Tempco TEC-2500 Instruction Manual

Page 1

Instruction Manual

TEC-2500 Self-Tune Fuzzy / PID Process Temperature Controller

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]

Serving Industry Since 1972

Web: www.tempco.com

Manual TEC-2500 Revision 9/2013

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 Chapters 1, 2

Basic Function User. . . . . . . . . . . . . . . . . Read Chapters 1, 3, 5

Enhanced Function User . . . . . . . . . . . Read Chapters 1, 3, 4, 5

System Designer . . . . . . . . . . . . . . . . . . . . . . Read All Chapters

Expert User. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Read Page 10

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 © 2011, 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.

CONTENTS

Chapter 1 Overview

1-1 Features . .

1-2 Ordering Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-3 Programming Port and DIP Switch . . . . . . . . . . . . . 4

1-4 Keys and Displays . . . . . . . . . . . . . . . . . . . . . . . . . 5

1-5 Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-6 System Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1-7 Parameter Description . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 2 Installation

2-1 Unpacking . .

2-2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2-3 Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . 18

2-4 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2-5 Sensor Installation Guidelines . . . . . . . . . . . . . . . 19

2-6 Thermocouple Input Wiring . . . . . . . . . . . . . . . . . 19

2-7 RTD Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 20

2-8 Linear DC Input Wiring . . . . . . . . . . . . . . . . . . . . . 20

2-9 CT/Heater Current Input Wiring . . . . . . . . . . . . . . 21

2-10 Event Input wiring . . . . . . . . . . . . . . . . . . . . . . . . 22

2-11 Output 1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2-12 Output 2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2-13 Alarm 1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2-14 Alarm 2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2-15 RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2-16 RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2-17 Analog Retransmission . . . . . . . . . . . . . . . . . . . . 30

2-18 Programming Port . . . . . . . . . . . . . . . . . . . . . . . 31

Chapter 3 Programming Basic Functions

3-1 Input 1 . .

3-2 OUT1 and OUT2 Types . . . . . . . . . . . . . . . . . . . . 34

3-3 Configuring User Menu . . . . . . . . . . . . . . . . . . . . . 35

3-4 Display SV Instead of PV . . . . . . . . . . . . . . . . . . . 35

3-5 Heat Only Control . . . . . . . . . . . . . . . . . . . . . . . . . 36

3-6 Cool Only Control . . . . . . . . . . . . . . . . . . . . . . . . . 37

3-7 Heat-Cool Control . . . . . . . . . . . . . . . . . . . . . . . . . 38

3-8 Dwell Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3-9 Process Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3-10 Deviation Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 42

3-11 Deviation Band Alarms . . . . . . . . . . . . . . . . . . . . 43

3-12 Heater Break Alarm . . . . . . . . . . . . . . . . . . . . . . 44

3-13 Loop Break Alarm . . . . . . . . . . . . . . . . . . . . . . . . 45

3-14 Sensor Break Alarm . . . . . . . . . . . . . . . . . . . . . . 46

3-15 SP1 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3-16 PV1 Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3-17 Failure Transfer . . . . . . . . . . . . . . . . . . . . . . . . . 48

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Page No.

CONTENTS

Page No.

3-18 Bumpless Transfer . . . . . . . . . . . . . . . . . . . . . . . 49

3-19 Self-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3-20 Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3-21 Manual Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3-22 Signal Conditioner DC Power Supply . . . . . . . . . 55

3-23 Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3-24 Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3-25 Heater Current Monitoring . . . . . . . . . . . . . . . . . 58

3-26 Reload Default Values . . . . . . . . . . . . . . . . . . . . . 58

Chapter 4 Full Function Programming

4-1 Event Input . .

4-2 Second Set Point . . . . . . . . . . . . . . . . . . . . . . . . . 60

4-3 Second PID Set . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4-4 Ramp and Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4-5 Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . 63

4-6 Differential Control . . . . . . . . . . . . . . . . . . . . . . . . 64

4-7 Output Power Limits . . . . . . . . . . . . . . . . . . . . . . . 65

4-8 Data Communication . . . . . . . . . . . . . . . . . . . . . . 66

4-9 Analog Retransmission . . . . . . . . . . . . . . . . . . . . . 67

4-10 Digital Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4-11 Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4-12 Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4-13 Remote Lockout . . . . . . . . . . . . . . . . . . . . . . . . . 70

Chapter 5 Applications

5-1 Pump/Pressure Control . . 5-2 Variable Period Full Wave SSR (VPFW SSR) . . . 73

5-3 Heat Only Control . . . . . . . . . . . . . . . . . . . . . . . . . 75

5-4 Cool Only Control . . . . . . . . . . . . . . . . . . . . . . . . . 76

5-5 Heat-Cool Control . . . . . . . . . . . . . . . . . . . . . . . . . 77

5-6 Ramp and Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5-7 Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . 80

5-8 Differential Control . . . . . . . . . . . . . . . . . . . . . . . . 81

5-9 Dual Set Point/PID . . . . . . . . . . . . . . . . . . . . . . . . 82

5-10 RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

5-11 RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5-12 Retransmit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Chapter 6 Calibration Chapter 7 Error Codes and Troubleshooting Chapter 8 Specifications Appendix

A-1 Menu Existence Conditions . .

A-2 Factory Menu Description . . . . . . . . . . . . . . . . . 100

A-5 Memo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

A-6 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

. . . . . . . . . . . . . . . . . . 71

. . . . . . . . . . . . . . . . . . . . . . . . 87

. . . . 91

. . . . . . . . . . . . . . . . . . . . . 95

. . . . . . . . . . . . . . . 97

Page 4

NOTES

Page 5

Chapter 1 Overview

1–1 Features

Unique

** High accuracy 18-bit input A–D ** High accuracy 15-bit output D–A ** Fast input sample rate (5 times/second)

* Fuzzy plus PID microprocessor-based control * Automatic programming * Differential control * Auto-tune function * Self-tune function * Sleep mode function * "Soft-start" ramp and dwell timer * Programmable inputs(thermocouple, RTD, mA, VDC) * Analog input for remote set point and CT * Event input for changing function and set point * Programmable digital filter

TEC-2500 Fuzzy Logic plus PID microprocessor-based controller

incorporates a bright, easy to read, 4-digit LED display which indicates the process value. Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time, with the minimum of overshoot during power-up or external load disturbance. The units are housed in a 1/32 DIN case, measuring 24mm x 48mm with 98mm behind-panel depth. The units feature three touch keys to select the various control and input parameters. Using a unique function, you can put up to five parameters at the front of the user menu by using SEL1 to SEL5 found in the setup menu. This is particularly useful to OEM's as it is easy to configure the menu to suit the specific application.

TEC-2500 is powered by 11–26 or 90–264VDC/AC supply, incorporating a 2 amp control relay output, 5V logic alarm output and a 2 amp alarm relay output as standard with a second alarm that can be configured in the second output for cooling purposes or as a dwell timer. Alternative output options include SSR drive, triac, 4–20mA and 0–10 volts. TEC-2500 is fully programmable for PT100, thermocouple types J, K, T, E, B, R, S, N, L, 0–20mA, 4–20mA, and voltage signal input, with no need to modify the unit. The input signals are digitized by using an 18-bit A to D converter. Its fast sampling rate allows the TEC-2500 to control fast processes such as pressure and flow. Self-tuning is incorporated. Self-tuning can be used to optimize the control parameters as soon as undesired control results are observed. Unlike auto-tuning, self-tuning will produce less disturbance to the process during tuning, and can be used at any time.

** Two function complexity levels ** User menu configurable ** Pump control

* Hardware lockout and remote lockout protection * Loop break alarm * Heater break alarm * Sensor break alarm and bumpless transfer * RS-485, RS-232 communication * Analog retransmission * Signal conditioner DC power supply * A wide variety of output modules available * Safety UL/CSA/IEC1010–1 * EMC/CE EN61326 * Front panel sealed to NEMA 4X and IP65

Two different methods can be used to program the TEC-2500.

1. Use the keys on the front panel to program the unit manually or

2. use a PC with setup software to program the unit via the RS485 or RS-232 COMM port.

For nearly a hundred years, PID control has been used and has proven to be an efficient controlling method by many industries, yet PID has difficulty dealing with some sophisticated systems such as second and higher order systems, long time-lag systems, during set point changes and/or load disturbances, etc. The PID principle is based on a mathematical model which is obtained by tuning the process. Unfortunately, many systems are too complex to describe precisely in numerical terms. In addition, these systems may vary from time to time. In order to overcome the imperfections of PID control, Fuzzy Logic was introduced.

What is Fuzzy Control? It works like a good driver. Under different speeds and circumstances, he can control a car well based on previous experience, and does not require knowledge of the kinetic theory of motion. Fuzzy Logic is a linguistic control which is different from numerical PID control. It controls the system by experience and does not need to simulate the system precisely as a PID controller would.

Digital communications formats RS-485, RS-232 or 4–20mA retransmission are available as an additional option. These options allow the TEC-2500 to be integrated with supervisory control systems and software, or alternatively to drive remote displays, chart recorders, or data loggers.

Page 6

The function of Fuzzy Logic is to adjust PID parameters internally in order to make manipulation of output value MV more flexible and adaptive to various processes.

The Fuzzy Rule may work like this: If the temperature difference is large, and the temperature rate is large, then ΔMV is large.

If the temperature difference is large, and the temperature rate is small, then ΔMV is small.

PID+Fuzzy Control has been proven to be an efficient method to improve the control stability as shown by the comparison curves below:

Page 7

1–2 Ordering Code

Accessories

TEC-101-101 — Isolated 4–20mA/0–20mA analog output module TEC-101-114 — Isolated 1–5V/0–5V analog output module TEC-101-115 — Isolated 0–10V analog output module TEC-101-109 — Isolated 1A/240VAC triac output module (SSR) TEC-101-111 — Isolated 20V/25mA DC output power supply TEC-101-112 — Isolated 12V/40mA DC output power supply TEC-101-113 — Isolated 5V/80mA DC output power supply TEC-102-101 — Isolated RS-485 interface module TEC-102-103 — Isolated RS-232 interface module TEC-102-104 — Isolated 4–20mA/0–20mA retransmission module TEC-102-105 — Isolated 1–5V/0–5V retransmission module TEC-102-106 — Isolated 0–10V retransmission module TEC99014 — RS-232 interface cable (2M) TEC99999 — 0–50amp AC current transformer

Related Products

TEC99001 — Smart network adapter for third party software; converts 255 channels of RS-485 or RS-422 to RS-232 network TEC99002 — Smart network adapter for BC-Net software; converts 255 channels of RS-485 or RS-422 to RS-232 network TEC99927 — RS-232/485 ->USB Adapter

Page 8

1–3 Programming Port and DIP Switch

The programming port is used for off-line automatic setup and testing procedures only. Do not attempt to make any connection to these pins when the unit is being used for normal control purposes.

When the unit leaves the factory, the DIP switch is set so that TC and RTD are selected for input 1 and all parameters are unlocked.

Lockout function is used to disable the adjustment of parameters as well as operation of calibration mode. However, the menu can still be viewed even under lockout condition.

*SEL1-SEL5 represent those parameters which are selected by using SEL1, SEL2,...SEL5 parameters contained in the setup menu. The parameters that have been selected are then allocated at the beginning of the user menu.

Page 9

1–4 Keys and Displays

The unit is programmed by using the three keys on the front panel. The available key functions are listed in the following table.

How to display a 5-digit number:

For a number with a decimal point, the display will be shifted one digit to the right:

-199.99 will be displayed as -199.9

4553.6 will be displayed as 4553

For a number without a decimal point, the display will be divided into two alternating phases:

Page 10

Page 11

1–5 Menu Overview

Page 12

1–6 System Modes

The controller performs closed loop control in its normal control mode condition. The controller will maintain its normal control mode when you are operating the user menu, setup menu, or display mode, reloading default values, or applying event input signals. Under certain conditions, the normal control mode will transfer to an exception mode. The exception modes include: sleep mode, manual mode, failure mode, calibration mode, and auto-tuning mode. All of these modes perform in an open loop control except auto-tuning mode which performs ON-OFF plus PID closed loop control. The mode transfer is governed by the priority conditions. A lower priority mode can not alter a higher priority mode, as shown in figure 1.6.

System Modes Sleep mode:

See section 4-11.

Manual mode:

See section 3-23.

Failure mode:

See section 3-17.

Calibration mode:

See chapter 6.

Auto-tuning mode:

See section 3-20.

Normal control mode:

See section 3-24, 3-26, 4-1

Calibration mode, auto-tuning mode, and normal control mode are in the same priority level. Sleep mode is in the highest priority level.

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1–7 Parameter Description

Page 14

Page 15

Low:

High:

IN2U

DP2

IN2L

IN2H

IN2 Unit Selection

IN2 Decimal Point Selection

IN2 Low Scale Value

IN2 High Scale Value

-19999

45536

Same as IN1U

Same as DP1

1000

Parameter Description

RangeRange

Default Value

Contained in

Basic Function

Parameter Notation

Display Format

IN1U

IN1

DP1

IN1L

IN1H

IN1 Unit Selection

IN1 Sensor Type Selection

IN1 Decimal Point Selection

IN1 Low Scale Value

IN1 High Scale Value

-19999

45536

N type thermocouple

L type thermocouple

PT 100 ohms DIN curve

PT 100 ohms JIS curve

4 - 20 mA linear current input

0 - 20 mA linear current input

0 - 1V linear Voltage input

0 - 5V linear Voltage input

1 - 5V linear Voltage input

0 - 10V linear Voltage input

Special defined sensor curve

Low:

High:

1000

0 (1)

1 ( 0 )

IN2

IN2 Signal Type Selection

IN2 no function

Current transformer input

0 - 1V linear voltage input

0 - 5V linear voltage input

1 - 5V linear voltage input

0 - 10V linear voltage input

Degree C unit

Degree F unit

Process unit

No decimal point

1 decimal digit

2 decimal digits

3 decimal digits

Output 1 Function

OUT1

O1TY

Reverse (heating ) control action

Direct (cooling) control action

Relay output

Solid state relay drive output

Solid state relay output

4 - 20 mA current module

Output 1 Signal Type

Setup Menu

Perform Event input function

Table 1.4 Parameter Description (page 3 of 7)

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1213141516

Page 17

Page 18

Page 19

Page 20

NOTES

Page 21

Chapter 2 Installation

Dangerous voltage capable of causing death can be 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.

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 conditions such as excessive shock, vibration, dirt, moisture, corrosive gases, or oil. The ambient temperature of the areas should not exceed the maximum rating specified in chapter 8.

2–1 Unpacking

Upon receipt of the shipment, remove the unit from the carton and inspect the unit for shipping damage. If there is any damage due to transit, report the damage and file a claim with the carrier. Write down the model number and serial number for future reference when corresponding with our service center. The serial number (S/N) is located on the box and the housing of the controller.

2–2 Mounting

Make the panel cutout to fit the dimensions shown in figure 2.1.

Remove both mounting clamps and insert the controller into the panel cutout. Reinstall the mounting clamps. Gently tighten the screws in the clamp until the controller front panel fits snugly in the cutout.

Page 22

2–3 Wiring Precautions

• Before wiring, check the label to verify the correct model number and options. Switch off the power while checking.

• Care must be taken to ensure that the maximum voltage ratings specified on the label are not exceeded.

• It is recommended that the power source for these units be protected by fuses or circuit breakers rated at the minimum value possible.

• All units should be installed inside a suitably grounded metal enclosure to prevent live parts from being accessible to human hands and metal tools.

• All wiring must conform to the appropriate standards of good practice and local codes and regulations. Wiring must be suitable for the voltage, current, and temperature ratings of the system.

• The "stripped" leads as specified in figure 2.2 below are used for power and sensor connections.

• Beware not to over-tighten the terminal screws.

• 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 in chapter 8 are not exceeded.

• Electrical power in industrial environments contain 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 we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the controller. This wire is a twisted-pair construction with foil wrap and drain wire. The drain wire is to be attached to ground at one end only.

2–4 Power Wiring

The controller is supplied to operate at 11–26VAC/VDC or 90–264VAC. Check that the installation voltage corresponds to the power rating indicated on the product label before connecting power to the controller.

This equipment is designed for installation in

an enclosure which provides adequate protection against electrical shock. The enclosure must be connected to earth ground.

Local requirements regarding electrical installation should be rigidly observed. Consideration should be given to prevent unauthorized personnel from gaining access to the power terminals.

Page 23

2–5 Sensor Installation Guidelines

11 22 33 44

ONON

8910

121314

Figure 2.5 Thermocouple Input Wiring

DIP Switch

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 experiments with probe location are often required to find the optimum position.

In a liquid process, the addition of a stirrer will help eliminate thermal lag. Since a 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.

2–6 Thermocouple Input Wiring

The thermocouple input connections are shown in figure

2.5. The correct type of thermocouple extension lead-wire or compensating cable must be used for the entire distance between the controller and the thermocouple, ensuring that the correct polarity is maintained throughout. Joints in the cable should be avoided, if possible.

The 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 additional requirements such as leak-proof, anti-vibration, antiseptic, etc.

Standard sensor limits of error are ±4°F (±2°C) or 0.75% of 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.

If the length of the thermocouple plus the extension wire is too long, it may affect the temperature measurement. A 400 ohms K type or a 500 ohms J type thermocouple lead resistance will produce approximately 1°C temperature error.

The color codes used on the thermocouple extension leads are shown in Table 2.1.

Table 2.1 Thermocouple Cable Color Codes

Thermocouple Cable British American German French

Type Material BS ASTM DIN NFE

K (Ni-Cr)

R Pt-13%Rh, Pt S Pt-10%Rh, Pt

Copper (Cu) Constantan (Cu-Ni)

Iron (Fe) Constantan (Cu-Ni)

Nickel-Chromium

Nickel-Aluminum (Ni-Al)

Pt-30%Rh Pt-6%Rh

+ white + blue + red + yellow – blue – red – brown – blue * blue * blue * brown * blue + yellow + white + red + yellow – blue – red – blue – black * black * black * blue * black

+ brown + yellow + red + yellow – blue – red – green – purple * red * yellow * green * yellow

+ white + black + red + yellow – blue – red – white – green * green * green * white * green

Use + grey + red Use

Copper – red – grey Copper

Wire * grey * grey Wire

* Color of overall sheath

Page 24

2–7 RTD Input Wiring

The RTD connections are shown in figure 2.6, with the compensating lead connected to terminal 9. For two-wire RTD inputs, terminals 9 and 10 should be linked. A three-wire RTD offers the capability of lead resistance compensation, provided that the three leads are the same gauge and equal in length.

For the purpose of accuracy, two-wire RTD should be avoided if possible. A 0.4ohm lead resistance in a two-wire RTD will produce 1°C temperature error.

2–8 Linear DC Input Wiring

DC linear voltage and linear current connections for input 1 are shown in figure 2.7 and figure 2.8.

DC linear voltage and linear current connections for input 2 are shown in figure 2.9 and figure 2.10.

Page 25

2–9 CT/Heater Current Input Wiring

Page 26

2–10 Event Input wiring

The event input can accept a switch signal as well as an open collector signal. The event input function (EIFN) is activated when the switch is closed or an open collector (or a logic signal) is pulled down.

Modification from RS-232 to event input:

Because of the limited number of pins, pin 11 is used for both event input and RS-232. If you want to change function of the TEC-2500 from RS-232 to event input, you must modify jumpers J51 and J52 on the CPU board by opening jumper J52 and shorting jumper J51. Refer to section 2-16 for the location of jumpers J51 and J52.

Also refer to section 4-1 for event input functions.

2–11 Output 1 Wiring

Figure 2.14 continued on next page

Page 27

2–11 Output 1 Wiring (Continued)

Page 28

2–12 Output 2 Wiring

120V/240V Mains Supply

Max. 2A Resistive

LoadLoa d

120V /240V Mains Supply

No Fuse Breaker

Three Phase Heater Power

Three Phase Delta Heater Load

ContactorContactor

8910

121314

8910

121314

Relay Output Direct Drive

SSRSSR

8910

121314

Load

120V / 240V Mains Supply

5V5V

0V0V

333 3

Internal Circuit

30mA/5V Pulsed Voltage

Figure 2.15 Output 2 Wiring

Relay or Triac (SSR) Output to Drive Contactor

Pulsed Voltage to Drive SSR

Page 29

Page 30

120V/240V Mains Supply

Max. 2A Resistive

5V DC Relay

120V /240V Mains Supply

No Fuse Breaker

Three Phase Heater Power

Three Phase Delta Heater Load

ContactorContactor

8910

121314

8910

121314

LoadL o a d

Internal C ircuitInterna l C irc uit

5V5V

1414

1K1K

0V0V

Single Phase Load

Figure 2.16 Alarm 1 Wiring

2–13 Alarm 1 Wiring

Page 31

2–14 Alarm 2 Wiring

Page 32

2–15 RS-485

Page 33

2–16 RS-232

When you connect an RS-232 module (CM94-2) to the connectors on a CPU board (C250), jumpers J51 and J52 must be modified as following: J52 must be shorted and J51 must be cut and left open. The location of the jumpers are shown in the following diagram.

If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable must be modified according to the following circuit diagram.

Page 34

2–17 Analog Retransmission

Page 35

2–18 Programming Port

See figure 1.3 in section 1-3 to find the programming port location.

Page 36

NOTES

Page 37

Chapter 3 Programming Basic Functions

IN1

IN1U

This unit provides a useful parameter "FUNC" which can be used to select the function complexity level before setup. If Basic Mode (FUNC=BASC) is selected for a simple application, then the following functions are ignored and deleted from the full function menu: RAMP, SP2, PB2, TI2, TD2, PL1, PL2, COMM, PROT, ADDR, BAUD, DATA, PARI, STOP, AOFN, AOLO, AOHI, IN2, IN2U, DP2, IN2L, IN2H, EIFN, PVMD, FILT, SLEP, SPMD, and SP2F.

Basic Mode capabilities:

1. Input 1: thermocouple, RTD, volt, mA

2. Input 2: CT for heater break detection

3. Output 1: heating or cooling (relay, SSR, SSRD, volt, mA)

4. Output 2: cooling (relay, SSR, SSRD, volt, mA), DC power supply

5. Alarm 1: relay for deviation, deviation band, process, heater break, loop break, sensor break, latch, hold, or normal alarm.

6. Alarm 2: relay for deviation, deviation band, process, heater break, loop break, sensor break, latch, hold, or normal alarm.

7. Dwell timer

8. Heater break alarm

9. Loop break alarm

10. Sensor break alarm

11. Failure transfer

12. Bumpless transfer

13. PV1 shift

14. Programmable SP1 range

15. Heat-cool control

16. Hardware lockout

17. Self-tune

18. Auto-tune

19. ON-OFF, P, PD, PI, PID control

20. User-defined menu (SEL)

21. Manual control

22. Display mode

23. Reload default values

24. Isolated DC Power supply

25. PV or SV selection

If you don't need:

1. Second setpoint

2. Second PID

3. Event input

4. Soft start (RAMP)

5. Remote set point

6. Complex process value

7. Output power limit

8. Digital communication

9. Analog retransmission

10. Power shut off (sleep mode)

11. Digital filter

12. Pump control

13. Remote lockout

then you can use basic mode.

3–1 Input 1

Press to enter setup mode. Press to select the desired parameter. The upper display indicates the parameter symbol, and the lower display indicates the selection or the value of the parameter.

IN1:

IN1U:

Selects the sensor type and signal type for Input 1.

Range:

Default:

Selects the process unit for Input 1.

Range: Default:

(Thermocouple) J_TC, K_TC, T_TC, E_TC, B_TC, R_ TC, S_TC, N_TC, L_TC (RTD) PT.DN, PT.JS (Linear) 4–20, 0–20, 0–1V, 0–5V, 1–5V, 0–10

J_TC if °F is selected, K_TC if °C is selected.

°C, °F, PU (process unit). If the unit is neither °C nor °F, then PU is selected.

°C or °F

Page 38

DP1:

DP1

IN1L

IN1H

O2TY

O1TY

Selects the location of the decimal point for most (not all) process-related parameters.

Range:

Default:

IN1L:

Selects the low scale value for Linear type input 1.

Hidden if:

IN1H:

Selects the high scale value for Linear type input 1.

Hidden if:

How to use IN1L and IN1H: If 4–20mA is selected for IN1, 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:

(T/C and RTD) NO.DP, 1-DP

(Linear) NO.DP, 1-DP, 2-DP, 3-DP

NO.DP

T/C or RTD type is selected for IN1.

Example: If a 4–20mA current loop pressure transducer with range 0–15 kg/cm≈ is connected to input 1, then perform

the following setup: IN1=4–20 IN1L=0.0 IN1U=PU IN1H=15.0 DP1=1-DP Of course, you may select another value for DP1 to alter the resolution.

3–2 OUT1 and OUT2 Types

O1TY:

O2TY:

Selects the signal type for Output 1. The selection should be consistent with the output 1 module installed. The available output 1 signal types are: RELY: Mechanical relay SSRD: Pulsed voltage output to drive SSR SSR: Isolated zero-switching solid-state relay 4–20: 4–20mA linear current output 0–20: 0–20mA linear current output 0–1V: 0–1V linear voltage output 0–5V: 0–5V linear voltage output 1–5V: 1–5V linear voltage output 0–10V: 0–10V linear voltage output

Selects the signal type for Output 2 The selection should be consistent with the output 2 module installed. The available output 2 signal types are the same as for O1TY.

The range for linear current or voltage may not be very accurate. For 0% output, the value for 4–20mA may be

3.8–4mA; while for 100% output, the value for 4–20mA may be 20–21mA. However, this deviation will not degrade the control performance at all.

Page 39

3–3 Configuring User Menu

SEL1

SEL2

SEL3

SEL4

SEL5

Most conventional controllers are designed with a fixed order in which the parameters scroll. The TEC-2500 has the flexibility to allow you to select those parameters which are most significant to you and put these parameters at the front of the display sequence.

SEL1: Selects the most significant parameter for view and change. SEL2: Selects the 2nd most significant parameter for view and change. SEL3: Selects the 3rd most significant parameter for view and change. SEL4: Selects the 4th most significant parameter for view and change. SEL5: Selects the 5th most significant parameter for view and change.

Range: NONE, TIME, A1.SP, A1.DV, A2.SP, A2.DV, RAMP, OFST, REFC, SHIF, PB1, TI1,

TD1, C.PB, DB, SP2, PB2, TI2, TD2 When using the up and down keys to select the parameters, you may not see all of the above parameters. The number of visible parameters is dependent on the setup condition. The hidden parameters for the specific application are also deleted from the SEL selection.

Example:

A1FN selects TIMR

A2FN selects DE.HI

PB1=10

TI1=0

SEL1 selects TIME

SEL2 selects A2.DV

SEL3 selects OFST

SEL4 selects PB1

SEL5 selects NONE

Now, the upper display scrolling becomes:

3–4 Display SV Instead of PV

In certain applications where set point value (SV) is more important than process value (PV), the parameter

Press keys to enter setup menu , then press several times until

appears on the display. If you need the process value to be displayed, then select by using or key while in DISF. If you need set point value instead of process value displayed, then select for DISF. Refer to the flow chart in section 1-5 to see the location of DISF.

DISF

(display format) can be used.

DISF

has two values:

Display process value

Display set point value

Page 40

3–5 Heat Only Control

SP1+O1HY/2

SP1 O1HY/2

SP1

OFF

OUT1 Action

Dead band = O1HY

Time

Figure 3.2 Heat Only ON-OFF Control

Heat Only ON-OFF Control:

Select REVR for OUT1, set PB1 to 0, SP1 is used to adjust set point value, O1HY is used to adjust dead band for ON-OFF control, TIME is used to adjust the dwell timer (enabled by selecting TIMR for A1FN or A2FN). Output 1 hysteresis (O1HY) is enabled in the case of PB1=0.

Setup ON-OFF:

OUT1= PB1=0 Adjust:SP1, O1HY, TIME(if enabled)

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 to the smallest. If ONOFF control is set (i.e., PB1=0), TI1, TD1, CYC1, OFST, CPB and PL1 will be hidden and have no function to the system. The manual mode, auto-tuning, self-tuning and bumpless transfer will be disabled too.

Heat only P ( or PD ) control:

used to adjust set point value, TIME is used to adjust the dwell timer (enabled by selecting TIMR for A1FN or A2FN). OFST been enabled in case of TI1=0 and is used to adjust the control offset (manual reset). Adjust CYC1 according to the output 1 type (O1TY). Generally, CYC1=0.5~2 seconds for SSRD and SSR, CYC1=10~20 seconds for relay output. CYC1 is ignored if linear output is selected for O1TY.

O1HY is hidden

Select REVR for OUT1, set TI1 to 0, SP1 is

Setup P:

OUT1= TI1=0 CYC1 (if RELAY, SSRD or SSR is selected for O1TY)

if PB1 is not equal to 0.

Adjust:

OFST Function:

OFST is measured by % with range 0–100.0%. In the steady

state (i.e., process has been stabilized), if the process value is lower than the

SP1, OFST, TIME (if enabled),

PB1(≠0), TD1 set point a definite value, say 5°C, while 20°C is used for PB1, that is lower than the process value by 25%, then increase OFST 25%, and vice versa. After adjusting OFST value, the process value will be varied and eventually coincide with set point. Using the P control (TI1 set to 0), the auto-tuning and self-tuning are disabled. Refer to section 3-21 "manual tuning" for the adjustment of PB1 and TD1. Manual reset (adjust OFST) is not practical because the load may change from time to time and often need to adjust OFST repeatedly. The PID control can avoid this situation.

Setup PID:

OUT1=

O1TY

CYC1 if RELAY, SSRD or SSR is

Heat only PID control:

Selecting REVR for OUT1, SP1 is used to adjust set point value. TIME is used to adjust the dwell timer (enabled by selecting TIMR for A1FN or A2FN). PB1 and TI1 should not be zero. Adjust CYC1 according to the output 1 type (O1TY). Generally, CYC1=0.5~2 seconds for SSRD and SSR, CYC1=10~20 seconds for relay output. CYC1 is ignored if a linear output is selected for O1TY. In most cases, self-tuning can be used to substitute for auto-tuning. See section 3-19. If self-tuning is not used (select NONE for SELF), then use auto-tuning for the new process, or set PB1, TI1, and TD1 with historical values. See section 3-20 for auto-tuning operation. If the control result is still unsatisfactory, then use manual tuning to improve control. See section 3-21 for manual tuning. The TEC-2500 contains a very clever PID and Fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is properly tuned.

selected for O1TY) SELF=NONE or YES

Adjust:

SP1, TIME (if enabled), PB1(≠0), TI1(≠0), Td1

Auto-tuning:

Used for new process during initial tuning

Self-tuning:

Used for a process any time.

Manual Tuning:

May be used if self-tuning and autotuning are inadequate.

Page 41

3–6 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 the descriptions in section 3-5 for heat only control except that the output variable (and action) for the cool control is inverse to the heat control, such as the following diagram shows:

Refer to section 3-5, in which similar descriptions for heat only control can be applied to cool only control.

Setup Cool Control:

OUT1=

Page 42

3–7 Heat-Cool Control

The heat-cool control can use one of six combinations of control modes. Setup of parameters for each control mode are shown in the following table.

NOTE:

The P (or PD) control will result in a deviation process value from the set point. It is recommended to use PID control for the heat-cool control to produce a stable and zero offset process value.

Other Setup Required :

O1TY and O2TY are set in accordance with the types of OUT1 and OUT2 installed. CYC1 and CYC2 are set 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. Select 10~20 seconds if relay is used for O1TY; CYC1 is ignored if linear output is used. Similar conditions are applied to CYC2 selection. If OUT2 is configured for ONOFF control (by selecting AL2), OUT2 will act as alarm output, and the process alarm as well as deviation alarm (see sections 3-9 and 3-10) can be used. Adjust A2SP to change the set point if process alarm is used, and adjust SP1 (with preset A2DV) to change the set point if deviation alarm is used.

Examples: Heat PID+Cool ON-OFF:

PB1≠0, TI1≠0, TD1≠0, and set appropriate values for O1TY and CYC1.

Heat PID+Cool PID:

set appropriate values for O1TY, CYC1, O2TY, CYC2.

If you have no idea about a new process, then use the self-tuning program to optimize the PID values by selecting YES for SELF to enable the self-tuning program. See section 3-19 for a description of the selftuning program. You can use the auto-tuning program for the new process or directly set the appropriate values for PB1, TI1, and TD1 according to the historical records for the repeated systems. If the control behavior is still inadequate, then use manual tuning to improve the control. See section 3-21 for more information on manual tuning.

The ON-OFF control may result in excessive overshoot and undershoot problems in the process.

O1TY, CYC1, O2TY, CYC2, A2SP, A2DV

Set OUT1=REVR, OUT2=AL2, A2FN=PV1.H, A2MD=NORM, A2HY=0.1,

set OUT1=REVR, OUT2=COOL, CPB=100, DB=-4.0, PB1≠0, TI1≠0, TD1≠0, and

Page 43

Error Code

CPB Programming:

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 self-tuning and auto-tuning procedures.

Adjustment of CPB is related to the cooling media used. If air is used as the cooling medium, set CPB at 100(%). If oil is used as the cooling medium, set CPB at 125(%). If water is used as the cooling medium, set CPB at 250(%).

The cooling proportional band is measured by % of PB with a range of 1~255. Initially

DB Programming:

DB (greater dead band) is used, unwanted cooling action can be avoided, but an excessive overshoot over the set point will occur. If a lower 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 PB1 (or PB2 if PB2 is selected). 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.

Adjustment of DB is dependent on the system requirements. If a higher positive value of

3–8 Dwell Timer

Alarm 1 or alarm 2 can be configured as dwell timer by selecting TIMR for A1FN or A2FN, but not both, otherwise TIME is used for dwell time adjustment. The dwell time is measured in minutes ranging from 0 to 6553.5 minutes. Once the process reaches the set point the dwell timer starts to count from zero until time out.The timer relay will remain unchanged until time out. The dwell timer operation is shown as following diagram.

Er07

will appear. As the dwell timer is configured, the parameter

If alarm 1 is configured as dwell timer, A1SP, A1DV, A1HY and A1MD are hidden. The case is the same for alarm 2.

Example:

Set A1FN=TIMR or A2FN=TIMR, but not both. Adjust TIME in minutes A1MD (if A1FN=TIMR) or A2MD (if A2FN=TIMR) is ignored in this case. If alarm 1 is selected for dwell timer, an external 5V DC relay is required to drive AC load.

Page 44

3–9 Process Alarms

Error Code

There are at most two independent alarms available by adjusting OUT2. If AL2 is selected for OUT2, then OUT2 will perform alarm 2 function. Now NONE can't be selected for A2FN, otherwise

Er06

will be displayed. A process alarm sets an absolute trigger level (or temperature). When the process (could be PV1, PV 2, or PV1-PV2) exceeds that absolute trigger level, an alarm occurs. A process alarm is independent from the set point. Adjust A1FN (Alarm 1 function) in the setup menu. One of eight functions can be selected for process alarm. These are: PV1.H, PV1.L, PV2.H, PV2.L, P1.2.H, P1.2.L, D1.2.H and D1.2.L.

When PV1.H or PV1.L is selected, the alarm examines the PV1 value. When PV2.H or PV2.L is selected, the alarm examines the PV2 value. When P1.2.H or P1.2.L is selected, the alarm occurs if the PV1 or PV2 value exceeds the trigger level. When D1.2.H or D1.2.L is selected, the alarm occurs if the PV1-PV2 (difference) value exceeds the trigger level. The trigger level is determined by A1SP (Alarm 1 set point) and A1HY (Alarm 1 hysteresis value) in User Menu for alarm 1. The hysteresis value is introduced to avoid interference action of alarm in a noisy environment. Normally A1HY can be set with a minimum (0.1) value. A1DV and/or A2DV are hidden if alarm 1 and/or alarm 2 are set for process alarm.

Normal Alarm: A1MD=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: A1MD=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 alarms are disabled when the power is shut off or if event input is applied with proper selection of EIFN.

Holding Alarm: A1MD=HOLD

A holding alarm prevents an alarm from powering up. The alarm is enabled only when the process reaches the set point value (may be SP1 or SP2, see section 4-1 event input ). Afterwards, the alarm performs the same function as a normal alarm.

Latching/Holding Alarm: A1MD=LT.HO

A latching/holding alarm performs both holding and latching function.

8 Types of Process Alarms:

PV1.H, PV1.L, PV2.H, PV2.L, P1.2.H, P1.2.L, D1.2.H, D1.2.L

Process Alarm 1

Setup: A1FN, A1MD Adjust: A1SP, A1HY Trigger level=A1SP-A1HY

Process Alarm 2

Setup: OUT2, A2FN, A2MD Adjust: A2SP, A2HY Trigger level=A2SP-A2HY

Reset Latching alarm

1. Power off

2. Apply event input in accordance with proper selection of EIFN

Examples:

Page 45

Although the above descriptions are based on alarm 1, the same conditions can be applied to alarm 2.

Page 46

3–10 Deviation Alarm

Error Code

OUT2 can be configured as alarm 2 by selecting AL2. If AL2 is selected for OUT2, then output 2 will perform alarm 2 function. Now NONE can't be selected for A2FN, otherwise

Er06

will appear. A deviation alarm alerts the user when the process deviates too far from the set point. The user can enter a positive or negative deviation value (A1DV, A2DV) for alarm 1 and alarm 2. A hysteresis value (A1HY or A2HY) can be selected to avoid interference problems in a noisy environment. Normally, A1HY and A2HY can be set with a minimum (0.1) value. The trigger level of the alarm moves with the set point.

For alarm 1, trigger level=SP1+A1DV±A1HY.

For alarm 2, trigger level=SP1+A2DV±A2HY.

A1SP and/or A2SP are hidden if alarm 1 and/or alarm 2 are set for deviation alarm. One of four alarm modes can be selected for alarm 1 and alarm 2. These are: normal alarm, latching alarm, holding alarm and latching/holding alarm. See section 3-9 for descriptions of these alarm modes.

Examples:

2 Types of deviation alarms:

DE.HI, DE.LO

Deviation alarm 1:

Setup: A1FN, A1MD Adjust: SP1, A1DV, A1HY Trigger levels: SP1+A1DV±A1HY

Deviation alarm 2:

Setup: OUT2, A2FN, A2MD Adjust: SP1, A2DV, A2HY Trigger levels: SP1+A2DV±A2HY

Page 47

3–11 Deviation Band Alarm

Error Code

A deviation band alarm presets two reference levels relative to set point. Two types of deviation band alarm can be configured for alarm 1 and alarm 2. These are deviation band high alarm (A1FN or A2FN select DB.HI) and deviation band low alarm (A1FN or A2FN select DB.LO). If alarm 2 is required, then select AL2 for OUT2. Now NONE can't be selected for A2FN, otherwise A1SP and A1HY are hidden if alarm 1 is selected as a deviation band alarm. Similarly, A2SP and A2HY are hidden if alarm 2 is selected as a deviation band alarm.

The trigger level for deviation band alarm moves with the set point. For alarm 1, the trigger level=SP1±A1DV. For alarm 2, the trigger level=SP1±A2DV. One of four alarm modes can be selected for alarm 1 and alarm 2. These are: normal alarm, latching alarm, holding alarm and latching/holding alarm. See section 3-9 for descriptions of these alarm modes.

DBHi will trigger an alarm if the process value is outside of the deviation value (out of band)

DBLo will trigger an alarm if the process value is within the deviation value (in band)

Examples:

Er06

will appear.

2 types of deviation band alarms:

DB.HI, DB.LO

Deviation band alarm 1:

Setup: A1FN, A1MD Adjust: SP1, A1DV Trigger level=SP1±A1DV

Deviation band alarm 2:

Setup: OUT2, A2FN, A2MD Adjust: SP1, A2DV Trigger level=SP1±A2DV

Page 48

3–12 Heater Break Alarm

A current transformer (Part Number TEC99999) should be installed to detect the heater current if a heater break alarm is required. The CT signal is sent to input 2, and the PV2 will indicate the heater current in 0.1amp resolution. The range of the current transformer is 0 to 50.0amp. For more detailed descriptions about heater current monitoring, please see section 3-25.

Example:

A furnace uses two 2KW heaters connected in parallel to warm up the process. The line voltage is 220V and the rating current for each heater is 9.09A. If we want to detect any one heater break, set A1SP=13.0A, A1HY=0.1, A1FN=PV2.L, A1MD=NORM, then:

Heater break alarm 1

Setup: IN2=CT

A1FN=PV2.L A1MD=NORM

A1HY=0.1 Adjust: A1SP Trigger level: A1SP±A1HY

Heater break alarm 2

Setup: IN2=CT

A2FN=PV2.L

A2MD=NORM

A2HY=0.1 Adjust: A2SP Trigger level: A2SP±A2HY

Limitations:

1. Linear output can't use heater break alarm.

2. CYC1 should use 1 second or longer to detect heater current reliably.

Page 49

3–13 Loop Break Alarm

A1FN selects LB if alarm 1 is required to act as a loop break alarm. Similarly, if alarm 2 is required to act as a loop break alarm, then set OUT2 to AL2 and A1FN to LB. TIME, A1SP, A1DV, and A1HY are hidden if alarm 1 is configured as a loop break alarm. Similarly, TIME, A2SP, A2DV, and A2HY are hidden if alarm 2 is configured as a loop break alarm.

One of four kinds of alarm modes can be selected for alarm 1 and alarm 2. These are: normal alarm, latching alarm, holding alarm and latching/holding alarm. However, the holding mode and latching/holding mode are not recommended for loop break alarm since loop break alarm will not perform the holding function even if it is set for holding or latching/holding mode. See section 3-9 for descriptions of these alarm modes.

Loop break conditions are detected during a time interval of 2TI1 (double the integral time, but 120 seconds maximum). Hence the loop break alarm doesn't respond as quickly as it occurs. If the process value doesn't increase (or decrease) while the control variable MV1 has reached its maximum (or minimum) value within the detecting time interval, a loop break alarm (if configured) will be activated.

Loop break alarm 1

Setup: A1FN=LB

A1MD=NORM, LTCH

Loop break alarm 2

Setup: OUT2=AL2

A2FN=LB A2MD=NORM, LTCH

Loop break alarm (if configured) occurs when any following conditions happen:

1. Input sensor is disconnected (or broken).

2. Input sensor is shorted.

3. Input sensor is defective.

4. Input sensor is installed outside (isolated from) the process.

5. Controller fails (A-D converter damaged).

6. Heater (or chiller, valve, pump, motor etc.) breaks or fails or is uninstalled.

7. Switching device (used to drive heater) is open or shorted.

Page 50

3–14 Sensor Break Alarm

Alarm 1 or alarm 2 can be configured as a sensor break alarm by selecting SENB for A1FN or A2FN. If alarm 2 is required as a sensor break alarm, then AL2 should be selected for OUT2. The sensor break alarm is activated as soon as failure mode occurs. Refer to section 3-17 for failure mode conditions. Note that A-D failure also creates a sensor break alarm. TIME, A1SP, A1DV, and A1HY are hidden if alarm 1 is configured as a sensor break alarm. Similarly, TIME, A2SP, A2DV and A2HY are hidden if alarm 2 is configured as a sensor break alarm. One of four kinds of alarm modes can be selected for sensor break alarm. These are: normal alarm, latching alarm, holding alarm, and latching/holding alarm. However, the holding alarm and latching/holding alarm are not recommended for the sensor break alarm since the sensor break alarm will not perform the holding function even if it is set for holding or latching/holding mode. See section 3-9 for the descriptions of these alarm modes.

3–15 SP1 Range

SP1L (SP1 low limit value) and SP1H (SP1 high limit value) in the setup menu are used to confine the adjustment range of SP1.

Example:

In order to avoid an abnormal set point, SP1L and SP1H are set with the following values:

Now SP1 can only be adjusted within the range of -10°C to -15°C.

A freezer is working in its normal temperature range -10°C to -15°C.

SP1L=-15°C SP1H=-10°C

Sensor Break Alarm 1 Setup:

Hidden:

Sensor Break Alarm 2 Setup:

Hidden:

Setup :

A1FN=SENB

A1MD=NORM, LTCH

TIME, A1SP, A1DV, A1HY

OUT2=AL2

A2FN=SENB

A2MD=NORM, LTCH

TIME , A2SP, A2DV, A2HY

SP1L, SP1H

Page 51

3–16 PV1 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 PV1 shift function.

Enter the configuration menu and press the "scroll" key to bring up the parameter SHIF. The value you adjust here, either positive or negative, will be added to the actual value. The SHIF function will alter PV1 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 (different temperature) 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 input -35°C so as 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.

Page 52

3–17 Failure Transfer

The controller will enter failure mode if one of the following conditions occurs:

SB1E

1. 4–20mA is selected or input 1 voltage below 0.25V if 1–5V is selected) if PV1, P1-2, or P2-1 is selected for PVMD or PV1 is selected for SPMD.

SB2E

2. 4–20mA is selected or input 2 voltage below 0.25V if 1–5V is selected) if PV2, P1-2, or P2-1 is selected for PVMD or PV2 is selected for SPMD.

ADER

Output 1 and output 2 will perform the failure transfer function as one of the following conditions occurs:

1. During power starts (within 2.5 seconds).

2. The controller enters failure mode.

3. The controller enters manual mode.

4. The controller enters calibration mode.

Output 1 failure transfer, if activated, will perform:

1. If output 1 is configured as proportional control (PB1≠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 (PB1≠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 (PB1≠0), then output 1 will be driven OFF if O1FN selects REVR and be driven ON if O1FN selects DIRT.

occurs (due to input 1 sensor break or input 1 current below 1mA if

occurs (due to input 2 sensor break or input 2 current below 1mA if

occurs if the A-D converter of the controller fails.

Failure mode occurs as:

1. SB1E

2. SB2E

3. ADER

Failure Transfer of output 1 and output 2 occurs as:

1. Power start (within 2.5 seconds)

2. Failure mode is activated

3. Manual mode is activated

4. Calibration mode is activated

Failure Transfer of alarm 1 and alarm 2 occurs as:

Failure Transfer Setup:

1. O1FT

2. O2FT

3. A1FT

4. A2FT

Failure mode is activated

Output 2 failure transfer, if activated, will perform:

1. If COOL is selected for OUT2, 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 COOL is selected for OUT2, 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.

Alarm 1 failure transfer

is activated as the controller enters failure mode.

Thereafter, alarm 1 will transfer to the ON or OFF state preset by A1FT.

Exception:

If A1FN is configured for loop break (LB) alarm or sensor break (SENB) alarm, alarm 1 will be switched to ON state independent of the setting of A1FT. If A1FN is configured for dwell timer (TIMR), alarm 1 will not perform failure transfer.

Alarm 2 failure transfer

is activated as the controller enters failure mode.

Thereafter, alarm 2 will transfer to the ON or OFF state preset by A2FT.

Exception:

If A2FN is configured for loop break (LB) alarm or sensor break (SENB) alarm, alarm 2 will be switched to ON state independent of the setting of A2FT. If A2FN is configured for dwell timer (TIMR), alarm 2 will not perform failure transfer.

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3–18 Bumpless Transfer

The bumpless transfer function is available for output 1 and output 2 (provided that OUT2 is configured as COOL).

Bumpless transfer is enabled by selecting BPLS for O1FT and/or O2FT and activated as one of the following cases occurs:

1. Power starts (within 2.5 seconds).

2. The controller enters failure mode. See section 3-17 for failure mode descriptions.

3. The controller enters manual mode. See section 3-23 for manual mode descriptions.

4. The controller enters calibration mode. See chapter 6 for calibration mode descriptions.

As bumpless transfer is activated, the controller will transfer to open-loop control and uses the previous averaging value of MV1 and MV2 to continue control.

Bumpless transfer setup:

1. O1FT=BPLS

2. O2FT=BPLS

Bumpless transfer occurs as:

1. Power starts (within 2.5 seconds)

2. Failure mode is activated

3. Manual mode is activated

4. Calibration mode is activated

When bumpless transfer is configured, the correct control variable is applied immediately as power is recovered, and the disturbance is small. During sensor breaks, the controller continues to control by using its previous value. If the load doesn't change, the process will remain stable. If the load changes, the process may run away. Therefore, you should not rely on bumpless transfer for extended periods of time. For fail safe reasons, an additional alarm should be used to announce to the operator when the system fails. For example, a sensor break alarm, if configured, will switch to failure state and tell the operator to use manual control or take proper security action when the system enters failure mode.

Warning: After the system fails, never depend on bumpless transfer for a long time, or it might cause the system to run away.

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3–19 Self Tuning

Self-tuning, which was designed using an innovative algorithm, provides an alternate option for tuning the controller. It is activated when YES is selected for SELF. When self-tuning is working, the controller will change its working PID values and compare the process behavior to previous cycles. If the new PID values achieve better control, then it changes the next PID values in the same direction. Otherwise, it changes the next PID values in the reverse direction. When an optimal condition is obtained, the optimal PID values will be stored in PB1, TI1, and TD1, or PB2, TI2, and TD2, as determined by the event input conditions. See section 4-1. When self-tuning is completed, the value of SELF will change from YES to NONE to disable the self-tuning function.

When self-tuning is enabled, the control variables are tuned slowly so that the disturbance to the process is less than auto-tuning. Usually, self-tuning will perform successfully with no need to apply additional auto-tuning.

Exceptions:

conditions occurs:

1. NONE is selected for SELF.

2. The controller is used for on-off control, that is PB=0.

3. The controller is used for manual reset, that is TI=0.

4. The controller is in a loop break condition.

5. The controller is in failure mode (e.g., sensor break).

6. The controller is in manual control mode.

7. The controller is in sleep mode.

8. The controller is being calibrated.

If self-tuning is enabled, auto-tuning can still be used any time. Self-tuning will use the auto-tuning results for its initial values.

Benefits of self-tuning:

1. Unlike auto-tuning, self-tuning will produce less disturbance to the process.

2. Unlike auto-tuning, self-tuning doesn't change the control mode during the tuning period. It always performs PID control.

3. Changing the set point during self-tuning is allowable. Therefore, self-tuning can be used for ramping set point control as well as remote set point control where the set point is changed from time to time.

Operation:

The parameter SELF is contained in the setup menu. Refer to section 1-5 to find SELF for initiating self-tuning.

Self-tuning will be disabled as soon as one of the following

Benefits of self-tuning:

1. Less disturbance to the process.

2. Perform PID control during tuning period.

3. Available for ramping set point control and remote set point control.

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3–20 Auto tuning

The auto-tuning process is performed at the set point. The process will oscillate around the set point during the tuning process. Set the set point to 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. The system has been installed normally.

2. Use the default values for PID before tuning. The default values are: PB1=PB2=18.0° TI1=TI2=100 seconds, TD1=TD2=25.0 seconds. Of course, you can use other reasonable values for PID before tuning according to your previous experiences. But don't use a zero value for PB1 and TI1 or PB2 and TI2, otherwise, the auto-tuning program will be disabled.

3. 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.

4. Press until appears on the display.

5. Press for at least 3 seconds. The upper display will begin to flash and the auto-tuning procedure is beginning.

Applicable conditions:

PB1≠0, TI1≠0 if PB1,TI1,TD1 assigned

PB2≠0, TI2≠0, if PB2, TI2, TD2 assigned

NOTE:

Ramping function, remote set point, or pump function, if used, will be disabled once auto-tuning is proceeding.

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). See figure 3.22.

If auto-tuning begins apart from the set point (cold start), the unit enters warm-up cycle. As the process reaches the set point value, the unit enters a waiting cycle. The waiting cycle elapses for a double integral time (TI1 or TI2, dependent on the selection, see section 4.1), then it enters a learning cycle. The double integral time is introduced to allow the process to reach a stable state. Before the learning cycle, the unit performs a pre-tune function with PID control. While in the learning cycle, the unit performs a post-tune function with an ON-OFF control. The learning cycle is used to test the characteristics of the process. The data is measured and used to determine the optimal PID values. At the end of two successive ON-OFF cycles, the PID values are obtained and automatically stored in the nonvolatile memory.

Once the auto-tuning procedures are completed, the process display will cease to flash and the unit will revert to PID control using its new PID values.

During the pre-tune stage the PID values will be modified if any instability is caused by incorrect PID values is detected. Without the pre-tune stage, like other conventional controllers, the tuning result will be strongly related to the time when the auto-tuning is applied. Hence, different values will be obtained every time auto-tuning is completed without pre-tune.

Pre-tune function advantage:

Consistent tuning results can be obtained

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If auto-tuning begins near the set point (warm start), the unit skips the warm-up cycle and enters the waiting cycle. Afterward, the procedures are the same as described for cold start.

Auto-Tuning Error

If auto-tuning fails, an ATER message will appear on the upper 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;

• or if the event input state is changed so that the set point value is changed.

Solutions to

1. Try auto-tuning again.

2. Don't change the set point value during the auto-tuning procedure.

3. Don't change the event input state during the auto-tuning procedure.

4. Use manual tuning instead of auto-tuning. (See section 3-21)

5. Touch any key to reset message.

Auto-tuning error

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3–21 Manual Tuning

Figure 3.23 Manual Tuning Procedure

F ig ure 3.23 Ma nual Tuning P roc edure

In certain applications (very few), when using both self-tuning and auto-tuning to tune a process proves inadequate for the control requirements, you can try manual tuning. Connect the controller to the process and perform the procedures according to the flow chart shown in the following diagram.

The above procedure may take a long time before reaching a new steady state since the P band was changed. This is particularly true for a slow process. As a result, the above manual tuning procedures will take from minutes to hours to obtain optimal PID values.

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The PBu is called the ultimate P band, and the period of oscillation Tu is called the ultimate period in the flow chart in figure 3.23. When this occurs, the process is said to be in a critical steady state. figure 3.24 shows an example of a critical steady state.

If the control performance using above tuning is still unsatisfactory, the following rules can be applied for further adjustment of PID values:

figure 3.25 shows the effects of PID adjustment on process response.

Page 59

3–22 Signal Conditioner DC Power Supply

Three types of isolated DC power supplies are available to supply an external transmitter or sensor. These are 20V rated at 25mA, 12V rated at 40mA and 5V rated at 80mA. The DC voltage is delivered to the output 2 terminals.

Caution:

To avoid damage, don't use a DC power supply beyond its current rating. Purchase one with the correct voltage to suit your external devices. See the ordering code in section 1-2.

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3–23 Manual Control

Manual control may be used for the following purposes:

1. To test the process characteristics to obtain a step response as well as an impulse response and use these data for tuning a controller.

2. To use manual control instead of a closed-loop control if the sensor fails or the controller's A-D converter fails. can not be used for an extended time. See section 3-18.

3. In certain applications, it is desirable to supply a process with a constant demand.

Operation:

Press and release until (hand control) appears on the display. Press for 3 seconds, then release. The display will begin to flash and will show . The controller is now in manual control mode. Press ; the display will show and alternately where indicates output 1 (or heating) “on” time % and indicates output 2 (or cooling) “on” time %. Now you can use the up and down keys to adjust the percentage values for H or C. This percentage of “on” time is in relation to CYC1 for output 1 or CYC2 for output 2.

The controller performs open loop control as long as it stays in manual control mode. The H value is exported to output 1 (OUT1) and C value is exported to output 2 provided that OUT2 is performing cooling function (i.e., OUT2 selects COOL).

NOTE

that bumpless transfer

Means

MV1=38.4% for OUT1 (or heating)

Means

MV2=7.63% for OUT2 (or cooling)

Exception

If OUT1 is configured as ON-OFF control (i.e., PB1=0 if PB1 is assigned or PB2=0 if PB2 is assigned by event input), the controller will never perform manual control mode.

Exiting Manual Control

Press keys the and the controller will revert to its previous operating mode (may be a failure mode or normal control mode).

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3–24 Display Mode

PVHI PVLO MV1 MV2 DV PV1 PV2 PB TI TD CJCT PVR PVRH PVRL

Operation

Press several times until (display) appears on the display. Then press to enter display mode. You can select more parameters to view by pressing or pressing in reverse sequence. The system mode of the controller and its operation will remain unchanged. When the controller enters display mode the display will alternate between showing the display parameter and the parameter value.

PVHI/PVLO

upper display. The historical extreme values are saved in a nonvolatile memory even when it is unpowered. Press for at least 6 seconds to reset both the historical values PVHI and PVLO and begin to record new peak process values.

control value for output 2.

shows the difference value between process and set point (i.e., PV-SV). This value is used

to control output 1 and output 2.

PV1

shows the process value of input 1.

PV2

shows the process value of input 2.

shows the current proportional band value used for control.

shows the current integral time used for control.

shows the current derivative time used for control. Since the controller is performing

FUZZY

CJCT

used.

show the historical extreme (maximum or minimum) values of the process on the

shows the percentage control value for output 1, while shows the percentage

control, the values of PB, TI, and TD may change from time to time.

shows the temperature at the cold junction, measured in °C independent of the unit

PVR

Shows the changing rate of the process in °C (or °F or PU) per minute. It may be

negative if the process is going down.

PVRH/PVRL

measured in °C (or °F or PU) per minute. PVRH is a positive value while PVRL is a negative value.

The maximum and minimum changing rate of the process since power up, as

NOTE

The controller will never revert to its PV/SV display from display mode unless you press the keys.

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3–25 Heater Current Monitoring

TEC99999, a current transformer, can be equipped to measure the heater current. Select CT for IN2. The input 2 signal conditioner measures the heater current while the heater is powered and the current value will remain unchanged while the heater is unpowered. The PV2 will indicate the heater current. For information on how to read PV2 value, please refer to section 3-24. Alarms and other actions can then be set using heater current as a process value

NOTES

If the heater to be measured is controlled by output 1, then CYC1 should be set for 1 second or longer and O1TY should use RELY, SSRD, or SSR. Similarly, if the heater to be measured is controlled by output 2, then CYC2 should be set for 1 second or longer and O2TY should use RELY, SSRD, or SSR to provide an adequate time for the A to D converter to measure the signal.

Since TEC99999 can detect a full-wave AC current only, a DC or half-wave AC current can't be measured.

3–26 Reload Default Values

The default values listed in table 1.4 are stored in the memory when the product leaves the factory. On certain occasions, it is desirable to retain these values after the parameter values have been changed. Here is a convenient way to reload the default values.

Operation

Press several times until appears. Then press . The upper display will show .Use the up and down keys to select 0 or 1. If °C units are required, select 0 for FILE and if °F units are required, select 1 for FILE. Then press for at least 3 seconds. The display will flash for a moment while the default values are reloaded.

Accessory installed:

TEC99999

Setup

IN2=CT O1TY or O2TY=RELY, SSRD or SSR CYC1 or CYC2≥1 second

Limitations

1. Linear output type can't be used.

2. CYC1 (or CYC2) should be set for 1 second or longer to detect heater current reliably.

3. Only full-wave AC current can be detected.

FILE 0

°C default file

FILE 1

°F default file

CAUTION

The procedure mentioned above will change the previous setup data. Before performing it, make sure that it is really required.

Page 63

Chapter 4 Full Function Programming

4–1 Event Input

Refer to section 2-10 for wiring an event input. The event input accepts a digital type signal. Dry contacts or open collector pull low can be used to switch the event input.

One of ten functions can be chosen by using (EIFN) in the setup menu.

NONE:

If chosen, the event input function is disabled. The controller will use PB1, TI1, and TD1 for PID control and SP1 (or other values determined by SPMD) for the set point.

SP2:

PID2:

and TD1 for control.

SP.P2:

control.

NOTE:

the new PID values will be stored in PB2, TI2, and TD2.

RS.A1:

is still existent, alarm 1 will be retriggered when the event input is released.

RS.A2:

is still existent, alarm 2 will be retriggered when the event input is released.

R.A1.2:

alarm 1 and/or alarm 2 are still existent, alarm 1 and/or alarm 2 will be triggered again when the event input is released.

RS.A1, RS.A2, and R.A1.2 are particularly suitable to be used for latching and/or latching/holding alarms.

D.O1

Event input no function

If chosen, the SP2 will replace the role of SP1 for control.

If chosen, the second PID set PB2, TI2, and TD2 will be used to replace PB1, TI1,

If chosen, SP2, PB2, TI2, and TD2 will replace SP1, PB1, TI1, and TD1 for

If the second PID set is chosen during auto-tuning and/or self-tuning procedures,

Resets alarm 1 as the event input is activated. However, if the alarm 1 condition

Resets alarm 2 as the event input is activated. However, if the alarm 2 condition

Resets both alarm 1 and alarm 2 as the event input is activated. However, if

: Disables output 1 as the event input is activated.

Terminals:

EIFN

0 NONE 1 SP2 2 PID2 3 SP.P2 4 RS.A1 5 RS.A2 6 R.A1.2 7 D.O1 8 D.O2 9 D.O1.2 10 LOCK

D.O2:

Disables output 2 as the event input is activated.

D.O1.2:

When any of D.O1, D.O2, or D.O1.2 are selected for EIFN, output 1 and/or output 2 will revert to their normal conditions as soon as the event input is released.

LOCK:

for more details.

Disables both output 1 and output 2.

All parameters are locked to prevent them from being changed. See section 4-13

Page 64

SP2F Function:

in the setup menu, the event input function will use the SP2 value for its second set point. If DEVI is selected for SP2F, the SP1 value will be added to SP2. The sum of SP1 and SP2 (SP1+SP2) will be used by the event input function for the second set point value. In certain applications, it is desirable to move the second set point value with respect to the value of set point 1. The DEVI function for SP2 provides a convenient way to do this.

Modification from RS-232 to event input:

Defines the format of SP2 value. If ACTU is selected for SP2F

4–2 Second Set Point

In certain applications it is desirable to have the set point change automatically, without the need to adjust it. You can apply a signal to the event input terminals (pin 10 and pin 11). The signal applied to the event input may come from a

timer

for EIFN, which is in the setup menu. This is available only when SP1.2, MIN.R, or HR.R is used for SPMD, where MIN.R and HR.R are used for the ramping function. See section 4-4.

, a

PLC

alarm relay

, an

manual switch,

, a

or other devices. Select SP2

SP2F=Format of SP2 value

ACTU: SP2 is an actual value DEVI: SP2 is a deviation value

Application 1:

soon as its pressure exceeds a certain limit. Set SPMD=SP1.2, EIFN=SP2 (or SP.P2 if the second PID is required for the higher temperature too). The pressure gauge is switched ON as it senses a higher pressure. Connect the output contacts of the pressure gauge to the event input. SP1 is set for a normal temperature and SP2 is set for a higher temperature. Choose ACTU for SP2F.

Application 2:

6:00PM. After 6:00PM it should be maintained at 80°C. Use a programmable 24 hour cycle timer for this purpose. The timer output is used to control the event input. Set SPMD=SP1.2, and EIFN=SP2 (or SP.P2 if the second PID is required to be used for the second set point). SP1 is set at 300°C and SP2 is set at 80°C. Choose ACTU for SP2F. After 6:00PM the timer output is closed. The event input function will then select SP2 (=80°C) to control the process.

Refer to section 4-1 for more descriptions about SP2F function.

A process is required to be heated to a higher temperature as

An oven is required to be heated to 300°C from 8:00AM to

Page 65

4–3 Second PID Set

In certain applications the characteristics of a process are strongly related to its process value. The TEC-2500 provides two sets of PID values. When the process is changed to a different set point, the PID values can be switched to another set to achieve optimum conditions.

Auto-tuning second PID

The optimal PID values for a process may vary with its process value and set point. Hence if a process is used for a wide range of set points, dual PID values are necessary to optimize control performance. If the first PID set is selected (event input is not applied) during auto-tuning procedure, the PID values will be stored in PB1, TI1, and TD1. Similarly, if the second PID set is selected (event input is applied while PID2 or SP.P2 is selected for EIFN) during auto-tuning, the PID values will be stored in PB2, TI2, and TD2 as soon as auto-tuning is completed.

Application 1: programmed by the set point

Choose set simultaneously. The signal applied to the event input may come from a timer, a PLC, an alarm relay, a manual switch or other devices.

Application 2: programmed by the process value

If the process value exceeds a certain limit, 500°C for example, it is desirable to use another set of PID values to optimize control performance. You can use a process high alarm to detect the limit of the process value. Choose PV1H for A1FN, NORM for A1MD, adjust A1SP to be equal to 500°C, and choose PID2 for EIFN. If the temperature is higher than 500°C, then alarm 1 is activated. If the alarm 1 output is connected to the event input, the PID values will change from PB1, TI1, and TD1 to PB2, TI2, and TD2.

SP.P2

for

EIFN

then both set point and PID values will be switched to another

Apply signal to

Setup

EIFN choose PID2 or SP.P2

EIFN=SP.P2

EIFN=PID2

Alarm output controls the event input

Refer to section 5-9 for more details.

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4–4 Ramp and Dwell

Ramp

The ramping function is performed during power up as well as any time the set point is changed. Choose MINR or HRR for SPMD, and the unit will perform the ramping function. The ramp rate is programmed by using RAMP, which is found in the user menu.

Example without dwell timer

Select MINR for SPMD, °C for IN1U, 1-DP for DP1, and set RAMP=10.0. SP1 is set to 200°C initially, then 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 below:

Note:

When the ramp function is used, the display will show the current process value. However, it will revert to show the set point value as soon as the up or down key is pressed for adjustment. Setting RAMP to zero means no ramp function at all.

Dwell

The dwell timer can be used separately or in conjunction with a ramp. If A1FN is set for TIMR, alarm 1 will act as a dwell timer. Similarly, alarm 2 will act as a dwell timer if A2FN is set for TIMR. The timer is programmed by using TIME which is in the user menu. The timer starts to count as soon as the process reaches its set point, and triggers an alarm when it times out. Here is an example.

Example without ramp

Select TIMR for A1FN, °F for IN1U, NODP for DP1, and set TIME=30.0. SP1 is set to 400°F initially, and corrected to 200°F before the process reaches 200°F. As the process reaches the set point (i.e., 200°F), the timer starts to count. The TIME value can still be corrected without disturbing the the timer before time out. TIME is changed to 40.0 28 minutes after the process has reached its set point. The behavior of the process value and alarm 1 are shown below.

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Once the timer output is energized, it will remain unchanged until power down or an event input programmed for resetting the alarm is applied.

Note:

TIMR can't be chosen for A1FN and A2FN simultaneously, or an error code will

result.

Ramp and dwell

A ramp may be accompanied with a dwell timer to control the process. Here is an example.

Example with ramp and dwell

Select HRR for SPMD, PU for IN1U, 2-DP for DP1, and set RAMP=60.00. Select TIMR for A2FN and set TIME=20.0. When power is applied, the process value starts at 0.00, SP1=30.00, and SP2=40.00. The timer output is used to control event input.

Error code

4–5 Remote Set Point

Selecting PV1 or PV2 for SPMD will enable the TEC-2500 to accept a remote set point signal. If PV1 is selected for SPMD, the remote set point signal is sent to input 1, and input 2 is used for the process signal input. If PV2 is selected for SPMD, the remote set point signal is sent to input 2, and input 1 is used for the process signal. To achieve this, set the following parameters in the setup menu.

Case 1:

FUNC=FULL IN2, IN2U, DP2, IN2L, IN2H, are set according to remote signal. PVMD=PV1 IN1, IN1U, DP1, are set according to the process signal IN1L, IN1H if available, are set according to the process signal SPMD=PV2

Case 2:

FUNC=FULL IN1, IN1U, DP1, IN1L, IN1H, are set according to remote signal. PVMD=PV2 IN2, IN2U, DP2, are set according to the process signal IN2L, IN2H if available, are set according to the process signal SPMD=PV1

Use Input 2 to accept remote set point

Use Input 1 to accept remote set point

Setup

FUNC=FULL

SPMD=PV2, PVMD=PV1

SPMD=PV1, PVMD=PV2

Note 1: If PV1 is chosen for both SPMD and PVMD, an error code will appear. If

PV2 is chosen for both SPMD and PVMD, an error code will appear. In either case, the TEC-2500 will not control properly.

Note 2: If PV1/PV2 is selected for SPMD, a signal loss will result in the controller reverting

to manual mode with 0% output.

Error message

Page 68

4–6 Differential Control

In certain applications it is desirable to control a second process such that its process value always deviates from the first process by a constant value. To achieve this, set the following parameters in the setup menu.

FUNC=FULL IN1, IN1L, IN1H are set according to input 1 signal IN2, IN2L, IN2H are set according to input 2 signal IN1U, DP1, IN2U, DP2, are set according to input 1 and input 2 signal PVMD=P1-2 or P2-1 SPMD=SP1.2

The response of PV2 will be parallel to PV1 as shown in the following diagram

Setup

PVMD=P1-2

or PVMD=P2-1

SPMD=SP1.2

The PV display will indicate PV1-PV2 value if P1-2 is chosen for PVMD, or PV2-PV1 value if P2-1 is chosen for PVMD. If you need PV1 or PV2 to be displayed instead of PV, you can use the display mode to select PV1 or PV2 to be viewed. See section 3-24.

Error messages

If P1-2 or P2-1 is selected for PVMD, while PV1 or PV2 is selected for SPMD, an error code will appear. In this case the signals used for input 1 and input 2 should be the same unit and the same decimal point, that is, IN1U=IN2U, DP1=DP2, otherwise an error code will appear.

Error message

Page 69

4–7 Output Power Limits

In certain systems the heater (or cooler) is over-powered such that the process is too heavily heated or cooled. To avoid an excessive overshoot and/or undershoot you can use the power limit function. Output 1 power limit PL1 is contained in the user menu. If output 2 is not used for cooling (that is, COOL is not selected for OUT2), then PL2 is

hidden

Operation:

Press for 3 seconds, then press several times to reach PL1 and PL2. PL1 and PL2 are adjusted by using the up and down keys with range of 0–100%.

Example:

OUT2=COOL, PB1=10.0°C, CPB=50, PL1=50, PL2=80 Output 1 and output 2 will act as the following curves:

. If the controller is used for ON-OFF control, then both PL1 and PL2 are

hidden

PL1 PL2

NOTE:

The adjustment range of MV1 (H) and MV2 (C) for manual control and/or failure transfer are not limited by PL1 and PL2.

Page 70

4–8 Data Communication

RS-485 Terminals

12 13

TX1 TX2

RS-232 Terminals

12 13

TX1 TX2 COM

Two types of interfaces are available for data communication. These are the RS-485 and RS-232 interfaces. Since RS-485 uses a differential architecture to drive and sense signal instead of a single ended architecture which RS-232 uses, RS-485 is less sensitive to noise and more suitable for communication over longer distances. RS-485 can communicate without error over a distance of 1km while RS-232 is not recommended for distances over 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 TEC99927 or TEC99928) has to be used to convert RS-485 to RS-232 for a PC. 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.

Setup

Enter the setup menu. Select FULL (full function) for FUNC. Select 485 for COMM if RS-485 is required, or 232 if RS-232 is required. Select RTU (i.e., Modbus protocol RTU mode ) for PROT. 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 the PC setup conditions.

NOTE:

If the TEC-2500 is configured for RS-232 communication, the EI (event input) and input 2 are disconnected internally. The unit can no longer perform event input function (EIFN) or other input 2 functions.

RS-485 Benefits:

Long distance Multiple units

RS-232 Benefits:

Direct connection to a PC

RS-485 Setup

FUNC=FULL COMM=485 PROT=RTU ADDR=Address BAUD=Baud Rate DATA=Data Bit Count PARI=Parity Bit STOP=Stop Bit Count

RS-485 Terminals

When you attach an RS-232 module (TEC-102-103) to the connectors on the CPU board (C250), you also need to modify jumpers J51 and J52 according to section 2-16. If you use a conventional 9-pin RS-232 cable instead of TEC99014, the cable should be modified for the proper operation of RS-232 communications according to section 2-16.

RS-232 Setup

FUNC=FULL COMM=232 PROT=RTU ADDR=Address BAUD=Baud Rate DATA=Data Bit Count PARI=Parity Bit STOP=Stop Bit Count

RS-232 Terminals

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4–9 Analog Retransmission

Setup Menu

FUNC

COMM

AOFN

AOLO

AOHI

Ter minals

12 13

AO+ AO

Parameter Value

Output Signal

AOS

AOLO AOV AOHI

Formula: AOS = SL + (AOV – AOLO)

SH – SL

AOHI – AOLO

AOV = AOLO + (AOS – SL)

SH – SL

AOHI – AOLO

Figure 4.6 Conversion Curve for Retransmission

Analog retransmission is available for model number TEC-2500-XXXXXNX where N=3, 4 or 5. See ordering code in section 1-2.

Setup

Select FULL for FUNC in the setup menu. Select a correct output signal for COMM which should be accordant with the retransmission option used. Five types of retransmission output are available. These are: 4–20mA, 0–20mA, 0–5V, 1–5V and 0–10V. There are eight types of parameters that can be retransmitted according to the analog function (AOFN) selected. These are: PV1, PV2, PV1–PV2, PV2–PV1, SV, MV1, MV2 and PV–SV. Refer to table 1.4 for a complete description. Select a value for AOLO corresponding to output zero and select a value for AOHI corresponding to output SPAN.

How to determine output signal:

AOLO and AOHI are set to scale output signal low SL (e.g., 4mA) and output signal high SH (e.g., 20mA) respectively. The analog output signal AOS, corresponding to an arbitrary value of parameter AOV, is determined by the following curve.

Notes:

The setup values used for AOHI and AOLO must not be equal, otherwise, incorrect values will occur. However, AOHI can be set either higher or lower than AOLO. If AOHI is set higher than AOLO it could result in a direct conversion. If AOHI is set lower than AOLO it could result in a reverse conversion.

Example

A control uses a 4–20mA analog output to retransmit the difference value between input 1 and input 2 (PV1–PV2). It is required that if the difference value is -100, 4mA will be transmitted, and if the difference value is 100, 20mA will be transmitted. Make the following setup for TEC-2500: IN1U=PU, DP1=NODP, IN2U=PU, DP2=NODP, FUNC=FULL, COMM=4-20, AOFN=P1-2, AOLO=-100, AOHI=100

NOTES

AOHI≠AOLO AOHI>AOLO: Direct conversion

AOHI<AOLO: Reverse conversion

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4–10 Digital Filter

In certain applications the process value is too unstable to be read. A programmable low-pass filter incorporated in the TEC-2500 can be used to improve this. This is a first order filter with the time constant specified by the menu. The default value of FILT is set at 0.5 seconds. 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 by the following diagram.

Note

The filter is available only for PV1, 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.

FILT

parameter in the setup

FILT

Filter is used to stabilize the process display.

4–11 Sleep Mode

To enter sleep mode: Set FUNC for FULL to provide full function. Select YES for SLEP to enable sleep mode. Press for 3 seconds; the unit will now enter sleep mode. During sleep mode:

1. All displays are shut off except a decimal point which is lit periodically.

2. All outputs and alarms are shut off.

To exit sleep mode:

1. Press to leave the sleep mode.

2. Disconnect the power.

The sleep function can be used in place of a power switch to reduce the system cost.

Default:

Note:

SLEP to disable sleep mode.

SLEP=NONE, sleep mode is disabled.

If sleep mode is not required by your system, NONE should be selected for

Sleep mode features:

Shut off display Shut off outputs Green power Replaces power switch

Setup menu

FUNC=FULL SLEP=YES

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4–12 Pump Control

Pump control function is one of the unique features of the TEC-2500. Using this function, the pressure in a process can be excellently controlled. The pressure in a process is commonly generated by a pump driven by a variable speed motor. The complete system has the following characteristics which affect control behavior.

1. The system is very noisy.

2. The pressure changes very rapidly.

3. The pump characteristics are ultra nonlinear with respect to its speed.

4. The pump can't generate any more pressure if its speed is lower than half of its rating speed.

5. An ordinary pump may slowly lose pressure even if the valves are completely closed.

Obviously, a conventional controller can't fulfill the conditions mentioned above. Only the superior noise rejection capability in addition to the fast sampling rate possessed by the TEC-2500 can handle such an application. To achieve this, set the following parameters in the setup menu:

FUNC=FULL EIFN=NONE PVMD=PV1 FILT=0.5 SELF=NONE SPMD=PUMP SP2F=DEVI

and program the following parameters in the user menu

PUMP: A cost effective solution

Key menu

SPMD SP2F REFC SP2

REFC=reference constant SP2=a negative value added to SP1 to obtain the set point for the idle state

Since the pump can't produce any more pressure at lower speeds, the pump may not stop running even if the pressure has reached the set point. If this happens, the pump will be overly worn and waste additional power. To avoid this, the TEC-2500 provides a reference constant REFC in the user menu. If PUMP is selected for SPMD, the controller will periodically test the process by using this reference constant after the pressure has reached its set point. If the test shows that the pressure is still consumed by the process, the controller will continue to supply appropriate power to the pump. If the test shows that the pressure is not consumed by the process, the controller will gradually decrease the power to the pump until the pump stops running. When this happens, the controller enters an idle state. The idle state will use a lower set point which is obtained by adding SP2 to SP1 until the pressure falls below this set point. The idle state is provided for the purpose of preventing the pump from being restarted too frequently. The value of SP2 should be negative to ensure that the controller functions correctly.

The pump functions are summarized as follows:

1. If the process is demanding material (i.e., loses pressure), the controller will precisely control the pressure at the set point.

2. If the process no longer consumes material, the controller will shut off the pump for as long as possible.

3. The controller will restart the pump to control the pressure at the set point as soon as the material is demanded again when the pressure falls below a predetermined value (i.e., SP1+SP2).

Pump control features:

1. Minimum oscillation of pressure

2. Rapidly stabilized

3. Guaranteed pump stop

4. Programmable pump stopping interval

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Programming Guide for Pump Control:

1. Perform auto-tuning to the system under such conditions that the material (i.e., pressure) is exhausted at typical rate. A typical value for PB1 is about 10Kg/cm≈, TI1 is about 1 second, TD1 is about 0.2 seconds.

2. If the process oscillates around the set point after auto-tuning, then increase PB1 until the process can be stabilized at the set point. The typical value of PB1 is about half to two times the range of the pressure sensor.

3. Increasing FILT (filter) can further reduce the oscillation amplitude. But a value of FILT higher than 5 (seconds) is not recommended. A typical value for FILT is 0.5 or 1.

4. Close the valves and observe whether the controller can shut off the pump each time. The value of REFC should be adjusted as little as possible so that the controller can shut off the pump each time when all the valves are closed. A typical value for REFC is between 3 and 5.

5. An ordinary pump may slowly lose pressure even if the valves are completely closed. Adjust SP2 according to the rule that a more negative value of SP2 will allow the pump to be shut off for a longer time when the valves are closed. A typical value for SP2 is about -0.50Kg/cm≈.

An example for pump control is given in section 5-1.

4–13 Remote Lockout

The parameters can be locked to prevent them from being changed by using either

hardware lockout

parameters to be locked by using an external switch (remote lockout function), then connect a switch to terminals 10 and 11 (see section 2-10), and choose LOCK for EIFN (see section 4-1).

If remote lockout is configured, all parameters will be locked when the external switch is closed. When the switch is left open, the lockout condition is determined by internal DIP switch (hardware lockout, see section 1-3).

Hardware lockout: Remote lockout:

(see section 1-3),

Can be used only during initial setup.

Can be used any time.

remote lockout

, or

both

. If you need the

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Chapter 5 Applications

5–1 Pump/Pressure Control

Regulated water supply systems are widely used in residential areas, water plants, chemical plants, electrical plants, semiconductor plants, etc. By taking advantage of its PUMP function, the TEC-2500 can be used to create an economical yet versatile solution for these applications. Here is an example:

The water pressure in this example must be controlled at 10Kg/cm≈. To achieve this, the following devices are used for this example:

Inverter:

Motor:

Pump:

Pressure Sensor:

range.

Pressure Reservoir:

TEC-2500:

To supply a variable frequency AC voltage to the motor.

A 3- induction motor.

Any appropriate economical type of pump.

A three-wire or two-wire type of pressure transducer with a 0–20Kg/cm≈

Provides smoother pressure for the system.

Order a TEC-2500 with standard input, 4–20mA output 1, 20V DC output 2 for sensor power.

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Set the following parameters in the setup menu:

FUNC=FULL COMM: optional IN1=4-20 IN1U=PU DP1=2-DP IN1L=0 IN1H=20.00 IN2=NONE OUT1=REVR O1TY=4-20 O1FT=0 OUT2=DCPS A1FN: optional EIFN=NONE PVMD=PV1 FILT=1 SELF=NONE SLEP=NONE

SPMD=PUMP

SP1L=5.00 SP1H=15.00

SP2F=DEVI

Adjust the following parameters in the user menu:

A1SP: optional

REFC=3

PB1=10.00 TI1=1 TD1=0.2

SP2=-0.50

PL1=100

Refer to section 4-12 for more details.

Key menu:

SPMD SP2F REFC SP2

Page 77

5–2 Variable Period Full Wave SSR (VPFW SSR)

VPFW SSR is a variable period full wave solid-state relay. It can provide a zero cross output with superior controllability compared to a conventional SSR with a fixed time base. The block diagram of VPFW SSR is shown as follows:

Unlike a conventional SSR, the VPFW SSR always gives the output an even number of half cycles (full wave) as shown in the following diagram.

The VPFW switches the load without DC current, minimizing the harmonic current and stress on the load. This prolongs the load life.

Since the duty cycle (i.e., output power level) of the control input is small, the off-period will be extended to keep the output resolution such that the conversion error is minimized. As low as 0.1% timing error can be achieved. Hence, VPFW SSR is particularly suitable for smoother control.

NOTES:

1. The VPFW SSR can be used to drive a resistive load and some types of inductive loads such as relay, contactor, magnetic switch, solenoid valve, etc. However, it

2. Only

AC power

can supply a VPFW SSR, otherwise it will not operate properly.

can not drive motor or capacitive loads

Page 78

The advantages of VPFW SSR over conventional SSR are summarized in the following table:

Output 1 and output 2 of the TEC-2500 can be connected to the VPFW SSR directly provided that a pulsed voltage drive output is ordered.

Here is an example:

Three phase VPFW SSR's are also available upon request.

Page 79

5–3 Heat Only Control

An oven is designed to dry the products at 150°C for 30 minutes and then stay unpowered for another batch. A TEC2500 equipped with

dwell timer

is used for this purpose. The system diagram is shown as follows:

To achieve this function, set the following parameters in the setup menu.

FUNC=BASC (basic function) IN1=K_TC IN1U=°C DP1=1_DP OUT1=REVR O1TY=RELY CYC1=18.0 O1FT=0.0 A2FN=TIMR A2FT=ON SELF=NONE

Auto-tuning is performed at 150°C for a new oven.

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5–4 Cool Only Control

A TEC-2500 is used to control a refrigerator with the temperature below 0°C. To avoid set point adjustment beyond the desired range, SP1L is set at -10°C and SP1H is set at 0°C. Because the temperature is lower than the ambient, a cooling action is required, so select DIRT for OUT1. Since output 1 is used to drive a magnetic contactor, select RELY for O1TY. Because a small temperature oscillation is tolerable, use ON-OFF control to reduce the over-all cost. To achieve ON-OFF control, PB1 is set to zero and O1HY is set at 0.1°C.

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5–5 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:

PID heat-cool is used for the above example. To achieve this, set the following parameters in the setup menu:

FUNC=BASC IN1=PT.DN IN1U=°C DP1=1-DP OUT1=REVR O1TY=RELY CYC1=18.0 (seconds) O1FT=0.0 OUT2=COOL O2TY=4–20 O2FT=0.0 SELF=YES

Adjust SP1 to 120.0°C, CPB to 125 (%) and DB to -4.0 (%).

Apply auto-tuning at 120°C for a new system to get optimal PID values. See section 3-20.

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 (%).

Adjustment of DB is dependent on the system requirements. A more positive value of DB will prevent unwanted cooling action, but will increase the temperature overshoot, while a more negative value of DB will achieve less temperature overshoot, but will increase unwanted cooling action.

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5–6 Ramp and Dwell

Example 1: Temperature cycling chamber

A chamber is used to test the temperature cycling effect on personal computers. An external cycle timer is used to control the event input for switching the set point. The products under test are required to stay at 60°C for 1 hour and -10°C for 30 minutes. The transition interval between the high and low temperatures is required to be 5 minutes. Make the following setup:

EIFN=SP.P2 A1FN=TIMR OUT1=REVR, relay output OUT2=COOL, 4–20mA output SPMD=MINR IN1U=°C DP1=1-DP

The circuit diagram and its temperature profile are shown below:

Page 83

The TEC-2500 provides a 4–20mA signal to control the speed of the inverter. SP.P2 is chosen for EIFN in order to create a dual PID control. You can perform auto-tuning twice at SP1 and SP2 for the initial setup for the dual PID values. Refer to sections 3-20 and 4-3.

Example 2: Programmable bread baking oven

Bread is baked in batches. A ramp is incorporated to control the thermal gradient to suit for making the bread. A dwell timer is used to shut off the oven power and announce this to the baker. The system is configured as shown in the following diagram.

Push the ON switch to start a batch. The temperature will rise with a ramp rate determined by the RAMP value. The bread is baked with the set point temperature for a predetermined amount of time which is set in the TIME value, and then the power is shut off. The temperature profile is shown in the following figure.

Page 84

5–7 Remote Set Point

An on-line multiple zone oven is used to dry paint. Since heat demand varies at different positions in the production line, multiple zones with individual controls should be used to ensure a consistent temperature profile. If you order a TEC2500 with a retransmission unit for the master controller, and retransmit its set point to input 2 on the rest of the slave controllers, each zone will be synchronized with the same temperature. Here is an example:

Set the following parameters in the setup menu:

For the master unit For the slave units

FUNC=FULL FUNC=FULL COMM=1–5V IN2=1–5V AOLO=0°C IN2L=0°C AOHI=300°C IN2H=300°C PVMD=PV1 PVMD=PV1 SPMD=SP1.2 SPMD=PV2

Note:

AOHI and IN2H should be set with values higher than the set point range used.

Page 85

5–8 Differential Control

OutletOutlet

From Controller OutputFrom Controller Output

4-20 mA Valve Control Output4-20 mA Valve Control Output

Water Tank 1Water Tank 1

Water Tank 2Water Tank 2

Level Sensor 1Level Sensor 1

Level Sensor 2Level Sensor 2

5.12 M Height5.12 M Height

4.12 M Height4.12 M Height

IN1IN1 IN2IN2

SV=1.00 PV=1.00 PV1=5.12 PV2=4.12

OUT1OUT1

-2500

TE C

Figure 5.13 Differential Control Example

In certain applications it is desirable to control a second process so that its process value always deviates from the first process value by a constant amount. Water tank 1 is 5.12 meters in height, and the level in water tank 2 needs to be maintained at 1 meter lower than the tank 1 level.

Set the following parameters in the setup menu:

FUNC=FULL IN1, IN1L, IN1H: According to sensor 1 signal IN1U=PU DP1=2-DP IN2, IN2L, IN2H: According to sensor 2 signal (current signal has to be converted to a voltage signal through a shunt

resistor before sending to the controller input) IN2U=PU DP2=2-DP OUT1=REVR O1TY=4–20 PVMD=P1-2 SPMD=SP1.2

Adjust SP1(here it is 1.00) to control the difference between PV1 and PV2. Choose P1-2 for PVMD; the PV display will show the difference value (PV1-PV2) between PV1 and PV2, and this value will be stabilized to the set point (here it is

1.00). If you need PV1 or PV2 instead of PV, you can use the display mode to select PV1 or PV2 for display. See section 3-24. The above diagram indicates PV2 instead of PV.

Page 86

5–9 Dual Set Point/PID

The TEC-2500 will switch between the two PID sets based on the process value, the set point, or either of the event inputs. As the control ramps up to the higher process value, the process characteristics change. When this happens, the original PID values are no longer valid. To achieve optimal control over the entire range, a second PID set is used.

Example 1: Single set point/dual PID

A heat treating furnace is used over the range of 400°C to 1200°C.

1. Set the following parameters in the setup menu: FUNC=FULL A1FN=PV1H A1MD=NORM EIFN=PID2 PVMD=PV1 SPMD=MINR

2. Adjust the following parameters in the user menu: A1SP=800°C A1HY=1.0°C PL1=100(%) RAMP: According to the process requirement SP1: According to the process requirement

3. Tune the first PID set at SP1=50°C and tune the second PID set at SP1=1100°C, or set the proper values for PB1,

TI1, TD1, PB2, TI2, and TD2 directly according to previous records to eliminate the auto-tuning sequence.

The circuit diagram and its temperature profile are shown as follows:

Page 87

Example 2: Dual set point/PID

A heat treating furnace is required to harden the mold at a high temperature (1000°C) for 30 minutes, then the mold is cooled down with a programmable ramp (20°C/minute) to a lower set point (200°C). Use the dual set point/PID and ramp/dwell functions for this application.

1. Set the following parameters in the setup menu: FUNC=FULL A1FN=TIMR EIFN=SP.P2 PVMD=PV1 SPMD=MINR

2. Adjust the following parameters in the user menu: TIME=30.0 (minutes) RAMP=20.0 (°C/minute) SP1=1000°C SP2=200°C PL1=100(%)

3. Set the proper values for PB1, TI1, TD1, PB2, TI2, and TD2 directly according to previous records. For a new

system, tune the first PID set at SP1=800°C and tune the second PID set at SP2=400°C.

The circuit diagram is the same as shown in figure 5.14. The temperature profile is shown below:

Page 88

5–10 RS-485

Twisted-pair wire, max. distance 1 KmTwisted-pair wire, max. distance 1 Km

A tile making plant has five production lines. Each production line is equipped with 16 TEC-2500 units to control the temperature for the kiln. They want to program the controllers and monitor the process from the control room to improve quality and productivity. A cost-effective solution for the above application would be to use 80 TEC-2500 units plus an TEC99014 smart network adapter and BC-Net PC-based software for this purpose.

The system is installed as shown in the following diagram.

Setup

Enter setup mode to configure each TEC-2500. Choose FULL for FUNC, 485 for COMM, RTU for PROT, and select a different address (ADDR) for each unit. Use the same values of BAUD, DATA, PARI, and STOP for the TEC-2500's, SNA10B and BC-Net. Also refer to section 2-15 and section 4-8.

Taking advantage of BC-Net software, the operator can monitor the process on the PC screen, program the set point as well as other control parameters such as PID values, download the ramp and soak profile to the controllers, execute the manual control or trigger auto-tuning, etc., and print out reports as required. The historical data can be saved in the floppy drive, hard drive, or on a CD for permanent storage.

Setup menu

FUNC

COMM

PROT ADDR BAUD

DATA

PARI

STOP

Page 89

5–11 RS-232

Suppose a chemical experiment is performed in a laboratory, and an engineer wants to find the relationship between the chemical reaction and temperature. He uses a TEC-2500 to control the temperature of the solution being tested. He is particularly interested in generating a test report containing the relationship between the concentration and temperature.

For a single unit application, it is adequate to order a TEC-2500 with RS-232 communication and BC-Net software. Using the BC-Net software, the temperature data can be viewed and stored in a file. The user can program the temperature as well as other control parameters such as PID values. He can set up the controller, download a ramp and soak profile, execute manual control or auto-tuning procedure, etc. The results can be printed out or stored in a file for future reference.

Refer to section 2-16 for installation and section 4-8 for setup procedure.

Setup menu

FUNC

COMM

PROT ADDR BAUD

DATA

PARI

STOP

Page 90

5–12 Retransmit

An air-conditioned room uses two TEC-2500 units to control the temperature and humidity. The temperature and humidity must be recorded on a chart recorder. The preferred ranges for these two parameters are: 20°C to 30°C and 40% RH to 60% RH. The recorder inputs accept a 0–5V signal.

To achieve this, set the following parameters in the setup menu.

UNIT 1: UNIT 2:

FUNC=FULL FUNC=FULL COM=0–5V COMM=0–5V AOFN=PV1 AOFN=PV1 AOLO=20.0(°C) AOLO=40.0(%) AOHI=30.0(°C) AOHI=60.0(%) IN1=PTDN IN1=0–1V (according to humidity sensor) IN1U=°C IN1U=PU DP1=1-DP DP1=1-DP

SP1L and SP1H are used to limit the adjustment range of the set point.

Page 91

Chapter 6 Calibration

Do not proceed through this section unless there is a definite need to recalibrate the controller. If you do 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 5520A 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 (SW6400, optional for automatic calibration)

4. A calibration fixture equipped with programming units ( optional for automatic calibration)

5. A PC installed with calibration software, BC-Net, and smart network adapter SNA10B (optional for automatic

calibration)

The calibration procedures described in the following section are step by step manual procedures.

Since it takes 30 minutes to warm up a unit before calibration, calibrating the units one by one is quite inefficient. An automatic calibration system for small quantities as well as one for unlimited quantities is available upon request.

Manual calibration procedures

• Perform step 1 to enter calibration mode.

Step 1

Set the lockout DIP switch to the unlocked condition (both switches 3 and 4 are off).

Press both scroll and down keys and release them quickly. The operation mode menu will appear on the display. Repeat this operation several times until appears on the display. Press the scroll key for at least 3 seconds. The display will show and the unit will enter calibration mode. Output 1 and output 2 use their failure transfer values to control.

• Perform step 2 to calibrate zero for the A to D converter and step 3 to calibrate the gain for the

A to D converter. The DIP switch should be set for T/C input.

Step 2

Short terminals 10 and 11, then press the scroll key for at least 3 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 -360 or 360, then calibration failed.

Step 3

Press the scroll key until the display shows . Send a 60mV signal to terminals 10 and 11 with the correct polarity. Press the scroll key for at least 3 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.

• Perform step 4 to calibrate the voltage function (if required) for input 1.

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Step 4.

1234

DIP Switch Position

RTD Input

Set the DIP switch for voltage input. Press the scroll key until the display shows . Send a 10V signal to terminals 10 and 11 with the correct polarity. Press the scroll key for at least 3 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.

• Perform both steps 5 and 6 to calibrate RTD function (if required) for input 1.

Step 5.

Set the DIP switch for RTD input. Press the scroll key until the display shows . Send a 100 ohms signal to terminals 8, 9, and 10 using to the connection shown below:

Press the scroll key for at least 3 seconds. The display will blink for a moment; if it does not, calibration failed.

Step 6.

Press the scroll key and the display will show . Change the ohm's value to 300 ohms. Press the scroll key for at least 3 seconds. The display will blink for a moment while values are obtained for SR1 and REF1 (last step). If the display didn't blink or if any value obtained for SR1 or REF1 is equal to -199.9 or 199.9, then calibration failed.

• Perform step 7 to calibrate mA function (if required) for input 1.

Step 7.

Set the DIP switch for mA input. Press the scroll key until the display shows . Send a 20mA signal to terminals 9 and 10 with the correct polarity. Press the scroll key for at least 3 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.

• Perform step 8 to calibrate voltage as well as CT function (if required) for input 2.

Step 8.

Press the scroll key until the display shows . Send a 10V signal to terminals 10 and 11 with the correct polarity. Press the scroll key for at least 3 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.

• Perform step 9 to calibrate offset of cold junction compensation, if required. Set the DIP switch for T/C input.

• Perform step 10 to calibrate the gain of cold junction compensation if required. If a test chamber for calibration is not available, perform step 10N to use a nominal value for the cold junction gain.

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Step 9.

Set up the equipment according to the following diagram to calibrate the cold junction compensation. Note that a K type thermocouple must be used.

The 5520A calibrator is configured for 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 a temperature of 25±3°C. Allow at least 20 minutes to warm up. The DIP switch is located at the TC input. Perform step 1 as stated above, then press the scroll key until the display shows . Press the up and down keys until a value of 0.00 is obtained. Press the scroll key at least 3 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.

calibration mode. Output 1 and output 2 use their failure transfer values to control.

• Perform step 2 to calibrate zero for the A to D converter and step 3 to calibrate the gain for the A to D converter. The DIP switch should be set for T/C input.

Step 10.

Set up the equipment the same as in step 9. The unit under calibration is powered in a still-air room with a temperature of 50±3°C. Allow at least 20 minutes to warm up. The calibrator source is set at 0.00°C with internal compensation mode.

Perform step 1 as stated above, then press the scroll key until the display shows . Press the up and down keys until a value of 0.0 is obtained. Press the scroll key for at least 3 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.

Step 10N.

Perform step 1 as stated above, then press the scroll key until the display shows . Press the up and down keys until a value of 0.1 is obtained. Press the scroll key for at least 3 seconds. The display will blink for a moment until the new value 0.0 is obtained. Otherwise, calibration failed.

Caution:

using this step.

• Final step

Step 11.

Set the DIP switch to your desired position (refer to section 1-3).

not recommended

It is

to use step 10N, since the cold junction gain is not able to achieve the rated accuracy

Automatic calibration procedures

The programming port (see section 2-18) of the TEC-2500 can be used for automatic calibration. The equipment required for automatic calibration is available upon request.

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NOTES

Page 95

Chapter 7 Error Codes and Troubleshooting

This procedure requires access to the circuitry of a unit under live power. Accidental contact with line voltage is possible. Only qualified personnel should perform these procedures. Potentially lethal voltages are present.

Troubleshooting procedures:

1. If an error message is displayed, refer to table 7.1 to see what caused it and what action to take to correct the

problem.

2. Check each point listed below. Experience has proven that many control problems are caused by a defective

instrument.

• Line wires are improperly connected

• No voltage between line terminals

• Incorrect voltage between line terminals

• Connections to terminals are open, missing, or loose

• Thermocouple is open at tip

• Thermocouple lead is broken

• Shorted thermocouple leads

• Short across terminals

• Open or shorted heater circuit

• Open coil in external contactor

• Burned out line fuses

• Burned out relay inside control

• Defective solid-state relays

• Defective line switches

• Burned out contactor

• Defective circuit breakers

3. If the points listed on the above chart have been checked and the controller still does not function properly, it is

recommended that the instrument be returned to the factory for inspection. Do not attempt to make repairs without a qualified engineer and proper technical information, as damage may result. It is also recommended to use adequate packing materials to prevent damage during transportation.

4. Dismantle the controller according to figure 7.1. Refer to table 7.2 for some probable causes and actions.

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929394

Page 97

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NOTES

Page 99

Chapter 8 Specifications

Power

90–264VAC, 47–63Hz, 15VA, 7W maximum 11–26 VAC/VDC, 15VA, 7W maximum

Input 1 resolution: Sampling rate: Maximum rating:

Temperature effect:

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): Normal mode rejection ratio (NMRR): Sensor break detection:

Sensor open for TC, RTD, and mV inputs, 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.

Characteristics:

18 bits

5x/second

-2VDC minimum, 12VDC maximum (1 minute for mA input)

±1.5uV/°C for all inputs except mA input ±3.0uV/°C for mA input

120dB

55dB

Input 2 Resolution: Sampling rate: Maximum rating: Temperature effect: Common mode rejection ratio (CMRR): Sensor break detection:

below 0.25V for 1–5V input, unavailable for other inputs.

Sensor break responding time: Characteristics:

Input 3 (event input ) Logic low: Logic high: External pull-down resistance: External pull-up resistance: Functions:

alarm 1 and/or alarm 2, disable output 1 and/or output 2, remote lockout.

Output 1/Output 2

Relay rating:

resistive load

Pulsed voltage:

resistance 66Ω.

Linear output characteristics:

18 bits

1.66x/second

-2VDC minimum, 12VDC maximum ±1.5uV/°C

120dB

0.5 seconds

-10V minimum, 0.28V maximum. open or 0.32V minimum, 10V maximum

200KΩ maximum

not necessary

select second set point and/or PID, reset

2A/240 VAC, life cycles 200,000 for

source voltage 5V, current limiting

Linear Output Resolution: Output regulation: Output settling time: Isolation breakdown voltage: Temperature effect:

15 bits

0.01% for full load change

0.1 second (stable to 99.9%) 1000VAC

±0.0025% of SPAN/°C

Page 100

Triac (SSR) Output Rating : Inrush Current : Min. Load Current : Max. Off-state Leakage : Max. On-state Voltage : Insulation Resistance : Dielectric Strength :

DC voltage supply characteristics (installed at output 2)

Alarm 1/Alarm 2 Alarm 1:

Alarm 2 relay:

Alarm functions:

Alarm mode: Dwell timer:

Data Communication Interface: Protocol: Address: Baud Rate: Data Bits: Parity Bit: Stop Bit: Communication Buffer:

Analog Retransmission Functions:

Output Signal: Resolution: Accuracy: Load Resistance:

Output Regulation: Output Settling Time: Isolation Breakdown Voltage: Integral linearity error: Temperature effect:

1A/240VAC

20A for 1 cycle

50mA rms

3mA rms

1.5V rms

1000Mohms min. at 500VDC

2500VAC for 1 minute

5V DC logic output, max. source current 100mA,

short circuit unprotected.

Form A, max. rating 2A/240VAC,

200,000 life cycles for resistive load.

Dwell timer, Deviation high/low alarm, Deviation band high/low alarm, PV1 high/low alarm, PV2 high/low alarm, PV1 or PV2 high/low alarm, PV1-PV2 high/low alarm, Loop break alarm, Sensor break alarm.

Normal, latching, hold, latching/hold.

0–6553.5 minutes

RS-232 (1 unit), RS-485 (up to 247 units) Modbus protocol RTU mode 1–247

0.3~38.4Kbits/sec

7 or 8 bits

None, even or odd

1 or 2 bits

50 bytes

PV1, PV2, PV1-PV2, PV2-PV1, set point,

MV1, MV2, PV-SV deviation value

4–20mA, 0–20mA, 0–1V, 0–5V, 1–5V, 0–10V

15 bits

±0.05% of span ±0.0025%/°C

0–500ohms (for current output)

10Kohms minimum (for voltage output)

0.01% for full load change

0.1 sec. (stable to 99.9%) 1000VAC min.

±0.005% of span

±0.0025% of span/°C

Saturation low: Saturation high: Linear output range:

0–5.55V (0–5V, 1–5V), 0–11.1V (0–10V)

User Interface Dual 4-digit LED displays: Keypad: Programming port: Communication port:

Control Mode Output 1: Output 2: ON-OFF: P or PD: PID:

Cycle time: Manual control: Auto-tuning: Self-tuning: Failure mode:

Sleep mode: Ramping control: Power limit: Pump/pressure control: Remote set point:

Differential control:

Digital Filter Function: Time constant:

Environmental and Physical Operating temperature: Storage temperature: Humidity: Insulation resistance: Dielectric strength: Vibration resistance: Shock resistance: Moldings: Dimensions:

Weight:

Approval Standards Safety:

Protective class:

EMC:

3 keys

0.1–100.0(°F) hysteresis control (P band=0)

0–100.0% offset adjustment

Fuzzy logic modified Proportional band 0.1~900.0°F Integral time 0–1000 seconds Derivative time 0–360.0 seconds

break or A-D converter damage

current input

programmable

98.0mm depth behind panel

120 grams

UL873 (11th edition, 1994), CSA C22.2 No. 24-93,

EN61010-1 (IEC1010-1)

IP 20 housing and terminals

EN61326

0mA (or 0V)

22.2mA (or 5.55V, 11.1V min.) 0–22.2mA(0–20mA or 4–20mA),

Upper 0.4" (10mm), lower 0.3" (8mm)

For automatic setup, calibration, and testing

Connection to PC for supervisory control

Reverse (heating) or direct (cooling) action

PID cooling control, cooling P band 1~255% of PB

0.1–100.0 seconds Heat (MV1) and cool (MV2)

Cold start and warm start

Select NONE or YES

Auto-transfer to manual mode while sensor

Enable or disable

0–900.0°F/minute or 0–900.0°F/hour ramp rate

0–100% output 1 and output 2

Sophisticated functions provided

Programmable range for voltage or

Control PV1-PV2 at set point

First order

0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60 seconds

-10°C to 50°C

-40°C to 60°C

0 to 90% RH (non-condensing)

20Mohms min. (at 500VDC)

2000VAC, 50/60Hz for 1 minute

10–55Hz, 10m/s for 2 hours

200m/s (20g)

Flame retardant polycarbonate

50mm(W)X26.5mm(H)X110.5mm(D),

NEMA 4X (IP65) front panel, indoor use,