M-system R3-TC2, TC10EM Instruction Manual

INSTRUCTION MANUAL

TEMPERATURE CONTROL MODULE

MODEL

R3-TC2

CONTENTS

BEFORE USE .... ........................................................................................................... 2

POINTS OF CAUTION ...................................................................................................... 2

COMPONENT IDENTIFICATION ..........................................................................................2

INSTALLATION ............................................................................................................. 2

TERMINAL CONNECTIONS ............................................................................................... 3

WIRING INSTRUCTIONS .................................................................................................. 4

FUNCTION DESCRIPTIONS ............................................................................................... 5

SYSTEM CONFIGURATIONS & CONTROL EXAMPLES ................................................................ 6

OPERATION ................................................................................................................. 7

MODBUS COMMUNICATION ........................................................................................... 12

SETTING .................................................................................................................. 14

UNIVERSAL INPUT ...................................................................................................... 16

CONTROL OUTPUT ...................................................................................................... 19

LOOP ...................................................................................................................... 21

BANK ...................................................................................................................... 28

EVENT INPUT ............................................................................................................. 34

CT INPUT ................................................................................................................. 35

AUTO-TUNING............................................................................................................ 37

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EM-8468 Rev.3 P. 1 / 37

R3-TC2

BEFORE USE ....

Thank you for choosing M-System. Before use, please check
contents of the package you received as outlined below.
If you have any problems or questions with the product,
please contact M-System’s Sales Office or representatives.

■ PACKAGE INCLUDES:

Temperature control module

(control module + CJC sensor, 2 pcs.) .................................(1)

■ MODEL NO.

Confirm Model No. marking on the product to be exactly
what you ordered.

■ INSTRUCTION MANUAL

This manual describes necessary points of caution when
you use this product, including installation, connection and
basic maintenance procedures.

POINTS OF CAUTION

■ HOT INSERTION/REMOVAL OF MODULES

• Removing or replacing modules does not affect other mod­ules on the same backplane. It is possible to replace them
without removing the power supply. However, replacing
multiple modules at once may greatly change line voltage
levels. We recommend that you replace them one by one.

■ ENVIRONMENT

• Indoor use.

• When heavy dust or metal particles are present in the
air, install the unit inside proper housing with sufficient
ventilation.

• Do not install the unit where it is subjected to continuous
vibration. Do not subject the unit to physical impact.

• Environmental temperature must be within -10 to +55°C
(14 to 131°F) with relative humidity within 30 to 90% RH
in order to ensure adequate life span and operation.

COMPONENT IDENTIFICATION

■ FRONT VIEW

RUN LED

ERR LED

CJC SENSOR(2)

RUN1
AUTO1
ERR1
ALM1
RUN2
AUTO2
ERR2
ALM2

1

11

2

12

3

13

13

4

14

5

15

6

16

7

17

8

18

9

19

10

20

Loop Status Indicator

■ STATUS INDICATOR LED

RUN indicator: Bi-color (red/green) LED;

Red when the internal bus operates normally.
ERR indicator: Bi-color (red/green) LED;
Red at device error;
Green in normal operating conditions.

Loop status indicators: Red LED
RUN1: Turns on while loop 1 is in operation.
AUTO1: Turns on during auto mode, turns off during

manual mode with loop 1

ERR1: Turns on at error with loop 1
ALM1: Turns on at alarm with loop 1
RUN2: Turns on while loop 2 is in operation.
AUTO2: Turns on during auto mode, turns off during

manual mode with loop 2

ERR2: Turns on at error with loop 2
ALM2: Turns on at alarm with loop 2

INSTALLATION

Use the Installation Base (model: R3-BSx).

■ WIRING

• Do not install cables close to noise sources (relay drive
cable, high frequency line, etc.).

• Do not bind these cables together with those in which
noises are present. Do not install them in the same duct.

■ UNUSED INPUT CHANNELS

• Unused channels can be specified and set so on the PC
Configurator Software (model: R3CON) without needing
to short at the field terminals.

■ AND ....

• The unit is designed to function as soon as power is sup­plied, however, a warm up for 10 minutes is required for
satisfying complete performance described in the data
sheet.

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EM-8468 Rev.3 P. 2 / 37

TERMINAL CONNECTIONS

Connect the unit as in the diagram below.

■ EXTERNAL DIMENSIONS unit: mm (inch)

R3-TC2

CJC SENSOR (2)

130 (5.12)

■ CONNECTION DIAGRAM

27.5 (1.08)

1

11

20–M3

2

12

SCREW

3

13

13

4

14

5

15

6

16

7

17

8

18

9

19

10

20

TERMINAL COVER

Pv1

UNIVERSAL INPUT

CT 1

Pv2

UNIVERSAL INPUT

Di 1

CT 2

Di 2

109 (4.29)

POSITIONING
GUIDE

6.2

(.24)

1

2

INTERNAL BUS

3

4

5

6

7

11

12

13

14

INTERNAL POWER

BUS CONNECTOR

+

8

+

9

10

18

19

20

Mv2

–

+

+

Do2

–

Mv1

Do1

15

16

17

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EM-8468 Rev.3 P. 3 / 37

R3-TC2

INTERNAL BUS

8

9

18

19

20

10

1

2

3

4

5

6

7

11

12

13

14

15

16

17

+

+

–

Mv2

+

+

–

Pv1

UNIVERSAL INPUT

CT 1

Di 1

Di 2

INTERNAL POWER

CT 2

Pv2

UNIVERSAL INPUT

Mv1

Do2

Do1

UNIVERSAL INPUT CONNECTION (Pv2) e.g.

BUS CONNECTOR

■ UNIVERSAL INPUT CONNECTION (Pv1) e.g.

•DC Voltage (-10 – +10V DC)

•DC Current (0 – 20mA DC)

+

INPUT

•DC Voltage (-1000 – +1000mV DC)

INPUT

•Thermocouple

–+–

CJC

+

SENSOR

comp. leadwire

•RTD/Resistor (3-wire)

1

–

2

–

2

+

4

–

2

3

+

4

A

2

B

3

B

4

■

•DC Voltage (-10 – +10V DC)

•DC Current (0 – 20mA DC)

+

INPUT

11

–

12

•DC Voltage (-1000 – +1000mV DC)

INPUT

•Thermocouple

–+–

+

comp. leadwire

•RTD/Resistor (3-wire)

–

12

+

CJC

SENSOR

14

–

12

13

+

14

A

12

B

13

B

14

■ CT 1 / CT 2 CONNECTION e.g.

•Clamp-on current Sensor

Power Side

k

l

k

l

5

6

7

Load Side

■ DISCRETE INPUT CONNECTION e.g.

Di 1

Di2

15

16

17

■ CONTROL OUTPUT 1 & 2 CONNECTION e.g.

+

10

8

+

9

–

Mv1

Mv2

•RTD/Resistor (2-wire)

A

B

•Potentiometer

max.

min.

+

–

2

3

2

3

•RTD/Resistor (2-wire)

A

B

•Potentiometer

max.

min.

4

WIRING INSTRUCTIONS

■ SCREW TERMINAL

Torque: 0.5 N·m

■ SOLDERLESS TERMINAL

Refer to the drawing below for recommended ring tongue
terminal size. Spade tongue type is also applicable. Solder­less terminals with insulation sleeve do not fit.
Applicable wire size: 0.3 – 0.75 mm
Recommended manufacturer: Japan Solderless Terminal
MFG. Co., Ltd., Nichifu Co., Ltd.

2

■ CONTROL OUTPUT 3 & 4 CONNECTION e.g.

12

13

18

19

20

+

12

–

13

Do2

+

–

Do1

+

–

14

3max

6max

4min

12max

3.2 dia.

(mm)

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EM-8468 Rev.3 P. 4 / 37

FUNCTION DESCRIPTIONS

R3-TC2

■ UNIVERSAL INPUT

• Input types

1) DC: 0 − 20mA / -1000 − +1000mV / -10 − +10V

2) Potentiometer: Max. total resistance 4000Ω

3) Resistor: Max. 4000Ω

4) RTD: Pt 100 / Pt 500 / Pt 1000 / Pt 50Ω / JPt 100 /

Ni 508.4Ω / Cu 10

5) Thermocouple: (PR) / K / E / J / T / B / R / S / C / N / U /

L / P

• Two input points can be assigned respectively with one of
the selections (1) through (5).

• Sampling cycle: 100 milliseconds

• Burnout detection available for potentiometer, resistor,
RTD and thermocouple inputs

• Cold junction compensation sensors for thermocouple in­put included in the product package

• Fine input adjustment available

• DC, potentiometer and resistor inputs can be scaled into
temperature ranges.

• First order lag filter for input signals

■ CONTROL OUTPUT

• Output types

1) 12V pulse / 0 − 20mA DC / 0 − 10V DC

selected by model number suffix code when ordering

2) Open collector

• Two output points by the selection (1) plus two output
points with the selection (2)

• Control cycle 0.1 to 99.9 seconds
(100 msec. fixed for control output 0 − 20 mA and 0 − 10
V DC)

• Output resolution 1 millisecond

• PV, SP and MV signals can be scaled and provided as duty
ratio output; Alarm contact output (ON/OFF) also available

• Minimum ON/OFF pulse width can be specified for relay
life protection

■ EVENT INPUT

• Two discrete input points can be assigned to a specific
event.

• Event types

• Switching banks / Switching operation / Switching manu­al/auto mode / Switching local/remote SP

■ CT INPUT

• Input type

M-System clamp-on current sensor (model: CLSE)

• Two input points can be assigned respectively to monitor
specific control output status.

• One signal can watch heater wire break, SSR shortcircuit
failure and overload at once.

• Control output must be turned on for at the minimum
of 110 milliseconds to detect a heater wire break; must
be turned off for at the minimum of 200 milliseconds to
detect an SSR shortcircuit failure.

■ COMMUNICATION

• Monitoring and setting can be performed easily with PC
Configurator Software (model: R3CON).

• Various values can be read out via network communica­tion (data allocation mode: 8)

• Modbus interface module (model: R3-NM3) available with
the R3 extension area communication realizes a large ca­pacity data reading/writing.

■ CONTROL LOOP

• Control strategies

1) Standard PID control

2) Heating-cooling PID control

(independent PID operation for heating and cooling)

3) Heating-cooling ON/OFF control

(heating-only or cooling-only output is possible.)

• Two control loops can be assigned respectively to one of
the selections (1) through (3).

• Limit cycle method auto-tuning

• Direct/reverse action selectable for standard PID control

• Input 2 can be cascaded to loop 1 as its SP (remote SP)

• MV tracking function: MV in manual mode is carried on
into auto mode.

• High/low limits selectable for SP and MV values

• Specific MV values applicable at STOP/abnormality.

• Three PV alarm modes selectable for each loop

• Four bank settings available for each loop; Banks can be
switched during operation.

• Bank setting

• SP / SP rise ramp / SP fall ramp / P / I / D / Cooling P /
Cooling I / Cooling D / Heating sensitivity / Cooling sensi­tivity / Deadband / PV alarm high/low limits

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EM-8468 Rev.3 P. 5 / 37

SYSTEM CONFIGURATIONS & CONTROL EXAMPLES

CONTROL OUTPUT 3 (Do1)

■ 1 loop heating ON/OFF control and heater wire break detection

1. Installation example:

• Base (model: R3–BS)

• Interface Module (model: R3–NM3)

• Temperature Control Module (model: R3–TC2)

• Clamp-on Current Sensor (model: CLSE)

• Oven

• Heater

• Relay

• Temperature sensor

R3-TC2

2. Proccess until start operating:

Turn ON power supply

Set input sensor type and range

Set CT input to wire break detection

Temp. Sensor

Select control mode (ON/OFF Control)

Specify target temperature (SP)

Select operation mode (auto)

Start operation

■ 1 loop heating and cooling control (PID)

1. Installation example:

• Base (model: R3–BS)

• Power Supply Module (R3–PS1)

• Interface Module (model: R3–NM3)

• Temperature Control Module (model: R3–TC2)

• DC Voltage Input Module (model: R3–SV4)

(Other R3 modules also available)

• Object to heat/cool

• Temperature sensor

2. Proccess until start operating:

Turn ON power supply

Set input sensor type and range

Heater

Oven

UNIVERSAL INPUT 2 (Pv2)

CT INPUT 1

CLSE

UNIVERSAL INPUT 1 (Pv1)

R3–BS
R3–NM3
R3–TC2

Ry

Relay

Relay Power

Heater Power

R3–BS
R3–PS1
R3–NM3
R3–TC2
R3–SV4

Select control mode

Set deadband

Specify target temperature (SP)

(PID)

Temp. Sensor

Object to

heat/cool

Select operation mode (auto)

Start operation

Note: The examples above are for single loop, however, dual loop control is also availabe using only one R3-TC2.

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Control output 2 (Mv2) Control output 1 (Mv1)

Cold water

Hot water

EM-8468 Rev.3 P. 6 / 37

R3-TC2

OPERATION

■ GETTING READY WITH PC CONFIGURATOR SOFTWARE (model: R3CON)

The PC Configurator Software is used to set up various parameters for the Temperature Controller Module and to perform
auto-tuning.
Connect the CONFIG port to the PC and start up the R3CON. The flowchart below shows how to move to the Controller’s
setting window. In this example, the R3-TC2 is supposed to be installed in the slot 1.

Click [Connect] under [Connect] menu

Choose a COM port and click OK

Choose ‘TC2S’ from the list

Click [Settings] button

Click [Upload] button

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EM-8468 Rev.3 P. 7 / 37

■ R3CON CONFIGURATION WINDOW

For setting details, refer to the R3-TC2 instruction manual.

Alternatively press F5 button on the keyboard to reload.

The Controller’s setting window is as shown below.
The trend graph shows real time PV and MV status, and parameters and operation status can be monitored.

(1) MONITOR WINDOW

Trend graph shows PV, SP and MV for loop 1 and 2.
Choose Loop 1 or Loop 2 tub at the top.
Trend data for both loops is continuously stored

1

even though only one loop is chosen at a moment.

(2) SWITCHING OPERATION / MODE

Control operation and mode is set with the buttons.

8

7

6

2

(3) ALARM INDICATORS / RESET BUTTONS

3

Alarm status of the selected loop is indicated.
Various alarm status can be reset by clicking [Reset PV],
[Reset CT] and [Reset All].

5

(4) SETTING ITEMS TREE & LIST

Setting parameters are grouped in the menu tree.

4

Choose a specic group to show a parameter list
to choose from. Modied selections / values are written

9

in the device immediately.

13

(5) CT INPUT INDICATORS

CTx(ON) display shows current value when the relevant
control output is ON; while CTx(OFF) shows current
when it is OFF.
‘ - ’ shows that the control output has not been switched
on or off during the last control cycle.

R3-TC2

10

11

12

(6) BANK

[Switch Bank] dialog box appears when [Bank] button
is clicked.
Choose a bank and click OK to apply the change.

(7) AUTO-TUNING

[Auto-tuning] dialog box appears when [Auto-tuning]
is clicked.
Choose a bank and click OK to start auto-tuning for the
specied bank.

(8) MANUAL MV

[Set MV Manually] dialog box appears when
[Manual MV] button is clicked.
Enter a MV value and click OK to apply the change
(only in MAN mode).

(9) SETTINGS

Graph scales in the trend graph and display language
can be changed.
[Settings] dialog box appears when the button is clicked.

(10) Y axis max / Y axis min

Specify a full-scale temperature range for Y axis.
Selectable from -9999.9999 to +9999.9999.
Minimum span is of 0.2.

(11) X axis time span

Specify a full-scale time span for X axis.
Selectable among:
10 sec. 30 sec. 1 min. 3 min. 5 min.
10 min. 15 min. 30 min. 1 hour 2 hours

(12) Display Language

English and Japanese can be switched.

(13) RELOAD

Used to upload the setting from the device.

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EM-8468 Rev.3 P. 8 / 37

■ SETTING EXAMPLE 1: TEMPERATURE CONTROL WITH STANDARD PID

The following is an example to control temperature of loop 1 to 40.0°C by standard PID control.

R3-TC2

4

5

2

8

6

4

(1) Connect Pt100 to the universal input terminal 1 to measure temperature. Connect also an SSR and a heater to the control

output 1.

Pt100

Heater

SSR

Power Supply

Universal Input 1

Control Output 1

R3-TC2PS

(2) Go to the setting items tree and change the following parameters.

SETTING ITEMS TREE PARAMETER SELECTION

Universal input 1 Input type RTD Pt 100
Universal input 1 Wiring 3 wires
Control output 1 Output assignment Loop 1, Heating control
Loop 1, Bank 0 SP (setpoint value) 40.0

(3) Confirm that Pt100 is correctly connected to the universal input 1 and the controlled object (heater, etc) for heating control

to the control output 1.

(4) Click RUN button and AUTO button located below the trend graph to start control operations. Indicators STOP and MAN

are switched respectively to RUN and AUTO.

(5) Click Auto-tuning button located below the trend graph to show the Auto-tuning dialog box. Choose Bank 0 and click OK.

(6) The Controller starts auto-tuning. Indicator AT starts blinking. Click STOP button to stop the auto-tuning.

(7) Indicator AT stops blinking to start control operation when the auto-tuning is complete.

(8) Go to the setting items tree and change the following parameters so that the control operation automatically starts at the

start up of the device.

SETTING ITEMS TREE PARAMETER SELECTION

Loop 1 Operation at startup RUN
Loop 1 Control mode at startup AUTO

Now the setting is complete.

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EM-8468 Rev.3 P. 9 / 37

R3-TC2

■ SETTING EXAMPLE 2: HEATER WIRE BREAK

In addition to the setting example 1 configuration, the heater’s wire break can be detected using a CT input. Suppose that the
heater has 100V / 1kW rating, driven by an SSR.

(1) Current flowing through the heater is calculated in the equation: 1kW / 100V = 10A. Choose the current sensor model

CLSE-05, for the maximum of 50A rating. Connect the sensor to CT input 1 as in the figure below.

Heater

CLSE-05

SSR

Power Supply

CT Input 1

Control Output 1

R3-TC2

(2) Go to the setting items tree and change the following parameters.

SETTING ITEMS TREE PARAMETER SELECTION

CT input 1 CT sensor type CLSE-05
CT input 1 Output assignment Control output 1

(3) Once the above setting is complete, the Controller measures current values of the control output 1 at ON and OFF states.

The CT1(ON) display shows (approx.) 10A and the CT1(OFF) display shows (approx.) 0.0A.

(4) Set a threshold for the heater wire break.

Set to 5.0A, a value half the rating (approx. 10.0A).

SETTING ITEMS TREE PARAMETER SELECTION

CT input 1 Heater wire break alarm Enable
CT input 1 Heater wire break alarm setpoint 5.0

(5) Set also the following items if the wire break should be alerted at the control output 3 (open collector).

SETTING ITEMS TREE PARAMETER SELECTION

CT input 1 Heater wire break alarm output Control output 3
Control output 3 Output assignment Alarm OR

Now the heater wire break alarm setting is complete.

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EM-8468 Rev.3 P. 10 / 37

R3-TC2

■ SETTING EXAMPLE 3: SWITCHING SETPOINT VALUE BY EVENT INPUT

The Controller has two discrete inputs for event control input.
At the maximum of four sets of temperature setpoints and PID parameters can be predefined and stored in the ‘banks.’ The
external event input can be used to switch among these banks.
In this example, the Controller is set according to the example 1 for the setpoint 40.0°C. By using banks, an additional setting
to switch the setpoint to 50.0°C by an event input is created.

(1) Connect a switch to the discrete input 1 as shown below.

Di 1

R3-TC2

(2) Go to the setting items tree and change the following parameters.

SETTING ITEMS TREE PARAMETER SELECTION

Loop 1, Bank 1 SP (setpoint value) 50.0
Event input Event input 1 function assignment Loop 1, Bank bit 0

(3) Click Auto-tuning button located below the trend graph to show the Auto-tuning dialog box. Choose Bank 1 and click OK.

The Controller go through auto-tuning and then starts control operations.

Now the setting is complete to switch the temperature setpoint to 50.0°C with the switch closed (ON) and to 40.0°C with the
same opened (OFF).

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EM-8468 Rev.3 P. 11 / 37

R3-TC2

MODBUS COMMUNICATION

■ R3 I/O DATA

The Controller functions as an analog input module in the R3 remote I/O system. The following 8 words of analog input data
can be read out at Input Register area.

+0

+1

+2

+3

+4

+5

+6

+7

Loop 1 PV (number of decimal places as specified with the ‘input 1 decimal’)

Loop 1 SP (number of decimal places as specified with the ‘input 1 decimal’)

Loop 1 Heating MV (0.01% increments)

Loop 1 Cooling MV (0.01% increments)

Loop 2 PV (number of decimal places as specified with the ‘input 2 decimal’)

Loop 2 SP (number of decimal places as specified with the ‘input 2 decimal’)

Loop 2 Heating MV (0.01% increments)

Loop 2 Cooling MV (0.01% increments)

■ R3 EXTENSION AREA COMMUNICATION

The Controller is compatible with the R3 extension area communication.
By using the model R3-NM3 Modbus Extension Network Module, a large volume of its data can be read out and written in
from the Modbus host device via Holding Register area.

■ EXTENSION AREA ADDRESS ASSIGNMENTS

A Holding Register area of 3000 words is assigned per I/O module as shown in the table below.

SLOT ADDRESS

1 2001 through 5000
2 5001 through 8000
3 8001 through 11000
4 11001 through 14000

: :
15 44001 through 47000
16 47001 through 50000

■ READING EXAMPLE

In order to read the MV value in the table below from the R3-TC2 in the slot position 2, read 1 word at the address 5005, slot
2 top address 5001 added with 4.

ADDRESS PARAMETER UNIT

+4 Loop 1, Heating MV (control output) 0.01%

If 7510 is read, the register value is converted into actual engineering unit value by the following equation:
7510 × 0.01 = 75.10%

■ WRITING EXAMPLE

In order to write 40.0 at the SP value in the table below of the R3-TC2 in the slot position 3, write 400 (when the input 1
decimal is set to ‘1,’ disregard the decimal point) at the address 9153, slot 3 top address 8001 added with 1152.

ADDRESS PARAMETER RANGE DEFAULT

+1152 Loop 1, SP (setpoint) -3200.0 to +3200.0

(decimal by input 1 decimal setting)

25.0

With the decimal setting ‘2,’ write in ‘4000’ for ‘40.00.’
With the setting ‘3,’ ‘40000’ cannot be written as the maximum range is limited up to 32000.

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EM-8468 Rev.3 P. 12 / 37