Chromalox 8040 User Manual (English)

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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

Warranty and Returns Statement2
- Table of Contents3
Introduction11
Installation11
- Unpacking11
- Panel Cut-Outs12
- Panel-Mounting12
Plug-In Options13
- Options Modules and Functions13
- Auto Detection of Option Modules13
- Preparing to Install or Remove Options Modules14
- Removing/Replacing Option Modules ("Output" & "Option" Are Interchangeable Terms)14
- Replacing the Instrument in Its Housing15
Wiring Instructions15
- Installation Considerations15
- AC Power Wiring - Neutral (for 100 to 240V AC Versions)15
- Wire Isolation15
- Use of Shielded Cable16
- Noise Suppression at Source16
- Sensor Placement (Thermocouple or RTD)16
- Thermocouple Wire Identification Chart17
- Connections and Wiring18
Powering up24
- Powering up Procedure24
- Overview of Front Panel24
- Displays24
- Keypad25
- LED Functions25
Contents26
Messages and Error Indications26
Instrument Operation Modes27
- Select Mode27
  - Entry into the Select Mode27
  - Navigating in Select Mode27
- Unlock Codes27
- Automatic Tune Mode27
  - Navigating in Automatic Tune Mode27
- Product Information Mode28
  - Navigating in the Product Information Mode28
- Lock Code View29
  - Entry and Navigating in Lock Code View Mode29
6040, 8040 & 4040 Controller - Model Group29
- 6040, 8040 & 4040 Controllers - Configuration Mode29
- 6040, 8040 & 4040 - Setup Mode34
- 6040, 8040 & 4040 Controllers - Operator Mode37
  - 6040, 8040 & 4040 Controllers - Extended Operator Mode37
  - Navigating in Operator Mode37
- Adjusting the Local Setpoint(S)38
- Adjusting the Setpoint Ramp Rate38
- Manual Control Mode38
  - Selecting/Deselecting Manual Control Mode38
- 6040, 8040 & 4040 Controllers - Communications Parameters39
  - Bit Parameters39
  - Word Parameters39
6040, 8040 & 4040 VMD Controller - Model Group43
- Special Wiring Considerations for Valve Motor Control43
- 6040, 8040 & 4040 VMD Controllers - Configuration Mode44
- 6040, 8040 & 4040 Valve Motor Drive - Setup Mode50
- Adjusting the Valve Parameters50
  - Set Valve Opened Position & Set Valve Closed Position50
  - Valve Position Clamping50
- 6040, 8040 & 4040 Valve Motor Drive - Operator Mode52
  - 6040, 8040 & 4040 Valve Motor Drive - Extended Operator Mode52
  - Navigating in Operator Mode52
- Adjusting the Local Setpoint(S)54
- Adjusting the Setpoint Ramp Rate54
- Manual Control Mode54
  - Selecting/Deselecting Manual Control Mode54
- 6040, 8040 & 4040 VMD Controllers - Serial Communications Parameters54
  - Bit Parameters54
  - Word Parameters55
Contents57
6040 Heater Break Alarm Controller - Model Group57
- 6040 - Configuration Mode57
- 6040 HBA - Setup Mode62
- 6040 HBA Controllers - Operator Mode64
  - 6040, 8040 & 4040 Controllers - Extended Operator Mode64
  - Navigating in Operator Mode64
- Adjusting the Local Setpoint(S)65
- Adjusting the Setpoint Ramp Rate65
- Manual Control Mode66
  - Selecting/Deselecting Manual Control Mode66
- 6040 HBA Controller -Communications Parameters66
  - Bit Parameters66
  - Word Parameters66
11 6050 & 4050 Limit Controller - Model Group70
- 6050 & 4050 Limit Controllers - Configuration Mode70
- 6050 & 4050 Limit Controllers - Setup Mode74
- 6050 & 4050 Limit Controllers - Operator Mode76
  - Navigating in Operator Mode76
- Limit Setpoint Adjustment77
- Exceed Condition77
- Limit Output Function77
- Limit Annunciator Outputs77
- Resetting Limit Outputs & Annunciators77
  - Using the Reset Key to Reset Limit Outputs & Annunciators77
- Resetting Limit Hold and Exceed Time77
  - To Reset the Stored Limit Hold and Exceed Time Values77
- 6050 & 4050 Controllers - Serial Communications Parameters78
  - Bit Parameters78
  - Word Parameters78
12 Manually Tuning Controllers81
- 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 Tuning84
13 Modbus Serial Communications84
- Physical Layer84
- Link Layer84
Contents85
- Device Addressing85
- Supported Modbus Functions85
- Function Descriptions85
ASCII Communications87
- Physical Layer87
- Device Addressing87
- Session Layer87
- Error Response88
15 Calibration Mode89
- Equipment Required for Checking or Calibrating the Universal Input89
- Calibration Check89
- Recalibration Procedure89
16 Appendix 1 - Glossary90
- Active Setpoint Type: Controller Definition90
- Actual Setpoint Type: Controller Definition90
- Alarm Hysteresis Type: General Parameter91
- Alarm Operation Type: General Definition92
- Alarm Inhibit Type: General Parameter93
- Annunciator Type: Limit Controller Definition93
- Automatic Reset (Integral) Type: Controller Tuning Parameter93
- Auto Pre-Tune Type: Controller Tuning Parameter93
- Auxiliary Input Type: General Definition93
- Band Alarm 1 Value Type: General Parameter93
- Band Alarm 2 Value Type: General Paramete93
- Bias (Manual Reset) Type: Controller Tuning Parameter93
- Bumpless Transfer Type: Controller Definition93
- Boundless VMD Control Type: VMD Controller Definition94
- Cascade Control Type: Controller Definition94
- Communications Write Enable Type: General Definition94
- Control Type Type: Controller Parameter94
- Controller Type: Controller Definition94
- CPU Type: General Definition94
- Current Proportioning Control Type: Controller Definition95
- Cycle Time Type: Controller Definition95
- Deadband Type: Controller Parameter95
- Derivative Type: Controller Parameter95
- Deviation Alarm 1 Value Type Type: General Parameter95
- Deviation Alarm 2 Value Type: General Parameter95
- Differential (On-Off Hysteresis) Type: Controller Parameter95
- Direct/Reverse Action of Control Outputs Type: Controller Definition95
- Display Strategy Type: General Parameter95
- Elapsed Time Type: Indicator Definition95
- Exceed Time Type: Limit Controller Definition96
- Heater Current Monitor96
- Integral Type: Controller Tuning Parameter97
- Loop Alarm Enable Type: Controller Parameter98
- Manual Mode Enable Type: Controller Parameter99
- Offset Type: Controller Parameter100
- PI Control Type: Controller Definition102
- Process High Alarm 2 Value Type: General Parameter103
- Remote Setpoint Upper Limit Type: Controller Parameter104
  - Scale Range Upper Limit Type: General Parameter105
  - Scale Range Lower Limit Type: General Parameter105
  - Secondary Proportional Band Type: Controller Tuning Parameter105
  - Self-Tune Type: Controller Tuning Definition105
Contents105
- Retransmit Output 3 Scale Minimum Type: General Parameter105
17 Appendix 2 - Specification109
- Universal Input109
  - General Input Specifications109
  - Thermocouple110
- Thermocouple Ranges Available110
- Thermocouple Performance110
  - Resistance Temperature Detector (RTD)110
- RTD Ranges Available110
- RTD Performance111
  - DC Linear111
- DC Linear Ranges Available111
- DC Linear Performance111
- Control Specifications114
- Process Alarms115
- Digital Communications115
- Reference Conditions115
- Operating Conditions115
- Standards115
- Physical Specifications116
18 Appendix 3 - Order Tables117

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Chromalox 8040 Specifications

General

Display	LED
Output Voltage	Same as input voltage
Maximum Current	Depends on configuration
Phase	Single or Three Phase
Dimensions	Depends on model
Weight	Depends on model

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