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Chromalox 8040 - User Manual

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1
Installation & Operation Manual
6040, 8040, 4040 Temperature & Process Controllers
6040, 8040 & 4040 Valve Motor Drive Controllers
6040 Heater Break Alarm Controller
PK508-2
0037-75514
March 2017
6050, 4050 Limit Controllers

Table of Contents

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Summary

2 Installation

Installation

Guidelines for technical personnel on proper installation and adherence to local electrical safety regulations.

3 Plug-in Options

4 Wiring Instructions

Installation Considerations

Guidance on minimizing electrical noise effects from industrial environments for reliable instrumentation.

Connections and Wiring

Diagrams illustrating rear terminal connections for 1/16, 1/8, and 1/4 DIN instruments.

Power Connections - Mains Powered Instruments

Instructions for connecting mains powered instruments, including switch and fuse recommendations.

Power Connections - 24;48 V AC;DC Powered Instruments

Guidance for connecting 24/48V AC/DC powered instruments with switch and fuse recommendations.

5 Powering Up

Powering Up Procedure

Step-by-step guide for powering up the instrument, including self-test and configuration requirements.

6 Messages and Error Indications

7 Instrument Operation Modes

8 6040, 8040 & 4040 Controller - Model Group

6040, 8040 & 4040 Controllers - Configuration Mode

Mode for initial instrument configuration or major characteristic changes before setup or application use.

6040, 8040 & 4040 - Setup Mode

Mode for process setup changes after configuration, affecting Operator Mode adjustments.

6040, 8040 & 4040 Controllers - Operator Mode

Mode used for normal instrument operation, accessed from Select Mode or power-up.

6040, 8040 & 4040 Controllers - Communications Parameters

Details on Modbus parameter addresses and settings for 6040, 8040, and 4040 controllers.

9 6040, 8040 & 4040 VMD Controller - Model Group

Special Wiring Considerations for Valve Motor Control

Wiring recommendations for VMD controllers, especially interlocking relays to prevent simultaneous motor winding drive.

6040, 8040 & 4040 VMD Controllers - Configuration Mode

Mode for initial configuration or major characteristic changes for VMD controllers.

6040, 8040 & 4040 Valve Motor Drive - Setup Mode

Mode for process setup changes after configuration for VMD controllers.

6040, 8040 & 4040 Valve Motor Drive - Operator Mode

Mode for normal operation of VMD controllers, accessed from Select Mode or power-up.

6040, 8040 & 4040 VMD Controllers - Serial Communications Parameters

Details on Modbus parameter addresses for VMD controllers, not supporting ASCII protocol.

10 6040 Heater Break Alarm Controller - Model Group

6040 - Configuration Mode

Mode for initial configuration or major characteristic changes for HBA controllers.

6040 HBA - Setup Mode

Mode for process setup changes after configuration for HBA controllers.

6040 HBA Controllers - Operator Mode

Mode for normal operation of HBA controllers, accessed from Select Mode or power-up.

6040 HBA Controller - Communications Parameters

Details on Modbus parameter addresses for HBA controllers, not supporting ASCII protocol.

11 6050 & 4050 Limit Controller - Model Group

6050 & 4050 Limit Controllers - Configuration Mode

Mode for initial configuration or major characteristic changes for limit controllers.

6050 & 4050 Limit Controllers - Setup Mode

Mode for process setup changes after configuration for limit controllers.

6050 & 4050 Limit Controllers - Operator Mode

Mode for normal operation of limit controllers, accessed from Select Mode or power-up.

Resetting Limit Outputs & Annunciators

Procedures for resetting limit outputs and annunciators using keys, digital input, or serial commands.

6050 & 4050 Controllers - Serial Communications Parameters

Details on Modbus parameter addresses for limit controllers, not supporting ASCII protocol.

12 Manually Tuning Controllers

Single Control Tuning (PID with Primary Output only)

Technique for balancing setpoint achievement and overshoot for single-output PID control.

Dual Control Tuning (PID with Primary and Secondary Outputs)

Method for tuning PID parameters in dual control systems like Heat & Cool.

Valve Control Tuning (PI with VMD or Linear Outputs)

Tuning technique for modulating valves using PI control with VMD or linear outputs.

13 Modbus Serial Communications

Supported Modbus Functions

Details on the Modbus function codes supported by the instruments for data reading and writing.

15 Calibration Mode

Summary

2 Installation

Installation

Guidelines for technical personnel on proper installation and adherence to local electrical safety regulations.

3 Plug-in Options

4 Wiring Instructions

Installation Considerations

Guidance on minimizing electrical noise effects from industrial environments for reliable instrumentation.

Connections and Wiring

Diagrams illustrating rear terminal connections for 1/16, 1/8, and 1/4 DIN instruments.

Power Connections - Mains Powered Instruments

Instructions for connecting mains powered instruments, including switch and fuse recommendations.

Power Connections - 24;48 V AC;DC Powered Instruments

Guidance for connecting 24/48V AC/DC powered instruments with switch and fuse recommendations.

5 Powering Up

Powering Up Procedure

Step-by-step guide for powering up the instrument, including self-test and configuration requirements.

6 Messages and Error Indications

7 Instrument Operation Modes

8 6040, 8040 & 4040 Controller - Model Group

6040, 8040 & 4040 Controllers - Configuration Mode

Mode for initial instrument configuration or major characteristic changes before setup or application use.

6040, 8040 & 4040 - Setup Mode

Mode for process setup changes after configuration, affecting Operator Mode adjustments.

6040, 8040 & 4040 Controllers - Operator Mode

Mode used for normal instrument operation, accessed from Select Mode or power-up.

6040, 8040 & 4040 Controllers - Communications Parameters

Details on Modbus parameter addresses and settings for 6040, 8040, and 4040 controllers.

9 6040, 8040 & 4040 VMD Controller - Model Group

Special Wiring Considerations for Valve Motor Control

Wiring recommendations for VMD controllers, especially interlocking relays to prevent simultaneous motor winding drive.

6040, 8040 & 4040 VMD Controllers - Configuration Mode

Mode for initial configuration or major characteristic changes for VMD controllers.

6040, 8040 & 4040 Valve Motor Drive - Setup Mode

Mode for process setup changes after configuration for VMD controllers.

6040, 8040 & 4040 Valve Motor Drive - Operator Mode

Mode for normal operation of VMD controllers, accessed from Select Mode or power-up.

6040, 8040 & 4040 VMD Controllers - Serial Communications Parameters

Details on Modbus parameter addresses for VMD controllers, not supporting ASCII protocol.

10 6040 Heater Break Alarm Controller - Model Group

6040 - Configuration Mode

Mode for initial configuration or major characteristic changes for HBA controllers.

6040 HBA - Setup Mode

Mode for process setup changes after configuration for HBA controllers.

6040 HBA Controllers - Operator Mode

Mode for normal operation of HBA controllers, accessed from Select Mode or power-up.

6040 HBA Controller - Communications Parameters

Details on Modbus parameter addresses for HBA controllers, not supporting ASCII protocol.

11 6050 & 4050 Limit Controller - Model Group

6050 & 4050 Limit Controllers - Configuration Mode

Mode for initial configuration or major characteristic changes for limit controllers.

6050 & 4050 Limit Controllers - Setup Mode

Mode for process setup changes after configuration for limit controllers.

6050 & 4050 Limit Controllers - Operator Mode

Mode for normal operation of limit controllers, accessed from Select Mode or power-up.

Resetting Limit Outputs & Annunciators

Procedures for resetting limit outputs and annunciators using keys, digital input, or serial commands.

6050 & 4050 Controllers - Serial Communications Parameters

Details on Modbus parameter addresses for limit controllers, not supporting ASCII protocol.

12 Manually Tuning Controllers

Single Control Tuning (PID with Primary Output only)

Technique for balancing setpoint achievement and overshoot for single-output PID control.

Dual Control Tuning (PID with Primary and Secondary Outputs)

Method for tuning PID parameters in dual control systems like Heat & Cool.

Valve Control Tuning (PI with VMD or Linear Outputs)

Tuning technique for modulating valves using PI control with VMD or linear outputs.

13 Modbus Serial Communications

Supported Modbus Functions

Details on the Modbus function codes supported by the instruments for data reading and writing.

15 Calibration Mode

Chromalox 8040 Specifications

General IconGeneral
DisplayLED
Output VoltageSame as input voltage
Maximum CurrentDepends on configuration
PhaseSingle or Three Phase
DimensionsDepends on model
WeightDepends on model

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