Rockwell Automation 900-TC32 User Manual

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Temperature Controllers

USER MANUAL

Bulletin 900-TC8, 900-TC16, & 900-TC32

Series B

ATTENTION

Important User Information

Because of the variety of uses for the prod ucts described in this publi cation, those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards.

The illustrations, charts, sample programs and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Rockwell Automation does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples sho wn in this publication.

Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation and Maintenance of Solid-State Control (available from your local Allen-Bradley sales office), describes some important differences between solid-state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication.

Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited.

Safety Precautions

Safety Signal Words

This manual uses the following signal word to mark safety precautions for the Bulletin 900-TC8, 900-TC16, and 900-TC32 Temperature/Process Controllers.

These precautions provide important information for the safe application of the Temperature/Process Controller. You must make sure to follow the instructions provided in all safety precautions.:

Identifies information about practices or circumstance s that can lead to personal injury or death, property damage or economic loss

IMPORTANT

Attention statements help you to:

• identify a hazard

• avoid a hazard

• recognize the consequences

Identifies information that is critical for successful application and understanding of the product.

Trademark List

900Builder and 900BuilderLite are registered trademarks of Rockwell Automation, Inc.

European Communities (EC) Directive Compliance

If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and tested to meet the following directives.

EMC Directive

This product is tested to meet the Council Directive 89/336/EC Electromagnetic Compatibility (EMC) by applying the following standards, in whole or in part, documented in a technical construction file:

EN 61326 EMC Requirements — Electrical Equipment for Control, Measurement and Laboratory Use

This product is intended for use in an industrial environment.

Low Voltage Directive

This product is tested to meet Council Directive 73/23/EEC Low Voltage, by applying the safety requirements of EN 61010-1 Safety Requirements for Electrical Equipment for Control, Measurement and Laboratory Use — General Requirements. For specific information, see the appropriate sections in this publication, as well as the Allen-Bradley publication Industrial Automation Wiring and Grounding Guidelines For Noise Immunity, Publication 1770-4.1.

This equipment is classified as open equipment and must be mounted in an enclosure during operation to provide safety protection.

Table of Contents

Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Safety Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

European Communities (EC) Directive Compliance . . . . . . . . . 1-4

Low Voltage Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Preface

Bulletin 900 Input & Output Overview

Conventions Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-i

Meanings of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-i

Series B Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-ii

Series B Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-ii

900-TC8x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-ii

900-TC16x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-ii

900-TC32x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-ii

Terminal Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-iv

Body Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-v

900-TC8, 900-TC16, & 900-TC32 Ratings . . . . . . . . . . . . . . . . . . . . P-vi

Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-vi

Communications Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-vii

Other Upgrades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-viii

Option Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-ix

How to Read Display Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-x

Chapter 1

I/O Configurations & Main Functions. . . . . . . . . . . . . . . . . . . . . . . . 1-1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Main Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Controller Hardware Versions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

900-TC8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

900-TC16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

900-TC32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Front Panels & General Functions . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Display Meanings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Operation Indicators 1,2,3... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Basic Keypad Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Chapter 2

Preparations

1-1 Publication 900-UM007D-EN-E - January 2011

Hardware Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Approximate Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Panel Cutout Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

System Wiring and Installation Guidelines. . . . . . . . . . . . . . . . . . 2-4

Panel Mounting — 900-TC8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Setting Up the 900-TC8 Controller with the Optional Units . . . 2-9

1-2 Table of Contents

Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Bulletin 900 Wiring Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Wiring Guidelines and Precautions. . . . . . . . . . . . . . . . . . . . . . . 2-17

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Using the Direct PC Communications Port . . . . . . . . . . . . . . . . . . . 2-30

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Chapter 3

Configuration & Basic Operation

How Function Groups Are Configured and Operating the Keys on the

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Selecting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Changing Parameters/Loading Values into Controller Memory. 3-7

Communications Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Setting Up Communications Parameter Data . . . . . . . . . . . . . . . 3-9

Initial Setup Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Configuring the Input Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Input Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Selecting °C/°F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Temperature Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Configuring the SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Changing the SP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Selecting PID Control or ON/OFF Control . . . . . . . . . . . . . . . . . . 3-16

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

2-PID Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

ON/OFF Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Configuring the Output Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Control Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Direct/Reverse Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Assigned Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Auxiliary Output Opening or Closing in Alarm . . . . . . . . . . . . . . . . 3-25

Executing the ON/OFF Control Method . . . . . . . . . . . . . . . . . . . . 3-25

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

ON/OFF Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

ON/OFF Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Determining PID Constants (AT, ST, Manual Setup) . . . . . . . . . . . 3-30

AT (Auto-Tuning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

ST (Self-Tuning). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Conditions that Start Self-Tuning (SRT) . . . . . . . . . . . . . . . . . . 3-34

Self-Tuning (ST) Stable Range . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

RT (Robust Tuning). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Manual PID Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Alarm Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42

Alarm Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

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Table of Contents 1-3

PV Change Rate Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Precaution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

Heater Burnout Alarm (HBA), Heater Short Alarm (HSA), and Heater

Overcurrent Alarm (HOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46

HBA, HSA, and HOA Alarm Detection . . . . . . . . . . . . . . . . . . 3-46

Installing Current Transformers (CT). . . . . . . . . . . . . . . . . . . . . 3-48

How to Calculate Heater Current Detection Values . . . . . . . . . 3-50

Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Heater Burnout Alarm (HBA) Setup . . . . . . . . . . . . . . . . . . . . . 3-55

HS Alarm Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58

Heater Overcurrent Alarm Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60

Moving to the Advanced Setting Function Group . . . . . . . . . . 3-60

Configure Overcurrent Detection. . . . . . . . . . . . . . . . . . . . . . . . 3-61

Set-up of the No. 3 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62

MV Display for Heating and Cooling Control . . . . . . . . . . . . . . . . . 3-63

System Setup/Operational Considerations. . . . . . . . . . . . . . . . . . . . 3-65

Chapter 4

Parameter Adjustments & Application Considerations

Shifting Input Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

1-Point (Uniform) Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

2-Point Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

How to Calculate Input Shift Values . . . . . . . . . . . . . . . . . . . . . . 4-3

Using the 1-Point Shift Method . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Using the 2-Point Shift Method . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Alarm Functions/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Alarm Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Standby Alarm Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Alarm Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Summary of Alarm Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Configuration of Scaling Upper-Limits and Scaling Lower-Limits for

Analog Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Executing the Heating and Cooling Control Mode . . . . . . . . . . . . . 4-12

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Dead Band (Heating and Cooling Control) . . . . . . . . . . . . . . . . 4-13

Setup of Heating and Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Using the Event Input Feature — 900-TC8 & 900-TC16. . . . . . . . 4-16

Multi-SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Selecting Multi-SP by Keypad Operation . . . . . . . . . . . . . . . . . . 4-19

Multi-SP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Executing RUN/STOP Controller Mode Change. . . . . . . . . . . 4-23

Switching Between Auto and Manual Control . . . . . . . . . . . . . . 4-23

Controlling the Start of the Simple Program Function . . . . . . . 4-23

Control by Inverting Direct/Reverse Operation . . . . . . . . . . . . 4-24

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1-4 Table of Contents

Switching 100% AT Execute/Cancel . . . . . . . . . . . . . . . . . . . . . 4-24

Switching 40% ATExecute/Cancel . . . . . . . . . . . . . . . . . . . . . . 4-25

Switching Setting Change Enable/Disable. . . . . . . . . . . . . . . . . 4-25

Switching Alarm Latch Cancel . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Configuring the SP Upper- and Lower-Limit Values. . . . . . . . . . . . 4-26

Set Point Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Application Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Set Point Limit Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

Executing the SP Ramp Function to Limit the SP Rate of Change 4-29

SP Ramp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

SP Ramp Application Considerations. . . . . . . . . . . . . . . . . . . . . 4-30

To Move to the Advanced Setting Function Group . . . . . . . . . . . . 4-31

Using the Key Protect Function Group . . . . . . . . . . . . . . . . . . . . . . 4-33

Key Protect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

PV Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

PV Color Change Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Alarm Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Alarm Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Loop Break Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Loop Break Alarm (LBA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

Performing Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Manual Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

Manual MV Limit Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54

Using the Transfer Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

Transfer Output Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62

Using the Simple Program Function . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Simple Program Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

Operation at the Program End . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69

Output Adjustment Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

Output Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

MV at Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75

MV at PV Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76

Using the Extraction of Square Root Parameter . . . . . . . . . . . . 4-77

Setting the Rate of MV Variation . . . . . . . . . . . . . . . . . . . . . . . . 4-80

Setting the PF Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82

Monitor/Setting Item. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83

Monitor/Setting Item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83

Counting Control Output ON/OFF Operations . . . . . . . . . . . . . . 4-87

Control Output ON/OFF Count Function. . . . . . . . . . . . . . . . 4-87

Displaying PV/SV Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90

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Chapter 5

Table of Contents 1-5

Parameter Functions & Definitions

Conventions Used in This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

About the Parameter Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Protect Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Move to Protect Function Group. . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Operation/Adjustment Protection . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Initial Setting/Communications Protection . . . . . . . . . . . . . . . . . 5-4

Setting/Configuration Change Protection . . . . . . . . . . . . . . . . . . 5-4

PF Key Protect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Parameter Mask Enable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Password to Move to Protect Function Group . . . . . . . . . . . . . . 5-5

Operation Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

PV (Process Value) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

PV/SP – Process Value/Set Point – No. 1 Display

PV/SP – Process Value/Set Point – No. 2 Display (900-TC8) . 5-8

No. 3 Display (900-TC8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Auto Manual Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Multi-SP (Set Point 0…3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Set Point During SP Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Heater Current 1 Value Monitor. . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Heater Current 2 Value Monitor. . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Leakage Current 1 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Leakage Current 2 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Program Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Soak Time Remain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

RUN/STOP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Alarm Value 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Alarm Value 2 (900-TC8, 900-TC16) . . . . . . . . . . . . . . . . . . . . . 5-17

Alarm Value 3 (900-TC8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Upper-Limit Alarm Value 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Lower-Limit Alarm Value 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Upper-Limit Alarm Value 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Lower-Limit Alarm Value 2 (900-TC8, 900-TC16) . . . . . . . . . . 5-19

Upper-Limit Alarm Value 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Lower-Limit Alarm Value 3 (900-TC8 only) . . . . . . . . . . . . . . . 5-20

MV Monitor (Heating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

MV Monitor (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Adjustment Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Adjustment Function Group Display . . . . . . . . . . . . . . . . . . . . . 5-24

AT Execute/Cancel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Communications Writing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Heater Current 1 Value Monitor. . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Heater Current 1 Value Monitor. . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Leakage Current 1 Monitor (900-TC8, 900-TC16) . . . . . . . . . . 5-28

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Leakage Current 2 Monitor (900-TC8, 900-TC16) . . . . . . . . . . 5-29

Heater Burnout Detection 1 (900-TC8, 900-TC16). . . . . . . . . . 5-30

Heater Burnout Detection 2 (900-TC8, 900-TC16). . . . . . . . . . 5-31

HS Alarm 1 (900-TC8, 900-TC16) . . . . . . . . . . . . . . . . . . . . . . . 5-31

HS Alarm 2 (900-TC8, 900-TC16) . . . . . . . . . . . . . . . . . . . . . . . 5-32

Set Point 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Set Point 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Set Point 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Set Point 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Temperature Input Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

Upper-Limit Temperature Input Shift Value,

Lower-Limit Temperature Input Shift Value . . . . . . . . . . . . . . . 5-35

Proportional Band, Integral Time, Derivative Time . . . . . . . . . 5-35

Cooling Coefficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36

Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Manual Reset Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Hysteresis (Heating)

Hysteresis (Cooling). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Soak Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

Wait Band. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

MV at Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

MV at PV Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

SP Ramp Set Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

MV (Manipulated Variable) Upper-Limit,

MV (Manipulated Variable) Lower-Limit . . . . . . . . . . . . . . . . . . 5-42

MV Upper-Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

MV Lower-Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

MV (Manipulated Variable) Change Rate Limit, . . . . . . . . . . . . 5-43

Extraction of Square Root Low-cut Point,. . . . . . . . . . . . . . . . . 5-44

Monitor/Setting Item Level (900-TC8) . . . . . . . . . . . . . . . . . . . . . . 5-45

Monitor/Setting Item Display 1 to 5 . . . . . . . . . . . . . . . . . . . . . 5-45

Manual Control Function Group . . . . . . . . . . . . . . . . . . . . . . . . 5-46

PV/MV (Manual MV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Initial Setting Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

Input Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Scaling Upper-Limit, Scaling Lower-Limit, Decimal Point . . . . 5-52

Temperature Units (°C/°F) Selection. . . . . . . . . . . . . . . . . . . . . 5-53

Set Point Upper-Limit, Set Point Lower-Limit . . . . . . . . . . . . . 5-54

PID ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Standard or Heating/Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

ST Self-Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

Program Pattern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

Control Period (Heat) ,Control Period (Cool) . . . . . . . . . . . . . . 5-57

Direct/Reverse Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

Alarm Type for Alarm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

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Alarm Type for Alarm 2 (900-TC8 & 900-TC16) . . . . . . . . . . . 5-59

Alarm Type for Alarm 3 (900-TC8) . . . . . . . . . . . . . . . . . . . . . . 5-59

Alarm 1 Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

Alarm 2 Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

Alarm 3 Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62

Transfer Output Type (900-TC8, 900-TC16). . . . . . . . . . . . . . . 5-62

Transfer Output Upper-Limit

Transfer Output Lower-Limit. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

Linear Current Output (900-TC8, 900-TC16) . . . . . . . . . . . . . . 5-64

Number of Multi-SP Uses (900-TC8, 900-TC16) . . . . . . . . . . . 5-65

Event Input Assignment (* 1 and 2) (900-TC8, 900-TC16) . . . 5-66

Extraction of Square Root Enable (900-TC8, 900-TC16) . . . . . 5-68

Move to Advanced Setting Function Group . . . . . . . . . . . . . . . 5-68

Advanced Setting Function Group . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69

Parameter Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71

Multi-SP Uses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71

SP Ramp Time Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71

Standby Sequence Reset Method . . . . . . . . . . . . . . . . . . . . . . . . 5-72

Auxiliary Output * Open in Alarm . . . . . . . . . . . . .(* = 1 to 3) 5-73

HB ON/OFF (900-TC8, 900-TC16) . . . . . . . . . . . . . . . . . . . . . 5-74

Heater Burnout Latch (900-TC8, 900-TC16). . . . . . . . . . . . . . . 5-74

Heater Burnout Hysteresis (900-TC8, 900-TC16) . . . . . . . . . . . 5-75

ST (Self-Tuning) Stable Range . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75

α . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76

AT Calculated Gain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77

AT Hysteresis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77

Limit Cycle MV Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77

Input Digital Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-77

Additional PV Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78

Manipulated Variable (MV) Display . . . . . . . . . . . . . . . . . . . . . . 5-78

Automatic Display Return Time . . . . . . . . . . . . . . . . . . . . . . . . . 5-79

Alarm 1 Latch, Alarm 2 Latch, Alarm 3 Latch. . . . . . . . . . . . . . 5-79

Protect Function Group Move Time . . . . . . . . . . . . . . . . . . . . . 5-80

Input Error Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81

Cold Junction Compensation Method . . . . . . . . . . . . . . . . . . . . 5-82

MB Command Logic Switching . . . . . . . . . . . . . . . . . . . . . . . . . 5-82

PV Color Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82

PV Stable Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

Alarm 1 ON Delay, Alarm 2 ON Delay, Alarm 3 ON Delay . . 5-85

Alarm 1 OFF Delay, Alarm 2 OFF Delay, Alarm 3 OFF Delay 5-86

Input Shift Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86

MV at Stop and Error Addition . . . . . . . . . . . . . . . . . . . . . . . . . 5-87

Auto/Manual Selection Addition . . . . . . . . . . . . . . . . . . . . . . . . 5-87

Robust Tuning (RT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88

Heater Short Alarm (HSA) Use (900-TC8, 900-TC16) . . . . . . . 5-88

Heater Short Alarm (HSA) Latch (900-TC8, 900-TC16). . . . . . 5-89

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Heater Short Alarm (HSA) Hysteresis

(900-TC8, 900-TC16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89

Loop Break Alarm (LBA) Detection Time. . . . . . . . . . . . . . . . . 5-90

Loop Break Alarm (LBA) Level . . . . . . . . . . . . . . . . . . . . . . . . . 5-90

Loop Break Alarm (LBA) Band . . . . . . . . . . . . . . . . . . . . . . . . . 5-91

Control Output 1 Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92

Control Output 2 Assignment (900-TC8 & 900-TC16) . . . . . . 5-93

Auxiliary Output 1 Assignment. . . . . . . . . . . . . . . . . . . . . . . . . . 5-93

Auxiliary Output 2 Assignment (900-TC8, 900-TC16) . . . . . . . 5-94

Auxillary Output 3 Assignment. . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

Character Select LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96

Soak Time Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-96

Alarm SP Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

Manual MV Limit Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

PV Rate of Change Calculation Period. . . . . . . . . . . . . . . . . . . . 5-98

Automatic Cooling Coefficient Adjustment. . . . . . . . . . . . . . . . 5-98

Heater Overcurrent Use (900-TC8, 900-TC16) . . . . . . . . . . . . . 5-99

Heater Overcurrent Latch (900-TC8, 900-TC16) . . . . . . . . . . . 5-99

Heater Overcurrent Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . 5-100

(900-TC8, 900-TC16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100

PF Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101

Monitor/ Setting Item * (*: 1 to 5) . . . . . . . . . . . . . . . . . . . . . . 5-102

PV/SP Display Screen Selection. . . . . . . . . . . . . . . . . . . . . . . . 5-103

MV Display Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-103

PV Decimal Point Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104

PV Status Display Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105

SV Status Display Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106

Display Refresh Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106

Control Output 1 ON/OFF Count Monitor . . . . . . . . . . . . . . 5-107

Control Output 2 ON/OFF Count Monitor

(900-TC8 & 900-TC16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107

Control Output 1 ON/OFF Count Alarm Set Value

(900-TC8, 900-TC16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107

Control Output 2 ON/OFF Count Alarm Set Value

(900-TC8, 900-TC16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108

ON/OFF Counter Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108

Move to Calibration Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109

Communications Setting Function Group . . . . . . . . . . . . . . . . . . . 5-109

Protocol Setting

Communications Unit No.

Communications Baud Rate

Communications Data Length

Communications Stop Bits

Communications Parity

Send Data Wait Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-110

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Troubleshooting & Error Indication

Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Input Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Display Range Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

AD Converter Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Memory Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Current Value Exceeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Heater Burnout Alarm (HBA)

Heater Short Alarm (HSA)

Heater Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Appendix A

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Heater Burnout Alarm (HBA), Heater Short Alarm (HSA), and

Heater Overcurrent Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

900-CPOEM1 USB-Serial Conversion Cable. . . . . . . . . . . . . . . A-5

Current Transformer (CT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

Approximate External Dimensions . . . . . . . . . . . . . . . . . . . . . . A-7

Sensor Input Setting

and Indication Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9

Control Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10

Calibration

Appendix B

Parameter Operations List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Function Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Setup Function Group Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . B-16

Parameter Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-17

Appendix C

Parameter Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Registering Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3

User Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Calibrating Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Registering Calibration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4

Calibrating Thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5

Calibrating 0…50 mV Analog Input. . . . . . . . . . . . . . . . . . . . . . . . . C-10

Calibrating Platinum Resistance Thermometers. . . . . . . . . . . . . . . . C-12

Calibrating Analog Input (e.g., 4…20 mA Analog Input) . . . . . . . . C-14

Calibrating an Analog Current Input (900-TC8 & 900-TC16) . C-14

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Calibrating an Analog Voltage (e.g., 1…5V DC) Input

(900-TC8 & 900-TC16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16

Checking Indication Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-18

Checking Accuracy of a Thermocouple or Non-Contact

Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-18

Checking Indication Accuracy of a Platinum Resistance

Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-19

Analog Input (900-TC & 900-TC16) . . . . . . . . . . . . . . . . . . . . . C-20

Appendix D

Glossary

Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Index

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Preface

Conventions Used in This Manual

Meanings of Abbreviations

The following abbreviations are used in parameter names, figures, and in text explanations. These abbreviations mean the following:

Table P.A

Symbol Term

PV Process value SP Set point SV Set value AT Auto-tuning ST Self-tuning HB Heater Burnout HS Heater Short ➊ EU Engineering unit ➋ OC Overcurrent LBA Loop Burnout Alarm

➊ A heater short indicates that the heater remains ON even when the control output from the Temperature

Controller is OFF because the SSR has failed or for any other reason.

➋ “EU” stands for Engineering Unit. EU is used as the minimum unit for engineering units such as °C, m, and g.

The size of EU varies according to the Input Type. For example, when the input temperature setting range is –200…+1300°C, 1 EU is 1°C, and when the input temperature setting range is –20.0…+500.0°C, 1 EU is 0.1°C. For analog inputs, the size of EU varies according to the decimal point position of the scaling setting, and 1 EU becomes the minimum scaling unit.

Note: For additional definitions of terms used in this manual, refer to

Appendix D, Glossary.

P-i Publication 900-UM007C-EN-E - January 2011

P-ii Preface

Series B Controllers

Series B Upgrades

Series B controllers have the following upgrades.

900-TC8x

Although the upgraded controllers are compatible with the previous controllers, terminal arrangements have been changed. Terminal sizes and panel mounting depth have not been changed.

Other changes are outlined in the following tables. Refer to the relevant pages in the manual for details.

900-TC16x

The upgraded controllers are basically compatible with the previous controllers. Terminal arrangements, terminal sizes, and panel mounting depth have not been changed.

900-TC32x

Model numbers have changed accompanying the introduction of universal input capability. The default setting of the input type parameter of the 900-TC32x (models with resistance thermometers) has been changed from a Pt100 resistance thermometer to a K thermocouple. Make sure the setting of the input type parameter agrees with the temperature sensor that is being used.

The terminal block has also been changed, which means the wiring methods and terminal arrangement are different.

Publication 900-UM007C-EN-E - January 2011

Table P.B

STOPOUT1

MANU

CMWOUT2

SUB2

SUB3

SUB1

CMW STOP OUT

Preface P-iii

Series A Series B

900-TC16

900-TC8

ALM1

ALM2

ALM3

OUT1

STOP

MANU

CMW

OUT2

ALM2

ALM1

ALM3

OUT1

STOP

OUT2

CMW

MANU

• Number of displays: 2 (PV and SV)

ALM1

ALM2

ALM3

OUT1

STOP

MANU

CMW

OUT2

• ALM indicator was changed to SUB indicator

• Number of displays: 3 (PV, SV, and MV) ➊

• ALM indicator was changed to SUB indicator.

900-TC32

• Display Segments – PV: 7 segments, SV: 7

• Character Heights – PV: 7 mm, SV: 3.5 mm

segments

CMW STOP OUT

SUB1

MANU

• Display Segments – PV: 11 segments, SV: 11 segments

• Character Heights – PV: 7.5 mm, SV: 3.6 mm

• Changes to Display Contents – “AL” LED indicator eliminated, LED indicators and key indicator added

➊ A 2-level display is configured when shipped from the factory. A 3-level display is activated if parameters are

initialized.

Publication 900-UM007C-EN-E - January 2011

P-iv Preface

−

CT1

CT2

−

DO NOT USE

One CT

Two CTs

Analog inputTC/Pt universal input

Control Output 2

14 15

16 17

18 19

1212

1111

1010

3 5

InputInput

Power Power SupplySupply

ControlControl

Output 1Output 1

AuxillaryAuxillary Output 1Output 1

DO NOTDO NOT USEUSE

Universal TC/Pt Input

DO NOTDO NOT USEUSE

B(+)

A(-)

RS-495 Communications

Terminal Arrangements

Table P.C — Terminal Arrangements

Series A Series B

One CT

Two CTs

CT1

CT2

900-TC8

Voltage output

Control Output 2

−

TC/Pt universal input

12 VDC , 21 mA

−

Long-life relay output

Control Output 2

250 VAC, 3 A

(Resistive load)

−

Analog input

−

Terminals 16...20 were changed and 1...15 were not.

900-TC16 --- No change for terminal layout

900-TC32

• 100 to 240 VAC

• 24 VAC/DC (no polarity)

Number of terminals: 9 (1 to 9) Input terminals: 7 to 9 RS-485 communication terminals: 5 & 6

Publication 900-UM007C-EN-E - January 2011

Number of terminals: 14 (1 to 14) Input terminals: 10 to 12 RS-485 communication terminals: 7 & 8

Body Removal

Table P.D — Body Removal

Series A Series B

Preface P-v

• Removal using screws

900-TC8

900-TC16 --- • No change for body removal 900-TC32 --- • No change for body removal

• Removal using hooks

900-TC8, 900-TC16, & 900-TC32 Ratings

Table P.E — 900-TC8, 900-TC16, & 900-TC32 Ratings

---

Input sensor types for thermocouple inputs

Input range for E thermocouple: 0...600 ºC

• Thermocouple: ±0.5% PV or ±1ºC,

• Platinum resistance thermometer:

Input accuracy

• Analog input: ±0.5% FS ± digit

Series A Series B

whichever is greater) ±1 digit

(±0.5%PV or ±1ºC, whichever is greater) ± 1 digit

The following types of thermocouple input were added: W and PLII.

Input range increased for E thermocouple:

-200...600 ºC

• Thermocouple: ±0.3% PV or ±1ºC, whichever is greater) ±1 digit

• Platinum resistance thermometer: (±0.2%PV or ±.08ºC, whichever is greater) ± 1 digit

• Analog input: ±0.2% FS ± digit

Publication 900-UM007C-EN-E - January 2011

P-vi Preface

PF Key

900-TC8, 900-TC16, & 900-TC32 Ratings

Table P.E — 900-TC8, 900-TC16, & 900-TC32 Ratings

---

Input sensor types for thermocouple inputs

Input range for E thermocouple: 0...600 ºC

• Thermocouple: ±0.5% PV or ±1ºC,

• Platinum resistance thermometer:

Input accuracy

• Analog input: ±0.5% FS ± digit

Series A Series B

whichever is greater) ±1 digit

(±0.5%PV or ±1ºC, whichever is greater) ± 1 digit

The following types of thermocouple input were added: W and PLII.

Input range increased for E thermocouple:

-200...600 ºC

• Thermocouple: ±0.3% PV or ±1ºC, whichever is greater) ±1 digit

• Platinum resistance thermometer: (±0.2%PV or ±.08ºC, whichever is greater) ± 1 digit

• Analog input: ±0.2% FS ± digit

Influence of signal source resistance

Current outputs

Alarm outputs

Characteristics

• Thermocouple: 0.1ºC/Ω (except B, R, S), 0.2ºC/Ω (B, R, S)

• Platinum resistance thermometer:

0.4ºC/Ω

• Current output resolution, approx.: 2,700

• 250 VAC, 1A (900-TC16 & 900-TC32) • 250VAC, 3A (900-TC16)

Table P.F — Characteristics

Series A Series B

--- PV Status Display

Front Panel (900-TC8)

• Thermocouple: 0.1ºC/Ω (for all specifications)

• Platinum resistance thermometer:

0.1ºC/Ω

• Current output resolution, approx.: 10,000

• 250VAC, 2A (900-TC32)

PF Key Added

Publication 900-UM007C-EN-E - January 2011

---

Inputs ---

PV/SP display selection for three-level display

Square root extraction (for models with analog inputs)

Table P.F — Characteristics

Series A Series B

---

Outputs

--- MV change rate limiter

--- 40% AT

Preface P-vii

Control output ON/OFF count alarm

Communications Characteristics

Controls

Alarms

Other ---

Table P.G

Communication Access Size

Communication Service

Communications buffer size

Baud rate

Automatic cooling coefficient

---

--- PV rate of change alarm

---

Series A Series B

Double word access only

---

40 bytes 217 bytes

38.4 kbits/s max. (900-TC08, 900-TC16)

19.2 kbits/s max. (900-TC32)

adjustment for heating/cooling control

OC alarm (only for models with heater burnout detection)

Inverting direct/reverse operation using event inputs or communications commands

Word access and double word access

Composite Read from Variable Area and Composite Write to Variable Area

57.6 kbits/s max.

External communications

RS-485/RS-232C external communications and communications via 900BuilderLite ™ cannot be used at the same time.

Publication 900-UM007C-EN-E - January 2011

RS-485/RS-232C external communications and communications via 900BuilderLite ™ can be used at the same time.

P-viii Preface

Modified section

Other Upgrades

Table P.H

Mounting Bracket (900-TC8 only)

Terminal Cover for 900-TC16

Series A Series B

Note: The mounting bracket for the Series A models cannot be used for Series B models.

Terminal Cover for 900-TC8

Note: The terminal covers for the Series A models cannot be used for Series B models.

Publication 900-UM007C-EN-E - January 2011

Preface P-ix

Option Units (Series B Controller Compatible— One Option Unit per Controller)

This unit provides communications event input etc. functionality.

Table P.I

Bulletin No. Name Function Cat. No. (Series)

900-TC8 (Series B)

900-TC16 (Series B)

➊ Enables direct RS-232 connection to personal computer using 900BuilderLite™ software. A Cat. No. 900-CP1X cable or equivalent is

also required.

➋ Provides two event inputs. Allows selecting up to 4 different pre-configured set points, controller Run/Stop or Auto/Manual mode,

from 2 external inputs.

➌ Heater burnout is not available for 0...20 or 4…20 mA analog output style 900-TC16 controllers such as the 900-TC16AC. ➍ To obtain 57.6 k baud rate, Series B communication units must be used with any Series A or Series B 900-TC8 controller catalog

number.

➎ Series B option units must be used with Series B 900-TC16 controllers. Series A option units cannot be used with Series B controllers

and vice versa.

➏ Series B provides 57.6 K baud rate.

Communications Unit

Event Input Unit Event Input➋ 900-TC8EIM(A)

Communications and 1-Phase Heater Burnout Unit and Heater Short

Event Input Unit with 1-Phase Heater Burnout and Heater Short

Event Input Unit Event Input➋ 900-TC16NACEIM(B)➎ Communications Unit RS-485 communications 900-TCNACCOM(B)➎➏

Communications and 3-Phase Heater Burnout and Heater Short Unit

Communications and Second Voltage (SSR) Output Unit

1-Phase Heater Burnout and second voltage (SSR) output

RS-232C communications➊ 900-TC8232 (B)➍ RS-485 communications 900-TC8COM(B)➍

RS-485 communications with single-phase heater burnout (open) and heater short-circuit failure detection➌

Event Input with single-phase heater burnout (open) and heater short-circuit failure detection➋➌

RS-485 communications with 3-phase heater burnout (open) and heater short-circuit failure detection

RS-485 communications and a second voltage (SSR) output

1-Phase Heater burnout (open) and heater short-circuit failure detection with a second control voltage (SSR) output

900-TC16NCOM(B)➎➏

900-TC16NEIM(B)➎

900-TC16NCOMP3(B)➎➏

900-TC16NCOMV2(B)➎➏

900-TC16P1V2(B)➎

Publication 900-UM007C-EN-E - January 2011

P-x Preface

ABCDEFGHI JKLM

NOPQRSTUVWXYZ

Symbol

Alphabet

ABCDEFGHI JKLM

NOPQRSTUVWXYZ

Symbol

Alphabet

How to Read Display Symbols

The following table shows the relationship between the symbols exhibited on the controller’s front panel displays to alphabet characters.

Table P.J 11 — Segment Display Selection

The Character Select parameter in the Advanced Setting function group can be turned OFF to display the following 7-segment characters.

Table P.K 7 — Segment Characters

Publication 900-UM007C-EN-E - January 2011

I/O Configurations & Main

Overcurrent Alarm

Temperature Input

or Analog Input

Control Section

CT1 Input

CT2 Input

Event Inputs

2 Channels

Set point input functions from external digital switches:

• RUN/STOP

• Program Start

• Auto/Manual

Control Output

Heating

Control Output

Cooling

Control Ouput 1

Control Ouput 2

Auxillary Output 3

Auxillary Output 2

Auxillary Output 1

Auxillary Output 3

Auxillary Output 2

Auxillary Output 1

HB Alarm

HS Alarm

Input Error

Simple Program

END Output

Communications

Function

QQ303T

Heating/Cooling

Chapter

Bulletin 900 Input & Output Overview

Functions

Figure 1.1 — 900-TC8 I/O Configuration

1-1 Publication 900-UM007D-EN-E - January 2011

1-2 Bulletin 900 Input & Output Overview

Temperature Input

or Analog Input

CT1 Input

CT2 Input

Event Inputs

2 Channels

Set point input functions from external digital switches:

• RUN/STOP

• Program Start

• Auto/Manual

Control Section

Control Output

Heating

Control Output

Cooling

Auxillary Output 2

Auxillary Output 1

Auxillary Output 2

Auxillary Output 1

Control Ouput 1

Control Ouput 2

Heating/Cooling

Overcurrent Alarm

HB Alarm

HS Alarm

Input Error

Simple Program

END Output

Communications

Function

QQ303T

Figure 1.2 — 900-TC16 I/O Configuration

Publication 900-UM007D-EN-E - January 2011

Figure 1.3 — 900-TC32 I/O Configuration

Bulletin 900 Input & Output Overview 1-3

Temperature Input

Control Section

Control Output

(Heating)

Control Output

(Cooling)

Alarm 1

Input Error

Program End

Output

Communications

Function

Heating/ Cooling

Standard

Control

Output 1

Auxillary Output 1

Bulletin 900-TC8, 900-TC16, and 900-TC32 temperature controllers allow the user to:

• Select from thermocouple and platinum RTD temperature sensors, plus non-contact temperature sensor and analog voltage or current inputs.

➊

• Individually assign the function for each output by changing the configured values of the following parameters: Control Output 1, Assignment, Control Output 2 Assignment Assignment

➊, and Aux 3 Assignment (900-TC8).

➊, Aux 1 Assignment, Aux 2

• Select heating and cooling control in addition to standard control

• Select AT (Auto-Tuning) and ST (Self-Tuning) as tuning functions

• Use multi-SP, switch between automatic and manual operation, start/reset the simple program function, and initiate the RUN/STOP function according to event input.

➊

• Use the Heater Burnout Alarm (HBA) and Heater Short Alarm (HSA) function.

➊

• Use the communications function (for units equipped with the optional communications function modules)

• Calibrate sensor input

• Configure the color of the PV display to switch between amber, red, and green, making the process status easy to understand at a glance.

➊ The Bulletin 900-TC32 Temperature Controller does not support this function

Publication 900-UM007D-EN-E - January 2011

1-4 Bulletin 900 Input & Output Overview

Features

• Watertight construction (equivalent to IP66 indoor use).

• Conform to cULus/IEC safety standards and EMC standards.

Main Functions

The following introduces the main functions of the Bulletin 900-TC8, 900-TC16, and 900-TC32 temperature controllers. For details on each function and how to use them, refer to Chapter 3 and onward.

• Input Sensor Types — The following input sensors can be connected for temperature input:

– Thermocouple: K, J, T, E, L, U, N, R, S, B, W, PL11

– Infrared non-contact temperature sensor type: Type K thermocouple

(10…70XC), K (60…120XC), K (115…165XC), K (160…260XC)

– Platinum resistance thermometer: Pt100, JPt100

– Analog millivolt input: 0…50 mV

• High level analog inputs:

– Current input:4…20 mA DC, 0 to 20 mA DC

– Voltage input:1…5V DC, 0…5V DC, 0…10V DC

• Control Output — Control output is either an On/Off electro-mechanical relay (EMR) ON/OFF triac output (AC only) On/Off voltage (input to solid-state relay) output, or analog current (DC: 4...20 mA or 0…20 mA) output

• Triac Relay Outputs closing andopening the AC voltage circuit, thereby eliminating relay chatter and arcing and improving durability versus an EMR. However, if high levels of noise or surge are imposed between the output terminals, short-circuit faults may occasionally occur. If the triac output becomes permanently shorted, there is the danger of fire due to overheating of the heater element. To avoid this danger, design safety into the system, including measures to prevent excessive temperature rise and fire. Take countermeasures such as installing a surge absorber. As an additional safety measure, provide error detection in the control loop. Use the Loop Break Alarm (LBA) and Heater Short Alarm (HSA) that are provided for Bulletin 900 temperature controllers.

➊ The Bulletin 900-TC32 Temperature Controller does not support this function

➊

➊, Refer to Table 1.B or 1.D.

➊ — use semiconductors for switching when

➊,

Publication 900-UM007D-EN-E - January 2011

Bulletin 900 Input & Output Overview 1-5

Triac

Relay Output

Varistor

Inductive

Load

Figure 1.4 — Triac Diagram

Select a surge absorber that satisfies the following conditions.

Publication 900-UM007D-EN-E - January 2011

1-6 Bulletin 900 Input & Output Overview

Table 1.A — Surge Absorber Selection

Voltage Used Varistor Voltage Surge Resistance

100…120V AC 240…270V 200…240V AC 440…470V

1000 A minimum

• Always connect an AC load to the triac relay output. The output will not turn OFF if a DC load is connected.

• Alarms — Alarms are supported on the Bulletin 900 temperature controllers. You can configure the alarm type and alarm value, or Upper and Lower-Limit alarms.

If necessary, a more comprehensive alarm function can be achieved by configuring the Standby Sequence, Alarm Hysteresis, Close in Alarm/Open in Alarm and Alarm Latch ON/OFF parameters.

When the input error output is configured to ON, Alarm Output 1 turns ON when an input error occurs.

• Control Adjustment — Optimum PID constants can be configured easily by using the AT (Auto-Tuning) and ST (Self-Tuning) parameters.

• Event Input — When the optional event input unit is mounted, the following functions can be achieved by event input:

Multiple set point selection (multi-SP max. 4 points), RUN/STOP mode change switching between automatic and manual operation, and starting/stopping the simple program. Refer to Table 1.C and 1.E.

• HBA and HS Alarms — The Heater Burnout Alarm (HBA) and Heater Short Alarm (HSA) and heater overcurrent function is supported by selecting the appropriate controller (900-TC8) or option module (900-TC16). Refer to Table 1.B for the TC8 and Table 1.E for the TC16.

• Communications Function — Personal computer (PC) communicationsare supported when the option communications unit is mounted on the temperature controller. Refer to Table 1.C and 1.E.

Note: The PC must have 900BuilderLite software installed.

Note: 900-TC protocol is an integrated general-purpose serial

communications protocol.

Publication 900-UM007D-EN-E - January 2011

Note: Modbus is a communications control method conforming to the RTU.

Mode of Modicon Inc.'s Modbus Protocol.

Note: The 900-TC16 and 900-TC32 do not support the RS-232C interface.

Bulletin 900 Input & Output Overview 1-7

Controller Hardware Versions

The following tables provide a list of controller base features with associated Cat. Nos.

Publication 900-UM007D-EN-E - January 2011

1-8 Bulletin 900 Input & Output Overview

900-TC8

Table 1.B — Controller Versions

DIN Size

(mm)

1/8th DIN

(48 x 96 x 78)

No. of

Alarms

Sensor Input

Ty pe

Thermocouple

or RTD

Power Supply

Voltage

100…240V

Control

Output 1

Ty pe

Relay On/Off NA Yes (1-Phase) 900-TC8RGTH1Z25

Volts On/Off

(SSR)

Analog NA No 900-TC8ACGTZ25

Relay On/Off NA Yes (1-Phase) 900-TC8RGTH1U25

Control

Output 2

Ty pe

NA No 900-TC8RGTZ25

Volt On/Off

(SSR)

NA Yes (3-Phase) 900-TC8RGTH3Z25 NA Yes (1-Phase) 900-TC8VGTH1Z25 NA No 900-TC8VGTZ25

Triac On/Off

(3 A)

Volt On/Off

(SSR)

NA Yes (3-Phase) 900-TC8VGTH3Z25

Triac On/Off

(3 A)

Volt On/Off

(SSR)

Supports

Heater Burnout

Alarm

No 900-TC8RVGTZ25

No 900-TC8VYGTZ25

No 900-TC8VVGTZ25

No 900-TC8ACYGTZ25

No 900-TC8ACVGTZ25

Cat. No. for

Enhanced

900-TC8 Line

Analog

Current and

Voltage

Publication 900-UM007D-EN-E - January 2011

NA No 900-TC8RGTU25

24V AC/DC

100…

240V AC

Volts On/Off

(SSR)

Analog NA No 900-TC8ACGTU25

Relay On/Off NA Yes (1-Phase) 900-TC8RABH1Z25

Volts On/Off

(SSR)

Analog NA No 900-TC8ACABZ25

NA Yes (1-Phase) 900-TC8VGTH1U25 NA No 900-TC8VGTU25

NA No 900-TC8RABZ25 NA Yes (1-Phase) 900-TC8VABH1Z25 NA No 900-TC8VABZ25

Triac On/Off

(3 A)

No 900-TC8VYABZ25

Note: To implement the HBA and HSA function, a current transformer (Cat.

No. 900-CT1 or 900-CT2) is required. A current transformer is NOT provided with the controller.

Note: When the heating and cooling function or the HBA or HSA is used,

one of the alarm outputs will be disabled for each function used.

Table 1.C — Controller Option Units

Event Out Comms Cat. No. for Enhanced Option Units Series

— RS232 900-TC8232B B

Option Unit

— RS485 900-TC8COMB B

Yes — 900-TC8EIMA A

900-TC16

Table 1.D — Controller Versions

Bulletin 900 Input & Output Overview 1-9

DIN Size (in mm)

1/16th DIN

Number of Alarms

Sensor Input Ty pe

Thermocouple or RTD

Analog Current and Voltage

Power Supply Voltage

100…240V AC Relay On/Off 900-TC16RGTZ25

24V AC/DC Relay On/Off 900-TC16RGTU25

100…240V AC Relay On/Off 900-TC16RABZ25

24V AC/DC Relay On/Off 900-TC16RABU25

Control Output Ty pe

Triac On/Off (3 A) 900-TC16YGTZ25 Volts On/Off (SSR) 900-TC16VGTZ25 Analog Current 900-TC16ACGTZ25

Volts On/Off (SSR) 900-TC16VGTU25 Analog Current 900-TC16ACGTU25

Triac On/Off (3 A) 900-TC16YABZ25 Volts On/Off (SSR) 900-TC16VABZ25 Analog Current 900-TC16ACABZ25

Volts On/Off (SSR) 900-TC16VABU25 Analog Current 900-TC16ACABU25

Cat. No for Enhanced 900-TC16 Line

Publication 900-UM007D-EN-E - January 2011

1-10 Bulletin 900 Input & Output Overview

Table 1.E — Controller Option Units

DIN Size (in mm)

1/16th DIN

Number of Alarms

Heater Burnout Event Out Comms

1-Phase HB — RS485 — 900-TC16NCOM B — — RS485 — 900-TC16NACCOM 1-Phase HB Yes — — 900-TC16NEIM — Yes — — 900-TC16NACEIM 3-Phase HB — RS485 — 900-TC16NCOMP3 — — RS485 Yes 900-TC16NCOMV2 1-Phase HB — — Yes 900-TC16P1V2

Voltage (SSR) Control Output 2

Cat. No. for Enhanced Option Units Series

➊ Series B option units must be used with Series B controllers. DO NOT use series B option units

with Series A controllers.

900-TC32

Table 1.F — Controller Versions

Sensor Input Ty pe

Thermocouple or RTD

Power Supply Voltage

100…240V AC Relay On/Off Yes 900-TC32CRGTZ25

24V AC/DC Relay On/Off Yes 900-TC32CRGTZ25

Control Output Ty pe

Volts On/Off (SSR) Yes 900-TC32CVGTZ25 Relay On/Off No 900-TC32RGTZ25 Volts On/Off (SSR) No 900-TC32CVGTZ25

Comm Function (RS-445)

Cat. No for Enhanced 900-TC32 Line

Publication 900-UM007D-EN-E - January 2011

Bulletin 900 Input & Output Overview 1-11

A/M

SUB2

SUB3

STOPOUT1

MANU

CMWOUT2

SUB1

Operation Indicators

Temperature Unit

Operation Indicators

Mode Key

No.1 Display

No.2 Display

No.3 Display

Up Key

Down Key

Function Key/ Auto/Manual Key

Function Group Key

Mode Key

Temperature Unit

Operation Indicators

No. 1 Display

No. 2 Display

Up Key

Function Group Key

Down Key

Front Panels & General Functions

Figure 1.5 — Bulletin 900-TC8

Figure 1.6 — Bulletin 900-TC16

Publication 900-UM007D-EN-E - January 2011

1-12 Bulletin 900 Input & Output Overview

SUB2

SUB3

STOPOUT1

MANU

CMWOUT2

SUB1

Figure 1.7 — Bulletin 900-TC32

Display Meanings

Display Meaning No. 1 Displays the Process Value or Parameter Type during configuration. Lights for

No. 2 Displays the Set Point, parameter operation read value, manipulated variable,

No. 3 (900-TC8 only)

approximately 1 second during startup.

or during configuration, the value of the displayed (No. 1 display) parameter. Displays MV, soak time remaining, or multi SP. Lights for approximately 1

second during startup. A 2-level display is configured when shipped from the factory. A 3-level display is activated if parameters are initialized.

Publication 900-UM007D-EN-E - January 2011

Bulletin 900 Input & Output Overview 1-13

Operation Indicators 1,2,3...

Operation Indicator Definition Function

SUB 1 Sub 1 Lights when the function configured for the Auxiliary Output 1 Assignment parameter

SUB2 Sub 2 900-TC8 and 900-TC16 Only:

SUB3 Sub 3 900-TC8 Only:

HA Heater Burnout, Heater Short Alarm, Heater

OUT1 Control Output 1 Lights when the control output function assigned to control output 1 turns ON. For a

OUT2 Control Output 2 900-TC8 and 900-TC16 Only:

STOP Operation Stopped Lights when operation is stopped. During operation, this indicator lights when

CMW Communications Writing Lights when communications writing is enabled and is not lit when it is disabled. MANU Manual Mode Lights when the auto/manual mode is configured to manual mode.

c or f

Overcurrent Detection Output Display

Key Lights when setting change protect is ON (i.e., when the up and down Keys are

Temperature Unit The temperature unit is displayed when the display unit parameter is configured to a

is ON.

Lights when the function configured for the Auxiliary Output 2 Assignment parameter is ON.

Lights when the function is configured for the Auxiliary Output 3 Assignment parameter is ON.

900-TC8 and 900-TC16 Only:

Lights when a heater burnout, heater short alarm, or heater overcurrent occurs.

current output, however, OFF for a 0% output only.

Lights when the control output function assigned to control output 2 turns ON. For a current output, however, OFF for a 0% output only.

operation is stopped by an event or by key input using the RUN/STOP function.

disabled by protected status.

temperature. Indication is determined by the currently selected Temperature Unit parameter value. When the parameter value is configured for °C, c is displayed, and when configured for °F, f is displayed. The display flashes during self-tuning (ST) operation.

Publication 900-UM007D-EN-E - January 2011

1-14 Bulletin 900 Input & Output Overview

A/M

Key Definition Function

Function (Auto/Manual) 900-TC8 Only:

Function Group Select Press this key to select the desired function group. The groups are selected in the following order:

Mode Select Press this key to select the various parameters within each function group. The selection of

Basic Keypad Functions

The following describes the basic functions of the front panel keys.

This is a function key. When it is pressed for at least 1 second, the function configured in the PF Setting parameter will operate. Example: When A-M (auto/manual) is selected in the PF Setting parameter (initial value: A-M), the key operates as an auto/manual switch, switching between Auto Mode and Manual Mode. If the key is pressed for more than 1 second (regardless of key release timing), the mode will switch.

Operation function group ←→ Adjustment function group, Initial Setting function group ←→ Communications Setting function group.

parameters can be reversed by holding this key down.

Up Each press of this key increments values displayed on the No. 2 (SV) display. Holding down this

key continuously increments values.

Down Each press of this key decrements values displayed on the No. 2 (SV) display. Holding down this

key continuously decrements values.

Key Combination — Function Group and Mode Select

Key Combination — Function Group and Up or Function Group and Down

This key combination settings the Bulletin 900 to the Protect function group. For details on the Protect function group, refer to Chapter 5 , Parameter Functions & Definitions.

To restrict changing parameter values and to prevent accidental or incorrect operations, these keys require simultaneously pressing of the key along with the or key.

The key applies only to the parameter configured for the Password to Move to Protect function group . Refer to Chapter 5 for more detailed information on this function group.

Publication 900-UM007D-EN-E - January 2011

Preparations

Front View Side View Back View

Allen-Bradley

900-TC8

6.0

79.2

112

Allen-Bradley

All

Chapter

Hardware Installation

Approximate Dimensions

The recommended panel thickness for mounting the 900-TC16 and 900-TC32 is 1 to 5 mm and the 900-TC8 is 1 to 8 mm.

Note: Dimensions are in millimeters. Dimensions are not intended to be used

for manufacturing purposes.To convert millimeters to inches, multiply by 0.0394.

Figure 2.1 — 900-TC8

Figure 2.2 — 900-TC16

48 4

en-

2-1 Publication 900-UM007D-EN-E- January 2011

900-TC1

44.

2-2 Preparations

44.8

1 2 3 4 5 6

7 8 9 10 11 12

(48 x number of units -2.5)

120 min.

➊

60 min.

Figure 2.3 — 900-TC32

Panel Cutout Dimensions

Dimensions are in millimeters. Dimensions are not intended to be used for manufacturing purposes.

Figure 2.4 — 900-TC8

Publication 900-UM007D-EN-E - January 2011

min.

Figure 2.5 — 900-TC16

Figure 2.6 — 900-TC32

x60 min.

(48 number of units -2.5)

Preparations 2-3

Publication 900-UM007D-EN-E - January 2011

2-4 Preparations

ATTENTION

• Horizontal group-mounting of two or more temperature controllers, or mounting temperature controllers above each other may cause heat to build up inside the temperature controllers. This will shorten their service life. When mounting temperature controllers like this, consider forced cooling measures, such as a cooling fan.

• If forced air cooling is used, limit cooling to the terminal block. Rapid variation or transients in temperature at the terminal block may result in a measurement error.

System Wiring and Installation Guidelines

Risk of Electrical Shock

• Devices are Open Type, Listed Process Control Equipment and must be mounted in an enclosure.

• More than one disconnect switch may be required to de-energize the equipment before servicing.

• Signal inputs are SELV, limited energy.

• To reduce risk of fire or electrical shock, do not

interconnect the outputs of different Class 2 circuits.

• Disconnect all power (including field device) before installing and/or servicing.

• Do not touch the controller’s wiring terminals while the power is ON. Doing so may cause an electric shock.

Publication 900-UM007D-EN-E - January 2011

Preparations 2-5

ATTENTION

• Do not allow metal fragments or lead wire scraps to fall inside the Bulletin 900 Controller. These may cause electric shock, fire, or malfunction.

• Never disassemble, repair, or modify the Bulletin 900 Controller with line or field device power applied. Doing so may cause electric shock, fire, or malfunction.

• Do not use the Bulletin 900 Controller in flammable and explosive gas atmospheres.

• Use the Bulletin 900 Controller within the rated supply voltage. Not doing so may cause controller damage or fire.

• Configure all controller settings according to the control target of the Bulletin 900 Controller. If the settings are not appropriate for the control target, the controller may operate in an unexpected manner, resulting in damage to the product or personal injury.

• To maintain safety in the event of a product malfunction, always take appropriate safety measures, such as installing an alarm on a separate line to prevent excessive temperature rise. If a malfunction prevents proper control, an accident may result.

• Do not wire unused terminals.

• Make sure to observe correct polarity when wiring the

controller terminals.

• Power supply, input, output, and communication terminals (for models with communications) have basic insulation between them. When double insulation is required, apply supplemental insulation defined in IEC 60664 that is suitable for the maximum operating voltage with clearances or solid insulation.

Publication 900-UM007D-EN-E - January 2011

2-6 Preparations

ATTENTION

• Do not use the Bulletin 900 Controller in the following places which might exceed its specifications:

– Places subject to dust or corrosive gases (in

particular, sulfide gas, and ammonia gas)

– Places subject to high humidity, condensation, or

freezing

– Places subject to direct sunlight

– Places subject to vibration and large shocks

– Places subject to splashing liquid or oily atmosphere

– Places directly subject to heat radiated from heating

equipment

– Places subject to intense temperature changes

• To allow heat to escape, do not block the area around the Bulletin 900 Controller. Ensure that enough space is left for the heat to escape. Do not block the ventilation holes on the casing.

• Cleaning: Do not use paint thinner or the equivalent. Use standard grade alcohol to clean the Bulletin 900 Controller.

• Use within the following temperature and humidity ranges:

Temperature: –10…+55 °C Humidity: 25…85% (with no icing or condensation)

If the Bulletin 900 Controller is installed inside a control panel, the ambient temperature must be kept to under 55 °C, including the temperature around the controller.

If the Bulletin 900 Controller is subjected to heat radiation, use a fan to cool the surface of the controller to under 55 °C.

• Never place heavy objects on, or apply pressure to the Bulletin 900 Controller as it may cause it to deform and deteriorate during use or storage.

Publication 900-UM007D-EN-E - January 2011

ATTENTION

• Store within the following temperature and humidity

Upper Panel Mounting Adaptor

Gasket material for NEMA 4X (waterproof) material

Lower Panel Mounting Adaptor

Control Panel

ranges:

Temperature: –25…+65 °C Humidity: 25…85% (with no icing or condensation)

• Avoid using the Bulletin 900 Controller in places near a radio, television configured, or wireless installation. These devices can cause radio disturbances which may adversely affect the performance of the Bulletin 900 Controller.

Panel Mounting — 900-TC8

How to Attach the Bulletin 900-TC8 on the Panel

Preparations 2-7

Figure 2.7 — 900-TC8

1. If water-proofing is required, ensure the gasket material is inserted between the front of the controller’s case and the control panel.

2. Insert the Bulletin 900-TC8 into the mounting hole in the panel (1…8 mm panel thickness).

3. Pull the upper and lower panel mounting adapters along the Bulletin 900-TC8 body from the rear of the case up to the panel, and fasten temporarily.

Publication 900-UM007D-EN-E - January 2011

2-8 Preparations

4. Tighten the upper and lower adapter mounting screws alternately with only one turn of the screwdriver at a time to maintain an even torque balance. Tighten the screw until the ratchet mechanism operates.

5. To allow heat to escape, do not block the area around the Bulletin 900-TC8 Temperature Controller. (Ensure that enough space is left for the heat to escape.) Do not block the ventilation holes on the casing.

6. Allow as much space as possible between the Bulletin 900-TC8 and devices that generate powerful high-frequency noise (e.g., high-frequency welders, high-frequency sewing machines) or surges.

7. Install the controller so that it is horizontal (can read the display properly).

Note: When group mounting two or more Bulletin 900-TC8s, make sure that

the surrounding temperature does not exceed the allowable operating temperature given in the specifications.

Mounting the Terminal Cover

To attach the terminal cover to the terminal block, slightly bend the terminal cover, as shown below. The terminal cover cannot be attached in the opposite direction.

Figure 2.8 — 900-TC8 Mounting the Terminal Cover

Enlarged Illustration of Terminal Section

Slightly bend the terminal cover in the direction shown by the arrows.

Publication 900-UM007D-EN-E - January 2011

Preparations 2-9

IMPORTANT

900-TC8 (Series B) Case Removal while Panel-Mounted

The control unit can be removed from its case whether or not it is mounted on the control panel. This allows you to perform maintenance or to add option units without opening the control panel enclosure or removing the terminal compartment.

Figure 2.9 — 900-TC8 (Series B) Case Removal while Panel-Mounted

Tool Insertion Holes

(1)

(2)

(3)

(1)

Top View

Rear

Case

Front Panel

Gap

Flat-blade Screwdriver

(Unit: mm)

2.00.4 5.0

Ensure controller and I/O power is OFF before removing the internal mechanism. When you remove the internal mechanism from the housing, never touch electric components inside or subject the internal mechanism to shock.

1. Insert a flat-blade screwdriver into the two tool insertion holes (one on the top and one on the bottom) to release the hooks.

2. Insert the flat-blade screwdriver in the gap between the front panel and the rear case (two on the top and two on the bottom), and use it to pry and pullout the front panel slightly. Then, pull out on the front panel gripping both sides. Be sure not to impose excessive force on the panel.

Setting Up the 900-TC8 Controller with the Optional Units

If RS-232, RS-485 communications inputs are required, mount the RS-232 communications unit (Cat. No. 900-TC8232), the RS-485 communications unit (Cat. No. 900-TC8COM), or the event input unit (Cat. No. 900-TC16EIM) in the Bulletin 900-TC8 controller. These units provide optical isolation (approx. 32V DC) between the controller electronics and field input.

Publication 900-UM007D-EN-E - January 2011

2-10 Preparations

(1)

(3)

(2)

Location for Boards: 900-TC8EIM: Event Input 900-TC8232: RS-232 900-TC8COM: RS-485

Table 2.A

Name Cat. No.

(Series)➊

Communications board 900-TC8COM (B) RS-485 Communications support

900-TC8232 (B) RS-232 Communications support

Event input unit 900-TC8EIM (A) Event input support

➊ One (1) unit per controller. This series of option units are compatible with Series A or Series B controllers.

Function

Panel Mounting — 900-TC16

How to Attach the Bulletin 900-TC16 on the Panel

To prevent electrostatic damage to the board, make sure you are properly grounded before installing it. Follow the steps below.

Figure 2.10

Publication 900-UM007D-EN-E - January 2011

1. Insert the controller through the hole in the panel from the front, and push the panel mounting adapter on from the rear. Push the adapter up to the back of the panel ensuring that the controller is pushed all the way in, removing any gap between the controller, panel, and adapter. Finally, use the two screws on the adapter to secure the unit in place. The recommended panel thickness is 1…5 mm.

2. To mount the Bulletin 900-TC16 so that it is waterproof, insert the waterproof packing on the Bulletin 900-TC16. The Bulletin 900-TC16 cannot be waterproofed when it is group-mounted in the horizontal fashion.

3. Maintain the specified mounting space between each controller.

Preparations 2-11

Panel

Safety Terminal Block Cover

Rear Case Terminal Block

Panel Mounting Adaptor

Front Case

4. Tighten the two screws on the adapter against the panel. Tighten the two screws alternately keeping the torque to approximately

0.29…0.39 N•m (2.57…3.45 lb-in.).

5. To allow heat to escape, do not block the area around the Bulletin 900-TC16 Temperature Controller. (Ensure that enough space is left for the heat to escape.) Do not block the ventilation holes on the casing.

6. Allow as much space as possible between the Bulletin 900-TC16 and devices that generate powerful high-frequency noise (e.g., high-frequency welders, high-frequency sewing machines) or surges.

7. Install the controller so that it is horizontal (can read the display properly).

How to Attach the 900-TC16 Wiring Terminal Block Cover

Figure 2.11

Make sure that the UP mark on the adapter is facing up, and then fit the terminal cover into the holes on the top and bottom. The Bulletin 900-TC16 is provided with a protective terminal block cover (finger protection per VDE 0106).

Setting Up the 900-TC16 Controller with the Optional Units

If RS-485 communications, Event Input, second Control Output, or Heater Burnout functions are required, mount the appropriate option unit in the Bulletin 900-TC16 controller.

900-TC16 Option Units

Table 2.B below provides the list of available options.

Publication 900-UM007D-EN-E - January 2011

2-12 Preparations

(1)

(2)

(4)

(3)

20 min.

Flat-blade Screwdriver Units: mm

Table 2.B

Function 900-TC16 Option

Module Cat.

Heater Burnout & Heater Short

Event

Input

Comms.

Voltage (SSR)

Control Output 2

No.(Series)

➊➋

1-Phase HB — RS485 — 900-TC16NCOM (B)

— — RS485 — 900-TC16NACCOM (B)

1-Phase HB Yes — — 900-TC16NEIM (B)

— Yes — — 900-TC16NACEIM (B)

3-Phase HB — RS485 — 900-TC16NCOMP3 (B)

— — RS485 Yes 900-TC16NCOMV2 (B)

1-Phase HB — — Yes 900-TC16P1V2 (B)

➊ One (1) option unit per controller. ➋ The option unit provides optical isolation (approximately 32V DC) between the controller electronics and the

field input. Series B option units must be used with Series B controllers and vice versa.

Installing the Option Unit/Board in the Controller

Figure 2.12

Note: When you remove the internal mechanism from the housing, never

touch electric components inside or subject the internal mechanism to shock.

Publication 900-UM007D-EN-E - January 2011

Panel Mounting — 900-TC32

Mounting to the Panel

Figure 2.13

Preparations 2-13

Note: For waterproof mounting, waterproof packing must be installed on the

controller. Waterproofing is not possible when group mounting several controllers. Waterproof packing is not necessary when there is no need for the waterproofing function.

1. For waterproof mounting: Install waterproof packing on the controller.

2. Insert the 900-TC32 into the mounting hole in the panel.

3. Push the adapter from the terminals up to the panel, and temporarily

fasten the 900-TC32

4. Tighten the two fastening screws on the adapter. Alternately tighten the two screws little by little to maintain a balance. Tighten the screws to a torque of 0.29 to 0.39 N·m.

Publication 900-UM007D-EN-E - January 2011

2-14 Preparations

The body of the controller can be replaced by removing the terminal block from the 900-TC32.

Figure 2.14

1. Insert a flat-blade screwdriver into the tool holes (one on the top and one on the bottom) to release the hooks. Do not apply excessive force.

2. Pull the terminal block out while the hooks are released.

Publication 900-UM007D-EN-E - January 2011

Bulletin 900 Wiring

Input power supply

Auxiliary output 2

Control output 1

Analog input

TC/Pt universal input

Auxiliary output 3

CT1

CT2

EV1

EV2

CT1/CT2 Control Output 2

Control output 2

DO NOT USE

Auxiliary output 1

Event Inputs

A heater burnout alarm, heater short alarm, heater overcurrent alarm, or input alarm is sent to the output to which the alarm 1 function is assigned.

250 VAC, 3 A

(resistive load)

Relay outputs

Auxiliary output

1, 2, 3

• 100 to 240 VAC

• 24 VAC/VDC (no polarity)

Current output

0 to 20 mA DC

Voltage output (for driving SSR)

12 VDC, 40 mA

Load: 600 Ω max.

4 to 20 mA DC

Relay output

250 VAC, 5A

(resistive load)

Control output 2

Voltage output (for driving SSR)

12 VDC, 21 mA

Control output 1

Triac output

250 VAC, 3 A (resistive load)

Communications

900-TC8COM RS-485

B (+)11

DO NOT USE13

900-TC8232 RS-232C

SD11 RD12 SG13

900-TC8EIM Event inputs

11 12 13

EV2

CT1/CT2

Option Units

CT1 CT1

EV2

EV1

13 14 15

11 12 13 14 15

RS-485

CT1

CT2

−

Relay output 250V AC, 3 A (Resistive load)

Voltage output 12V DC, 21 mA

Current output 4 to 20 mA DC 0 to 20 mA DC Load 600 Ω max.

Analog input TC/Pt

Multi-input

Control output 1

Auxiliary output (Relay output)

Auxiliary output 2

Input power supply

100 to 240V AC 24V AC/DC (no polarity)

900-TC16NEIM

900-TC16NCOMP3

900-TC16NCOMV2

900-TC16PIV2

Voltage output 12V DC, 21 mA

Control Output 2

Auxiliary output 1, HBA/HS alarm/input error

Do not connect.

CT1

11 12 13 14 15

−

Do not connect.

900-TC16NCOM

EV2

EV1

11 12 13 14 15

900-TC16NACEIM

Auxiliary output (Relay output), 250V AC, 1 A (Resistive load)

RS-485

13 14 15

−

Do not connect.

900-TC16NACCOM

RS-485

Preparations 2-15

Terminals

Figure 2.15 — 900-TC8 (Series B) Terminal Arrangement

Figure 2.16 — 900-TC16 Terminal Arrangement

Publication 900-UM007D-EN-E - January 2011

2-16 Preparations

1212

1111

1010

3 5

InputInput

Power Power SupplySupply

ControlControl

Output 1Output 1

AuxillaryAuxillary Output 1Output 1

DO NOTDO NOT USEUSE

Universal TC/Pt Input

DO NOTDO NOT USEUSE

B(+)

A(-)

RS-495 Communications

Relay Output 250 VAC, 2 A

(resistive load)

Voltage Output

12 VDC, 21 mA

(for driving SSR)

Relay Output 250 VAC, 2 A

(resistive load)

Control Output 1

Auxillary Output 1

Figure 2.17 — 900-TC32 Terminal Arrangement

Publication 900-UM007D-EN-E - January 2011

Preparations 2-17

ATTENTION

Wiring Guidelines and Precautions

• Do not wire unused terminals.

• Make sure to observe correct polarity when wiring the

controller terminals.

• To reduce induction noise, separate the high-voltage or large-current power lines from other lines, and avoid parallel or common wiring with the power lines when you are wiring to the terminals. We recommend using separating pipes, ducts, or shielded lines.

• Allow as much space as possible between the Bulletin 900 Controller and devices that generate powerful high-frequency noise (e.g., high-frequency welders, high-frequency sewing machines) or surges.

• Separate input leads and power lines in order to protect the Bulletin 900-TC8, 900-TC16, 900-TC32, and its low voltage sensors (e.g., thermocouple) lines from external noise.

• For 900-TC32: Use a shielded AWG24 to AWG18 (cross-sectional area of 0.205 to 0.823 mm2) twisted-pair cable. The stripping length is

6 to 8 mm.

• We recommend using solderless lugs when wiring to the Bulletin 900-TC8 and 900-TC16 screw terminals. However, if lugs are not used, the controller’s screw terminals will accept two solid or stranded wires (no mixing) between 24 (0.205 mm

)AWG. Wire strip length 5...6 mm.

• For 900-TC8 & 900-TC16: Tighten the terminal screws properly. Tighten them to a torque 0.74…0.9 N•m (6.6…8 lb-in.) Loose screws may cause malfunction. For 900-TC32: Tighten the terminal screws to a torque of 0.5 N•m

• Use the type of solderless lugs referenced in Figure 2.18 for your proper Bulletin type.

)...14 (2.081

Publication 900-UM007D-EN-E - January 2011

2-18 Preparations

ATTENTION

Figure 2.18 — Wiring

7.2 mm max.

Wiring

Power Supply

The controller requires an external power source for operation. For the 900-TC8 connect to terminals 1 and 2 and for the 900-TC16 connect to terminals 9 and 10. The following table shows the specifications.

Table 2.C

Input Power Supply Bulletin 900-TC8 Bulletin 900-TC16

100…240V AC, 50/60 Hz 10VA 7.5VA 24V AC, 50/60 Hz 5.5VA 5VA 24V DC (not polarity sensitive) 4 W 3 W

Use a power supply matched to the power specifications of the Bulletin 900 Controller. Also, make sure that rated voltage is attained within 2 seconds of turning the power ON.

Publication 900-UM007D-EN-E - January 2011

Preparations 2-19

When mounting a noise filter on the power supply, make sure to first check the filter’s voltage and current capacity, and then mount the filter as close as possible to the Bulletin 900 Controller. Reinforced insulation is applied to the power supply I/O sections.

Wiring Input/Sensor Devices

Connect sensors to the terminals as follows according to the Input Type and controller.

4 5

Thermocouple

900-TC16 Input Sensor Wiring

Thermocouple

900-TC8 Input Sensor Wiring

−

4 5

Platinum resistance thermometer

−

Platinum resistance thermometer

4 5

Analog input

−

Input/Sensor Wiring Considerations

• When the thermocouple leads are extended, make sure to use shielded thermocouple extension wire matched to the type of thermocouple.

• For a thermocouple, make sure to follow the polarity color code convention.

• If there is a large error in the measurement values, make sure that the correct sensor type is configured and for thermocouples that input compensation has been properly configured.

• RTDs can be either 2- or 3-wire types. If a 3-wire type is used, the controller provides lead wire resistance compensation up to 5 Ω resistance. If using 24 AWG lead wire, this is approximately 59 m of wire. Use larger gauge wire if longer length is required.

• For RTDs, the controller source is approximately 1 mA of current.

• If a cooling fan is used in the panel enclosure, prevent only the terminal block from being cooled when using thermocouples. Otherwise, this may result in a measurement error.

Publication 900-UM007D-EN-E - January 2011

2-20 Preparations

900-TC16 Control Output 1

−

GND

−

1 2

Relay Voltage (SSR) Analog Current

−

900-TC8 Control Output 1

Relay Voltage (SSR) Analog Current

−

GND

−

900-TC32 Control Output 1

• To reduce induced electrical noise, the leads on the temperature controller’s terminal block must be wired separately from large-voltage/large-current power leads. Also, avoid wiring leads in parallel with power leads or in the same wiring path. Other methods such as separating conduits and wiring ducts, or using shield wire are also effective and recommended.

Wiring Control Output 1

The following diagrams show the available outputs and their internal equalizing circuits.

Figure 2.19

Publication 900-UM007D-EN-E - January 2011

Preparations 2-21

The following tables show the specifications for each output type.

Table 2.D — 900-TC8

Output Type Output 1 Specifications

Relay 250V AC, 5 A (resistive load), electrical durability: 100,000

operations

Voltage (PNP) PNP type, 12V DC +15%/−20%, 40 mA (with short-circuit

protection). Series B 12V DC ± 15%.

Current DC 4… 20 mA/DC 0…20 mA, resistive load: 600 Ω max.

Resolution: Approx.10,000

Table 2.E — 900-TC16

Output Type Output 1 Specifications

Relay 250V AC, 3 A (resistive load), electrical durability: 100,000

operations

Triac (AC) relay 250V AC, 3 A (resistive load), electrical durability: 1,000,000

operations Voltage (PNP) PNP type, 12V DC ±15%, 21 mA (with short-circuit protection) Current DC 4…20 mA/DC 0…20 mA, resistive load: 600 Ω max.

Resolution: Approx. 10,000

Table 2.F — 900-TC32

Output Type Output 1 Specifications

Relay 250V AC, 2 A (resistive load), electrical durability: 100,000

operations Voltage (PNP) PNP type, 12V DC ±15%, 21 mA (with short-circuit protection)

Publication 900-UM007D-EN-E - January 2011

2-22 Preparations

Output Wiring Considerations

• Do NOT connect a DC load to the Triac (AC) relay.

• The PNP voltage (SSR) output (Control Output 1) is not electrically

isolated from the controller’s internal circuits. SSR Control Output 2 of the 900-TC16 is also not isolated. However, SSR Control Output 2 of the 900-TC8 is isolated. When using a grounded thermocouple, do not connect any control output terminals to earth ground. If the control output terminals are connected to earth ground, errors will occur in the measured temperature values as a result of ground loop leakage current.

• For 900-TC8 & 900-TC16: The 4...20 and 0…20 mA analog output is electrically isolated from the other controller circuits as follows:

– Analog Output to Sensor Input: 500V AC 50/60 Hz for 1 minute

– Analog Output to Alarm Output: 2000V AC 50/60 Hz for 1 minute

– Analog Output to Input Power Supply: 2000V AC 50/60 Hz for 1

minute

• The life expectancy of the electro-mechanical relay outputs vary greatly with the switching capacity and other switching conditions. Always use the output relays within their rated load and electrical life expectancy. If an output relay is used beyond its life expectancy, its contacts may become fused or burned.

• Use the Bulletin 900 Controller within the rated load. Not doing so may cause damage or fire.

• Attach a surge suppressor or noise filter to peripheral devices that generate noise (in particular, motors, transformers, solenoids, magnetic coils, or other equipment that have an inductance component).

• About 4 seconds are required for control and/or alarm outputs to turn ON when the power is initially turned ON to the controller. Take this into consideration when the temperature controller is incorporated into a sequence circuit.

• For 900-TC8 & 900-TC16: Triac (AC) relay outputs use semiconductors for switching when closing and opening the circuit, thereby eliminating relay chatter and arcing and improving durability compared to an electro-mechanical relay output. However, if high levels of electrical noise or surge are imposed between the output terminals, short-circuit faults may occasionally occur. If the output becomes permanently shorted, there is the danger of fire due to overheating of the heater. Design safety into the system, including measures to prevent excessive temperature rise and fire. Take countermeasures such as installing a surge absorber. As an additional safety measure, provide error detection in the control loop. (Use the Loop Burnout Alarm

Publication 900-UM007D-EN-E - January 2011

Preparations 2-23

Triac (AC) relay output

Varistor

Inductive load

900-TC8 Control Output 2

Relay Voltage

GND Voltage Voltage

900-TC16 Control Output 2

GND

➊

➋

(LBA) and Heater Short Alarm (HSA) that are provided for the Bulletin 900 Controller.)

Figure 2.20

Select a surge absorber that satisfies the following conditions.

Table 2.G

Voltage Used Varistor Voltage Surge Resistance

100…120V AC 240…270V 1,000 A min. 200…240V AC 440…470V

Control Output 2

• For 900-TC8 & 900-TC16: Output 2 is applied from terminals 11 and 12 or 14 and 15 with the 900-TC16, and from pins 14 and 15 with the 900-TC8. The following diagrams show the available outputs and their equal internal circuits.

Figure 2.21

➊ Option Unit: 900-TC16P1V2 ➋ Option Unit: 900-TC16NCOMV2

The following table shows the specifications for each output type.

Table 2.H — 900-TC8

Output Type Output 2 Specifications

Triac (AC) relay 250V AC, 3 A (resistive load), electrical durability: 1,000,000

operations

Voltage (PNP) PNP type, 12V DC +15%/−20%, 21 mA (with short-circuit

protection)

Publication 900-UM007D-EN-E - January 2011

2-24 Preparations

Table 2.I — 900-TC16

Output Type Output 2 Specifications

Voltage (PNP) PNP type, 12V DC ±15%, 21 mA (with short-circuit protection)

• Always connect an AC load to a Triac (AC) relay output. The output will not turn OFF if a DC load is connected.

• A voltage output (control output) is not electrically isolated from the internal circuits. Therefore, when using a grounded thermocouple, do not connect any of the control output terminals to earth ground. If control output terminals are connected to ground, errors will occur in the measured temperature values as a result of ground loop leakage current. With 900-TC8, however, voltage output (Control Output 2) is functionally isolated from the internal circuits.

• Control Output 2 of the 900-TC16 is a voltage output (SSR driver) only, and outputs across terminals 11(+) and 12(-), or 14(+) and 15(-).

• Control outputs 1 and 2 (voltage outputs) are not isolated.

• Triac (AC) relay outputs use semiconductors for switching when closing and opening the circuit, thereby eliminating relay chatter and arcing and improving durability compared to an electro-mechanical relay output. However, if high levels of electrical noise or surge are imposed between the output terminals, short-circuit faults may occasionally occur. If the output becomes permanently shorted, there is the danger of fire due to overheating of the heater. Design safety into the system, including measures to prevent excessive temperature rise and fire. Take countermeasures such as installing a surge absorber. As an additional safety measure, provide error detection in the control loop. (Use the Loop Burnout Alarm (LBA) and Heater Short Alarm (HSA) that are provided for the Bulletin 900.)

Figure 2.22

Triac (AC) relay output

Varistor

Inductive load

Publication 900-UM007D-EN-E - January 2011

Preparations 2-25

Select a surge absorber that satisfies the following conditions.

Table 2.J

Voltage Used Varistor Voltage Surge Resistance

100…120V AC 240…270V 1,000 A min. 200…240V AC 440…470V

Wiring Auxiliary Outputs (1, 2, and 3)

• On the 900-TC8, Auxiliary Output 1 (SUB1) is output across terminals 9 and 10, Auxiliary Output 2 (SUB2) is output across terminals 7 and 8, and Auxiliary Output 3 (SUB3) is output across terminals 5 and 6.

• When the HBA or the HS Auxiliary is used with the 900-TC8, Auxiliaries are output across terminals 9 and 10.

• On the 900-TC8, when heating/cooling control is used, Auxiliary Output 3 becomes control output (cooling).

• On the 900-TC16, Auxiliary Output 1 (SUB1) is output across terminals 7 and 8, and Auxiliary Output 2 (SUB2) is output across terminals 6 and 8.

• On the 900-TC32, Auxiliary Output 1 (SUB1) is output across terminals 5 and 6.

• On the 900-TC32, when heating/cooling control is used, auxiliary output 1 becomes control output (cooling).

• When the HB, the HS, or heater overcurrent alarm is used with the 900-TC16, alarms are output across terminals 7 and 8.

• On the 900-TC16, when heating/cooling control is used, Auxiliary Output 2 becomes control output (cooling).

• When the Input Error Output parameter is configured to ON, the output assigned to Alarm Output 1 turns ON when an input error occurs.

• For models that have a Heater Burnout Alarm (not supported by 900-TC32), an OR of the alarm 1 function and the HB/HS or heater overcurrent alarm is sent to the output assigned to the alarm 1 function (auxiliary output 1). If ALM1 is to be used for HBA only, configured the Alarm 1 type to 0 and do not use Alarm function 1.

• The following diagrams show the internal equalizing circuits for Alarm Outputs 1, 2, and 3.

Publication 900-UM007D-EN-E - January 2011

2-26 Preparations

900-TC16 Alarms

SUB2

SUB1

SUB3

SUB2

SUB1

900-TC8 Alarms

SUB1

900-TC32 Alarms

900-TC16 with Single-phase Burnout Option

900-TC16 with Three-phase Burnout Option

CT1

CT2

CT1

CT2

900-TC8-@@@H1 SIngle-phase Burnout

900-TC8-@@@H3 Three-phase Burnout

Figure 2.23

Note: ALM1, 2, 3 can be output to auxiliary output 1, 2, 3 or changed with the Advanced Function level.The auxiliary relay specifications are as follows:

Table 2.K

900-TC8 and 900-TC16 SPST-NO 250V AC 3 A 900-TC32 SPST-NO 250V AC 2 A

Current Transformer (CT) Input

To determine if your controller supports the heater burnout function, refer to Table 1.B for 900-TC8 or Table 1.E for 900-TC16. If the heater burnout parameter function is used, connect a current transformer (CT) across the terminals indicated in the following drawings in Figure 2.24.

Figure 2.24

Publication 900-UM007D-EN-E - January 2011

Preparations 2-27

900-TC16 Contact Event Input

EV1

EV2

900-TC8 Contact Event Input

EV1

EV2

Do NOT apply an external voltage source to the Event Input Terminals

EV1

EV2

−

EV1

EV2

900-TC16

900-TC8

−

Do NOT apply an external voltage source to the Event Input Terminals

Wiring the Event Input

When the appropriate option event input unit is mounted in the Bulletin 900-TC8 or 900-TC16 controller, an event input function is available by wiring to the controllers terminals as shown in the following diagrams.

Figure 2.25

Use event inputs under the following conditions:

• The output current from the controller is approximately 7 mA @ 5V.

• Contact input ON: 1 KΩ max., OFF: 100 KΩ min.

• Non-contact input ON: residual voltage 1.5V max., OFF: leakage current 0.1 mA max.

Polarities using non-contact input are as follows:

Figure 2.26

Publication 900-UM007D-EN-E - January 2011

2-28 Preparations

900-TC8

SD(TXD) RD(RXD) RS(RTS) CS(CTS) DR(DSR) SG ER(DTR) FG

RS-232C No.

11 SD 12 RD 13 SG

9 Pin

(RS232C)

➊

RS-232C Communication to a Personal Computer —Bulletin 900-TC8 Only

By using the appropriate option communications unit in the Bulletin 900-TC8 or 900-TC16 Controller, you can communicate with a personal computer.

Figure 2.27 — Communication Unit Connection Diagram

➊ RS232C for 900-TC8 only.

The RS-232C connection is one-to-one (PC to one Bulletin 900-TC8). The maximum cable length for RS-232 is 15 m. An optional 3 m RS-232C interface cable (Cat. No. 900-CP1x) is available as an extension cable if necessary. If you make your own cable, use shielded, twisted pair cable (AWG 28 or larger).

Publication 900-UM007D-EN-E - January 2011

Note: To configure the 900-TC8 using RS232 communication optional

software (900BuilderLite) is available.

RS-485 Communication to a Personal Computer

When the optional RS-485 communications unit is mounted in the Bulletin 900-TC8, 900-TC16, or 900-TS32, RS-485 communication with a personal computer is possible. Connect the RS-485 communications cable across controller terminals 11 and 12 for 900-TC8 or 900-TC16. Connect the RS-485 communications cable across controller terminals 7 and 8 for 900-TC32.

• Specify both ends of the transmission path, including the personal computer as the end node (that is, connect termination resistors to both ends).

The minimum terminal resistance is 54 Ω. (See Figure 2.28.)

Figure 2.28 — Communication Unit Connection Diagram

Terminator (120Ω, 1/2 W)

Shielded Cable

Abbr.

A<B : “1” mark A>B : “0” space

A (–)

B (+)

Abbr.

A (–)12 B (+)11

RS-485

PC with RS232 to RS485 converter such as 900-CONV

Controller No. X Controller X + 1

Terminator (120Ω, 1/2 W)

Shielded Cable

Abbr.

A<B : “1” mark A>B : “0” space

A (–)

B (+)

Abbr.

A (–) B (+)

RS-485

PC with RS232 to RS485 converter such as 900-CONV

Controller No. X Controller X + 1

8 7

900-TC32

900-TC8 & 900-TC16

Cross-sectional area of conductor AWG24: 0.205mm

AWG14: 2.081mm

Preparations 2-29

• The RS-485 connection can either be one-to-one or one-to-N. Up to 32 units including the personal computer can be connected one-to-N. For 900-TC8 & 900-TC16: Use shielded, twisted pair cable (24…14AWG), and keep the total length to 500 m or less. For 900-TC32: Use shielded, AWG24 to AWG18 twisted pair cable.

Figure 2.29

• To use a PC on an RS-485 link/network connection, a Bulletin 900-CONV RS-232-to-RS-485 or equivalent converter is required.

Publication 900-UM007D-EN-E - January 2011

2-30 Preparations

900-TC16900-TC8

RS-232

RS-485

900-CONV

900-TC8 and/or TC16

Figure 2.30

Note: The PC must have 900BuilderLite software installed to

configure/monitor the Bulletin 900-TC8, 900-TC16, and/or 900-TC32 on an RS-485 network.

Using the Direct PC Communications Port

The direct PC communication port, available on the Series A and Series B Bulletin 900-TC, 900-TC16, and 900-TC32 Controllers, enables direct PC to controller communications without the use of a communication option unit. A 900-CPOEM1 USB to serial conversion cable is required. The cable is approximately 1 meter in length and connects to your PC’s USB port and the controller’s direct communication port (refer to Figure 3).

➊

900BuilderLite

is used with the cable to configure the 900-TC8, 900-TC16, or

900-TC32 controller.

➊

900 BuilterLite version 1.1 for Series A controllers and Version 1.2 for Series B controllers.

Procedure

Use the following procedure to connect the Temperature Controller to the personal computer using the USB-Serial Conversion Cable. The USB-Serial Conversion Cable is used to communicate with the COM port of the personal computer. To perform communications using USB-Serial Conversion Cable, configured the communications port (COM port) number to be used for the software to the COM port assigned to the Cable.

Publication 900-UM007D-EN-E - January 2011

Hardware Installation

EXAMPLE

Personal Computer USB Port

900-CPOEM1 Cable

Communications

Port for Support

Software

900-TC8

Communications Port for Support Software

900-TC32

Communications Port for Support Software

900-TC16

Bottom View of Temperature Controllers

Communications Port for Support Software

Figure 2.31 — Temperature Controller Connection Method

Preparations 2-31

1. Turn ON the power to the Temperature Controller. Note: If the cable is connected when the power to the Temperature Controller is OFF, power will be supplied from the personal computer and impose a load on the internal circuits of the Temperature Controller.

2. Connect the cable. Connect the personal computer’s USB port with the Support Software port on the Temperature Controller using the Cable. Note: Hold the connector when inserting or disconnecting the cable.

3. Install the driver.

Note: The driver is available free of charge from the Bulletin 900 Temperature

Controller Website: www.ab.com/industrialcontrols/products/relays_timers_and_temp_ controllers/single_loop_temp_heater_controllers/900tc.html. Refer to the menu on the right and click on Get Software for Serial Conversion Cable. Install the driver to enable the cable to be used with the personal

computer.

➊

900 BuilterLite version 1.1 for Series A controllers and Version 1.2 for Series B controllers

➊

Publication 900-UM007D-EN-E - January 2011

2-32 Preparations

Driver Installation

When the cable is connected with the personal computer, the personal computer’s operating system detects the product as a new device. At this time, install the driver using the installation wizard. For details on installation methods, refer to the user’s manual for the 900-CPOEM1-Serial Conversion Cable.

When setting 900 BuilderLite for direct communication the port parameters of the direct communication port are fixed as shown in Table 2.L. Set the Bulletin 900 BuilderLite communication parameters to match those in Table 2.L

Table 2.L — Fixed Port Parameters

Parameter Value

Communication Unit # 01 Communication Baud Rate 38.4 (Kbps) Communication Data Length 7 (bits) Communication Stop Bits 2 (bits) Communication Parity Even

Publication 900-UM007D-EN-E - January 2011

Configuration & Basic Operation

Mode Key

Temperature Unit

Operation Indicators

No. 1 Display

No. 2 Display

Up Key

Function Group Key

Down Key

Figure 3.1 — 900-TC8

Chapter

Figure 3.2 — 900-TC16

Operation Indicators

Temperature Unit

Operation Indicators

Mode Key

Function Group Key

SUB2

SUB1

SUB3

No.1 Display

No.2 Display

STOPOUT1

MANU

CMWOUT2

Down Key

No.3 Display

Up Key

A/M

Function Key/ Auto/Manual Key

3-1 Publication 900-UM007D-EN-E - January 2011

3-2 Configuration & Basic Operation

Figure 3.3 — 900-TC32

Publication 900-UM007D-EN-E - January 2011

Configuration & Basic Operation 3-3

Note (1) You can return to the operation function group by executing a software reset.

(2) You cannot move to other function groups by operating the keys on the front panel

from the calibration function group. You must turn OFF the power supply.

(3) From the manual control function group, key operations can be used to move to the

operation function group only.

Start in manual mode.

100

a-m

Power ON

(See note

3.)

(See note 1.)

(See note 2.)

Press the Key or the PF Key for at least 1 s. (See note 4.)

Press the Key for at least 3 s while a-m is displayed. (a-m will flash after 1st second.)

Operation

Function Group

Press the

Key for

at least 1 s.

Press the Key for at least 1 s.

Input password.

Input password while amoV is displayed. (Set value −169)

Press the

Key less than 1 s.

Press the Key for at least 3 s. (Display will flash after 1st second.)

Control stops.

Press the

Key for less than 1 s.

Press the + M Keys for at least 3 s. (Display will flash after 1st second.)

Protect Function Group

Control in progress

Function Group change

Not displayed for some models

Control stopped

Start in automatic mode.

Adjustment

Function Group

(See note 4.)

PF Key (See note 5.)

Initial Setting Function Group

Manual Control

Function Group

Monitor/Setting

Item Function Group

Advanced Function

Setting Function Group

Calibration Function Group

Press the PF Key for at least 1 s.

Communications Setting

Function Group

Press the + M Keys for at least 1 s.

Note The time taken to move

to the protect function group can be adjusted by changing the "Move to protect function group time" setting.

(4) When the PF Setting is configured to A-M in models with a PF Key (900-TC8) (5) When the PF Setting is configured to PFDP in models with a PF Key (900-T C8 )

How Function Groups Are Configured and Operating the Keys on the Front Panel

Parameters are divided into control categories, each called a function group. Each of the items/values that can be configured in these function groups is called a parameter. The function groups on the Bulletin 900 controller are divided into the following:

Figure 3.4 — Function Group Configuration

Publication 900-UM007D-EN-E - January 2011

3-4 Configuration & Basic Operation

Table 3.A — Control Categories

Function Group Control In Progress Control Stopped

Protect — Operation — Adjustment — Manual Control — Monitor/Setting Item — Initial Setting — Advanced Setting Calibration — Communications Setting —

 To activate the Advanced Setting function group, set the Protect function group of the Initial/Communications

Protect to 0. Indicates items that can be configured.

 —

Of these control categories, the Initial Setting, Communications Setting, Advanced Setting, and Calibration function groups can be used only when control has stopped. Note that controller outputs are stopped/reset when any of these four function groups are selected.

• Protect Function Group — To move to this function group,

simultaneously press the

O and M keys for at least 3 seconds in the

Operation, Adjustment, or Monitor/Setting Item function group. This function group is used to prevent unwanted or accidental modification of parameters. Protected parameters will not be displayed, and so the parameters in that function group cannot be modified.

Publication 900-UM007D-EN-E - January 2011

Configuration & Basic Operation 3-5

Note: The key pressing time can be altered to your requirements. Refer to the

Move to Protect function group Time parameter in the Advanced Setting function group.

• Operation Function Group — This function group is displayed when

you turn the power ON. You can move to the Protect, Initial Setting, and Adjustment function groups from this point. This function group is typically selected during operation. During operation, the process value (PV), and manipulated variable (MV) can be monitored, and the SP, Alarm Value, and Upper- and Lower-Limit Alarm parameters can be monitored and modified.

• Adjustment Function Group — To move to this function group,

press the group. This function group is used to enter configuration values and offset values for control. This function group contains parameters for AT (Auto-Tuning), communications writing enable/disable, hysteresis, multi-SP, Heater Burnout Alarm (HBA), Heater Short Alarm (HSA), and PID constants. You can move to the top parameter of the Initial Setting, Protect, and Operation function groups from here.

O key for less than 1 second from the Operation function

• Monitor/Setting Item Function Group (900-TC8)— To switch to

the Monitor/Setting Item function group press the PF key from the Operation or Adjustment group. The parameter(s) configured for Monitor/Setting Item 1 to 5 can be displayed. You can move from the Monitor/Setting Item to the Operation of Initial Setting function groups. Only the 900-TC8 supports this function group.

• Manual Control Function Group — When the

at least 3 seconds from the Operation function group’s auto/manual switching display, the Manual Control function group will be displayed. (The MANU indicator will light.) When the PF setting is configured to A-M (auto/manual) and PF key is pressed for more than 1 second in the Operation or Adjustment function group the Manual Control group will be displayed (900-TC8 only).This is the function group for changing the MV in manual mode. To return to the Operation function group, press

O key for at least 1 second.

the

• Initial Setting Function Group — To move to the Initial Setting

function group from the Operation or the Adjustment function group, press the second. This function group is for specifying the Input Type and selecting the control method, control period, setting direct/reverse action, and setting the alarm types. You can move to the Advanced Setting or Communications Setting function group from this function group. To return to the Operation function group, press the at least 1 second. To move to the Communications Setting function group, press the Initial Setting function group to the Operation function group, all the indicators will light

O key for at least 3 seconds. The PV display flashes after 1

O key for less than 1 second. (When moving from the

O key is pressed for

O key for

Publication 900-UM007D-EN-E - January 2011

3-6 Configuration & Basic Operation

Note: Pressing the O key for at least 3 seconds in the Operation function group’s auto/manual switching display will move to the Manual Control function group, and not the Initial Setting function group.

• Advanced Setting Function Group — To move to the Advanced

Setting function group, set the Initial Setting/Communications Protect parameter in the protect function group to 0 and then, in the Initial Setting function group, input the password (−169). From the Advanced Setting function group, it is possible to move to the Calibration function group or to the Initial Setting function group. This function group is for setting the display auto-return time, event input assignments, standby sequence, and alarm hysteresis, and it is the function group for moving to the user calibration.

• Communications Setting Function Group — To move to the

Communications Setting function group from the Initial Setting group, press the

O key once (for less than 1 second). When using the

communications function, set the communications conditions in this group. Communicating with a personal computer (host computer) allows set points to be read and written, and Manipulated Variables (MV) to be monitored.

• Calibration Function Group — To move to the Calibration function

group, input the password (1201) from the Advanced Setting group. The Calibration function group is for offsetting error in the input circuit. You cannot move to other function groups from the Calibration group by operating the keys on the front panel. To cancel this function group, turn the power OFF then back ON again.

Publication 900-UM007D-EN-E - January 2011

Configuration & Basic Operation 3-7

Moves in order after M key is pressed (if key is released within 1 s).

Parameter 1

Parameter 2

Parameter 3

After M key is pressed

Parameter 4

Hold down the M key during this interval.

While the M key is being held down, the parameter will move each second in reverse order.

Parameter 2

Parameter 3

After M key has been held down for 2 s.

After M key has been held down for 1 s.

Selecting Parameters

Within each function group, the parameter is changed in order (or in reverse order) each time the M key is pressed. (In the Calibration function group, however, parameters cannot be changed in reverse order.) For details, refer to Parameter Functions & Definitions on page 5-1.

Figure 3.5 — Parameters

Changing Parameters and Loading Values into Controller Memory

If you press the M key at the final parameter, the display returns to the top parameter for the current function group.

To change parameter value or configuration (setup), modify the setting by using the U or D key, and either leave the setting alone/unchanged for at least 2 seconds or press the M key. This loads the present value displayed into the controller’s memory.

When another function group is selected, the parameter and value on the display are the ones currently loaded into controller memory.

When you turn the controller power OFF, ensure that the values are loaded into memory by pressing the M key. The values and parameters setups are sometimes not changed (loaded) by merely pressing the U or D key.

Publication 900-UM007D-EN-E - January 2011

3-8 Configuration & Basic Operation

psel

cwf

u-no

bps

9.6

len

sbit

prty

even

sdwt

Protocol setting

Communications Unit No.

Communications baud rate

Communications parity

Send data wait time

Communications data length

Communications stop bits



Communications Function

The Bulletin 900 temperature controller can be provided with a communications function that allows you to check and set controller parameters from a personal computer that has configuration and/or monitoring software installed. If the communications function is required, mount the appropriate option unit (refer to Table 1.C or 1.E) for the Bulletin 900 temperature controller.

Follow the procedure below to move to the Communications Setting function group.

1. Press the

O key for at least 3 seconds to move from the Operation

function group to the Initial Setting function group.

2. Press the

O key for less than 1 second to move from the Initial Setting

function group to the Communications Setting function group.

3. Select the parameters as shown below by pressing the M key.

4. Press the U or D key to change the parameter setting.

Figure 3.6 — Communications Setting Function Group

Publication 900-UM007D-EN-E - January 2011

 The Communication Data Length and Communication Stop Bits parameter is displayed only when 900-TC

communications are selected from the Protocol Setting parameter.

Configuration & Basic Operation 3-9

EXAMPLE

Setting Up Communications Parameter Data

Set the Bulletin 900 controller communication parameter specifications so that they match the communication parameter setup for the personal computer, using configuration/monitoring software such as 900BuilderLite. In a multidrop (RS-485) 1:N configuration, match the setting data except for the communications unit numbers on all 900-TC controllers. All Controllers must have unique communications unit numbers.

Table 3.B

Parameter Symbol Configurable (Monitor) Value Selection Symbols Default Unit

Protocol setting Communications Unit No. Communications baud rate Communications data

psel

u-no

bps

len

length ✟ Communications stop bits

sbit

✟

Communications parity Send data wait time

prty

sdwe

Initial Setup Examples

900-TC or Modbus

cwf, mod

900-TC None

0…99 1 None

1.2, 2.4, 4.8, 9.6, 19.2, 38.4, 57.6 1.2, 2.4, 4.8, 9.6, 19.2, 38.4, 57.6 9.6 kbit/s 7, 8 7 Bits

1, 2 2 Bits

None, Even, Odd None, Even, Odd Even None 0…99 20 ms

✟ The Communication Data Length and Communication Stop Bits parameter is displayed only when 900-TC

communications are selected from the Protocol Setting parameter.

The O and M keys are used to switch between configuration menus, and the amount of time that you hold the keys down determines which configuration menu you move to. This section describes two typical examples.

Figure 3.7 — Explanation of Examples

Changing Parameters

in-t

in-h

100

in-l

cntl

onof

cntl

onof

A image means that there are parameters. Continue pressing the M key to change parameters until you reach the intended parameter.

Changing Numbers

Numeric data and selections in each

screen can be changed by using the U and D keys.

Publication 900-UM007D-EN-E - January 2011

3-10 Configuration & Basic Operation

100

onof

pid

run stop

in-t

cntl

onof

alt1

100

r-s

run

al-1

Input type: 5 (K thermocouple,

−200°C to 1,300°C) Control method: ON/OFF control Alarm type: 2 (upper limit) Alarm value 1: 20°C (deviation) Set point: 100°C

Setup Procedure

Power ON

Initial Setting function group

Set input specifications

Set control specifications

Set alarm type

Operation function group

Set alarm values

Start operation

Power ON

Operation function group

PV/SP

Press the O key for at least 3 s.

Control stops.

Initial Setting function group

Input type: 5

Check that control method is ON/OFF control.

ON/OFF control:

PID

control:

Check alarm type.

Check input type.

Alarm 1 type: 2

Press the O key for at least 1 s.

Control starts.

Operation function group

Use the U and D keys to set the SP to 100°C.

PV/SP:

Confirm that control is running.

Running

Stopped:

Use the U and D keys to set the

alarm value to 20°C.

Alarm value 1:

Start operation.

Figure 3.8 — Typical Example 1

Publication 900-UM007D-EN-E - January 2011

Figure 3.9 — Typical Example 2

150

onof

pid

off

run stop

Input type: 9 (T thermocouple,

−200°C to 400°C) Control method: PID control PID constants found using auto-tuning (AT). Alarm type: 2 upper limit Alarm value 1: 30°C Set point: 150°C

Setup Procedure

Power ON

Initial Setting function group

Set input specifications

Set control specifications

Set alarm type

Adjustment function group

AT execution

(When PID control is selected)

Operation function group

Set alarm value

Start operation

Power ON

in-t

cntl

pid

off

alt1

150

off

150

r-s

run

al-1

off

150

Operation function group

PV/SP

Press the O key for at least 3 s.

Control stops.

Initial Setting function group

Use the U and D keys to select the input type.

Input type:

Use the U and D keys to select PID control.

ON/OFF control:

Use the U and D keys to set ST to OFF.

To execute ST:

PID control:

To cancel ST:

Check the control period.

Control period (heat) (Unit: Seconds)

Check the alarm type.

Alarm 1 type:

For PID, set pid.

When ON, self-tuning operates.

It is recommended that 20 seconds be set for a relay output and 2 seconds for an SSR voltage output.

Press the O key for at least 1 s.

Operation function group

Use the U and D keys to set the SP to 150°C.

PV/SP:

Adjustment function group

Execute AT.

To execute AT: To cancel AT:

To execute AT (auto-tuning), select on: (AT execute), and to cancel AT, select off: (AT cancel).

Press the O key (for less than 1 s).

Control starts.

Operation function group

Confirm that the set point is 150°C.

PV/SP

Confirm that control is running.

Running Stopped

Use the U and D keys to set the alarm value to 30°C.

Alarm value 1

Start operation.

PV/SP after AT is stopped

The set point flashes during auto-tuning (AT) execution.

After AT is stopped

During AT execution

Configuration & Basic Operation 3-11

Publication 900-UM007D-EN-E - January 2011

3-12 Configuration & Basic Operation

Configuring the Input Type

The Bulletin 900-TC8, 900-TC16, and 900-TC32 controller support three input/sensor types: (1) platinum resistance thermometer (RTD), (2) thermocouple, and (3) non-contact temperature sensor. The Bulletin 900-TC8 and 900-TC16 controller support a fourth input/sensor type, analog inputs.

Program/configure the Input Type matched to your sensor using the Input Type parameter (See Table 3.C). The Bulletin 900-TC8, 900-TC16, and 900-TC32 general controller specifications support two general types of Global Temperature (GT) inputs: (1) platinum resistance thermometer input and (2) thermocouple Input Types (refer to Table 3.C). The Bulletin 900-TC8 and 900-TC16 controller support a third a third GT input, analog inputs (refer to Table 3.D). Check the cat. no. of your Bulletin 900 components at purchase to ensure it matches your input requirements (refer to Tables 1.B and 1.D).

Input Type

Example Operation Procedure: Setting the Input Type to Thermocouple Type K (–20.0…500.0°C) (See Table 3.C, — List of Global Temperature (GT) Input Types)

1. Press the function group to the Initial Setting function group.

O key for at least 3 seconds to move from the Operation

Figure 3.10 — Operation Function Group

Figure 3.11 — Initial Setting Function Group

Input type

in-t

2. Press the U key to configure the Set Value for the type of sensor you

are using. Entering the Set Value will configure the controller for the applicable Input Type and range. Example: When you use K thermocouple (–20.0…+500.0°C), enter 6 as the Set Value (refer to Table 3.C).

Note: The selected Set Value is loaded into controller memory if you do not

operate the keys on the front panel for 2 seconds after changing the parameter, or by pressing the all values and/or parameters.

Figure 3.12 — Set Value

O or M keys. This applies to changing

in-t

Publication 900-UM007D-EN-E - January 2011

Table 3.C — List of Global Temperature (GT) Input Types

Input Type Specifications Set Value Input Temperature Setting Range

ControllerType with

Platinum Resistance Thermometer (RTD)

Pt100 0 −200…850 (°C)/−328…1,562 (°F)

Thermocouple and Resistance Thermometer (RTD)

JPt100 3 −199.9…500.0 (°C)/−327.8…932.0 (°F)

Multi-input

Configuration & Basic Operation 3-13

1 −199.9…500.0 (°C)/−327.8…932.0 (°F) 2 0.0…100.0 (°C)/32.0…212.0 (°F)

4 0.0…100.0 (°C)/32.0…212.0 (°F)

Thermocouple K

5 −200…1,300 (°C)/−328…2,372 (°F) 6 −20.0…500.0 (°C)/-4.0…932.0 (°F)

J7−100…850 (°C)/−148…1,562 (°F)

8 −20.0…400.0 (°C)/-4.0…752.0 (°F)

T9−200…400 (°C)/−328…752 (°F)

10 −199.9…400.0 (°C)/−327.8…752.0 (°F) E 11 -200…600 (°C)/-300…1,100 (°F) L12−100…850 (°C)/−148…1,562 (°F) U13−200…400 (°C)/−328…752 (°F)

14 −199.9…400.0 (°C)/−327.8…752.0 (°F) N15−200…1,300 (°C)/−328…2,372 (°F) R 16 0…1,700 (°C)/32…3,092 (°F) S 17 0…1,700 (°C)/32…3,092 (°F) B 18 100…1,800 (°C)/212…3,272 (°F)

Infrare

d (non-c

ontact)

temperature sensor ✟

10…70°C 19 0…90 (°C)/32…194 (°F) 60…120°C 20 0…120 (°C)/32…248 (°F) 115…165°C 21 0…165 (°C)/32…329 (°F) 140…260°C 22 0…260 (°C)/32…500 (°F)

Millivolt input 0…50 mV 23 Either of the following ranges, by scaling:

−1,999…9,999

−199.9…999.9

Thermocouple W 24 0…2,300 (°C)/0…3,200 (°F)

PL II 25 0…1,300 (°C)/0…2,300 (°F)

✟ The non-contact infrared sensor must be configurable for a Type K thermocouple output within either of the

four specified ranges. For example, in Omron ES1B or Calex EL Series (Convir) infrared sensor.

• The default is 5 (shaded).

• If an RTD is mistakenly connected while a setting for other than a platinum resistance thermometer is in effect, the controller error code s.err will be displayed. To clear the s.err display, check the wiring and then turn the controller power OFF and back ON.

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3-14 Configuration & Basic Operation

Table 3.D — Analog Input Types (not supported by 900-TC32)

Input Type Specifications Set Value Process Input Setting Range

Models with Analog Input

Current input 4…20 mA

Voltage input 1…5V 2

Selecting °C/°F

0 Either of the following ranges can be used by scaling

0…20 mA 1

0…5V 3 0…10V 4

• The default is 0 (shaded).

−1,999…9,999

−199.9…999.9

−19.99…99.99

−1.999…9.999

Temperature Units

The Bulletin 900 controller allows you to select either °C or °F as the temperature unit.

Configure the temperature units in the Temperature Unit parameter of Initial Setting function group.

Note: The default is °C.

Example Operation Procedure: Select °C

1. Press the function group to the Initial Setting function group.

Figure 3.13 — Operation Function Group

Figure 3.14 — Initial Setting

O key for at least 3 seconds to move from the Operation

Input type

in-t

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Configuration & Basic Operation 3-15

d-u

Temperature unit

2. Select the Temperature Unit parameter by pressing the M key. Press the

U or D key to select either °C (c) or °F (f).

Figure 3.15 — Temperature Unit Parameter

3. To return to the Operation function group press the O key for at least

1 second.

Figure 3.16 — Operation Function Group

The Operation function group is displayed when the Bulletin 900 controller is turned ON. The upper display (No. 1) shows the process value (PV), and the lower display (No. 2) shows the set point (SV or SP).

Configuring the SP

Changing the SP

The set point cannot be changed when the Operation/Adjustment Protection parameter is set to 3. For details, refer to page 4-33, Using the Key Protect Function Group.

To change the set point, press the U or D key in the PV/SP parameter (Operation function group), and load/program the desired value. The new set point is loaded/programmed into memory 2 seconds after you have specified the new value.

For 900-TC8 and 900-TC16 only: The Multi-SP parameter is used to switch between two or four pre-configured set point values. Refer to page 4-16, Using the Event Input Feature — 900-TC8 & 900-TC16 for details.

Example Operation Procedure

In this example, the set point will be changed from 0…200°C.

1. Normally, the PV/SP parameter is displayed. The current set point is 0 °C.

Figure 3.17

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3-16 Configuration & Basic Operation

2. Press the U or D key until the set point displayed is 200°C. To load

the value into the controller memory, either press the 2 seconds.

Figure 3.18

O key or wait

200

Selecting PID Control or ON/OFF Control

Overview

The Bulletin 900 Controller supports two control methods: (1) 2-PID control and (2) ON/OFF control. The control method is selected by the PID ON/OFF parameter in the Initial Setting function group. When this parameter is configured to pid, 2-PID control is set, and when configured to onof, ON/OFF control is set.

Note: The default is ON/OFF control.

2-PID Control

Controller configured/selected P, I, and D (Proportional, Integral, and Derivative) control parameters are set by the AT (Auto-Tuning) and ST (Self-Tuning) parameters, or by manual (user) setup. For manual (user) PID control, set the PID constants in the Proportional Band (P), Integral Time (I), and Derivative Time (D) parameters. For more details refer to page 3-30.

Publication 900-UM007D-EN-E - January 2011

ON/OFF Control

In the ON/OFF control method, the control output (MV) is turned ON when the process value (measured temperature, flow, etc.) is lower than the current set point, and the control output is turned OFF when the process value is higher than the current set point. This is known as reverse operation. Direct operation refers to control where the manipulated variable is increased according to the increase in the process value. Refer to page 3-25 for more details.

Configuration & Basic Operation 3-17

orev

Configuring the Output Parameters

Control Period

The Control Period parameter is used in the PID control method and allows you to adjust the minimum amount of time between ON cycles of the ON/OFF output (MV). This is sometimes referred to as timed proportional PID control.

Figure 3.19 — Control Period Parameter

Control period (OUT1)

Control period (OUT2)

A shorter period may provide better ON/OFF control performance. We recommend setting the control period to 20 seconds or more. In the case of electromechanical relay outputs, doing this will improve its life expectancy. If you are using an ON/OFF voltage output (SSR) setting, a shorter time will not drastically impact the life of the SSR, since it is rated by the number of ON hours. If necessary, readjust the Control Period by trial operation to meet the needs of your application.

• You can configure the individual control period values in the Control

Period (HEAT) and Control Period (COOL) parameters (Initial Setting function group). Note: The default is 20 seconds.

• The Control Period (COOL) parameter can be used only in the heating

and cooling control method.

• When Control Output 1 is used as an analog current output, the Control

Period (HEAT) parameter cannot be used.

Note: The Control Period parameter allows what is typically called Time

Proportioning ON/OFF Control to be done in the 2-PID method.

Direct/Reverse Operation

Figure 3.20 — Direct/Reverse Operation

Direct operation refers to control where the manipulated variable (MV) is increased according to the increase in the process value (PV). Alternatively, reverse operation refers to control where the manipulated variable (MV) is decreased according to the increase in the process value (refer to Figure 3.21). Direct/reverse operation can be used in ON/OFF or PID control.

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3-18 Configuration & Basic Operation

EXAMPLE

High temperature

Manipulated variable (MV)

Direct operation

Low temperature

Set value (SP)

High temperature

Manipulated variable (MV)

Reverse operation

Low temperature

Set value (SP)

100%

Figure 3.21 — Direct/Reverse Operation

For example, when the process value (PV) temperature is lower than the set point (SP) temperature in a heating control system, the manipulated variable (OUT1) increases (ON) by the difference between the PV and SP values.

Accordingly, this becomes reverse operation in a heating control system, or alternatively, direct operation in a cooling control system.

Direct/reverse operation is set in the Direct/Reverse Operation parameter (Initial Setting function group).

Note: The Direct/Reverse Operation parameter default is reverse operation.

Operation Procedure

In this example, the Input Type, Temperature Unit, Direct/Reverse Operation, and Control Period (HEAT) parameters will be monitored.

The setup of parameters is as follows:

Input Type = 5: K thermocouple Temperature Unit = c: °C Direct/Reverse Operation = or-r: reverse operation Control Period (HEAT) = 20 seconds

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1. Press the

O key for at least 3 seconds to move from the Operation

function group to the Initial Setting function group.

Configuration & Basic Operation 3-19

Control period (heat)

orev

or-r

Direct/reverse operation

Figure 3.22

2. The Input Type is displayed. When you are monitoring/configuring the

Input Type for the first time, the set value is 0: K type thermocouple default. (0 is set if you have a platinum resistance thermometer compatible controller. To select a different sensor, press the U or D keys. This changes the Set Value (refer to Table 3.A) to match your desired sensor input.

Figure 3.23

Input type

in-t

3. Select the Temperature Unit parameter by pressing the M key. Note:

The default is c: °C. To configure f: °F, press the U key.

Figure 3.24

Temperature unit

d-u

4. Select the Control Period (OUT1) parameter by pressing the M key.

Note: The default is 20.

Figure 3.25

5. Select the Direct/Reverse Operation parameter by pressing the M key. Note: The default is or-r: reverse operation. To configure or-d:

direct operation, press the U key.

Figure 3.26

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3-20 Configuration & Basic Operation

PV/SP

6. To return to the Operation function group press the O key for at least 1 second.

Figure 3.27

7. Select the Move to Advanced Setting function group parameter by pressing the M Key.

Figure 3.28

Move to

amov

Advanced Setting Function Group

Assigned Output Functions

• The control and auxiliary outputs of the 900-TC8, 900-TC16, and 900-TC32 can be individually assigned a function by using the Control Output Assignment parameter in the Advanced Settings function group.

• The default function assignment for each output is shown in Table 3.E.

Table 3.E — Default Fuction Assignment

Parameter Name Symbol Initial Status

Control Output 1 Assignment

Control Output 2 Assignment

Auxiliary Output 1 Assignment

Auxiliary Output 2 Assignment

Auxiliary Output 3 Assignment (900-TC8 only)

out 1

out 2

sub 1

sub 2

sub 3

Control Output (heating)

Not assigned

Alarm 1

Alarm 2

Alarm 3

Note: Each output is automatically initialized as shown below by

changing the control mode

Note: Control Output 2 Assignment and Auxillary Output 2

Assignment are not supported by 900-TC32.

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EXAMPLE

Table 3.F — 900-TC8 and 900-TC16

Without Control Output 2 With Control Output 2

Parameter Name Symbol

Control Output 1 Assignment

Control Output 2

out 1

out 2

Control output (heating)

Not assigned➊ Not

Assignment

Auxiliary Output

sub 1

Alarm 1➋ Alarm 1➋ Alarm 1➋ Alarm 1➋

1 Assignment

Standard

Configuration & Basic Operation 3-21

Heating/

Cooling Standard

Control output (heating)

Not

assigned

➊

assigned

Heating/

Cooling

Control output (heating)

Control output (cooling)

Auxiliary Output

sub 2

2 Assignment

➊ There is no control output 2 and no parameter assignment is displayed for that output. ➋ The Auxiliary Output 1 Assignment parameter becomes the program end output unless the Program

Pattern parameter is configured to OFF.

➌ For the 900-TC8, the Auxiliary Output 3 Assignment parameter is set as the control output for cooling.

(The Auxiliary Output 2 Assignment parameter is set for alarm 2).

Alarm 2➌ Control

output (cooling)

Alarm 2➌ Alarm 2➌

➌

Table 3.G — 900-TC32

Parameter Name Symbol Standard Heating/Cooling

Control Output 1 Assignment

Auxiliary Output 1

out 1

sub 1

Control output (heating)

Alarm 1➋ Control output

Assignment

➋ The Auxiliary Output 1 Assignment parameter becomes the program end output unless the

Program Pattern parameter is configured to OFF.

Control output (heating)

(cooling)

Alarms

It will be specified in this section when an alarm must be assigned (i.e., when an alarm must be set) for the Control Output 1 or 2 Assignment parameters, or for the Auxiliary Output 1 or 3 Assignment parameters. For example, if alarm 1 is set for the Control Output 1 Assignment parameter, then alarm 1 has been assigned.

Operating Procedure

The following example configures the following control and auxiliary out assignments: Control Output 1: Control Output (Heating); Control Output 2:

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3-22 Configuration & Basic Operation

100

PV/SP

5-hc

stnd

Standard or heating/cooling

5-hc

h-c

amov

Move to Advanced Setting Function Group

Control Output (Cooling); Auxiliary Output 1: Alarm 1; Auxiliary Output 2: Alarm 2

1. Press the function group to the Initial Setting function group.

Figure 3.29

2. Select the Standard or Heating/Cooling Control Mode parameter by

pressing the M key.

Figure 3.30

O key for at least 3 seconds to move from the Operation

Input type

in-t

Figure 3.31

3. Press the U key to set the parameter to h-c (Heating/Cooling)

Control Mode. Note: The following output assignments do not need to be set because they are set automatically as defaults by changing the control mode, but they are shown here as a reference for checking the assignments for each output.

Figure 3.32

4. Select the Move to Advanced Setting function group parameter by

pressing the M key.

5. Press the D key to enter the password (−169), and move from the

Initial Setting function group to the Advanced Setting function group.

Figure 3.33

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Configuration & Basic Operation 3-23

out1

out2

c-o

sub1

alm1

Auxiliary Output 1 Assignment

6. Select the Control Output 1 Assignment parameter by pressing the M

key.

Figure 3.34

Control output 1

out1

assignment

7. Press the U or D key to set o. (The default is o.)

Figure 3.35

8. Select the Control Output 2 Assignment parameter by pressing the M key.

Figure 3.36

Control Output 2

nmen

Assi

9. Press the U or D key to set c-o. (When h-c is selected for the Standard or Heating/Cooling Control Mode parameter, the setting will be c-o.)

Figure 3.37

10. Select the Auxiliary Output 1 Assignment parameter by pressing the M

key.

Figure 3.38

Auxiliary Output

sub1

1 Assignment

alm1

11. Press the U or D key to set alm1. (The default is alm1.)

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3-24 Configuration & Basic Operation

sub2

alm2

Auxiliary Output 2 Assignment

sub2

alm2

Auxiliary Output 2 Assignment

in-t

Input type

100

PV/SP

12. Select the Auxiliary Output 2 Assignment parameter by pressing the M

key.

Figure 3.39

13. Press the U or D key to set alm2. (The default is alm2.)

Figure 3.40

14. Press the O key for at least 1 second to move from the Advanced Setting to the Initial Setting function group.

Figure 3.41

15. Press the O key for at least 1 second to move from the Initial Setting function group to the Operation function group.

Figure 3.42

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Configuration & Basic Operation 3-25

Auxiliary Output Opening or

Note: Refer to Page 5.73,

definition and furhter explanation of open in and close in alarm.

Closing in Alarm

Table 3.H — Open In Alarm

Auxiliary Output * Open in Alarm (* = 1 to 3), for

• When “close in alarm” is configured, the status of the auxiliary output is output unchanged. When “open in alarm” is configured, the status of the auxiliary output function is reversed before being output.

• Each auxiliary output can be configured independently.

• These configurations are made in the Auxiliary Output 1 to 3 Open in Alarm parameters (Advanced Setting function group).

• The default is n-o: Close in Alarm.

• When “open in alarm” is configured for the alarm 1 output, the open in alarm status is also applied to heater burnout, HS alarm, heater overcurrent, and input error outputs.

Auxiliary Output functions 1...3 Auxiliary Output

Open in Alarm ON ON Lit

OFF OFF Not lit

Indicators (SUB1...SUB3)

Executing the ON/OFF Control Method

Overview

In the reverse operation ON/OFF control method, the control output (MV) turns OFF when the controlled temperature (PV) reaches the user-defined set point. When the control output (MV) turns OFF, the controlled temperature begins to fall and the control output turns ON again. This operation is repeated at a certain point. At this time, how much the temperature must fall before the control output turns ON again is determined by the Hysteresis (HEAT) parameter. Also, how much the manipulated variable must be adjusted in response to the increase or decrease in the process value is determined by the Direct/Reverse Operation parameter.

ON/OFF Control Parameters

Switching between the 2-PID control method and ON/OFF control method is carried out by the PID ON/OFF parameter (Initial Setting function group). When this parameter is configured to pid, 2-PID control is selected, and when configured to onof, ON/OFF control is selected.

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3-26 Configuration & Basic Operation

Set point

Hysteresis (OUT1)

Heating side

Dead band

Hysteresis (OUT2)

Cooling side

OFF

The default is onof.

Hysteresis

In the ON/OFF control method, hysteresis is used to provide a margin/differential for switching the control output ON when the controlled temperature moves away from the required set point. The Hysteresis parameter is used to give stability to the output around the set point.

The hysteresis value for HEAT control output and COOL control output functions are configured in the Hysteresis (HEAT) and Hysteresis (COOL) parameter functions respectively. In standard heating or cooling control, the HEAT Hysteresis setting is used as the hysteresis setting (Adjustment function group) regardless of the control mode, heating control or cooling control.

Figure 3.43 — Reverse Operation

Heat Hysteresis

OFF PV

Set point

3-Position Control

In the heating and cooling control method, a dead band (an area where both control outputs are 0) can be configured for either the heating or cooling side of the set point. This makes 3-position control possible.

Figure 3.44 — Reverse Operation with 3-Position Control

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Configuration & Basic Operation 3-27

EXAMPLE

Table 3.I — Parameters

Symbol Parameter Name and Group Location Application

s-hc

Standard or Heating/Cooling: Initial Setting function group

For specifying the control method

cntl

orev

c-db

hys

chys

PID ON/OFF: Initial Setting function group For specifying the control

method

Direct/Reverse Operation: Initial Setting function group

Dead Band: Adjustment function group Heating/cooling control Hysteresis (heating): Adjustment function group ON/OFF control Hysteresis (cooling): Adjustment function group ON/OFF control

For specifying the control method

ON/OFF Control Setup

To execute ON/OFF control, configure the PID ON/OFF parameter.

Operation Procedure: Configuring the PID ON/OFF and Hysteresis Parameters

In this example, first check that the PID ON/OFF parameter is set to onof in the Initial Setting function group. The Setpoint and Hysteresis parameters will also be adjusted.

1. Press the

O key for at least 3 seconds to move from the Operation

function group to the Initial Setting function group.

Figure 3.45

100

2. Display the Input Type parameter in the Initial Setting function group.

Figure 3.46

Input type

in-t

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3-28 Configuration & Basic Operation

100

PV/SP

200

3. Select the PID ON/OFF parameter by pressing the M key.

Figure 3.47

PID•ON/OFF

cntl

onof

4. Check that the configured control method parameter is onof

(Note: ON/OFF is the default).

5. To return to the Operation function group, press the 1 second.

O key for at least

Setting the SP

Operating Procedure

In the second part of this example, the set point is modified to 200. The set value (i.e., the SP) is shown on the controller’s bottom display.

1. Select the Process Value/Set Point parameter in the Operation function group.

Figure 3.48

2. Use the U and D keys to change the SP. (In this example, it is

configured to 200.) The new set value can be loaded into controller memory by pressing the M key, or it will go into effect after 2 seconds have elapsed. Next, set the hysteresis.

Figure 3.49

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Setting the Hysteresis

200

hys

1.0

Hysteresis (heating)

hys

2.0

Operating Procedure

Configuration & Basic Operation 3-29

The third part of the example is to configure the hysteresis to 2.0

1. Press the Adjustment function group.

Figure 3.50

Figure 3.51

2. The Adjustment function group Display parameter will be displayed in the adjustment function group.

Figure 3.52

3. Select the Hysteresis (Heating) parameter by pressing the M key.

Figure 3.53

O key to move from the Operation function group to the

Adjustment

1.adj

Display

°C.

4. Press the U and D keys to set the hysteresis (2.0 in this example). Either press the M key or wait for at least 2 seconds after setting the hysteresis value to load the new value into controller memory.

Figure 3.54

5. To return to the Operation function group, press the O key for at least 1 second.

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3-30 Configuration & Basic Operation

Adjustment Level

233

Proportional Band

Integral Time

Derivative Time

off

AT Execute/Cancel

No. 1 display

Determining PID Constants (AT, ST, Manual Setup)

AT (Auto-Tuning)

Figure 3.55

Overview

When you configure the controller to execute Auto-Tuning, the optimum PID constants for the current set point during program execution are automatically configured by the controller forcibly changing the manipulated variable (MV) to calculate the characteristics (called the limit cycle method) of the control target.

Either 40% AT or 100% AT can be selected depending on the width of MV variation in the limit cycle. In the AT Execute/Cancel parameter, specify at-2 (100% AT) or at-1 (40% AT). To cancel AT, specify off (AT cancel).

• Only 100% AT can be executed for heating and cooling control.

• AT cannot be executed when control has stopped or during ON/OFF control.

• The results of AT are reflected in the Proportional Band (P), Integral Time (I), and Derivative Time (D) parameters in the Adjustment function group.

The result of a controller AT cycle can be viewed/monitored from the Proportional Band (P), Integral Time (I), and Derivative Time (D) parameters in the Adjustment function group.

Figure 3.56 — PID

AT Description and Display Consideration

AT (Auto-Tuning) is started when you configure either at-2 (100%) or at-1 (40% AT).During execution of AT, the No. 1 display for the AT

Execute/Cancel parameter blinks (refer to Figure 3.57). When AT ends, the AT Execute/Cancel parameter turns OFF, and the No. 1 display stops blinking.

Figure 3.57 — AT Execute/Cancel Parameter

Publication 900-UM007D-EN-E - January 2011

Rockwell Automation 900-TC32 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface