Page 1
Instruction Manual
TEC-220 and TEC-920
Auto-Tune Fuzzy / PID Process
Temperature Controller
Serving Industry Since 1972
Agency Approvals
TEMPCO Electric Heater Corporation
607 N. Central Avenue • Wood Dale, IL 60191-1452 USA
Tel: 630-350-2252 • Toll Free: 800-323-6859
Fax: 630-350-0232 • E-mail: [email protected]
Web: www.tempco.com
Manual TEC-220/920 Revision 9/2016
Page 2
NOTES
Page 3
Warning Symbol
This symbol calls attention to an operating procedure, practice, or
the like which, if not correctly performed or adhered to, could
result in personal injury or damage to or destruction of part or all
of the product and system. Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met.
Using the Manual
Installers . . . . . . . . . . . . . . . . . . . . . . . . . . . Read Chapter 1, 2
System Designer . . . . . . . . . . . . . . . . . . . . . Read All Chapters
Expert User . . . . . . . . . . . . . . . . . . . . . . . . . Read Page 11
Contents
Page No.
Chapter 1 Overview
1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2 Ordering Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-3 Programming Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4 Keys and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5 Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6 Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 2 Installation
2-1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3 Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-4 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-5 Sensor Installation Guidelines . . . . . . . . . . . . . . . . . . . 8
2-6 Sensor Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-7 Control Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-8 Alarm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-9 Data Communication . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 3 Programming
3-1 Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-2 Signal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-3 Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-4 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-5 Configuring the Display . . . . . . . . . . . . . . . . . . . . . . . 14
3-6 Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-7 Dwell Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-8 PV Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-9 Digital Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-10 Failure Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-11 Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-12 Manual tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-13 Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-14 Data communication. . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-15 Process Variable (PV) Retransmission. . . . . . . . . . . . 17
Chapter 4 Applications
4-1 Heat Only Control With Dwell Timer . . . . . . . . . . . . . 19
4-2 Cool Only Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-3 Heat-Cool Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 5 Calibration . . . . . . . . . . . . . . . . . . 21
Chapter 6 Specifications . . . . . . . . . . . . . 23
Chapter 7 Modbus Communications
7-1 Functions Supported . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-2 Exception Responses . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-3 Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-4 Data Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-5 Communication Examples . . . . . . . . . . . . . . . . . . . . . . 29
Appendix
A-1 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A-2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
NOTE:
It is strongly recommended that a process should incorporate a LIMIT CONTROL like TEC-910 which will shut
down the equipment at a preset process condition in order to
preclude possible damage to products or system.
Information in this user's manual is subject to change without
notice.
Copyright © 2010, Tempco Electric Heater Corporation, all
rights reserved. No part of this publication may be reproduced,
transmitted, transcribed or stored in a retrieval system, or translated into any language in any form by any means without the
written permission of Tempco Electric Heater Corporation.
Figures & Tables
Page No.
Figure 1.1 Fuzzy Control Advantage. . . . . . . . . . . . . . . . . . 1
Figure 1.2 Programming Port Overview . . . . . . . . . . . . . . . 2
Figure 1.3 Front Panel Description . . . . . . . . . . . . . . . . . . 3
Figure 1.4 Display in Initial Stage. . . . . . . . . . . . . . . . . . . . 3
Figure 2.1 Mounting Dimensions and Panel Cutout . . . . . . 7
Figure 2.2 Lead Termination for TEC-920 . . . . . . . . . . . . . 7
Figure 2.3 Lead Termination for TEC-220 . . . . . . . . . . . . . 7
Figure 2.4 Rear Terminal Connection for TEC-220 . . . . . . 8
Figure 2.5 Rear Terminal Connection for TEC-920 . . . . . . 8
Figure 2.6 Power Supply Connections . . . . . . . . . . . . . . . . 8
Figure 2.7 Sensor Input Wiring . . . . . . . . . . . . . . . . . . . . . 8
Figure 2.8 Output 1 Relay or Triac (SSR) to
Drive Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2.9 Output 1 Relay or Triac (SSR) to
Drive Contactor . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2.10 Output 1 Pulsed Voltage to Drive SSR . . . . . . 9
Figure 2.11 Output 1 Linear Current . . . . . . . . . . . . . . . . . . 9
Figure 2.12 Output 1 Linear Voltage . . . . . . . . . . . . . . . . . . 9
Figure 2.13 Output 2 Relay or Triac (SSR) to
Drive Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 2.14 Output 2 Relay or Triac (SSR) to
Drive Contactor . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 2.15 Output 2 Pulsed Voltage to Drive SSR . . . . . . 9
Figure 2.16 Output 2 Linear Current . . . . . . . . . . . . . . . . . . 9
Figure 2.17 Output 2 Linear Voltage . . . . . . . . . . . . . . . . . 9
Figure 2.18 Alarm Output to Drive Load . . . . . . . . . . . . . 10
Figure 2.19 Alarm Output to Drive Contactor . . . . . . . . . . 10
Figure 2.20 RS-485 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 2.21 RS-232 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 2.22 Configuration of RS-232 Cable . . . . . . . . . . . 10
Figure 3.1 Conversion Curve for Linear Type
Process Value . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 3.2 Heat Only ON-OFF Control . . . . . . . . . . . . . . . 12
Figure 3.3 Output 2 Deviation High Alarm . . . . . . . . . . . . 13
Figure 3.4 Output 2 Process Low Alarm . . . . . . . . . . . . . . 13
Figure 3.5 RAMP Function . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 3.6 Dwell Timer Function . . . . . . . . . . . . . . . . . . . . 14
Figure 3.7 PV Shift Application . . . . . . . . . . . . . . . . . . . . . 15
Figure 3.8 Filter Characteristics . . . . . . . . . . . . . . . . . . . . . 15
Figure 3.9 Effects of PID Adjustment . . . . . . . . . . . . . . . . 16
Figure 4.1 Heat Control Example. . . . . . . . . . . . . . . . . . . . 19
Figure 4.2 Cooling Control Example . . . . . . . . . . . . . . . . . 19
Figure 4.3 Heat-Cool Control Example . . . . . . . . . . . . . . . 20
Figure 5.1 RTD Calibration . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 5.2 Cold Junction Calibration Setup . . . . . . . . . . . . 22
Table 1.1 Display Form of Characters . . . . . . . . . . . . . . . . 3
Table 3.1 Heat-Cool Control Setup Value . . . . . . . . . . . . . 11
Table 3.2 PID Adjustment Guide . . . . . . . . . . . . . . . . . . . . 16
Table A.1 Error Codes and Corrective Actions . . . . . . . . . 30
Appendix
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Page 4
NOTES
Page 5
Chapter 1 Overview
1–1 General
Tempco’s TEC-220 and TEC-920 Fuzzy Logic plus PID microprocessor-based controllers incorporate a bright easy to read 4digit LED display indicating process value or set point. Fuzzy
Logic technology enables a process to reach a predetermined set
point in the shortest time with a minimum of overshoot during
power-up or external load disturbances.
The TEC-220 is a 1/32 DIN size panel mount controller. The
TEC-920 is a 1/16 DIN size panel mount controller. These units
are powered by 11–26 or 90–250 VDC/VAC 50/60 Hz supply,
incorporating a 2 Amp control relay output as a standard. The
second output can be used as a cooling control, an alarm or a
dwell timer. Either output can use a triac, 5V logic output, linear
current or linear voltage to drive an external device. There are six
types of alarms or a dwell timer that can be configured for the
second output. The units are fully programmable for PT100 RTD
and thermocouple types J, K, T, E, B, R, S, N, and L with no need
to modify the unit. The input signal is digitized by using an 18bit A to D converter. Its fast sampling rate allows the unit to control fast processes.
Digital communications RS-485 is available for the TEC-220 or
TEC-920. RS-232 is available for the TEC-220 only. These
options allow the units to be integrated with supervisory control
systems and software.
A programming port is available for automatic configuration,
without the need to access the keys on the front panel.
By using proprietary Fuzzy modified PID technology, the control loop will minimize overshoot and undershoot in a short time.
The following diagram is a comparison of results with and without Fuzzy technology.
High accuracy
This series is manufactured with custom
designed ASIC (Application Specific
Integrated Circuit) technology which
contains an 18-bit A to D converter for
high resolution measurement (true 0.1°F
resolution for thermocouple and RTD)
and a 15-bit D to A converter for linear
current or voltage control output. The
ASIC technology provides improved
operating performance, low cost,
enhanced reliability, and higher density.
Fast sampling rate
The sampling rate of the input A to D
converter is 5 times/second. The fast
sampling rate allows this series to control
fast processes.
Fuzzy control
The function of Fuzzy control is to adjust
PID parameters from time to time in
order to make manipulation of the output
value more flexible and adaptive to various processes. The result is to enable a
process to reach a predetermined set
point in the shortest time with the minimum of overshoot and undershoot during
power-up or external load disturbance.
Digital communication
The units are equipped with an optional
RS-485 or RS-232 interface cards to provide digital communication. By using the
twisted pair wires up to 247 units can be
connected together via RS-485 interface
to a host computer.
Programming port
A programming port can be used to connect the unit to a PC for quick configuration.
Auto-tune
The auto-tune function allows the user to
simplify initial setup for a new system.
An advanced algorithm is used to obtain
an optimal set of control parameters for
the process, and it can be applied either as
the process is warming up (cold start) or
when the process is in a steady state
(warm start).
Lockout protection
Depending on security requirements, one
of four lockout levels can be selected to
prevent the unit from being changed
without permission.
Bumpless transfer
Bumpless transfer allows the controller to
continue to control if the sensor breaks by
using its previous value. Hence, the
process can be controlled temporarily as
if the sensor reading is normal and constant.
Soft-start ramp
The ramping function is performed during power up as well as any time the set
point is changed. It can be ramping up or
ramping down. The process value will
reach the set point at a predetermined
constant rate.
Digital filter
A first order low pass filter with a programmable time constant is used to
improve the stability of the process value.
This is particularly useful in certain
applications where the process value is
too unstable to be read.
1
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1–2 Ordering Code
1–3 Programming Port
A special connector can be used to
connect the programming port to a PC
for automatic configuration.
The programming port is used for offline automatic setup and testing procedures only. Don't attempt to make any
connection to these pins when the unit
is under power.
Figure 1.2
Programming Port Overview
2
Page 7
1–4 Keys and Displays
R
KEYPAD OPERATION
SCROLL KEY:
This key is used to select a parameter to be
viewed or adjusted.
UP KEY:
This key is used to increase the value of the
selected parameter.
DOWN KEY:
This key is used to decrease the value of the
selected parameter.
Figure 1.3
Front Panel Description
RESET KEY: for TEC-920,
for TEC-220
This key is used to:
1. Revert the display to show the process value.
2. Reset the latching alarm, once the alarm condition is removed.
3. Stop the manual control mode, auto-tuning
mode, and calibration mode.
4. Clear the message of communication error and
auto-tuning error.
5. Restart the dwell timer when the dwell timer has
timed out.
6. Enter the manual control menu when in failure
mode.
ENTER KEY: Press for 5 seconds or longer.
Press for 5 seconds to:
1. Enter setup menu. The display shows .
2. Enter manual control mode — when manual
control mode or is selected.
3. Enter auto-tuning mode — when auto-tuning
mode (for 220) or AT (for 920) is selected.
4. Perform calibration to a selected parameter during the calibration procedure.
Press for 6.2 seconds to select calibration mode.
Table 1.1 Display Form of Characters
Displays program code of the
instrument for 2.5 seconds.
The diagram at left shows
program no. 34, version 16
for the TEC-920.
The program no. is 33 for the
TEC-220.
Figure 1.4
Display in Initial Stage
3
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1–5 Menu Overview
4
Page 9
1–6 Parameter Descriptions
5
Page 10
1–6 Parameter Descriptions, continued…
6
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Chapter 2 Installation
Dangerous voltages capable of causing death are some-
times present in this instrument. Before installation or
beginning any troubleshooting procedures, the power to all
equipment must be switched off and isolated. Units suspected of
being faulty must be disconnected and removed to a properly
equipped workshop for testing and repair. Component replacement and internal adjustments must be made by a qualified maintenance person only.
This instrument is protected by double insulation. To
minimize the possibility of fire or shock hazards do not
expose this instrument to rain or excessive moisture.
Do not use this instrument in areas under hazardous con-
ditions such as excessive shock, vibration, dirt, moisture,
corrosive gases or oil. The ambient temperature of the area
should not exceed the maximum rating specified in chapter 6.
Remove stains from this instrument using a soft, dry
cloth. To avoid deformation or discoloration do not use
harsh chemicals, volatile solvent such as thinner or strong detergents to clean this instrument.
2–1 Unpacking
Upon receipt of the shipment, remove the unit from the carton
and inspect the unit for shipping damage.
2–2 Mounting
Make the panel cutout according to the dimensions shown in
Figure 2.1.
Take the mounting clamp away and insert the controller into the
panel cutout. Reinstall the mounting clamp.
2–3 Wiring Precautions
• Before wiring, verify the correct model number and options on the label.
Switch off the power while checking.
• Care must be taken to ensure that the maximum voltage rating specified on
the label is not exceeded.
• It is recommended that the power for these units be protected by fuses or circuit breakers rated at the minimum value possible.
• All units should be installed in a suitable enclosure to prevent live parts from
being accessible to human hands and metal tools. Metal enclosures and/or
subpanels should be grounded in accordance with national and local codes.
• All wiring must conform to appropriate standards of good practice and local
codes and regulations. Wiring must be suitable for the voltage, current, and
temperature rating of the system.
• Beware not to over-tighten the terminal screws. The torque should not
exceed 1 N-m (8.9 lb-in or 10 KgF-cm).
• Unused control terminals should not be used as jumper points as they may
be internally connected, causing damage to the unit.
• Verify that the ratings of the output devices and the inputs as specified are
not exceeded.
• Except for thermocouple wiring, all wiring should use stranded copper conductor with a maximum gage of 14 AWG.
• Electrical power in industrial environments contains a certain amount of
noise in the form of transient voltage and spikes. This electrical noise can
adversely affect the operation of microprocessor-based controls. For this
reason the use of shielded thermocouple extension wire which connects the
sensor to the controller is strongly recommended. This wire is a twisted-pair
construction with foil wrap and drain wire. The drain wire is to be attached
to ground in the control panel only.
Note: All model TEC-220 controls are supplied with
both mounting clamps and mounting screws. The
mounting screws have to be used in NEMA 4X applications as they allow the control to be held tighter
into the panel. The mounting clamp teeth are released
by depressing the ends of the clamp together.
Transit Damage
If there is any damage due to transit, report it and
file a claim with the carrier. Write down the model
number, serial number, and date code for future reference when corresponding with our service center.
The serial number (S/N) is labeled on the box and
the housing of the control.
Wiring, continued…
7
Page 12
Wiring, continued…
2–4 Power Wiring
The controller is designed to operate at 11–26VAC/VDC
or 90–250VAC. Check that the input voltage corresponds
to the power rating indicated on the product label before
connecting power to the controller.
2–5 Sensor Installation Guidelines
Proper sensor installation can eliminate many problems in a control system. The probe should be placed so that it can detect any
temperature change with minimal thermal lag. In a process that
requires fairly constant heat output, the probe should be placed
close to the heater. In a process where the heat demand is variable,
the probe should be close to the work area. Some experimentation
with probe location is often required to find the optimum position.
In a liquid process, the addition of a stirrer will help to eliminate
thermal lag. Since the thermocouple is basically a point measuring device, placing more than one thermocouple in parallel can
provide an average temperature readout and produce better
results in most air heated processes. Proper sensor type is also a
very important factor in obtaining precise measurements. The
sensor must have the correct temperature range to meet the
process requirements. In special processes, the sensor might have
requirements such as leak-proof, anti-vibration, antiseptic, etc.
Standard sensor limits of error are ±4°F (±2°C) or 0.75% of the
sensed temperature (half that for special) plus drift caused by
improper protection or an over-temperature occurrence. This
error is far greater than controller error and cannot be corrected
on the sensor except by proper selection and replacement.
This equipment is designed for installation in an
enclosure which provides adequate protection against
electric shock. Metal enclosures must be connected to
earth ground.
Local requirements regarding electrical installation should be
rigidly observed. Consideration should be given to prevent
unauthorized personnel from accessing the power terminals.
2–7 Control Output Wiring
2–6 Sensor Input Wiring
8
Page 13
Control Output Wiring, continued…
Load
120V / 240V
Mains Supply
SSR
30mA/5V
Pulsed
Volta ge
Internal Circuit
+
5V
0V
33
33
_
+
+
_
5
6
10
9
TEC
220
TEC
920
Figure 2.10 Output 1 Pulsed
Voltage to Drive SSR
_
+
9
Page 14
2–8 Alarm Wiring
2–9 Data Communication
10
If you use a conventional 9-pin RS-232 cable instead
of TEC99014, the cable must be modified according
to the following circuit diagram.
Page 15
Chapter 3 Programming
Press for 5 seconds and release to enter the setup menu.
Press and release to select the desired parameter. The display
indicates the parameter symbol. Press or to view or
adjust the value of the selected parameter.
3–1 Lockout
There are four security levels that can be selected using the
LOCK parameter.
If NONE is selected for LOCK, then no parameter is locked.
If SET is selected for LOCK, then all setup data are locked.
If USER is selected for LOCK, then all setup data as well as
user data (refer to section 1-5) except the set point are
locked to prevent them from being changed.
If ALL is selected for LOCK, then all parameters are locked to
prevent them from being changed.
How to use Conversion Curve for
Process Value:
If 4–20mA is selected for INPT, SL specifies the input signal low
(i.e., 4mA), SH specifies the input signal high (i.e., 20mA), S
specifies the current input signal value, and the conversion curve
of the process value is shown as follows:
3–2 Signal Input
INPT: Selects the sensor type or signal type for signal input.
Range: (thermocouple) Type J, K, T, E, B, R, S, N, L
(RTD) PT.DN, PT.JS
(Linear) 4–20 mA, 0–20 mA, 0–60 mA, 0–1V,
0–5V, 1–5V, 0–10V
UNIT: Selects the process unit
Range: °C, °F, PU (process unit). If the unit is set for
neither °C nor °F, then it defaults to PU.
DP: Selects the resolution of process value.
Range: (For T/C and RTD) NO.DP, 1-DP
(For linear) NO.DP, 1-DP, 2-DP, 3-DP
INLO: Selects the low scale value for the linear type input.
INHI: Selects the high scale value for the linear type input.
SL = Setpoint Low Limit SH = Setpoint High Limit
3–3 Control Outputs
There are four kinds of control modes that can be configured as shown in table 3.1.
11
Page 16
Control Outputs, continued…
Heat only ON-OFF control: Select REVR for OUT1. Set PB
(Proportional Band) to 0. O1HY is used to adjust dead band for
ON-OFF control. The output 1 hysteresis (O1HY) is enabled
when PB=0. The heat only on-off control function is shown in the
following diagram:
The ON-OFF control may introduce excessive process oscillation
even if hysteresis is minimized. If ON-OFF control is set (i.e.,
PB=0), TI, TD, CYC1, OFST, CYC2, CPB, and DB will be hidden and have no function in the system. The auto-tuning and
bumpless transfer function will be disabled as well.
Heat only P (or PD) control: Select H.TPC or H.L I N for OUT1
and set TI1 and TI2 to 0, OFST is used to adjust the control offset
(manual reset). O1HY is hidden if PB is not equal to 0.
OFST function: OFST is measured in % with a range of 0–
100.0%.
In a steady state (i.e. process has stabilized at a temperature), if
the process value is lower than the set point by a constant value
(we’ll say 5°C) while the PB setting is set for 20°C, we can say
the temperature is lower than the setpoint by 25% of the PB setting. This can be corrected by increasing the OFST setting to
25%. After adjusting the OFST value, the process value will
eventually coincide with set point.
Note that using the P control (TI set to 0), disables auto-tuning.
Refer to Section 3-12 “manual tuning” for the adjustment of P
and PD. Manual reset (adjust OFST) is sometimes not practical
since the load may change from time to time and OFST may need
to be adjusted repeatedly. PID control can avoid this situation.
Heat only PID control: If REVR is selected for OUT1, PB and
TI should not be zero. Perform auto-tuning for the new process,
or set PB, TI, and TD with historical values. See section 3-11 for
auto-tuning operation. If the control result is still unsatisfactory,
then use manual tuning to improve control. See section 3-12 for
manual tuning. The unit contains an advanced PID and Fuzzy
algorithm to create a small overshoot and very quick response to
the process if it is properly tuned.
Cool only control: ON-OFF control, P (PD) control, and PID
control can be used for cool control. Set OUT1 to DIRT (direct
action). The other functions for cool only ON-OFF control, cool
only P (PD) control, and cool only PID control are the same as for
heat only control except that the output variable (and action) for
cool control is inverse to heat control.
NOTE: ON-OFF control may result in excessive overshoot and
undershoot problems in the process. P (or PD) control will result
in a deviation of process value from the set point. It is recommended to use PID control for heat-cool control to produce a stable and zero offset process value.
Other setup required: O1TY, CYC1, O2TY, CYC2, O1FT and
O2FT are set in accordance with the types of OUT1 and OUT2
installed. CYC1 and CYC2 are selected according to the output 1
type (O1TY) and output 2 type (O2TY). Generally, select 0.5~2
seconds for CYC1 if SSRD or SSR is used for O1TY; 10~20 seconds if relay is used for O1TY and CYC1 is ignored if linear output is used. Similar conditions are applied for CYC2 selection.
You can use the auto-tuning program for the new process or
directly set the appropriate values for PB, TI, and TD according
to historical records for duplicate systems. If the control behavior
is still inadequate, then use manual tuning to improve the control.
See section 3-12 for manual tuning.
CPB (Cooling Proportional Band) Programming: The cooling
proportional band is measured by % of PB with a range of
50-300. Initially set 100% for CPB and examine the cooling
effect. If the cooling action should be enhanced, then decrease
CPB, if the cooling action is too strong, then increase CPB. The
value of CPB is related to PB and its value remains unchanged
throughout the auto-tuning procedures.
Adjustment of CPB is related to the cooling medium used. If air
is used as the cooling medium, initially set CPB to 100%, then
adjust as necessary. If oil is used as the cooling medium, initially
set CPB to 125%, then adjust as necessary. If water is used as the
cooling medium, initially set CPB to 250%, then adjust as necessary.
DB (Heating-Cooling Dead Band) programming: The adjustment of DB is dependent on the system requirements. If a more
positive value of DB (greater dead band) is used, an unwanted
cooling action can be avoided but an excessive overshoot over the
set point will occur. If a more negative value of DB (greater overlap) is used, an excessive overshoot over the set point can be minimized, but an unwanted cooling action will occur. It is adjustable
in the range -36.0% to 36.0% of PB. A negative DB value shows
an overlap area over which both outputs are active. A positive DB
value shows a dead band area over which neither output is active.
Output 2 ON-OFF control (alarm function): Output 2 can also
be configured with an alarm function. There are six kinds of
alarm functions that can be selected for output 2. These are:
DE.HI (deviation high alarm), DE.LO (deviation low alarm),
DB.HI (deviation band out of band alarm), DB.LO (deviation
band in band alarm), PV.HI (process high alarm), and PV.LO
(process low alarm). Refer to figure 3.3 and figure 3.4 for
descriptions of the deviation alarm and the process alarm.
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3.3 & 3.4 Alarm Figures
3–4 Alarm
Output 2 can be set as an alarm output. There are six types of
alarm functions and one dwell timer that can be selected, and
four kinds of alarm modes (ALMD) are available for each
alarm function.
A process alarm sets two absolute trigger levels. When the
process value is higher than SP2, a process high alarm
(PV.HI) occurs. The alarm is off when the process value is
lower than SP2-ALHY. When the process value is lower than
SP2, a process low alarm (PV.LO) occurs, and the alarm is
off when the process value is higher than SP2+ALHY. A
process alarm is independent of the set point.
A deviation alarm alerts the user when the process value
deviates too far from the set point. When the process value is
higher than SV+SP2, a deviation high alarm (DE.HI) occurs,
and the alarm is off when the process value is lower than
SV+SP2-ALHY. When the process value is lower than
SV+SP2, a deviation low alarm (DE.LO) occurs, and the
alarm is off when the process value is higher than
SV+SP2+ALHY. The trigger level of the deviation alarm
moves with the set point.
A deviation band alarm presets two trigger levels relative
to the set point. The two trigger levels are SV+SP2 and SVSP2 for alarm. When the process value is higher than
(SV+SP2) or lower than (SV-SP2), a deviation band high
alarm (DB.HI) occurs. When the process value is within the
trigger levels, a deviation band low alarm (DB.LO) occurs.
There are four types of alarm modes available for each alarm
function. These are: normal alarm, latching alarm, holding
alarm and latching/holding alarm. They are described as follows:
Normal alarm: ALMD=NORM
When a normal alarm is selected, the alarm output is de-energized in the non-alarm condition and energized in an alarm
condition.
Latching alarm: ALMD=LTCH
If a latching alarm is selected, once the alarm output is energized, it will remain unchanged even if the alarm condition
is cleared. The latching alarm is reset when the RESET key
is pressed after the alarm condition is removed.
Holding alarm: ALMD=HOLD
A holding alarm prevents an alarm when the control is powering up. The alarm is enabled only when the process reaches
the set point value. Afterwards, the alarm performs the same
function as a normal alarm.
Latching/holding alarm: ALMD=LT.HO
A latching/holding alarm performs both holding and latching
functions. The latching alarm is reset when the RESET key
is pressed after the alarm condition is removed.
Alarm failure transfer is activated as the unit enters failure
mode. The alarm will go on if ALFT is set for ON and go off
if ALFT is set for OFF. The unit will enter failure mode when
a sensor break occurs or if the A-D converter of the unit fails.
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3–5 Configuring the Display
The TEC-220 can be configured to display the process value by
selecting PV for DISP or to display the set point value by selecting SP1 for DISP.
If LOCK is set to NONE, OUT2 is set to DEHI, and DISP is set
to PV, set SEL1=SHIF, SEL2=ADDR. SEL3=PB,
SEL4~SEL8=NONE, then the display scrolling for the TEC-220
will become:
If LOCK is set to NONE, OUT1 is set to REVR, a non-zero value
is set for PB and TI, OUT2 is set to COOL, and DISP is set to
SP1, set SEL1=INPT, SEL2=PB, SEL3=TI, SEL4~SEL8=
NONE, then the display scrolling for the TEC-220 will become:
Example for TEC-920:
Set OUT2=PVLO, LOCK=NONE, SEL1=INPT, SEL2=UNIT,
SEL3=DP, SEL4~SEL8=NONE, then the display scrolling for
the TEC-920 will become:
Note: When the ramp function is used, the lower display will
show the current ramping value. The ramping value is an artificially determined setpoint created and updated by the control to
match the ramp rate set by the user. However, it will revert to
show the set point value as soon as the up or down key is touched
for adjustment. The ramping value is initiated to process value
either on power-up or when RR and/or the set point are changed.
Setting RR to zero means no ramp function.
3–7 Dwell Timer
Output 2 can be configured as a dwell timer by selecting TIMR
for OUT2. As the dwell timer is configured, the parameter SP2 is
used for dwell time adjustment. The dwell time is measured in
minutes ranging from 0.1 to 4553.6 minutes. Once the process
reaches the set point the dwell timer starts to count down to zero
(time out). The timer relay will remain unchanged until time out.
The dwell timer operation is shown in the following diagram.
After time out, the dwell timer can be restarted by pressing the
RESET key.
The timer stops counting during manual control mode, failure
mode, the calibration period and the auto-tuning period.
3–6 Ramp
Ramp
The ramping function is performed during power up as well as
any time the set point is changed. If MINR or HRR is chosen for
RAMP, the unit will perform the ramping function. The ramp rate
is programmed by adjusting RR. The ramping function is disabled as soon as failure mode, manual control mode, auto-tuning
mode or calibration mode is entered.
Example without dwell timer
Select MINR for RAMP, select °C for UNIT, select 1-DP for DP,
set RR=10.0. SV is set to 200°C initially, and changed to 100°C
30 minutes after power-up. The starting temperature is 30°C.
After power-up, the process runs like the curve shown in
Figure 3.5.
14
If output 2 is configured as a dwell timer, ALMD will be hidden.
Page 19
3–8 PV Shift
In certain applications it is desirable to shift the
controller display value from its actual value. This
can easily be accomplished by using the PV shift
function.
The SHIF function will alter PV only.
Here is an Example: A process is equipped with a
heater, a sensor, and a subject to be warmed up. Due
to the design and position of the components in the
system, the sensor could not be placed any closer to
the part. Thermal gradient (differing temperatures)
is common and necessary to an extent in any thermal system for heat to be transferred from one point
to another. If the difference between the sensor and
the subject is 35°C, and the desired temperature at
the subject to be heated is 200°C, the controlling
value or the temperature at the sensor should be
235°C. You should enter -35°C to subtract 35°C
from the actual process display. This in turn will
cause the controller to energize the load and bring
the process display up to the set point value.
3–9 Digital Filter
In certain applications, the process value is too unstable to be read due
to possible electrical noise. A programmable low-pass filter incorporated in the controller can be used to improve this. It is a first-order
filter with the time constant specified by the FILT parameter. The
default value of FILT is set at 0.5 seconds before shipping. Adjust
FILT to change the time constant from 0 to 60 seconds. 0 seconds
means no filter is applied to the input signal. The filter is characterized
in Figure 3.8.
Note
The filter is available only for PV, and is performed for the displayed
value only. The controller is designed to use unfiltered signal for control even if the filter is applied. A lagged (filtered) signal, if used for
control, may produce an unstable process.
3–10 Failure Transfer
The controller will enter failure mode if
one of the following conditions occurs:
1. SBER occurs due to input sensor break
or input current below 1mA if 4–20 mA
is selected or input voltage below 0.25V
if 1–5V is selected.
2. ADER occurs due to the A-D converter
of the controller failing.
Output 1 and output 2 will perform the failure transfer function as the controller
enters failure mode.
Output 1 failure transfer, if activated,
will perform:
1. If output 1 is configured as proportional
control (PB≠ 0), and BPLS is selected
for O1FT, then output 1 will perform
bumpless transfer. Thereafter, the previous averaging value of MV1 will be
used for controlling output 1.
2. If output 1 is configured as proportional
control (PB≠ 0), and a value of 0 to
100.0% is set for O1FT, then output 1
will perform failure transfer. Thereafter,
the value of O1FT will be used for controlling output 1.
3. If output 1 is configured as ON-OFF
control (PB=0), then output 1 will be
driven OFF if OFF is set for O1FT and
will be driven ON if ON is set for
O1FT.
Output 2 failure transfer, if activated,
will perform:
1. If OUT2 is configured as COOL, and
BPLS is selected for O1FT, then output
2 will perform bumpless transfer.
Thereafter, the previous averaging
value of MV2 will be used for controlling output 2.
2. If OUT2 is configured as COOL, and a
value of 0 to 100.0% is set for O2FT,
then output 2 will perform failure transfer. Thereafter, the value of O1FT will
be used for controlling output 2.
3. If OUT2 is configured as alarm function, and O2FT is set to OFF, then output 2 will go off. Otherwise, output 2
will go on if O2FT is set to ON.
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3–11 Auto-tuning
For best results the auto-tuning process should be
performed near the set point. The process will oscillate around the set point during the tuning process. Set the set
point at a lower value if overshooting beyond the normal
process value is likely to cause damage.
Auto-tuning is applied in cases of:
• Initial setup for a new process
• The set point is changed substantially from the previous
auto-tuning value
• The control result is unsatisfactory
Operation:
1. Do not set a zero value for PB and TI, or the auto-tuning program will be disabled. The LOCK parameter should also be
set at NONE.
2. Set the set point to a normal operating value, or a lower value
if overshooting beyond the normal process value is likely to
cause damage.
3. Press several times until appears on the display
(for TEC-220), or an AT indicator on lower-right of screen is
lit (for TEC-920).
4. Press and hold for at least 5 seconds. The AT indicator (for
TEC-920) or the display (for TEC-220) will begin to flash
indicating the auto-tuning procedure has begun.
NOTE: The ramping function, if used, will be disabled while
auto-tuning is taking place.
Auto-tuning mode is disabled as soon as either failure mode or
manual control mode is entered.
Procedures:
Auto-tuning can be applied either as the process is warming up
(cold start), or when the process has been in a steady state
(warm start). After the auto-tuning procedures are completed,
the AT indicator will cease to flash and the unit will revert to
PID control using its new PID values. The PID values
obtained are stored in the nonvolatile memory.
3–12 Manual Tuning
In certain applications auto-tuning may be inadequate for the
control requirements. You can try manual tuning for these
applications.
If the control performance using auto-tuning is still unsatisfactory, the following rules can be applied for further adjustment
of PID values:
Figure 3.9 shows the effects of PID
adjustment on process response.
Auto-Tuning Error
If auto-tuning fails an ATER message will appear on the display
in the following cases:
• If PB exceeds 9000 (9000 PU, 900.0°F or 500.0°C),
• if TI exceeds 1000 seconds,
• if the set point is changed during the auto-tuning procedure.
Solutions to
1. Try auto-tuning again.
2. Don't change the set point value during the auto-tuning proce-
dure.
3. Don't set a zero value for PB and TI.
4. Use manual tuning instead of auto-tuning (see section 3-12).
5. Touch RESET key to reset message.
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3–13 Manual Control
R
Operation:
To enable manual control, the LOCK parameter should be set to
NONE.
Press several times; (heating output) or
(cooling output) will appear on the display. Press and hold for
5 seconds or until the MAN indicator (for TEC-920) or the display (for TEC-220) begins to flash. The controller is now in manual control mode. indicates output control variable for
output 1, and indicates control variable for output 2. Now
you can use the up and down keys to adjust the percentage values
for the heating or cooling output.
The controller performs open loop control as long as it stays in
manual control mode.
Exit Manual Control
Model TEC-920: Pressing the key will cause the controller to
revert to its normal display mode.
Model TEC-220: Press and release the up and down buttons.
3–14 Data Communication
The controllers support RTU mode of Modbus protocol for data
communication. Other protocols are not available for this series.
Two types of interface are available for data communication.
These are RS-485 and RS-232. Since RS-485 uses a differential
architecture to drive and sense signal instead of a single-ended
architecture like the one used for RS-232, RS-485 is less sensitive to noise and more suitable for communication over a longer
distance. RS-485 can communicate without error over a 1km distance while RS-232 is not recommended for a distance of over 60
feet (20 meters).
Using a PC for data communication is the most economical
method. The signal is transmitted and received through the PC
communication port (generally RS-232). Since a standard PC
can't support an RS-485 port, a network adapter (such as
TEC99001) has to be used to convert RS-485 to RS-232 for a PC
if RS-485 is required for data communication. Up to 247 RS-485
units can be connected to one RS-232 port; therefore a PC with
four comm ports can communicate with 988 units.
3–15 Process Variable (PV)
Retransmission
The TEC-220 controller can output (retransmit) a process value
via its retransmission terminals RE+ and RE- provided that the
retransmission option is ordered. The correct signal type should
be selected for COMM parameter to meet the retransmission
option installed. RELO and REHI are set to specify the low
scale and high scale values of retransmission.
The TEC-920 does not have this feature.
Setup
Enter the setup menu. Select RTU for COMM. Set individual
addresses for any units that are connected to the same port. Set
the baud rate (BAUD), data bit (DATA), parity bit (PARI) and
stop bit (STOP) so that these values are accordant with PC setup
conditions.
If you use a conventional 9-pin RS-232 cable instead of
TEC99014, the cable should be modified for proper operation of
RS-232 communication according to section 2-9 on page 10.
Refer to Chapter 7 for a complete technical description of the
Modbus Communications Protocol.
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NOTES
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Chapter 4 Applications
4–1 Heat Only Control with
Dwell Timer
An oven is designed to dry products at 150°C for
30 minutes and then stay unpowered for another
batch. A TEC-920 equipped with dwell timer is
used for this purpose. The system diagram is
shown at right:
To achieve this function, set the following parameters in the setup menu:
INPT=K_TC UNIT=°C
DP=1_DP OUT1=REVR
O1TY=RELY CYC1=18.0
O1FT=BPLS OUT2=TIMR
O2FT=ON
Auto-tuning is performed at 150°C for a new oven.
4–2 Cool Only Control
A TEC-920 is used to control a refrigerator at temperatures
below 0°C. This temperature is lower than the ambient, so a
cooling action is required. Select DIRT for OUT1. Since output
1 is used to drive a magnetic contactor, the O1TY should be set
for RELY. A small temperature oscillation is tolerable, so use
ON-OFF control to reduce the over-all cost. To use ON-OFF
control, set PB to zero and O1HY at 0.1°C.
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4–3 Heat-Cool Control
An injection mold is required to be controlled at 120°C to ensure a consistent
quality for the parts. An oil pipe is buried in the mold. Since plastics are
injected at a higher temperature (e.g., 250°C), the circulation oil needs to be
cooled as its temperature rises. Here is an example:
The PID heat-cool operation is used for the above
example. To achieve this, set the following parameters
in the setup menu:
INPT=PT.DN
UNIT=°C
DP= 1-DP
OUT1=REVR
O1TY=RELY
CYC1=18.0 (sec.)
O1FT=BPLS
OUT2=COOL
O2TY=4–20
O2FT=BPLS
Set SV at 120.0°C, CPB at 125(%) and DB at -4.0(%).
Apply auto-tuning at 120°C for a new system to get
optimal PID values. See section 3-11.
Adjustment of CPB is related to the cooling medium
used. If water is used as the cooling medium instead of
oil, the CPB should be set at 250(%). If air is used as
the cooling medium instead of oil, the CPB should be
set at 100(%). The adjustment of DB is dependent on
the system requirements. A higher positive value of DB
will prevent unwanted cooling action, but will increase
the temperature overshoot, while a lower negative
value of DB will result in less temperature overshoot,
but will increase unwanted cooling action.
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Chapter 5 Calibration
Do not proceed through this section unless there is a def-
inite need to recalibrate the controller. If you recalibrate,
all previous calibration data will be lost. Do not attempt recalibration unless you have the appropriate calibration equipment. If
the calibration data is lost, you will need to return the controller
to your supplier who may charge you a service fee to recalibrate
the controller.
Entering calibration mode will break the control loop.
Make sure that the system is ready to enter calibration
mode.
Equipment needed for calibration:
1. A high-accuracy calibrator (Fluke 552A calibrator
recommended) with the following functions:
0–100mV millivolt source with ±0.005% accuracy
0–10V voltage source with ±0.005% accuracy
0–20mA current source with ±0.005% accuracy
0–300 ohm resistant source with ±0.005% accuracy
2. A test chamber providing 25°C–50°C temperature range
3. A switching network (SWU16K, optional for automatic
calibration)
4. A calibration fixture equipped with programming units
(optional for automatic calibration)
The calibration procedure described in the following section is a
step-by-step manual procedure.
Manual Calibration Procedures
• Perform step 1 to enter calibration mode.
Step 1.
Set the lock parameter to the unlocked condition
(LOCK=NONE).
Press and hold the scroll key until appears on the display, then release the scroll key.
Press the scroll key for 2 seconds, and the display will show
and the unit will enter the calibration mode.
• Perform step 2 to calibrate zero of A to D converter and
step 3 to calibrate gain of A to D converter.
Step 2.
Short the thermocouple input terminals, then press the scroll key
for at least 5 seconds. The display will blink for a moment until
a new value is obtained. If the display didn't blink or if the
obtained value is equal to -199.9 or 199.9, then calibration failed.
Step 3.
Press scroll key until the display shows . Send a 60mV
signal to the thermocouple input terminals in the correct polarity.
Press the scroll key for at least 3 seconds. The display will blink
for a moment and a new value is obtained. If the display didn't
blink or if the obtained value is equal to -199.9 or 199.9, then the
calibration failed.
• Perform both steps 4 and 5 to calibrate RTD function (if
required) for input.
Step 4.
Press scroll key until the display shows . Send a 100
ohms signal to the RTD input terminals according to the connection shown below:
Press scroll key for at least 5 seconds. The display will blink for
a moment; if it does not this calibration failed.
Step 5.
Press the scroll key and the display will show . Change
the ohm's value to 300 ohms. Press the scroll key for at least 5
seconds. The display will blink for a moment and two values will
be obtained for RTDH and RTDL (step 4). If the display didn't
blink or if any value obtained for RTDH or RTDL is equal to -199.9
or 199.9, then calibration failed.
• Perform step 6 to calibrate offset of cold junction compensation, if required.
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Manual Calibration Procedures, continued…
Step 6.
Set up the equipment according to the diagram above for calibrating the
cold junction compensation. Note that a K type thermocouple must be
used.
The 525A calibrator is configured as K type thermocouple output with
internal compensation. Send a 0.00°C signal to the unit under calibration.
The unit under calibration is powered in a still-air room with temperature
25±3°C. Wait at least 20 minutes for warming up. Perform step 1 as stated
above, then press the scroll key until the display shows .
Press the scroll key for at least 5 seconds. The display will blink for a
moment until a new value is obtained. If the display didn't blink or if the
obtained value is equal to –5.00 or 40.00, then calibration failed.
• Perform step 7 to calibrate gain of cold junction compensation if
required.
Step 7.
Setup the equipment same as step 6. The unit under calibration is powered
in a still-air room with temperature 50 ±3°C. Wait at least 20 minutes for
warming up. The calibrator source is set at 0.00°C with internal compensation mode.
Perform step as 1 stated above, then press the scroll key until the display
shows . Press the scroll key for at least 5 seconds. The display will
blink for a moment until a new value is obtained. If the display didn't blink
or if the obtained value is equal to –199.9 or 199.9, then calibration failed.
This setup is performed in a high-temperature chamber, therefore it is recommended to use a computer to perform the procedures.
• Input modification and recalibration procedures for a linear voltage or a
linear current input:
1. Remove R60(3.3K) and install two 1/4W resistors RA and RB on the
control board with the recommended values specified in the following
table.
Low temperature coefficient resistors should be used for RA and RB.
2. Perform step 1 and step 2 to calibrate the linear input zero.
3. Perform step 3 but send a span signal to the input terminals instead of
60mV. The span signal is 1V for 0~1V input, 5V for 0~5V or 1~5V
input, 10V for 0~10V input and 20mA for 0~20mA or 4~20mA input.
• Final step
Step 8.
Set the LOCK value to your desired function.
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Chapter 6 Specifications
Power
90–250VAC, 47–63 Hz, 10VA, 5W maximum
11–26VAC/VDC, 10VA, 5W maximum
Input
Resolution: 18 bits
Sampling rate: 5 times/second
Maximum rating: -2VDC minimum, 12VDC maximum
(1 minute for mA input)
Temperature effect: ±1.5uV/°C for all inputs except mA
input
±3.0uV/°C for mA input
Sensor lead resistance effect:
T/C: 0.2uV/ohm
3-wire RTD: 2.6°C/ohm of resistance difference of two leads
2-wire RTD: 2.6°C/ohm of resistance sum of two leads
Common mode rejection ratio (CMRR): 120dB
Normal mode rejection ratio (NMRR): 55dB
Sensor break detection:
Sensor open for TC, RTD and mV inputs,
Sensor short for RTD input,
Below 1mA for 4–20mA input,
Below 0.25V for 1–5V input,
unavailable for other inputs.
Sensor break responding time:
Within 4 seconds for TC, RTD, and mV inputs, 0.1 second
for 4–20mA and 1–5V inputs.
Output 1/Output 2
Relay rating: 2A/240VAC, 200,000 life cycles for
resistive load
Pulsed voltage: Source voltage 5V, current limiting
resistance 66Ω.
Linear Output
Resolution: 15 bits
Output regulation: 0.02% for full load change
Output settling time: 0.1 sec. (stable to 99.9 %)
Isolation breakdown voltage: 1000VAC
Temperature effect: ±0.01% of SPAN/°C
Triac (SSR) Output
Rating: 1A/240 VAC
Inrush current: 20A for 1 cycle
Min. load current: 50mA rms
Max. off-state leakage: 3mA rms
Max. on-state voltage: 1.5VAC rms
Insulation resistance: 1000MΩ min. at 500 VDC
Dielectric strength: 2500VAC for 1 minute
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Specifications, continued…
Output 2 functions: Dwell timer
Deviation high/low alarm
Deviation band high/low alarm
PV high/low alarm
PID cooling control
Alarm modes: Normal, latching, hold, latching/hold.
Dwell timer: 0.1–4553.6 minutes
Data Communication
Interface: RS-232 (1 unit), RS-485 (up to 247 units)
Protocol: Modbus protocol RTU mode
Address: 1–247
Baud rate: 0.3 - 38.4Kbits/sec
Data bits: 7 or 8 bits
Parity bit: None, even or odd
Stop bit: 1 or 2 bits
Communication buffer: 160 bytes
Analog Retransmission
Output Signal: 4-20 mA, 0-20 mA, 0-5V, 1-5V, 0-10V
Resolution: 15 bits
Accuracy: ±0.05% of span ±0.0025%/°C
Load Resistance: 0-500 ohms (for current output)
10K ohms minimum (for voltage output)
Output Regulation: 0.01% for full load change)
Digital Filter
Function: First order
Time constant: 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60 seconds
programmable
Environmental and Physical
Operating temperature: 14°F (-10°C) to 122°F (50°C)
Storage temperature: -40°F (-40°C) to 140°F (60°C)
Humidity: 0 to 90% RH (non-condensing)
Insulation resistance: 20Mohms min. (at 500VDC)
Dielectric strength: 2000VAC, 50/60 Hz for 1 minute
Vibration resistance: 10–55 Hz, 10 m/s≈ for 2 hours
Shock resistance: 200m/s ≈ (20g)
Moldings: Flame retardant polycarbonate
Dimensions:
TEC-220 — 1-3/64" (26.5 mm) H × 2" (50 mm) W
× 4-3/8" (110.5 mm) D
Depth behind panel: 3-7/8" (98 mm)
TEC-920 — 1-7/8" (48 mm) H × 1-7/8" (48 mm) W
× 3-3/4" (94 mm) D
Depth behind panel: 3-3/8" (86 mm)
Weight: TEC-220—.26 lbs. (120 grams)
TEC-920—.31 lbs. (140 grams)
User Interface
Single 4-digit LED display
Keypad: 3 keys for TEC-220, 4 keys for TEC-920
Programming port: For automatic setup, calibration, and
testing
Communication port: Connection to PC for supervisory
control
Control Mode
Output 1: Reverse (heating) or direct (cooling) action
Output 2: PID cooling control, cooling P band 50~300% of
PB, dead band -36.0-36.0% of PB
ON-OFF: 0.1-90.0 (°F) hysteresis control (P band=0)
P or PD: 0–100.0% offset adjustment
PID: Fuzzy logic modified
Proportional band 0.1-900.0°F
Integral time 0–1000 seconds
Derivative time 0–360.0 seconds
Cycle time: 0.1–90.0 seconds
Manual control: Heat (MV1) and cool (MV2)
Auto-tuning: Cold start and warm start
Failure mode: Auto-transfer to manual mode while sensor
break or A-D converter damage
Ramping control: 0–900.0°F/minute or
0–900.0°F/hour ramp rate
Approval Standards
Safety: UL61010C-1
CSA C22.2 No. 24-93
EN61010-1 (IEC1010-1)
Protective class:
IP65 front panel for TEC-220
IP30 front panel for TEC-920, all indoor use
IP20 for terminals and housing with protective cover.
All indoor use.
EMC: EN61326
24
Page 29
Chapter 7 Modbus Communications
This chapter specifies the Modbus Communications protocol as
RS-232 or RS-485 interface module is installed. Only RTU mode is supported. Data is transmitted
as eight-bit binary bytes with 1 start bit, 1 stop bit and optional parity checking (None, Even or
Odd). Baud rate may be set to 2400, 4800, 9600, 14400, 19200, 28800 and 38400.
7-1 Functions Supported
Only function 03, 06 and 16 are available for this series of controllers. The message formats for
each function are described as follows:
Function 03: Read Holding Registers
Query: (from Master) Response: (from Slave)
Slave address (0-255)
Function code (3)
Starting address of register Hi (0) Byte count
Starting address of register Lo Data 1 Hi
(0-79, 128-131) Data 1 Lo
No. of words Hi (0) Data 2 Hi
No. of words Lo (1-79) Data 2 Lo
CRC16 Hi •
CRC16 Lo •
•
•
•
CRC16 Hi
CRC16 Lo
Function 06: Preset Single Register
Query: (from Master) Response: (from slave)
Slave address (0-255)
Function code (6)
Register address Hi (0)
Register address Lo (0-79, 128-131)
Data Hi
Data Lo
CRC16 Hi
CRC16 Lo
Function 16: Preset Multiple Registers
Query: ( from master ) Response: (from slave)
Slave address (0-255)
Function code (16)
Starting address of register Hi (0)
Starting address of register Lo (0-79, 128-131)
No. of words Hi (0)
No. of words Lo (1-79)
Byte count (2-158) CRC16 Hi
Data 1 Hi CRC16 Lo
Data 1 Lo
Data 2 Hi
Data 2 Lo
•
•
•
•
•
CRC16 Hi
CRC16 Lo
25
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7-2 Exception Responses
If the controller receives a message which contains a corrupted character (parity check error, framing error etc.),
or if the CRC16 check fails, the controller ignores the message. However, if the controller receives a syntactically
correct message which contains an illegal value, it will send an exception response, consisting of five bytes as follows:
slave address +offset function code + exception code + CRC16 Hi +CRC16 Lo
Where the offset function code is obtained by adding the function code with 128 (ie. function 3 becomes H'83), and the exception
code is equal to the value contained in the following table:
Exemption Code Name Cause
1 Bad Function Code Function code is not supported by the controller
2 Illegal data address Register address out of range
3 Illegal data value
Data value out of range or attempt to write
a read-only or protected data
7-3 Parameter Table
Register Parameter Parameter Scale Scale Notes
Address Notation Low High
0 SP1 Set Point 1 *4 *4 R/W
1 SP2 Set Point 2 *7 *7 R/W
2 SP3 Set Point 3 *6 *6 R/W
3 LOCK Lock code 0 65535 R/W
4 INPT Input sensor selection 0 65535 R/W
5 UNIT Measuring unit 0 65535 R/W
6 DP Decimal point position 0 65535 R/W
7 INLO Low scale value for linear input *4 *4 R/W
8 INHI High scale value for linear input *4 *4 R/W
9 SP1L Low limit of SP1 *4 *4 R/W
10 SP1H High Limit of SP1 *4 *4 R/W
11 SHIF PV shift value *4 *4 R/W
12 FILT Filter time constant 0 65535 R/W
13 DISP Display form 0 65535 R/W
14 PB P (proportional) band *5 *5 R/W
15 TI Integral time 0 65535 R/W
16 TD Derivative time 0.0 6553.5 R/W
17 OUT1 Output 1 function 0 65535 R/W
18 O1TY Output 1 signal type 0 65535 R/W
19 O1FT Output 1 failure transfer -1999.9 4553.6 R/W
20 O1HY Output 1 ON-OFF hysteresis *5 *5 R/W
21 CYC1 Output 1 cycle time 0.0 6553.5 R/W
22 OFST Offset value for P control 0.0 6553.5 R/W
23 RAMP Ramp function 0 65535 R/W
24 RR Ramp rate *5 *5 R/W
25 OUT2 Output 2 function 0 65535 R/W
26 RELO Retransmission low scale value *4 *4 R/W
27 O2TY Output 2 signal type 0 65535 R/W
28 O2FT Output 2 failure transfer -1999.9 4553.6 R/W
29 O2HY Output 2 ON-OFF hysteresis *5 *5 R/W
30 CYC2 Output 2 cycle time 0.0 6553.5 R/W
31 CPB Cooling P band 0 65535 R/W
32 DB Heating-cooling dead band -1999.9 4553.6 R/W
26
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Register Parameter Parameter Scale Scale Notes
Address Notation Low High
33 ALFN Alarm Function 0 65535 R/W
34 REHI Retransmission high scale value *4 *4 R/W
35 ALMD Alarm operation mode 0 65535 R/W
36 ALHY Alarm hysteresis *5 *5 R/W
37 ALFT Alarm failure transfer 0 65535 R/W
38 COMM Communication function 0 65535 R/W
39 ADDR Address 0 65535 R/W
40 BAUD Baud rate 0 65535 R/W
41 DATA Data bit count 0 65535 R/W
42 PARI Parity bit 0 65535 R/W
43 STOP Stop bit count 0 65535 R/W
44 SEL1 Selection 1 0 65535 R/W
45 SEL2 Selection 2 0 65535 R/W
46 SEL3 Selection 3 0 65535 R/W
47 SEL4 Selection 4 0 65535 R/W
48 SEL5 Selection 5 0 65535 R/W
49 SEL6 Selection 6 0 65535 R/W
50 SEL7 Selection 7 0 65535 R/W
51 SEL8 Selection 8 0 65535 R/W
52 ADLO mV calibration low coefficient -1999.9 4553.6 R/W
53 ADHI mV calibration high coefficient -1999.9 4553.6 R/W
54 RTDL RTD calibration low coefficient -1999.9 4553.6 R/W
55 RTDH RTD calibration high coefficient -1999.9 4553.6 R/W
56 CJLO Cold junction calibration low coefficient -199.99 455.36 R/W
57 CJHI Cold junction calibration high coefficient -1999.9 4553.6 R/W
58 DATE Date code 0 65535 R/W
59 SRNO Serial number 0 65535 R/W
60 HOUR Working hours of the controller 0 65535 R/W
61 BPL1 Bumpless transfer of OP1 0 65535 R
62 BPL2 Bumpless transfer of OP2 0.00 655.35 R
63 CJCL Cold junction signal low 0.000 65.535 R
64, 128 PV Process value *4 *4 R
65, 129 SV Current set point value *4 *4 R
66 MV1 OP1 control output value 0.00 655.35 Read only unless
130 in manual control
67 MV2 OP2 control output value 0.00 655.35 Read only unless
131 in manual control
68 TIMER Remaining time of dwell timer -1999.9 4553.6 R
69 EROR Error code *1 0 65535 R
70 MODE Operation mode and alarm status *2 0 65535 R
71, 140 PROG Program code *3 0.00 655.35 R
72 CMND Command code 0 65535 R/W
73 JOB1 Job code 0 65535 R/W
74 JOB2 Job code 0 65535 R/W
75 JOB3 Job code 0 65535 R/W
76 CJCT Cold Junction Temperature -199.99 455.36 R
77 Reserved 0 65535 R
78 Reserved 0 65535 R
79 Reserved 0 65535 R
27
Page 32
*1 The error code is shown in the first column of Table A.1 page 30.
*2 Definition for the value of MODE register:
H’000X = Normal mode
H’010X = Calibration mode
H’020X = Auto-tuning mode
H’030X = Manual control mode
H’040X = Failure mode
*3 The PROG Code is defined in the following table
Model No. TEC-9100 TEC-8100 TEC-4100 TEC-7100 TEC-220 TEC-920
PROG Code 6.XX 11.XX 12.XX 13.XX 33.XX 34.XX
(xx denotes the software version)
*4 The scale high/low values are defined in the following table for SP1, INLO, INHI, SP1L, SP1H, SHIF, PV, SV, RELO and REHI:
Conditions Non-linear Linear input Linear input Linear input Linear input
input DP = 0 DP = 1 DP = 2 DP = 3
Scale low -1999.9 -19999 -1999.9 -199.99 -19.999
Scale High 4553.6 45536 4553.6 455.36 45.536
*5 The scale high/low values are defined in the following table for PB, O1HY, RR, O2HY, and ALHY:
Conditions Non-linear Linear input Linear input Linear input Linear input
input DP = 0 DP = 1 DP = 2 DP = 3
Scale low 0.0 0 0.0 0.00 0.000
Scale High 6553.5 65535 6553.5 655.35 65.535
H’0X00 = Alarm status is off
H’0x01 = Alarm status is on
The alarm status is shown in MV2 instead of
MODE for models TEC-220 and TEC-920.
*6 The scale high/low values are defined in the following table for SP3:
Conditions ALFN=1 Non-linear Linear input Linear input Linear input Linear input
(TIMR) input DP = 0 DP = 1 DP = 2 DP = 3
Scale low -1999.9 -1999.9 -19999 -1999.9 -199.99 -19.999
Scale High 4553.6 4553.6 45536 4553.6 455.36 45.536
*7 The scale high/low values are defined in the following table for SP2:
For TEC-220 and TEC-920
Conditions OUT2=1 Non-linear Linear input Linear input Linear input Linear input
(TIMR) input DP = 0 DP = 1 DP = 2 DP = 3
Scale low -1999.9 -1999.9 -19999 -1999.9 -199.99 -19.999
Scale High 4553.6 4553.6 45536 4553.6 455.36 45.536
For TEC-9100, TEC-8100, TEC-7100 and TEC-4100:
Conditions Non-linear Linear input Linear input Linear input Linear input
input DP = 0 DP = 1 DP = 2 DP = 3
Scale low -1999.9 -19999 -1999.9 -199.99 -19.999
Scale High 4553.6 45536 4553.6 455.36 45.536
7-4 Data Conversion
The word data are regarded as unsigned (positive) data in the Modbus message. However, the actual value of the parameter may be
a negative value with decimal point. The high/low scale values for each parameter are used for the purpose of such conversion.
Let M = Value of Modbus message A = Actual value of the parameter
SL = Scale low value of the parameter SH = Scale high value of the parameter
28
M =
SH – SL
65535
× (A – SL)
)(
SH – SL
A =
(
65535
× (M + SL)
)
Page 33
7-5 Communication Examples:
R
Example 1: Download the default values via the programming port
The programming port can perform Modbus communications regardless of the incorrect setup values of address, baud, parity, stop
bit, etc. It is especially useful during the first time configuration for the controller. The host must be set with 9600 baud rate, 8 data
bits, even parity and 1 stop bit.
The Modbus message frame with hexadecimal values is shown as follows:
01 10 00 00 00 34 68 4F 19 4E 83 4E 83 00 00
Addr. Func. Starting Addr. No. of words Bytes SP1=25.0 SP2=10.0 Sp3=10.0 LOCK = 0
00 01 00 00 00 01 4D 6D 51 C4 4D 6D 63 21
INPT = 1 UNIT = 0 DP = 1 INLO = -17.8 INHI = 93.3 SP1L = -17.8 SP1H = 537.8
4E 1F 00 02 00 00 00 64 00 64 00 FA 00 00
SHIF = 0.0 FILT = 2 DISP = 0 PB = 10.0 TI = 100 TD = 25.0 OUT1 = 0
00 00 4E 1F 00 01 00 B4 00 FA 00 00 00 00
O1TY = 0 O1FT = 0 O1HY = 0.1 CYC1 = 18.0 OFST = 25.0 RAMP = 0 RR = 0.0
00 02 4E 1F 00 00 4E 1F 00 01 00 B4 00 64
OUT2 = 2 RELO = 0.0 O2TY = 0 O2FT = 0 O2HY = 0.1 CYC2 = 18.0 CPB = 100
4E 1F 00 02 52 07 00 00 00 01 00 00 00 01
DB = 0 ALFN = 2 REHI = 100.0 ALMD = 0 ALHY = 0.1 ALFT = 0 COMM = 1
00 01 00 02 00 01 00 00 00 00 00 02 00 03
ADDR = 1 BAUD = 2 DATA = 1 PARI = 0 STOP = 0 SEL1 = 2 SEL2 = 3
00 04 00 06 00 07 00 08 00 0A 00 11 Hi Lo
SEL3 = 4 SEL4 = 6 SEL5 = 7 SEL6 = 8 SEL7 = 10 SEL8 = 17 CRC16
Example 2: Read PV, SV, MV1 and MV2
Send the following message to the controller via the COMM
port or programming port:
03 00
H’80
Addr. Func. Starting Addr. No. of words CRC16
Example 4: Enter Auto-tuning Mode
Query
06 00 H’48 H’68 H’28 Hi Lo
Addr. Func. Register Addr. Data Hi/Lo CRC16
H’40
00 04 Hi Lo
Example 3: Perform Reset Function
(same effect as pressing key)
Query
06 00 H’48 H’68 H’25 Hi Lo
Addr. Func. Register Addr. Data Hi/Lo CRC16
Example 5: Enter Manual Control Mode
Query
06 00 H’48 H’68 H’27 Hi Lo
Addr. Func. Register Addr. Data Hi/Lo CRC16
Example 6: Read All Parameters
Query
Example 7: Modify the Calibration Coefficient
Preset the CMND register with 26669 before attempting to
change the calibration coefficient.
29
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A–1 Error Codes
Table A.1 Error Codes and Corrective Actions
30
Page 35
A–2 Warranty
WARRANTY
Tempco Electric Heater Corporation is pleased to offer suggestions on the use of its products. However, Tempco makes no warranties or representations of any sort regarding the fitness for
use, or the application of its products by the Purchaser. The
selection, application, or use of Tempco products is the
Purchaser's responsibility. No claims will be allowed for any
damages or losses, whether direct, indirect, incidental, special, or
consequential. Specifications are subject to change without
notice. In addition, Tempco reserves the right to make changes–
without notification to the Purchaser–to materials or processing
that do not affect compliance with any applicable specification.
TEC Temperature Controllers are warranted to be free from
defects in material and workmanship for two (2) years after
delivery to the first purchaser for use. Tempco's sole responsibility
under this warranty, at Tempco's option, is limited to replacement or repair, free of charge, or refund of purchase price within
the warranty period specified. This warranty does not apply to
damage resulting from transportation, alteration, misuse, or
abuse.
RETURNS
No product returns can be accepted without a completed Return
Material Authorization (RMA) form.
TECHNICAL SUPPORT
Technical questions and troubleshooting help is available from
Tempco. When calling or writing please give as much background information on the application or process as possible.
E-mail: [email protected]
Phone: 630-350-2252
800-323-6859
Note: Information in this manual was deemed correct at the time of printing.
The policy of Tempco is one of continuous development and product
improvement, and we reserve the right to modify specifications and designs
without prior notice. Not responsible for typographical errors.
31
Page 36
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