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6050
Chromalox 6050 User Manual
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1
Installation & Operation Manual
6040, 8040, 4040 T
emperatur
e & Pr
ocess Contr
ollers
6040, 8040 & 4040 V
alve Motor Drive Contr
ollers
6040 Heater Br
eak Alarm Contr
oller
PK508-2
0037-75514
March 2017
6050, 4050 Limit Contr
ollers
2
Table of Contents
Warranty and Returns Statement
2
Table of Contents
3
Introduction
11
Installation
11
Unpacking
11
Panel Cut-Outs
12
Panel-Mounting
12
Plug-In Options
13
Options Modules and Functions
13
Auto Detection of Option Modules
13
Preparing to Install or Remove Options Modules
14
Removing/Replacing Option Modules ("Output" & "Option" Are Interchangeable Terms)
14
Replacing the Instrument in Its Housing
15
Wiring Instructions
15
Installation Considerations
15
AC Power Wiring - Neutral (for 100 to 240V AC Versions)
15
Wire Isolation
15
Use of Shielded Cable
16
Noise Suppression at Source
16
Sensor Placement (Thermocouple or RTD)
16
Thermocouple Wire Identification Chart
17
Connections and Wiring
18
Power Connections - Mains Powered Instruments
19
Power Connections - 24/48V AC/DC Powered Instruments
20
Universal Input Connections - Thermocouple (T/C)
20
Universal Input Connections - PT100 (RTD) Input
20
Universal Input Connections - Linear Volt, MV or Ma Input
20
Option Slot 1 - Relay Output Module
21
Option Slot 1 - SSR Driver Output Module
21
Option Slot 1 - Triac Output Module
21
Option Slot 1 - Linear Voltage or Madc Output Module
21
Option Slot 2 - Relay Output Module
21
Option Slot 2 - SSR Driver Output Module
21
Option Slot 2 - Triac Output Module
22
Option Slot 2 - Dual Relay Output Module
22
Option Slot 2 - Linear Voltage or Madc Output Module
22
Option Slot 3 - Relay Output Module
22
Option Slot 3 - SSR Driver Output Module
22
Option Slot 3 - Linear Voltage or Madc Output Module
22
Option Slot 3 - Dual Relay Output Module
23
Option Slot 3 - Transmitter Power Supply Module
23
Option Slot a Connections - RS485 Serial Communications Module
23
Option Slot a Connections - Digital Input Module
23
Option Slot a Connections - Basic Auxiliary Input Module
23
Option Slot B Connections - Digital Input 2 (Full Auxiliary Module)
24
Option Slot B Connections - 1/4 DIN & 1/8 DIN Full Auxiliary Input Module
24
Powering up
24
Powering up Procedure
24
Overview of Front Panel
24
Displays
24
Keypad
25
LED Functions
25
Contents
26
Messages and Error Indications
26
Instrument Operation Modes
27
Select Mode
27
Entry into the Select Mode
27
Navigating in Select Mode
27
Unlock Codes
27
Automatic Tune Mode
27
Navigating in Automatic Tune Mode
27
Product Information Mode
28
Navigating in the Product Information Mode
28
Lock Code View
29
Entry and Navigating in Lock Code View Mode
29
6040, 8040 & 4040 Controller - Model Group
29
6040, 8040 & 4040 Controllers - Configuration Mode
29
Entry into the Configuration Mode
29
Scrolling through Parameters and Values
29
Changing Parameter Values
29
6040, 8040 & 4040 - Setup Mode
34
Entry into the Setup Mode
34
Scrolling through Parameters & Values
34
Changing Parameter Values
34
6040, 8040 & 4040 Controllers - Operator Mode
37
6040, 8040 & 4040 Controllers - Extended Operator Mode
37
Navigating in Operator Mode
37
Adjusting the Local Setpoint(S)
38
Adjusting the Setpoint Ramp Rate
38
Manual Control Mode
38
Selecting/Deselecting Manual Control Mode
38
6040, 8040 & 4040 Controllers - Communications Parameters
39
Bit Parameters
39
Word Parameters
39
6040, 8040 & 4040 VMD Controller - Model Group
43
Special Wiring Considerations for Valve Motor Control
43
6040, 8040 & 4040 VMD Controllers - Configuration Mode
44
Entry into the Configuration Mode
44
Scrolling through Parameters and Values
44
Changing Parameter Values
44
6040, 8040 & 4040 Valve Motor Drive - Setup Mode
50
Entry into the Setup Mode
50
Scrolling through Parameters & Values
50
Changing Parameter Values
50
Adjusting the Valve Parameters
50
Set Valve Opened Position & Set Valve Closed Position
50
Valve Position Clamping
50
6040, 8040 & 4040 Valve Motor Drive - Operator Mode
52
6040, 8040 & 4040 Valve Motor Drive - Extended Operator Mode
52
Navigating in Operator Mode
52
Adjusting the Local Setpoint(S)
54
Adjusting the Setpoint Ramp Rate
54
Manual Control Mode
54
Selecting/Deselecting Manual Control Mode
54
6040, 8040 & 4040 VMD Controllers - Serial Communications Parameters
54
Bit Parameters
54
Word Parameters
55
Contents
57
6040 Heater Break Alarm Controller - Model Group
57
6040 - Configuration Mode
57
Entry into the Configuration Mode
57
Scrolling through Parameters and Values
57
Changing Parameter Values
57
6040 HBA - Setup Mode
62
Entry into the Setup Mode
62
Scrolling through Parameters & Values
62
Changing Parameter Values
62
6040 HBA Controllers - Operator Mode
64
6040, 8040 & 4040 Controllers - Extended Operator Mode
64
Navigating in Operator Mode
64
Adjusting the Local Setpoint(S)
65
Adjusting the Setpoint Ramp Rate
65
Manual Control Mode
66
Selecting/Deselecting Manual Control Mode
66
6040 HBA Controller -Communications Parameters
66
Bit Parameters
66
Word Parameters
66
11 6050 & 4050 Limit Controller - Model Group
70
6050 & 4050 Limit Controllers - Configuration Mode
70
Entry into the Configuration Mode
70
Scrolling through Parameters and Values
70
Changing Parameter Values
70
6050 & 4050 Limit Controllers - Setup Mode
74
Entry into the Setup Mode
74
Scrolling through Parameters & Values
74
Changing Parameter Values
74
6050 & 4050 Limit Controllers - Operator Mode
76
Navigating in Operator Mode
76
Limit Setpoint Adjustment
77
Exceed Condition
77
Limit Output Function
77
Limit Annunciator Outputs
77
Resetting Limit Outputs & Annunciators
77
Using the Reset Key to Reset Limit Outputs & Annunciators
77
Resetting Limit Hold and Exceed Time
77
To Reset the Stored Limit Hold and Exceed Time Values
77
6050 & 4050 Controllers - Serial Communications Parameters
78
Bit Parameters
78
Word Parameters
78
12 Manually Tuning Controllers
81
Single Control Tuning (PID with Primary Output Only)
81
Dual Control Tuning (PID with Primary and Secondary Outputs)
82
Valve Control Tuning (PI with VMD or Linear Outputs)
82
Manually Fine Tuning
84
13 Modbus Serial Communications
84
Physical Layer
84
Link Layer
84
Contents
85
Device Addressing
85
Supported Modbus Functions
85
Function Descriptions
85
Read Coil/Input Status (Function 01/02)
85
Read Holding/Input Registers (Function 03/04)
85
Force Single Coil (Function 05)
86
Pre-Set Single Register (Function 06)
86
Loopback Diagnostic Test (Function 08)
86
Pre-Set Multiple Registers (Function 10 Hex)
86
Exception Responses
86
ASCII Communications
87
Physical Layer
87
Device Addressing
87
Session Layer
87
Type 1 Message
87
Type 2 Message
88
Type 3 Message
88
Type 4 Message
88
Error Response
88
15 Calibration Mode
89
Equipment Required for Checking or Calibrating the Universal Input
89
Calibration Check
89
Recalibration Procedure
89
16 Appendix 1 - Glossary
90
Active Setpoint Type: Controller Definition
90
Actual Setpoint Type: Controller Definition
90
Alarm Hysteresis Type: General Parameter
91
Alarm Operation Type: General Definition
92
Alarm Inhibit Type: General Parameter
93
Annunciator Type: Limit Controller Definition
93
Automatic Reset (Integral) Type: Controller Tuning Parameter
93
Auto Pre-Tune Type: Controller Tuning Parameter
93
Auxiliary Input Type: General Definition
93
Band Alarm 1 Value Type: General Parameter
93
Band Alarm 2 Value Type: General Paramete
93
Bias (Manual Reset) Type: Controller Tuning Parameter
93
Bumpless Transfer Type: Controller Definition
93
Boundless VMD Control Type: VMD Controller Definition
94
Cascade Control Type: Controller Definition
94
Communications Write Enable Type: General Definition
94
Control Type Type: Controller Parameter
94
Controller Type: Controller Definition
94
CPU Type: General Definition
94
Current Proportioning Control Type: Controller Definition
95
Cycle Time Type: Controller Definition
95
Deadband Type: Controller Parameter
95
Derivative Type: Controller Parameter
95
Deviation Alarm 1 Value Type Type: General Parameter
95
Deviation Alarm 2 Value Type: General Parameter
95
Differential (On-Off Hysteresis) Type: Controller Parameter
95
Direct/Reverse Action of Control Outputs Type: Controller Definition
95
Display Strategy Type: General Parameter
95
Elapsed Time Type: Indicator Definition
95
Exceed Time Type: Limit Controller Definition
96
Heater Current Monitor
96
Integral Type: Controller Tuning Parameter
97
Loop Alarm Enable Type: Controller Parameter
98
Manual Mode Enable Type: Controller Parameter
99
Offset Type: Controller Parameter
100
PI Control Type: Controller Definition
102
Process High Alarm 2 Value Type: General Parameter
103
Remote Setpoint Upper Limit Type: Controller Parameter
104
Scale Range Upper Limit Type: General Parameter
105
Scale Range Lower Limit Type: General Parameter
105
Secondary Proportional Band Type: Controller Tuning Parameter
105
Self-Tune Type: Controller Tuning Definition
105
Contents
105
Retransmit Output 3 Scale Minimum Type: General Parameter
105
Serial Communications Option Type: General Definition
106
Set Valve Closed Position Type: VMD Controller Parameter
106
Set Valve Opened Position Type: VMD Controller Parameter
106
Setpoint Type: Controller Definition
106
Setpoint Upper Limit Type: Controller Parameter
106
Setpoint Lower Limit Type: Controller Parameter
106
Setpoint Ramping Enable Type: Controller Parameter
107
Setpoint Ramp Rate Type: Controller Parameter
107
Setpoint Select Type: Controller Parameter
107
Setpoint Select Enable Type: Controller Parameter
107
Soft Start
107
Solid State Relay (SSR) Type: General Definition
107
Solenoid Valve Type: General Definition
107
Tare Type: Indicator Parameter
108
Three Point Stepping Control Type: VMD Controller Definition
108
Time Proportioning Control Type: Controller Definition
108
Tuning Type: Controller Definition
108
Triac Type: General Definition
108
Valve Close Limit Type: VMD Controller Parameter
108
Valve Motor Drive Control Type: VMD Controller Definition
108
Valve Position or Flow Indication Type: VMD Controller Definition
108
Valve Open Limit Type: VMD Controller Parameter
109
VMD Type: VMD Controller Parameter
109
17 Appendix 2 - Specification
109
Universal Input
109
General Input Specifications
109
Thermocouple
110
Thermocouple Ranges Available
110
Thermocouple Performance
110
Resistance Temperature Detector (RTD)
110
RTD Ranges Available
110
RTD Performance
111
DC Linear
111
DC Linear Ranges Available
111
DC Linear Performance
111
Auxiliary Inputs
112
Digital Inputs
112
Output Specifications
112
Output Module Types
112
Specifications of Output Types
113
Control Specifications
114
Process Alarms
115
Digital Communications
115
Reference Conditions
115
Operating Conditions
115
Standards
115
Physical Specifications
116
18 Appendix 3 - Order Tables
117
4
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Chromalox 6050 Specifications
General
Brand
Chromalox
Model
6050
Category
Controller
Language
English
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