0037-75276
Table of Contents Sections Section Topic 1 Getting Started ..................................................... 1 2 Installation ........................................................... 3 3 Operation ............................................................. 21 4 Controller Setup Pages ........................................ 33 5 Ramp/Soak Operation ......................................... 41 6 Alarms .................................................................
Illustrations Figure Topic 1.1 1.2 Application ............................................................. 1 Model Identification............................................... 2 2.1 2.2 2.3 Sensor Selection Dip Switch Settings ................... 3 Mounting Dimensions ............................................ 5 Mounting Diagram ................................................. 5 2.4 2.5 2.6 Wiring Terminal Identification .............................. 7 Thermocouple Connections.................
Illustrations Figure 2.25 2.26 2.27 Topic Page Dual Output SSR/Relay Wiring ............................. 17 Dual Output SSR/Triac Wiring .............................. 17 Dual Output Analog/Relay Wiring ........................ 18 2.28 2.29 2.30 Dual Output Analog/Triac Wiring ......................... 18 100-240 Vac Instrument Power Connections ........ 19 12-24 Vac/Vdc Instrument Power Connections .... 19 2.31 2.32 Alarm/Event Outputs #3 and #4 ............................ 19 Alarm/Event Output #5 .
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Section 1 Getting Started The Chromalox 2104 1/4 DIN temperature and process controller is a low-cost, high-performance, single-loop controller that can be used for temperature, flow, pressure and level control applications. With universal sensor inputs and front panel operator setup, one 2104 controller can be easily field configured for a wide variety of applications, and simply reconfigured as application needs change.
Model Identification Before installation, please identify your controller model number. The model number is written on the tag on the side of the housing. Figure 1.2 Model Identification Model Temperature Controller 2104 Microprocessor-based 1/4 DIN Temperature Controller. Universal Sensor Input accepts Thermocouple, RTD, Current or Voltage Inputs. PID, ON/OFF with Fuzzy Logic Control Capability. One Digital Input and Analog Remote Set Point.
Section 2 Installation Inspection and Unpacking On receipt of your 2104 controller, immediately make note of any visible damage to the shipment packaging and record this damage on the shipping documents. Unpack the controller and carefully inspect it for obvious damage due to shipment. If any damage has occurred, YOU must file a claim with the transporter, as they will not accept a claim from the shipper.
Sensor Selection Switches Sensor selection requires that you: 1. Set the sensor switches for the correct sensor type. 2. Program the input sensor type in sensor selection setup on the INPT Page (see page 36). It is much easier to set the sensor input switches before you mount and wire the controller. To set the sensor switches: 1. Locate the sensor switches—#1, #2 and #3— on the bottom of the controller, as shown in Figure 2.1 on the previous page. 2.
Figure 2.2 Mounting Dimensions 3.8 (96) 0.8 (19) 3.8 (96) 4.0 (102) 3.6 (92) 3.6 (92) 3.5 (90) Measurements are shown in inches. Millimeters are shown in parentheses. Figure 2.
Wiring Instructions Good Wiring Practices 1. When planning the system wiring, separate wiring into functionally similar bundles - i.e., power leads, sensor leads, output signal lines, etc. If the power leads and sensor leads must cross, they should cross at a 90° angle to each other (perpendicular). 2. Locate all sources of electrical noise in your system, and separate these sources from the control systems— motors, contacts, solenoids, etc. Electrical noise can affect the function of any control system.
Figure 2.
Thermocouple Inputs It is important to observe polarity (+, -) when connecting thermocouple leadwires. The table below shows ANSI color coding for the thermocouples used with this instrument.
Figure 2.6 3-Wire RTD Connections 2104 7 8 9 18 Shield Grnd 2-Wire RTD Inputs If using a 2-wire RTD input, use heavier gauge leadwires to reduce leadwire resistance. Any leadwire resistance adds directly to sensor resistance, thus adding error to the process temperature measurement. It is also necessary to jumper terminals 8 and 9 on the instrument to complete a 2-wire hookup. Figure 2.7 2-Wire Connections 2104 7 8 9 Current/Voltage Inputs Figure 2.
Figure 2.9 Voltage Input Wiring (Self-powered) 2104 + 7 1-5 Vdc 0-5 Vdc 8 9 The 2104 has a +24 Vdc power supply which can be used to power a 4-20mA transmitter. Figure 2.10 Current Input Wiring (Loop-powered by controller) 2104 3 +24 Vdc + 4-20mA 7 Digital Input Connections The digital input can be used in a number of ways: • to control ramp/soak operations • to switch between two setpoints, PID parameters, or Auto/Manual control • to reset an alarm • to disable the control output.
The 2104 is supplied with either: • 1 Control Output for Single Output Control (#1) • 2 Control Outputs for Heat/Cool Control (#1 and #2) Output Wiring The output wiring varies depending on the control type and applications. The wiring instructions are presented separately for each of these two controller types/applications. ☛ Warning Incorrect output wiring may cause system/process damage.
Figure 2.
Solid State Relay Drive Connections The solid state relay drive output drives solid-state relays, such as the Chromalox 4115 or 4117 power modules, which accept 3 to 32 Vdc input ON signals and 0 Vdc OFF signals. See Figure 2.15 for solid state relay drive output connections. Note: Negative lead connects to Terminal #2. Figure 2.
Figure 2.16 Current/Voltage Output Jumper Positions Output Module Top Controller Rear View Output #1* 4-20mA 1-5 Vdc Output #2 4-20mA 1-5 Vdc *All controllers with Analog Output (output codes AR, AT) for output #1 use same 4-20mA/1-5 Vdc jumper positions as shown here.
Figure 2.17 Triac Output Connections 2104 Heat Load 10 AC Neutral Fuse 11 120 Vac or 230 Vac Figure 2.18 4-20mA Analog Output Connections 2104 + 10 +24 Vdc 4-20mA 11 - Power Controller or Valve (0-800 ohms) Figure 2.
Heat/Cool Control Output Wiring Figure 2.20 Dual Relay Output Wiring 2104 10 Output #1 11 Heat Load AC Neutral Fuse 120 Vac or 230 Vac Output #2 12 Cool Load AC Neutral 10 Heat Load AC Neutral Figure 2.21 Dual Triac Output Wiring 2104 Output #1 11 Fuse 120 Vac or 230 Vac Output #2 12 Cool Load AC Neutral Figure 2.
Heat/Cool Control Output Wiring (continued) Figure 2.24 Dual 1-5 Vdc Output Wiring* Output #1 2104 1-5 Vdc + 10 - 11 Output #2 1-5 Vdc - 12 + Input GND Heat Control GND Input Cool Control *Note: See page 14 for Analog/Voltage jumper positions. Figure 2.25 Dual Output SSR/Relay Wiring 2104 - - 2 Solid State Relay Heat Load 120 Vac or 230 Vac AC Neutral Fuse 11 (Output #2) Fuse + 10 (Output #1) 120 Vac or 230 Vac MOV 12 Cool Load AC Neutral Figure 2.
Heat/Cool Control Output Wiring (continued) Figure 2.27 Dual Output Analog/Relay Wiring 2104 (Output #1) 4-20mA + 10 - Common (Output #2) 2 11 Heater Power Controller Fuse 120 Vac or 230 Vac MOV 12 Cool Load AC Neutral Figure 2.
Instrument Power Wiring Make 120 Vac or 230 Vac instrument power connections to terminals 16-18 as shown in Figure 2.29. Figure 2.29 100-240 Vac Instrument Power Connections (2104-****0) 2104 Figure 2.30 12-24 Vac/Vdc Instrument Power Connections (2104-****1) 2104 16 100 - 240 Vac 17 Neutral 18 Chassis Ground 16 12-24 Vac/Vdc 17 Common 18 Chassis Ground Alarm/Events The two independent alarm (Output #3 or #4) relay Outputs outputs are connected as shown in Figure 2.31. #3 & #4 Figure 2.
Alarm/Event Output #5 The Form C Relay Output is connected as shown in Figure 2.32. Figure 2.32 Alarm/Event Output #5 2104 25 Normally Open Load AC Neutral MOV Fuse* 26 Output #5 Normally Closed 120 or 230 Vac MOV 27 Load AC Neutral * Fuse should be sized for the current of Output #5.
Section 3 Operation Section Contents Pushbuttons and Indications Security Codes and Levels Controller Operation Pushbuttons and Indications Control programming is easily accomplished with the front panel pushbuttons. The displays provide a constant overview of the process. Figure 3.1, on the next page, summarizes the functions of the pushbuttons and displays.
Figure 3.
PAGE/MENU Setup All control parameters, selections and calibration procedures for the 2104 are accomplished through simple MENU selections. These MENU selections are organized into PAGES. On each PAGE you will find a specific set of related functions. This organization allows you to go directly to the parameter to be adjusted, without stepping through a long series of unrelated entries. Figure 3.2 illustrates the 2104 PAGE/MENU setup structure. Only pages that apply to your unit will be displayed (i.e.
Accessing a MENU is accomplished by entering the Setup Mode, then selecting a PAGE and MENU. To enter Setup Mode: Hold down the RESET pushbutton for longer than 3 seconds. 250 250 ☛ RESET AUX ▲ L OC H OCH ➮ ▼ 123 RESET Hold for at least 3 seconds. AUX ▲ ▼ Setup Mode entered. To select a PAGE: Press and hold the Reset pushbutton, while pressing the ▲ or ▼ Pushbutton. The upper display will increment (or decrement) through the PAGEs, and PAGE will be displayed in the lower display.
To change a MENU value: After the MENU is selected and displayed, use the ▲ and ▼ pushbuttons to change the value. For large adjustments (for example, 100 to 200), hold the pushbutton pressed and the display will change more quickly. ➮ ☛ 1.0 RESET ▲ AUX C Y CL ▼ 1.5 RESET ☛ C Y CL AUX ▲ ▼ To return to Operating Mode: Press and hold RESET for more than 3 seconds. The controller will automatically return to operating mode after 10 minutes of no pushbutton activity.
Security Levels Every parameter or selection in the 2104 controller’s setup PAGEs has an identifying MENU. Each MENU is assigned one of four Security Levels, A-D. In each level you may view certain MENUs , and adjust certain MENUs. This allows you to set the Security level that is appropriate for your operating environment, prohibiting unauthorized access to or accidental changing of control parameters. Figure 3.
To access and enter the Security Code: 1. Press and hold RESET for more than 3 seconds to enter Setup Mode. Security Lock is the first menu that will appear. L OC H OCH ☛ 123 RESET AUX ▲ ▼ Security Codes Figure 3.5 lists the Security Codes for each of the four Security Levels, along with the levels that may be viewed and adjusted. Figure 3.
Control Operation C ONT HEAT RESET AUX ▲ ▼ C ONT C OO L OOL RESET AUX ▲ ▼ C ONT H T CL RESET AUX ▲ ▼ A IR AIR 28 AUX ▲ Control Algorithms PID is the standard control algorithm of the 2104. ON/OFF control action is selected by setting the proportional band (CTRL PAGE, PB1 or PB2) to zero. Two sets of PID and ON/OFF control parameters are located in the Control Page for increased flexibility.
Control Operation (continued) TUNE PR UP PRU RESET AUX ▲ ▼ TUNE B EGN RESET AUX ▲ ▼ Self-Tuning The 2104 tuning algorithm establishes PID constants (PBL, ARL, RATL) that will bring the process to setpoint as quickly as possible with little overshoot. Tuning can be performed at powerup (CTRL PAGE, TUNE = PRUP) or can be initiated immediately (CTRL PAGE, TUNE = BEGN). When tuning, the 2104 will flash “TUNE” in the lower display.
Control Operation (continued) FL ON RESET AUX ▲ ▼ RR AT RRA 20 RESET AUX ▲ ▼ Fuzzy Logic Overshoot Protection Fuzzy Logic Overshoot Protection (CTRL PAGE, FL) works to minimize the overshoot that accompanies standard PID control. The 2104 actively learns the characteristics of the load and adjusts the PID control algorithm to reduce overshoot.
Control Operation (continued) ENTI A UTO RESET AUX ▲ ▼ Manual Operation Manual operation allows the controller output command to be controlled from the front panel Keyboard. On initial powerup, the controller enters Automatic control mode (closed loop). When Manual Mode is entered, the output command appears in the lower display. The output command can be adjusted using the up and down arrow keys. The manual mode can be entered by using the Aux Key or the Digital Input (CTRL PAGE, ENTI or AUTO).
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Section 4 Controller Setup PAGEs This section contains detailed information for the following controller setup pages: DISP: Display CTRL: Control INPT: Input SCAL: Custom Scaling OUT1: Output #1 OUT2: Output #2 Section Contents Setup PAGEs specific to certain functions are located in the section of this manual that addresses that function specifically.
DISP P A GE RESET AUX ▲ ▼ The Display Page is for status only. None of the settings can be changed. Display Page MENU Description Displays PROC Process Variable Sensor Span A SP Active Setpoint Sensor Span O UT1 Output #1 Command 0.0 TO 100.0 100.0% O UT2 Output #2 Command 0.0 TO 100.0 100.0% RSP Remote Setpoint Input Sensor Span RS Ramp/Soak Status O FF RUN H OLD STB Y STBY GS INT Ramp/Soak Interval Number 0 - 16 L EFT Ramp/Soak Time Left in Interval 0.0 TO 999.
C TRL P A GE RESET AUX ▲ ▼ Control Page MENU Description Available Settings LO C H CH Security Lock 0 to 9999 A SP Setpoint Instrument sensor span B A U SP Auxiliary SP Auxiliary setpoint is accessible only if AUX pushbutton or Event Input is set up for Auxiliary Setpoint. Instrument Sensor Span TUN E TUNE Self-Tune 26 29 Security Self-Tune automatically adjusts PID C parameters on powerup (PRUP) or on demand (BEGN).
C TRL P A GE RESET AUX ▲ ▼ Control Page (continued) MENU Description Available Settings OFS T OFST Manual Reset FL Fuzzy Logic O RNG Open Sensor Output Command L OOP Control Loop Protection Timer 55 OFF, 0.1 to 999.9 minutes A UTO Auto/Manual Disintegration Timer 0 to 100 seconds RR AT RA Ramp Rate OFF 1 to 9999 degrees/hour C ONT Controller Type -99.9 to 99.
C TRL P A GE RESET AUX ▲ ▼ Control Page (continued) MENU Description Available Settings AU Auxiliary Pushbutton Function 60 A OUT Analog Output Assignment 70 NONE PROC ASP OUT1 OUT2 RS E N EN Ramp/Soak 41 Ramp/Soak “On” enables the Ramp/Soak Setup Page (R5PG) OFF ON CO D E DE User Selected Security Code 26 Allows you to establish your own user-defined security code.
I NPT P A GE RESET AUX ▲ ▼ Input Page MENU Description 38 Sensor Type Available Settings Security 4 Sensor Type selected here must C agree with dip switch settings. J = J Thermocouple K = K Thermocouple T = T Thermocouple E = E Thermocouple R = R Thermocouple S = S Thermocouple B = B Thermocouple RTD = 100Ω Pt RTD (α = .00385) 4-20 = 4 to 20mA 0-5 = 0 to 5 Vdc 1-5 = 1 to 5 Vdc RTDT = 100 Ω Pt RTD (0.
SC AL SCA P A GE RESET ▲ AUX This PAGE appears only when Analog Input is selected, Remote SP is enabled, or Analog Output is enabled on CTRL PAGE. ▼ Custom Scaling Page MENU Description Available Settings DP Analog Input Decimal Pts.
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Section 5 Ramp/Soak Operation The 2104 controller features a Ramp/Soak Program. The program consists of 16 intervals plus a standby interval. The time span and setpoint for each interval are individually adjustable. These intervals make up a Ramp/Soak Profile. An example of a typical 8-interval Ramp/Soak program is shown below. Figure 5.1 Ramp/Soak Profile Temperature + Dev.
Looping means that intervals within a Program may be repeated 1 to 9999 times. If a loop is inserted in the program shown in Figure 5.1, so that intervals 4, 5 and 6 will be repeated 2 times in addition to the single Program run of these intervals, the final profile would look Figure 5.3. Looping Intervals Figure 5.
RSPG P A GE RESET AUX ▲ This setup PAGE appears only if Ramp/Soak control is turned on. The Ramp/Soak Enable parameter is the next to the last menu on CTRL PAGE, Menu CONT.
Control Operation In order to use the Ramp/Soak program, it must be enabled on the CTRL Page, RSEN = ON. Control of ramp/soak operation (Start, Stop and Hold) can be accomplished via the front panel. In the Setup mode, first return to the Normal Display Mode by holding the reset button for 3 seconds. Pressing the up arrow key Starts the program, pressing the down arrow key Holds the program, and pressing both together Stops the program. To Start Ramp/Soak Program: 80 R/S Indicator ON ☛ 70 .
Ramp/Soak (continued) Alternately, the Digital Input or Chromasoft™ can be used to control program operation. The ramp/soak indicator LED (right-most decimal point in the lower display) is ON when a program is running, OFF in standby, and flashes in hold mode.
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Section 6 Alarms The 2104 controller can provide up to three alarm outputs using Output #3, #4 and #5.
Alarm Types Each of the alarms can be set up for the following alarm types: HI High Alarm—Absolute Temperature Alarm LO Low Alarm—Absolute Temperature Alarm HILO High/Low Alarm—Absolute Temperature Alarm PDE +Deviation Alarm—Setpoint Tracking Alarm -DE -Deviation Alarm—Setpoint Tracking Alarm DE ±Deviation Alarm—Setpoint Tracking Alarm L OO P Control Loop Protection Alarm—System Alarm OOP (see page 53 for detailed information) The Absolute Temperature Alarms are set to a specific value; i.e.
Alarm Relay Action Output Relays #3, #4 and #5 can be set to be normally energized or de-energized, latching or non-latching. A normally de-energized relay is in its non-energized state when not in alarm. For example, Outputs #3 and #4 are normally-open contacts. When setup as normally de-energized, the relays will be open when not in alarm, and closed when in alarm. A non-latching relay will not stay in alarm if the alarm condition goes away.
O UT3 P A GE RESET AUX ▲ This setup PAGE appears only if the controller is equipped with Outputs #3 and #4.
O UT4 P A GE RESET AUX ▲ This setup PAGE appears only if the controller is equipped with Outputs #3 and #4.
O UT5 P A GE RESET AUX ▲ ▼ This setup PAGE appears only if the controller is equipped with Output #5.
Control Loop Protection Alarm (CLP) Control Loop Protection (CLP) monitors the controller’s process variable input and load output to detect and respond to conditions indicating a failure in the control loop (Sensor, Controller Output, Load or Process flow). CLP is selected by setting the LOOP Timer on the CTRL PAGE menu to a value from 0.1 to 999.0 minutes (0.0 disables CLP). ➮ ☛ P A GE RESET AUX ▲ L OOP ▼ Loop Timer 120.
Control Loop Protection Alarm (continued) If the control loop does not respond with a change in the process variable of 0.25% of span (3.75°F for a J thermocouple) within the programmed loop time, a Loop Error will result and the control output will turn off. The error will be indicated by the lower display flashing LOOP and Loop Alarm Output (Output #3, #4, or #5 as selected on the menu) will be activated. The Loop Alarm is cleared by pressing RESET.
CLP Loop Alarm Conditions The following table details conditions that activate a loop alarm, and gives the controller response to the condition. Figure 6.1 CLP Loop Alarm Conditions Probable Cause Control Output Response Loss of process flow Turns control output off Display 8888 L OOP Flashing In a control application where the process is being heated at one point and measured at a point downstream, CLP Alarm could be used to detect a flow failure.
Figure 6.1 CLP Loop Alarm Conditions (continued) Probable Cause Control Output Response Controller or remote power Turns control output off control output fails (open circuit) Display 8888 OP LO O P Flashing If the controller output or the remote power control device (SCR or contactor) fails open, the Loop Alarm will be activated when the process variable goes outside of the proportional band for a time greater than the preset Loop Timer value.
Figure 6.1 CLP Loop Alarm Conditions (continued) Probable Cause Control Output Response Display Sensor fails (short circuit, RTD only) Defaults to preset (0-100%) OPEN SENS Flashing If the RTD sensing device fails shorted, the controller defaults to the preset output condition (0-100% ORNG setting selected on the CTRL PAGE menu) and uses both displays to indicate OPEN SENS. The Loop alarm is not activated for this condition.
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Section 7 Digital Input and AUX Function The 2104 controller gives you two different options for actuation of any one of several field-selectable controller functions: 1. A Digital Input that is hardwired to terminals 1 and 2 of the controller. 2. The AUX pushbutton located on the controller front faceplate. You may choose to use either the Digital Input or the AUX pushbutton, but you cannot use both.
AUX Pushbutton The AUX front panel pushbutton can be assigned to perform any one of six possible functions and the AUX LED is used for indication of that function. Like the Digital Input, its function is selected in the CTRL PAGE programming. No wiring or hardware adjustments are required to use the AUX pushbutton as a function key.
Digital Input ENTI P ID 2 ID2 RESET AUX ▲ ▼ NONE = None When disabled, the Digital Input has no effect on controller operation. If the AUX key is also disabled, the AUX light is used to indicate the output state (ON or OFF) of Output #5, if the controller has Output #5. PID2 = Enable This function can be used in single output control applications only (CTRL PAGE, CONT = HEAT or COOL). When this function is selected, the controller uses PID1 parameters (CTRL PAGE) when the Digital Input switch is open.
Digital Input (continued) ENTI O UTD RESET AUX ▲ ▼ OUTD = Output Disable When this function is selected, the control output(s) are enabled when the Digital Input switch is open, and disabled, when the switch is closed. The AUX indicator is ON, when the control output(s) are disabled and OFF, when enabled. Note: Disabling the outputs allows all control parameters to be set up without starting the process. ☛ 41 62 This setting is NOT intended for process shutdown.
Digital Input (continued) ENTI A UTO RESET 31 AUX ▲ ▼ AUTO = Auto/Manual Control This function allows the Digital Input to act as an Auto/Manual Control selector. Manual operation is selected when the Digital Input switch is closed. Automatic operation is selected when the switch is open. The AUX light is ON in Manual, and OFF in Automatic Mode. ALR = Alarm Reset This function allows the Digital Input switch to be used as a remote Alarm Reset button for use with latching type alarms.
AUX Key (continued) AU P ID 2 ID2 RESET AUX ▲ ▼ PID2 = PID2 Enabled This function can be used in single output control applications only (CTRL PAGE CONT = HEAT or COOL). When this function is selected, pressing the AUX Key will toggle between PID1 (CTRL PAGE, menus PB1, AR1, RAT1) and PID2 (CTRL PAGE, menus PB2, AR2, RAT2) parameters. If the power is interrupted, the last active PID parameters will be used when power is restored.
AUX Key (continued) AU O UTD RESET AUX ▲ ▼ OUTD = Output Disable When this function is selected, pressing the AUX Key will toggle between outputs enabled and outputs disabled. The AUX indicator is ON when the control output(s) are disabled and OFF when enabled. Note: Disabling the outputs allows for all the parameters to be set without starting the process. ☛ 31 This setting is not intended for shutdown of the process. An external disconnect should be used.
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Section 8 Remote Setpoint & Analog Output Option Remote Setpoint The Remote Setpoint standard feature allows an external device to control the setpoint of the controller. The Remote Setpoint input accepts either 4-20mA or 1-5 Vdc input signals, selectable by a switch on the bottom of the controller. The Digital Input or AUX pushbutton can be set up to switch between the Local Setpoint and the Remote Setpoint.
To Scale the Input Signal Go to the SCAL PAGE, MENUs RSPL (remote setpoint low) and RSPH (remote setpoint high). Enter the sensor span low and high ranges. For example, for a 100 to 500°F range, 4mA would equal 100°F setpoint, and 20mA would equal 500°F setpoint. SC AL SCA P A GE RESET AUX ▲ ▼ This page appears only if Remote Setpoint and/or Analog Process Output are Enabled.
Analog Output Option The Analog Output Option is provided on controllers with model number • 2104 - ***3* • 2104 - ***4* • 2104 - ***5* This option can be used to transmit any one of four process parameters: • PROC ............ Process Variable • ASP .............. Active Setpoint • OUT1 ............. Output #1 Command (%ON) • OUT2 ............
To Enable the Analog Output Option: Go to MENU AOut on the CTRL PAGE and select one of the 4 parameters. C TRL P A GE RESET Figure 8.6 Process Output Wiring AUX ▲ AO UT AOUT ➮ ▼ PROC RESET 2104 AUX ▲ ▼ + 4-20mA, 1-5 Vdc Input Analog Output 4 Common 6 - Common To Scale the Output Signal When the Process Variable or Active Setpoint is selected for transmission, the output signal is scaled using the Analog Output scaling MENUs.
Section 9 Digital Communications The Digital Communications option is provided on the following controllers: Model 2104 - ***2* 2104 - ***5* 2104 - ***1* 2104 - ***4* Communications RS232 RS232 RS485/422 RS485/422 The Digital Communications option gives the 2104 the ability to interface with computers using either Chromalox’s Computer Interface mode or ASCII Line mode. These modes implement communications that can address up to 255 Chromalox controllers on an RS422A/RS485 multidrop line.
Hardware Setup (continued) When shipped from the factory, the multidrop communications interface is set for RS422. If you are using RS485, two switches in the controller hardware must be positioned for the communications interface. Locate the switches on the bottom of the controller and position them as shown in Figure 9.1. Figure 9.1 RS422/RS485 Communications Switches Controller Bottom Surface Switch .................. #1 RS-422 ..... Down RS-485 .....
Figure 9.3 RS422A Wiring Connections (4-wire) 2104 2104 GND RCV- RCV+ XMT- XMT+ 23 20 19 22 21 GND RCV- RCV+ XMT- XMT+ 23 20 19 22 21 Computer with RS422 Interface Card 270 Ω RCV+ 270 Ω RCVXMT+ XMTGND Note: 270 Ω resistors recommended across receive line on computer and last controller. Figure 9.
Digital Communications Programming and Setup All programmed selections are made on the DIG AGE P of the controller. DIG PA GE RESET AUX ▲ ▼ This setup PAGE appears only if the controller is equipped the digital Communications option. Digital Communications Page: DIG AGE P MENU Description Available Settings DIGT Mode Selection OFF = CPIF = LINE = BA UD Baud Rate 1200 2400 4800 9600 19.
Section 10 Calibration In this section you will find calibration instructions for calibrating: • Sensor Input • Remote Setpoint Input • Analog Output Instructions are also given for: • Factory Calibration Recovery • Calibration Offset When is Calibration Required? The 2104 controller is factory calibrated before shipment to you, therefore, it is not necessary to calibrate the controller when you receive and install it.
Important Calibration Notes 1. Disconnect load power when calibrating or disable the control output using the AUX pushbutton. 2. RTD inputs should be calibrated using copper (Cu) wire, and thermocouple inputs should be calibrated using thermocouple extension wire of the same type as the thermocouple you are calibrating. 3. Substitute a precision sensor simulator (thermocouple simulator or resistance decade box) for the sensor inputs.
Sensor Input Calibration (continued) 3. Adjust the simulator to output the low end of the selected sensor range. Sensor minimum ranges are: Sensor °F °C J T/C K T/C T E R S B -100 -300 -350 -100 0 0 50 -73 -184 -212 -73 -18 -18 10 RTD RTDT (0.1°) 4-20mA 0-5 Vdc 1-5 Vdc 48.46Ω 70.98Ω 4mA 0 Vdc 1 Vdc 4. Wait 30 seconds for the electronics to fully stabilize. Press ▲. Dashes will appear in the lower display while the controller calibrates the low end of span.
Sensor Input Calibration (continued) 6. Wait 30 seconds for the electronics to stabilize. Press ▲. Dashes will appear in the lower display while the controller calibrates the high end of span. When finished, the controller will display DONE. CALS ☛ IN HI NH RESET AUX ▲ CALS ➮ ▼ ➮ ---RESET AUX ▲ ▼ CALS DONE RESET AUX ▲ ▼ 7. Press RESET to exit calibration. Remote Setpoint Input Calibration The Remote Setpoint Input is calibrated using an appropriate 4-20mA or 1-5 Vdc simulator.
Remote Setpoint Input Calibration (continued) 3. Adjust the simulator to output the low end of the selected range. Wait 30 seconds for the electronics to fully stabilize. Press ▲. Dashes will appear in the lower display while the controller calibrates the low end of span. CAL R CALR ☛ IN LO NL RESET AUX ▲ CAL R CALR ➮ ▼ ---RESET AUX ▲ CAL R CALR ➮ ▼ IN HI NH RESET AUX ▲ ▼ 4.
Analog Output Option Calibration The Analog Output signal is calibrated using an appropriate current or voltage meter. Calibration is performed in the two analog output calibration menus (Ao O and Ao S) on the Input Page. 1. Connect the meter to the analog process output terminals. To calibrate the analog output, the output must be forced to the low end of span. If the setpoint is selected for transmission (CTRL PAGE, AOUT = ASP) this can be done by adjusting the setpoint to the low end of span (i.e.
Factory Calibration Recovery This option allows you to return the controller to its factory calibration settings in the event that it is severely out of calibration due to poor technique or unauthorized calibration. Although the factory calibration settings are recovered, this does not guarantee original calibration accuracy. The Factory Calibration Recovery should be used as a “starting point” for recalibration, should the unit become severely out of calibration.
Display Calibration Offset If an offset on the temperature reading is desired, the Display/Calibration Offset menu may be used. In some applications, this offset may be desired to match another instrument or an inferred temperature in another part of the system. To establish the calibration offset: 1. Go to menu COFF on the Input Page. C O FF 0 RESET AUX ▲ ▼ 2. Use ▲ and ▼ to set the calibration offset, adjustable from -100 to 100°F.
Section 11 Specifications Control Modes Automatic Control Adjustments Control Setpoint Setpoint Limits Deadband Proportional Band Manual Reset Automatic Reset Rate Output Cycle Time Output Limit Open Sensor & Out of Range Output Command Display Offset Heat/Cool Adjustments Output Offsets Cooling Medium Alarm Adjustments Setpoints Alarm Types Relay Action Alarm Deadband Alarm Inhibit Control/Alarm Outputs Relay On/Off Proportional (P) PID-Proportional with Integral and/or Derivative (PID, PI, PD) PID + Fuz
Input Specifications J T/C K T/C T T/C Range °F -100 to 1400 -300 to 2400 -350 to 750 Range °C -73 to 760 -184 to 1316 -212 to 399 E T/C -100 to 1100 -73 to 593 R T/C S T/C B T/C 0 to 3200 0 to 3200 50 to 3300 -18 to 1760 -18 to 1760 10 to 1816 100Ω Pt RTD (α = .00385) RTDT (0.1° res.) -200 to 1000 -99.9 to 899.9 4-20mA 0-5 Vdc 1-5 Vdc -500 to 5000 (programmable) -500 to 5000 (programmable) -500 to 5000 (programmable) Transmitter Power +24 Vdc Output Accuracy @ 77°F ambient ± 0.
Digital Input Analog Output Option Assignable Functions Accepts dry-contact closure Process Variable Active Setpoint Output #1 Command Output #2 Command Output Signal 4-20mA into 0-800Ω load 1-5 Vdc into 100KΩ or greater load Selectable via DIP switch Range Programmable over selected sensor span for retransmission of Process Variable and Active Setpoint, fixed to 0 to 100% for transmission of output commands Accuracy ± 0.
Sensor Leadwire Effect J Thermocouple K Thermocouple E Thermocouple R Thermocouple S Thermocouple B Thermocouple T Thermocouple RTD, 4-20mA, 1-5 Vdc 86 +1°F for 1000 Ft. of 18 AWG extension wire +5°F for 1000 Ft. of 18 AWG extension wire +4°F for 1000 Ft. of 18 AWG extension wire +3°F for 1000 Ft. of 18 AWG extension wire +3°F for 1000 Ft. of 18 AWG extension wire +6°F for 1000 Ft. of 18 AWG extension wire +1°F (temperatures > -80°C) +2°F (temperatures < -80°C) ± 0.
Section 12 Troubleshooting The following Troubleshooting Guide gives simple solutions to common problems, and explains the 2104’s Error Messages. Should you have a problem with your controller, it is a good idea to check this Guide for possible corrections before contacting the factory. The corrections are listed in the order in which they should be performed. Note: A specific List of Loop Alarms and probable causes are given on pages 55-57.
Troubleshooting Guide Symptom Process not in control Probable Cause 1. Incorrect “control action” selected 2. Not tuned correctly Correction 1. Check “control type” entered CTRL PAGE, CONT 2. See Self-Tuning and PID settings, CTRL PAGE Instrument continually goes 1. Internal electronic failure through power-up reset 2. Drastic power line anomalies 1. Contact factory ERR3 displayed with PAGE in lower display 1. EEPROM failed redundancy check 1. Power down and back up to retest EEPROM 2.
Section 13 Warranty & Return Warranty Chromalox warrants only that the Products and parts manufactured by Chromalox, when shipped, and the work performed by Chromalox when performed, will meet all applicable specification and other specific product and work requirements (including those of performance), if any, and will be free from defects in material and workmanship under normal conditions of use.
Upon buyer’s submission of a claim as provided above and in its substantiation, Chromalox shall at its option either (i) repair or replace its Products, parts or work at the original f.o.b. point of delivery or (ii) refund an equitable portion of the purchase price.
Appendix 1 PAGE/MENU Tables Setup Page PAGE Name PAGE Contents DISP Display Allows you to monitor any of 11 real time variables in the lower digital display: process variable; setpoint; outputs; timers and alarm status. This is useful during troubleshooting or brief trending periods. Values on this page are for display only and cannot be changed on this PAGE.
Security Levels See pages 26-27 for details.
Control Page See pages 35-37 for details. Control Page Menu Description Available Settings Factory Settings Security LOC H OCH Security Lock 0 to 9999 458 A SP Setpoint Instrument sensor span Span Low B AUSP Auxiliary SP Instrument Sensor Span Span Low TUNE Self Tune OFF = Self tuning disabled PRUP = Powerup tuning BEGN = Begin tuning OFF PB1 Proportional Band 1 0°F to sensor range 25°F AR1 Automatic Reset 1 0.00 to 99.99 repeats/minute 0.
Control Page See pages 35-37 for details.
Ramp/Soak Page See pages 41-45 for details.
Input Page See page 38 for details. Input Page MENU Description SENS Sensor Type UNIT Display Units COFF Display/ Cal. Offset Setpoint Low Limit Setpoint Upper Limit Sensor Calibration SP LL SPLL SP UL SPUL CALS CAL R CALR AO 0 AO 5 RE CC REC FILT HPRC LPRC HI A HIA L OA 96 Remote Setopint Calibration Analog Output Zero Calibration Analog Output Span Calibration Factory Calibration Recovery Digital Filter High (max.) Process Input Low (min.) Process Input High (max.) Ambient Temp. Low (min.
Custom Scaling Page See page 39 for details. Custom Scaling Page MENU Description Available Settings = = = = Factory Settings Security 1 C DP Analog Input Decimal Pts. 0 1 2 3 none 123.4 12.34 1.234 AIN L INL Analog Input Low -500 to 5000 0.0 AIN H INH Analog Input High -500 to 5000 100.
Output # 2 Page See page 39 for details. Output #2 Page MENU Description Available Settings Factory Settings Security 1.0 C CYC2 Output #2 0.0 to 60.0 seconds 0.0 = Voltage/Current algorithm OL2 Output #2 Limit 0.0 to 100.0% HOFF Heat Offset 0°F to PB1 setting 0 Available Settings Factory Settings 100.0% Output # 3 Page See page 50 for details.
Output # 3 Page See page 50 for details. Output #3 Page (continued) MENU Description Available Settings Factory Settings Security C AOL3 Alarm #3 Low Setpoint Instrument Sensor Span Span Low AHI3 Alarm #3 High Setpoint Instrument Sensor Span Span High DB3 Output #3 0 to 100°F Dead Band (Alarm Hysteresis) 1°F INH3 Alarm #3 Inhibit OFF OFF ON Output # 4 Page See page 51 for details.
Output # 4 Page See page 51 for details.
Output # 5 Page See page 52 for details. Output #5 Page (continued) MENU Description Available Settings Factory Settings Security NDE C RLY5 Alarm #5 Relay Action = Normally de-energized non-latching NE = Normally energized non-latching NDEL = Normally de-energized latching NEL = Normally energized latching AOL5 Alarm #5 Low Setpoint Instrument Sensor Span Span Low AHI5 Alarm #5 High Setpoint Instrument Sensor Span Span High DB5 Output #5 0 to 100°F Dead Band 0.00 to 6.
Display Page The Display Page is for status only. None of the settings can be changed. See page 34 for details. Display Page MENU Description Displays PROC Process Variable Sensor Span A SP Active Setpoint Sensor Span O UT1 Output #1 Command 0.0 TO 100.0 100.0% O UT2 Output #2 Command 0.0 TO 100.0 100.0% RSP Remote Setpoint Input Sensor Span RS Ramp/Soak Status O FF RUN H OLD STB Y STBY GS INT Ramp/Soak Interval Number 0 - 16 L EFT Ramp/Soak Time Left in Interval 0.0 TO 999.
1382 HEIL QUAKER BLVD., LAVERGNE, TN 37086 Phone: (615) 793-3900 www.chromalox.com 1382 HEIL QUAKER BLVD., LAVERGNE, TN 37086 Phone: (615) 793-3900 www.chromalox.
