USER’S OPERATING MANUAL FOR DIGITAL TEMPERATURE CONTROLLER

(Models: AI - 5982 )

AI - 5982
(96 X 96)

SPECIFICATIONS : - SAFETY INSTRUCTION :

1. DISPLAY TYPE : Dual 4- Digit 7 segment LED This controller is meant for temperature control
4 Digit Bright White (PV) applications. It is important to read the manual prior to
4 Digit Luminous Green (SV) installing or commissioning of controller. All safety related
instruction appearing in this manual must be followed to
Model no. AI-5982
ensure safety of the operating personnel as well as the
Display height (PV) 0.56” instrument.
Display height (SV) 0.56”
GENERAL
STATUS LED’S : OP1 : Main Control Output v The controller must be configured correctly for intended
OP2 : Alarm Status
operation. Incorrect configuration could result in damage
SOAK : Soak Timer to the equipment or the process under control or it may
2. INPUT

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lead personnel injury.
Sensor : TC:J,K,R,S & RTD: Pt-100 v The controller is generally part of control panel and in
Range : Refer below table such a case the terminals should not remain accessible
Sensor Type Range Resolution Accuracy to the user after installation.
Fe-k(J) T/C 0 ~ 760oC 1 oC

}
Cr-AL(K) T/C -99 ~ 1300oC 1 oC
MECHANICAL
o o o
v The Controller in its installed state must not come in close
(R) T/C 0 ~ 1700 C 1 C ±1 C
proximity to any corrosive/combustible gases, caustic
(S) T/C 0 ~ 1700oC 1 oC
vapors, oils, steam or any other process by-products.
Pt-100(RTD) -100 ~ 450oC 1 oC v The Controller in its installed state should not be exposed
o
Pt-100(RTD 0.1) -99.9 ~ 450.0 C 0.1 oC ± 0.3 oC to carbon dust, salt air, direct sunlight or radiant heat.
Sampling Time : 125 msec. v Ambient temperature and relative humidity surrounding
Resolution : 1°C/0.1°C(Only for RTD) the controller must not exceed the maximum specified
CJC for TC : Built in automatic limit for proper operation of the controller.
LWC for Pt-100 : Built in up to 18E max. v The controller in its installed state must be protected
Digital Filter : 1 to 10 Sec. against excessive electrostatic or electromagnetic
interferences. Ventilation holes provided on the chassis
3. RELAY OUTPUT
of the instrument are meant for thermal dissipation hence
Contact Type : N/O, CM, N/C
should not be obstructed in the panel.
Contact Rating : 5A @ 250VAC or 30 VDC
Life Expectancy : > 5,00,000 operations ELECTRICAL
Isolation : Inherent v The controller must be wired as per wiring diagram & it
4. SSR DRIVE OUTPUT must comply with local electrical regulation.
Drive Capacity : 12V @ 30mA. v Care must be taken not to connect AC supplies to low
Isolation : Non-Isolated. voltage sensor input.
5. FUNCTION v Circuit breaker or mains s/w with fuse (275V/1A) must be
Output 1 : Main Control output installed between power supply and supply terminals to
Output 2 : Programmable protect the controller from any possible damage due to
1) Auxiliary control high voltage surges of extended duration.
2) Alarm v Circuit breaker and appropriate fuses must be used for
3) Soak timer driving high voltage loads to protect the controller from
any possible damage due to short circuit on loads.
Control Action : ON-OFF/T.P (user selectable) v To minimize pickup of electrical noise, the wiring for low
Control Mode : Heat/Cool (user selectable) voltage DC and sensor input must be routed away from
Compliance : ---- high current power cables. Where it is impractical to do
6. ENVIRONMENTAL this, use shielded ground at both ends.
v The controller should not be wired to a 3-Phase supply
Operating Range : 0 ~50°C, 5~90% Rh
with unearthed star connection. Under fault condition
Storage Humidity : 95% Rh (Non-Condensing)
such supply could rise above 264 VAC which will damage
7. POWER SUPPLY the controller.
Supply Voltage : 90~270VAC, 50/60Hz. v The Electrical noise generated by switching inductive
Consumption : 4W Maximum. loads might create momentary Fluctuation in display,
8. PHYSICAL alarm latch up, data loss or permanent damage to the
Housing : ABS Plastic. instrument. To reduce this use snubber circuit across the
load.
v It is essential to install a over Temp. Protection device to
Model No. AI-5982 avoid any failure of heating system. Apart from spoiling
the product, this could damage the process being
Weight (gms.) 240 controlled.

1 OIM AI-5X82 V2.1 Page 1 of 6

 CAUTION: To prevent the risk of electrical shock, switch off the power before making/removing any connection or removing
the controller from its enclosure.

MECHANICAL INSTALLATION
The label on the controller identifies the serial number, wiring connections and batch number.
OVER ALL DIMENSIONS & PANEL CUT OUT (IN MM) INSTALLATION GUIDELINES
MODEL:- AI - 5982 1. Prepare the cut-out with proper dimension as shown in figure.
2. Remove clamp from controller.
3. Push the controller through panel cut-out and secure the
A E PANEL F controller in its place by tightening the side clamp.
CUTOUT

B D G

TABLE : 1
Dim A B C D E F G H
Model
AI-5982 96 96 10 45 89 92 92 9

ELECTRICAL INSTALLATION FRONT PANEL LAYOUT

The electrical connection diagram is shown on the controller enclosure as below.

1 2 3 4 5 6 7 8 9
i-therm AI-5982
1 2
OP1
PV
OP2

SOAK
SV
3

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4 7
SET RESET START
10 11 12 13 14 15 16 17 18
L N NO CM NC NO CM NC
5 6
SUPPLY AI - 5982
RELAY1 RELAY2

SSR1 SSR2
AI - 5982

FRONT PANEL LAYOUT DESCRIPTION :

Sr. NAME FUNCTION

OP1 LED Glows when OP1 is ON & flashes when delay time (dly1) is in operation(if selected mode is ON-OFF)
Glows when OP2 is ON & flashes when alarm condition persists even after acknowledged. or
1 OP2 LED delay time (dly2) is in operation(if selected mode is ON-OFF).
SOAK LED Glows when Soak mode is selected & flashes when Soak timer is in operation.
UPPER It will display (1) Measured value of selected input or Error massages in run mode.
2 DISPLAY (2) Parameters Value in program mode.
LOWER It will display (1) SP (Main set point) / SP2 (Auxiliary/Alarm) set value / Set Soak time value/
3 DISPLAY balance or elapsed soak time in run mode. (2) Parameter code in program mode.
SET ( 1) For SP programming. ( 2) To access Control mode. ( 3) To access Configuration mode
4 KEY along with UP key. (4) To scroll the parameter & to store its value.
SHIFT (1) To increase/alter parameter value in program mode with Up / Dn Key.
5 KEY (2) Press for 3Sec in Programming this will help to go back to previous parameter.
UP ( 1) To increase/alter parameter value in program mode. ( 2) To Enter in configuration mode
6 KEY (with SET key) . (3) To acknowledge Alarm. (4) To Reset the SOAK timer
DOWN ( 1) To decrease / alter parameter value in program mode. ( 2) To start Soak timer.
7 KEY

2 OIM AI-5X82 V2.1 Page 2 of 6

POWER UP:
At power on, following sequence will be prompted on the display till it reaches to Home Display mode.
In home display mode, by pressing DOWN key, user
UPPER can view SP1 & SP2 value (If OP2 = AUXILIARY or
PV ALARM mode) or Timer value (If OP2 = SOAK
DISPLAY
mode). By pressing UP key, user can view the
LOWER
SV parameter code (SP1/SP2/SOAK TIME) of
DISPLAY respective set value. If soak time is in operation,
VERSION MODEL INPUT HOME lower display will show either elapsed time (E.tmr) if
stdr=up or balance time (r.tmr), if stdr=dn.

PROGRAMMING :
USER LIST : To access User list press SET key once.
PARA LOWER UPPER
RANGE DESCRIPTION DEFAULT
METER DISPLAY DISPLAY
User can change SP1 value using UP/DOWN keys. Holding the key will
CONTROL
LSPL~HSPL change the value at a faster rate. Press SET key to store the desired value & 0°C
SET POINT
move on to the next parameter.

This parameter is prompted only, if output 2 is configured as

SET (1) Either absolute auxiliary control or as an alarm (High/Low) mode.
LSPL~HSPL 0°C
POINT 2 (2) Either deviation auxiliary control or as a deviation alarm mode.
(3) As a band alarm (For all above SP2 has to be enable)

SOAK 0 min. to This parameter is prompted only, if output 2 is configured for soak timer
1 min.
TIME 999 min. application.

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CONTROL LIST : To enter in this mode, press SET & DOWN key simultaneously for 3sec. User can then set the
following control parameters.
PARA LOWER UPPER
RANGE DESCRIPTION DEFAULT
METER DISPLAY DISPLAY

Set this parameter to 15 (Default LOCK CODE) to access Control List. User
LOCK has a choice to set different Lock Code via USER LOCK CODE in Config.
1 ~ 9999 0
CODE
List.

This parameter will be prompted only, if selected control action is PID. It sets
PROPOR 0.5
bandwidth over which the output power is adjusted depending upon the error
TIONAL to 5.0°C
999.9°C
(SV-PV). The value of this parameter is automatically set by Auto tune
BAND
function.
This parameter will be prompted only, if selected control action is PID. User
1
CYCLE can set this value based on process being controlled & type of output being
to 16.0 sec.
TIME
100.0 sec.
selected. For Relay O/P, cycle time should be more than 12sec & for SSR
O/P, cycle time should be less than 10sec.
This parameter will be prompted only, if selected control action is ON-OFF. It
sets the dead band between ON & OFF switching of the output. Larger value
CONTROL
1 to100°C of hysteresis minimize the number of ON-OFF operation to the load. This 2°C
HYS.
increases the life of actuators like contactors but also produces large errors
(between PV & SV)
This parameter will be prompted only, if selected control action is ON-OFF. It
0 sets the main output restart time where o/p once turned off will turn ON only
DELAY 1 to after restart time, regardless difference between PV & SP in Heat or Cool 120 sec.
500 sec. mode. If set to ‘0', o/p will be switched without delay. Delay will be applicable
also in case of every power ON.
This parameter will be prompted only, if selected control mode for output2 is
HYS. 2 1 to 100°C auxiliary control or an alarm. The value of this parameter sets the dead band 2°C
between ON & OFF switching of output load.

This parameter will be prompted only, if output 2 is configured as an auxiliary

0 control output. In this mode, output once turned off will restart only after set
DELAY 2 to time regardless of the difference between PV and SP2. The time delay is 0 sec.
500 sec. settable upto 500 seconds. If time delay is set to 0, there is no delay
executed between output switching.
This parameter will be prompted only, if selected control mode for output2 is
SOAK 0 Soak timer. Depending on end of soak strategy selected by user, the value of
TIME to this parameter sets the activation time for OP2 when Soak timer is over. 10 sec.
DELAY 100 sec. Setting this parameter to 0 will make OP2 continuously ON at the end of soak
time till user starts the next cycle.
MANUAL This parameter will appear only, if selected C.A. is time proportional (For
RESET -25 to 25°C 0°C
more details, refer User guide).
MODE

3 OIM AI-5X82 V2.1 Page 3 of 6

CONFIGURATION LIST :
(1) To enter in this mode, Press and hold SET & UP key simultaneously for 3 sec.
(2) Press UP or DOWN key to scroll between parameter options.
(3) Press SET key to store the current parameter & move on to the next parameter.

PARA LOWER UPPER

DESCRIPTION DEFAULT
METER DISPLAY DISPLAY

LOCK Set this parameter to 15 (Default LOCK CODE) to access Config. List.
0
CODE User has a choice to set different Lock Code via USER LOCK CODE in Config. List.

This parameter value is set according to the type of sensor (Thermocouple or RTD
input) connected to the Controller’s Input Terminals.

Sensor Type Range Resloution Accuracy

Fe-k(J) T/C 0 ~ 760°C 1°C

INPUT
TYPE
Cr-AL(K) T/C
(R) T/C
(S) T/C
Pt-100(RTD)
Pt-100(RTD 0.1)
-99 ~ 1300°C
0 ~ 1700°C
0 ~ 1700°C
-100 ~ 450°C
-99.9 ~ 450.0°C
1°C
1°C
1°C
1°C
0.1°C
} ± 1°C

± 0.3°C
tC-J

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LOWER
SET Sets the minimum limit for set point adjustment. It can be set from minimum specified
0°C
POINT range of selected sensor to HSPL value.
LIMIT
HIGHER
SET Sets the maximum limit for set point adjustment. It can be set from LSPL value to
400°C
POINT maximum specified range of selected sensor.
LIMIT
Function of this parameter is to add/subtract a constant value to the measured PV to
PROCESS obtain the final PV for control applications. This parameter value can be altered
VALUE (1) To compensate for known thermal gradient. 0°C
OFFSET (2) To match the display values with another recorder or indicator measuring the same
PV.
The controller is equipped with an adaptive digital filter which is used to filter out any
INPUT extraneous pulses on the PV. The filtered PV value is used for all PV dependent
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FILTER functions. If the PV signal is fluctuating due to noise, increase the filter time constant
value.

CONTROL
MODE User can select between TP or ON-OFF action algorithm to be adopted for output. PID
FOR O/P 1

This parameter will appear only, if selected control mode is ON-OFF.

User can select heating logic in which OP1 will remain ON till PV < SP.
CONTROL (PV increases when output is ON).
LOGIC HEAT
FOR O/P 1 This parameter will appear only, if selected control mode is ON-OFF.
User can select cooling logic in which OP1 will remain ON till PV > SP.
(PV decreases when output is ON).

This parameter allows the user to select output 2 as an ‘Auxiliary’ control.

For options refer Table 3.

OUTPUT 2 This parameter allows the user to select output 2 as an ‘Alarm’ control. Auxiliary
FUNCTION For options refer Table 4.

This parameter allows the user to select output 2 as a ‘Soak timer’ mode.

4 OIM AI-5X82 V2.1 Page 4 of 6

TABLE 3 :
Below listed options will appear only, if OP2 is selected as an Auxiliary control mode.
PARA LOWER UPPER
DESCRIPTION DEFAULT
METER DISPLAY DISPLAY

If selected, User can set SP2 value independently, irrespective of SP1.

INPUT
Abs
TYPE
In this mode, SP2 is always related with SP1.
User can set SP2 value with deviation of ± 99°C w.r.t SP1.

User can select Heat logic for control Output 2 in which OP2 will remain ON till PV < SP
(PV increases when output is ON)
OUTPUT 2
Heat
LOGIC
User can select Cool logic for control Output 2 in which OP2 will remain ON till PV > SP
(PV decreases when output is ON)

If Enabled, User can view & edit the Set Point (SP1) in USER list.
SET
POINT Enable
1
If Disabled, User cannot view or edit Set Point (SP1) in USER list.

If Enabled, User can view & edit the Set Point (SP2) in USER list.
SET
POINT Enable
2
If Disabled, User cannot view or edit Set Point (SP2) in USER list.

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USER Default USER LOCK CODE is 15 to access Control & Configuration List.
LOCK User has a choice to set its own USER LOCK CODE between 1 to 9999, this is to 15
CODE prevent unauthorized access of Control & Configuration List.

TABLE 4 :
Below listed parameters will appear only, if OUTPUT 2 is selected as ALARM mode. In ALARM mode, controller
continuously compares PV with either SP (For Deviation or Band alarm) or an independent ALARM SP2 (For
process high and process low Alarm). Alarm will occur when PV falls outside the set alarm limits. Also, OP2 will
energize or de-energize under Alarm condition as per the Alarm logic(AL.LG) selected. HYS2 in control List
decides when to switch OFF the alarm. Instrument supports four types of Alarm as described below :-
PARA LOWER UPPER
DESCRIPTION DEFAULT
METER DISPLAY DISPLAY
Low Alarm : OP2 activates when PV < SP2.

OUTPUT-2 ON OUTPUT-2 OFF OUTPUT-2 OFF OUTPUT-2 ON

PV PV
SP2 SP2
(Direct acting) (Reverse acting)
High Alarm : OP2 activates when PV > SP2.

OUTPUT-2 OFF OUTPUT-2 ON OUTPUT-2 ON OUTPUT-2 OFF

PV PV
SP2 SP2
(Direct acting) (Reverse acting)
ALARM
DEVIATION
TYPE Deviation Alarm : OP2 activates when PV exceeds SP1 ± set deviation value.
SP1 SP1
OUTPUT OFF OUTPUT ON OUTPUT ON OUTPUT OFF
PV PV
SP2 SP2
(Direct acting) (Reverse acting)
Band Alarm : OP2 activates when PV falls outside the band w.r.t SP1 either direction

SP1 SP1
OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF OUTPUT ON OUTPUT OFF
PV PV
SP2 SP2 SP2 SP2

(Direct acting) (Reverse acting)

5 OIM AI-5X82 V2.1 Page 5 of 6

 PARA LOWER UPPER
DESCRIPTION DEFAULT
METER DISPLAY DISPLAY
If this parameter is set as ‘Direct’, Relay/SSR energizes under Alarm condition &
remains de-energized otherwise. ‘Direct’ setting is generally used for Audio/Visual alarm
ALARM output.
DIRECT
LOGIC If this parameter is set as ‘Reverse’, Relay/SSR de-energizes under Alarm condition &
remains energized otherwise. ‘Reverse’ setting is generally used for tripping the process
under alarm conditions.

If this parameter is set to ‘YES’ & Alarm condition persists, it will disable Alarm O/P at
power ON.
ALARM
NO
INHIBIT
If this parameter is set to ‘NO’ & Alarm condition persists, it will enable Alarm O/P at
power up.

Once the Alarm is activated, User has following three options to de-activate it. When PV
falls within the programmed limits, the alarm will be de-activated automatically.
ALARM Once the alarm is activated, it remains activated until acknowledged manually by UP AUTO
ACK.
key.
Once the alarm is activated, it can be de-activated either by pressing UP key or when
PV falls within the alarm limits.

USER GUIDE :
TEMP (°C) TEMP (°C)
1) ON-OFF ACTION : HYSTERISIS
AMB
In this mode, output (Relay/SSR) remains ON, till SP
HYSTERISIS

actual temperature reaches to the set point. On SP

reaching SP, output turns OFF & remains OFF, till AMB
actual temperature drops down (in heat logic) or O/P ON OFF ON OFF ON O/P
O/P ON OFF ON OFF ON
raises (in cool logic) equal to hysterisis set by user.

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HEAT LOGIC / ON-OFF COOL LOGIC / ON-OFF
(As shown in Fig : 3.1 & 3.2) TIME TIME
Fig: 3.1 Fig: 3.2

TEMP (°C) PROPORTIONAL BAND (P.BAND)

SET BY USER
2) TIME PROPORTIONAL ACTION :
In this mode, ON & OFF time of Output (Relay/SSR) SP
varies proportionally in every cycle (cycle time
settable by User) depending on the deviation of PV AMB
OUTPUT
w.r.t SP. This action starts/continues only, when PV ON
100%
OFF
100%
ON
100%
TIME PROPORTIONAL ACTION
ACTIVE ZONE
enters or is within the band. (As shown in Fig : 3.3) Fig: 3.3 TIME

3) MANUAL RESET (OFFSET ADJUSTMENT) : TEMP (°C)

OFFSET
In some applications, after adopting Time
Proportionating action, system may stabilize at SP

particular temperature over a period of time which

can be different than the set value. This steady state After offset adjustment

(error) offset can be eliminated by setting this value,

equal and opposite to the existing offset. (As shown AMB
Fig: 3.4 TIME
in Fig : 3.4)

ABBREVIATION C.A.: Control Action NC : Normally Close terminal of relay SP : Set Point Value (Set temp.)
CJC: Cold Junction Compensation NO : Normally Open terminal of relay SSR : Solid State Relay
CM : Common terminal of relay OP1 : Output 1 T.P. : Time Proportional
EMI : Electro Magnetic Interference
OP2 : Output 2 T/C : Thermocouple
LWC: Lead Wire (Length) Compensation
PV : Process Value (Actual temperature)

Mfgd by: Innovative Instruments & Controls LLP

338, New Sonal Link Service Industrial Premises Co-op Society Ltd,

i Building No.2, Link Road, Malad (W), Mumbai - 400064.

Tel: 022-66939916/17/18;
E-mail : [email protected]
Website : www.itherm.co.in

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