Tempco TEC-9300 Instruction Manual

Page 1

Instruction Manual

TEC-9300 Self-Tune Fuzzy / PID Process Temperature Controller

Serving Industry Since 1972

Agency Approvals: RoHS

TEMPCO Electric Heater Corporation 607 N. Central Avenue • Wood Dale, IL 60191-1452 USA Tel: 630-350-2252 • Toll Free: 800-323-6859 Fax: 630-350-0232 • E-mail: [email protected] Web: www.tempco.com

Manual TEC-9300 Revision 9/2016

Page 2

NOTES

Page 3

Warning Symbol

This symbol calls attention to an operating procedure, practice, or the like which, if not correctly performed or adhered to, could result in personal injury or damage to or destruction of part or all of the product and system. Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met.

Using the Manual

Installers . . . . . . . . . . . . . . . . . . . . . . . . . . . Read 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 8

CONTENTS

Chapter 1 - Overview

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

1-2 Hardware Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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

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

1-5 Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1-6 System Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-7 Parameter Description . . . . . . . . . . . . . . . . . . . . . . . . . 8

Page No

Chapter 2 - Installation

2-1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2-2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2-3 Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

2-4 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2-5 Sensor Installation Guidelines . . . . . . . . . . . . . . . . . . . 16

2-6 Thermocouple Input Wiring . . . . . . . . . . . . . . . . . . . . 16

2-7 RTD Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2-8 Linear DC Input Wiring . . . . . . . . . . . . . . . . . . . . . . . 17

2-9 CT/Heater Current Input Wiring . . . . . . . . . . . . . . . . . 18

2-10 Event Input wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2-11 Output 1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2-12 Output 2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2-13 Alarm 1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2-14 Alarm 2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2-15 RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2-16 RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2-17 Analog Retransmission . . . . . . . . . . . . . . . . . . . . . . . 24

Chapter 3 - Programming Basic Functions

3-1 Input 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3-2 OUT1 and OUT2 Types . . . . . . . . . . . . . . . . . . . . . . . 26

3-3 Configuring User Menu . . . . . . . . . . . . . . . . . . . . . . . . 26

3-4 Heat Only Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3-5 Cool Only Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3-6 Heat-Cool Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3-7 Dwell Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3-8 Process Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3-9 Deviation Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3-10 Deviation Band Alarms . . . . . . . . . . . . . . . . . . . . . . . 32

3-11 Heater Break Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3-12 Loop Break Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3-13 Sensor Break Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 34

3-14 SP1 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3-15 PV1 Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3-16 Failure Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3-17 Bumpless Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3-18 Self-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3-19 Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3-20 Manual Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3-21 Signal Conditioner DC Power Supply . . . . . . . . . . . 39

3-22 Manual Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3-23 Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3-24 Heater Current Monitoring . . . . . . . . . . . . . . . . . . . . 40

3-25 Reload Default Values . . . . . . . . . . . . . . . . . . . . . . . . 40

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 © 2016, 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

Page No

Chapter 4 - Full Function Programming

4-1 Event Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4-2 Second Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4-3 Second PID Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4-4 Ramp and Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4-5 Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4-6 Differential Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4-7 Output Power Limits . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4-8 Data Communication . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4-9 Analog Retransmission . . . . . . . . . . . . . . . . . . . . . . . . 45

4-10 Digital Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4-11 Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4-12 Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4-13 Remote Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Chapter 5 - Applications

5-1 Pump/Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . 47

5-2 Variable Period Full Wave SSR (VPFW SSR) . . . . . . 47

5-3 Heat Only Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5-4 Cool Only Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5-5 Heat-Cool Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5-6 Ramp and Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5-7 Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5-8 Differential Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5-9 Dual Set Point/PID . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5-10 RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5-11 RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5-12 Retransmit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Chapter 6 - Calibration . . . . . . . . . . . . . . . . . . . . 55

Chapter 7 - Error Codes and

Troubleshooting

. . . . . . . . . . . . . . 57

Chapter 8 - Specifications. . . . . . . . . . . . . . . . . 61

Chapter 9 - Modbus Communications . . . 63

Appendix

A-1 Menu Existence Conditions . . . . . . . . . . . . . . . . . . . . 77

A-2 Factory Menu Description . . . . . . . . . . . . . . . . . . . . . 80

A-3 Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

A-4 Memo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

A-5 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Page 4

NOTES

Page 5

Chapter 1 Overview

__+_

++++

Figure 1.1 Fuzzy PID System Block

PID

+ FUZZY CONTROL

1–1 Features

** High accuracy 18-bit input

A–D

** High accuracy 15-bit out-

put D–A

** Fast input sample rate (5

times/second)

** Two function complexity

levels ** User menu configurable ** Pump control * Fuzzy plus PID micro-

** Unique * Valuable

* Automatic programming * Differential control * Auto-tune function * Self-tune function * Sleep mode function * “Soft-start” ramp and dwell

timer

* Programmable inputs (ther-

mocouple, RTD, mA, VDC)

* Analog input for remote set

point and CT

processor-based control

TEC-9300 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 1/16 DIN case, measuring 48mm x 48mm with 75mm 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-9300 is powered by 11–26VAC/VDC or 90–264VAC supply, incorporating a 2 amp control relay output and dual 2 amp alarm relay outputs 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-9300 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-9300 to control fast processes such as pressure and flow.

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.

Digital communications formats RS-485, RS-232 or 4–20mA retransmission are available as an additional option. These options allow the TEC-9300 to be integrated with supervisory control systems and software, or alternatively to drive remote displays, chart recorders, or data loggers.

* Event input for changing

function and set point * Programmable digital filter * Hardware lockout and

remote lockout protection * Loop break alarm * Heater break alarm * Sensor break alarm and

bumpless transfer

* 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

* RS-485, RS-232 communi-

cation

Two different methods can be used to program the TEC-9300.

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

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

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 change and/or load disturbance circumstances, 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 be variable from time to time. In order to overcome the imperfections of PID control, Fuzzy Technology 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 the numerical PID control. It controls the system by experience and does not need to simulate the system precisely as a PID controller would.

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 at left:

Page 6

1–2 Hardware Code

Example

Communications

Alarm 1

Output 2 / Alarm 2

Output 1

Signal Input

Power Input

4: 90 - 264 VAC, 50/60 HZ 5: 11 - 26 VAC or VDC 9: Special Order

0: None 1: RS-485 2: RS-232 3: Retransmit 4-20mA/0-20mA 4: Retransmit 1 - 5V / 0 - 5V 5: Retransmit 0 - 10V 9: Special order

1: Standard Input Input 1 - Universal Input Thermocouple: J, K, T, E, B, R, S, N, L RTD: PT100 DIN, PT100 JIS Current: 4 - 20mA, 0 - 20 mA. Voltage: 0 - 1V, 0 - 5V, 1 - 5V, 0 - 10V Input 2 - CT and Analog Input

***

CT: 0 - 50 Amp. AC Current Transformer Analog Input: 4 - 20 mA, 0 - 20mA, 0 - 1V, 0 - 5V, 1 - 5V, 0 - 10V. Input 3 - Event Input ( EI ) 9: Special Order

1: Relay rated 2A/240VAC 2: Pulsed voltage to drive SSR, 5V/30mA 3: Isolated 4 - 20mA / 0 - 20mA 4: Isolated 1 - 5V / 0 - 5V 5: Isolated 0 - 10V 6: Triac Output 1A / 240VAC, SSR C: Pulsed voltage to

drive SSR, 14V/40mA 9: Special order

9: Special order

2A / 240VAC

2: Form B Relay

2A / 240VAC

1: Form A Relay

0: None

1 2

3 4

0: None 1: Form A Relay 2A/240VAC 2: Pulsed voltage to drive SSR, 5V / 30mA 3: Isolated 4 - 20mA / 0 - 20mA 4: Isolated 1 - 5V / 0 - 5V 5: Isolated 0 - 10V 6: Triac Output, 1A / 240VAC, SSR 7: Isolated 20V / 25mA DC Output Power Supply 8: Isolated 12V / 40 mA DC Output Power Supply 9: Isolated 5V / 80mA DC Output Power Supply

TEC-9300-411111 90 - 264 operating voltage Input: Standard Input Output 1: Relay Output 2: Relay Alarm 1: Form A Relay RS-485 Communication Interface

Range set by front keyboard

Alternative between RS-232 and EI

Need to order an accessory TEC99999 if Heater Break detection is required.

TEC-9300-

***

C: Pulsed voltage to drive SSR, 14V/40mA A: Special order

NOTE: A part number based on the hardware code and any software pre-programming

will be issued at time of order.

Related Products

TEC99001 Smart network adapter for third party software;

converts 255 channels of RS-485 or RS-422 to RS-232 network

TEC99003 Smart network adapter for connecting the

TEC99013 Programming cable for the TEC-9300 TEC99923 Data Acquisition Software (DAQ Software)

TEC-9300 programming cable to the PCs RS-232 serial port or to a Serial → USB adapter

Page 7

1–3 Programming Port and DIP Switch

Front Panel

Rear Te rm i na l

Figure 1. Access Hole Overview

. . . . .

Table 1.1 DIP Switch Configuration

TC, RTD, mV

0-1V, 0-5V, 1-5V, 0-1 0V

0-20 mA, 4-2 0 m A

Input 1 Select

All para m e te rs a re U nlocked

Only SP1, SEL1 SEL5 a re u n loc ked

Only SP1 is unlocked

All P arameters a re locked

Lockout

1 2

3 4

DIP Switc h

:O N :O F F

Factory Default Setting

Access Hole

ON DI P

2 3 4

The programming port is used to connect to the TEC99001 for instant programming from a computer

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.

The programming port

the factory, the DIP switch is set so that TC and RTD are selected for input 1 and all parameters are unlocked, unless another configuration is requested.

When the unit leaves

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 8

1–4 Keys and Displays

Alarm 1 Indicator

Alarm 2 / Output 2 Indicator

Process Value Indicator

Process Unit Indicator

Upper Display, to display process value, menu symbol and error code etc.

Lower Display, to display set point value, parameter value or control output value etc.

3 Silicone Rubber Buttons for ease of control setup and set point adjustment.

Set point Value Indicator

Output 1 Indicator

A1 A2 PV

°F

OUT

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

-19999 will be displayed by:

45536 will be displayed by:

-9999 will be displayed by:

How to display a 5-digit number

-199.99 will be displayed by -199.9

4553.6 will be displayed by 4553

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

TEC

-9300

Indicates Abstract Characters

A E

D h

°C

Figure 1.4 Front Panel Description

Table 1.3 Display Form of Characters

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

Page 9

1–4 Keys and Displays continued…

Page 10

1–5 Menu Overview

Page 11

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, 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 while configuring PID values 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.

Page 12

1–7 Parameter Description

NOTE: For RS-232:

Short J1, Open/Cut J2 Using RS-232 will disable Event Input Function

Page 13

NOTE: Parameter 1N1 continued on next page

Page 14

NOTE: Parameter O1TY continued on next page

Page 15

Page 16

Page 17

Note: Calibration menu is for supplier configuration use only.

Page 18

Page 19

Chapter 2 Installation

Figure 2.1 Mounting Dimensions

Figure 2.2 Lead Termination

Figure 2.3 Rear Terminal Connection Diagram

4.5 ~ 7.0 mm

0.18" ~ 0.27"

2.0 mm

0.08" max.

Dangerous voltage capable of causing death can be pres-

ent 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 con-

ditions 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, serial number, and date code for future reference when corresponding with our service center. The serial number (S/N) is labeled on the box and the housing of the 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 .

2–3 Wiring Precautions

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

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

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

• All units should be installed in a suitable enclosure to prevent live parts from being accessible to human hands and metal tools. Metal enclosures and/or subpanels should be grounded in accordance with national and local codes.

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

• Beware not to over-tighten the terminal screws. The torque should not exceed 1 N-m (8.9 lb-in or 10 KgF-cm).

• Unused control terminals should not be used as jumper points as they may be internally connected, causing damage to the unit.

• Verify that the ratings of the output devices and the inputs as specified are not exceeded.

• Except for thermocouple wiring, all wiring should use stranded copper conductor with a maximum gage of 14 AWG.

• Electrical power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes. This electrical noise can adversely affect the operation of microprocessor-based controls. For this reason the use of shielded thermocouple extension wire which connects the sensor to the controller is strongly recommended. This wire is a twisted-pair construction with foil wrap and drain wire. The drain wire is to be attached to ground in the control panel only.

Page 20

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. Metal enclosures must be connected to earth ground.

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

2–5 Sensor Installation Guidelines

Proper sensor installation can eliminate many problems in a control system. The probe should be placed so that it can detect any temperature change with minimal thermal lag. In a process that requires fairly constant heat output, the probe should be placed close to the heater. In a process where the heat demand is variable, the probe should be close to the work area. Some 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.

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 .

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.

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

* blue * blue * brown * blue

* black * black * blue * black

Nickel-Chromium

K (Ni-Cr)

Nickel-Aluminum (Ni-Al)

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

* green * green * white * green

Wire * grey * grey Wire

Copper (Cu) Constantan (Cu-Ni)

Iron (Fe) Constantan (Cu-Ni)

Pt-30%Rh Pt-6%Rh

+ white + blue + red + yellow

– blue – red – brown – blue

+ yellow + white + red + yellow

– blue – red – blue – black

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

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

Use + grey + red Use

Copper – red – grey Copper

* Color of overall sheath

Page 21

2–7 RTD Input Wiring

The RTD connections are shown in figure

2.6, with the compensating lead connected to terminal 12. For two-wire RTD inputs, terminals 12 and 13 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 0.4 ohm 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 22

2–9 CT/Heater Current Input Wiring

Make sure that the total current through TEC99999 does not exceed 100A rms in a 3-Phase system.

Page 23

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.

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

Page 24

2–11 Output 1 Wiring

Page 25

2–12 Output 2 Wiring

Page 26

2–13, 2–14 Alarm 1 and 2 Wiring

Note: Both Form A and B contacts are available for the alarm 1 relay. Order the correct form for alarm 1 to suit your needs.

Page 27

2–15 RS-485

Page 28

2–16 RS-232

Figure 2.20 Location of Jumper JP22

Figure 2.21 Configuration of RS-232 Cable

Figure 2.19 RS-232 Wiring

TEC99014

Note: If the TEC-9300 is configured for RS-232 communication, the EI (event input) is disconnected internally. The unit can no longer perform event input function (EIFN).

When you connect an RS-232 module (CM94-2) to the connectors on the CPU board (C930), jumper JP22 on the terminal board (T930) must be modified as following: J1 must be shorted and J2 must be cut and left open. The location of JP22 is shown in the diagram below, left (Fig. 2.20).

2–17 Analog Retransmission

If you use a conventional 9-pin RS-232 cable instead of TEC99014, the cable must be modified according to the circuit diagram above.

Page 29

Chapter 3 Programming Basic Functions

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

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: Selects the sensor type and signal type for Input 1.

Range: (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 Default: J_TC if °F

IN1U: Selects the process unit for Input 1.

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

DP1: Selects the location of the decimal point for most (not

all) process-related parameters. Range: (T/C and RTD) NO.DP, 1-DP (Linear) NO.DP, 1-DP, 2-DP, 3-DP Default: 0-DP

IN1L: Selects the low scale value for Linear type

input 1. Hidden if: T/C or RTD type is selected for IN1.

IN1H: Selects the high scale value for Linear type

input 1. Hidden if: T/C or RTD type is selected for IN1.

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

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.

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:

Example: If a 4–20mA current loop pressure transducer with

range 0–15 kg/cm≈ is connected to input 1, then per-

form 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.

Page 30

3–2 OUT1 and OUT2 Types

O1TY: 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

3–3 Configuring User Menu

Most conventional controllers are designed with a fixed order in which the parameters scroll. The TEC-9300 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

O2TY: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.

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 Heat Only 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. The heat only on-off control function is shown in the diagram at right:

Setup ON-OFF:

OUT1 = PB1 = 0 Adjust: SP1, O1HY, TIME

(if enabled)

3–4 Heat Only Control continued next page…

Page 31

3–4 Heat Only Control continued…

The ON-OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest. If ON-OFF 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:

Select REVR for OUT1, set TI1 to 0, SP1 is 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 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 if PB1 is not equal to 0.

Setup P:

OUT1 = TI1 = 0 CYC1 (if RELAY,

SSRD or SSR is selected for O1TY)

Adjust:

SP1, OFST, TIME (if enabled), PB1(≠0), TD1

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 set point a definite value, say 5°C, while 20°C is used for PB1, that is lower 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 selftuning 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.

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 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. TEC9300 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.

Setup PID:

OUT1 = O1TY CYC1 if RELAY,

SSRD or SSR is 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 auto-tuning are inadequate.

3–5 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:

Setup Cool Control:

OUT1 =

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

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3–6 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 ON-OFF control may result in excessive overshoot and undershoot problems in the process. 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, CYC1, O2TY, CYC2,

A2SP, A2DV

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 ON-OFF control (by selecting AL2), OUT2 will act as alarm output, and the process alarm as well as deviation alarm (see sections 3-8 and 3-9) 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: Set OUT1=REVR, A1FN or A2FN=PV1.H, A1FN or A2MD=NORM, A1HY or A2HY=0.1, PB1≠0, TI1≠0,TD1≠0, and set appropriate values for O1TY and CYC1.

Heat PID+Cool PID: set OUT1=REVR, OUT2=COOL, CPB=100, DB=-4.0, PB1≠0, TI1≠0, TD1≠0, and 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 3-18 for a description of the self-tuning 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 3-20 for more information on manual tuning.

CPB Programming: The cooling proportional band is measured by % of PB with a range of 1~255. Initially set 100% for CPB and examine the cooling effect. If the cooling action should be enhanced then decrease CPB, if the cooling action is too strong then increase CPB. The value of CPB is related to PB and its value remains unchanged throughout the self-tuning and autotuning 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(%).

DB Programming: Adjustment of DB is dependent on the system requirements. If a higher positive value of DB (greater dead band) is used, unwanted cooling action can be avoided, but an excessive overshoot over the set point may 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 may 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

Page 33

3–7 Dwell Timer

Alarm 1 or alarm 2 can be configured as dwell timer by selecting TIMR for A1FN or A2FN, but not both, otherwise Er07 will appear. As the dwell timer is configured, the parameter TIME is used for dwell time adjustment. The dwell time is measured in minute 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.

If alarm 1 is configured as dwell timer, A1SP, A1DV, A1HY and A1MD are hidden.

The case is the same for alarm 2.

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.

Page 34

3–8 Process Alarms

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 PV1PV2) 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, 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.

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

Latching/Holding Alarm: A1MD=LT.HO

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

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

Page 35

3–9 Deviation Alarm

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 3-8 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 36

3–10 Deviation Band Alarm

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). 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 3-8 for descriptions of these alarm modes.

Examples:

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 37

3–11 Heater Break Alarm

A current transformer (Part No. 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 3-24.

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.

3–12 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 3-8 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

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:

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 generally, chiller, valve, pump, motor etc.) breaks or fails or is uninstalled.

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

Page 38

3–13 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 3-16 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 sensor break alarm since sensor break alarm will not perform the holding function even if it is set for holding or latching/holding mode. See section 3-8 for the descriptions of these alarm modes.

3–14 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: A freezer is working in its normal temperature range -10°C to -15°C. In order to avoid an abnormal set point, SP1L and SP1H are set with the following values:

SP1L=-15°C SP1H=-10°C

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

Sensor Break Alarm 1

Setup: A1FN=SENB

A1MD=NORM, LTCH

Hidden: TIME, A1SP, A1DV, A1HY

Sensor Break Alarm 2

Setup: OUT2=AL2

A2FN=SENB A2MD=NORM, LTCH

Hidden: TIME, A2SP, A2DV, A2HY

Setup: SP1L, SP1H

3–15 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.

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 39

3–16 Failure Transfer

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

1. SB1E occurs (due to input 1 sensor break or input 1 current below 1mA if 4–

20mA is selected or input 1 voltage below 0.25V if 1–5V is selected) if PV1, P12, or P2-1 is selected for PVMD or PV1 is selected for SPMD.

2. SB2E occurs (due to input 2 sensor break or input 2 current below 1mA if 4–

20mA is selected or input 2 voltage below 0.25V if 1–5V is selected) if PV2, P12, or P2-1 is selected for PVMD or PV2 is selected for SPMD.

3. ADER occurs if the A-D converter of the controller fails. Output 1 and output 2 will perform the failure transfer function as one of the fol-

lowing 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.

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 mode is activated

Failure Transfer Setup:

1. O1FT

2. O2FT

3. A1FT

4. A2FT

Output 2 failure transfer, if activated,

will perform:

1. If OUT2 selects COOL, and BPLS is selected for O1FT, then output 2 will perform bumpless transfer. Thereafter, the previous averaging value of MV2 will be used for controlling output 2.

2. If OUT2 selects COOL, and a value of 0 to 100.0% is set for O2FT, then output 2 will perform failure transfer. Thereafter, the value of O1FT will be used for controlling output 2.

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.

Page 40

3–17 Bumpless Transfer

Self-tune Menu

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 3-16 for failure mode descriptions.

3. The controller enters manual mode. See section 3-22 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

3–18 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 selftuning 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: Self-tuning will be disabled as soon as one

of the following 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.

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.

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.

Page 41

3–19 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°F TI1=TI2=100 seconds, TD1=TD2=25.0 sec-

onds. 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.

NOTE: Ramping function, remote set point,

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

will be strongly related to the time when the auto-tuning is applied. Hence, different values will be obtained every time autotuning is completed without pre-tune. It is particularly true when auto-tuning is applied using cold start and warm start.

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.

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 the 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 unstable phenomenon which is caused by incorrect PID values is detected. Without the pretune stage, like other conventional controllers, the tuning result

Pre-tune function advantage:

Consistent tuning results can be obtained

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 3-20)

5. Touch any key to reset message.

Page 42

3–20 Manual Tuning

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.

If the control performance using auto or selftuning 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 43

3–21 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.

3–22 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. NOTE that bumpless transfer can not be used for an extended time. See section 3-17.

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

a constant demand.

Operation:

Press until (hand control) appears on the display. Press for 3 seconds, then the upper display will begin to flash and the lower display will show . The controller is now in manual control mode. Press ; the lower display will show

and alternately where indicates output 1 (or heating) control variable value MV1 and indicates output 2 (or cooling) control variable value MV2. Now you can use the up and down keys to adjust the percentage values for H or C.

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).

MV1=38.4% for OUT1 (or heating)

MV2=7.63% for OUT2 (or cooling)

Means

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.

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).

Page 44

3–23 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 upper display will show the parameter value and the lower display will show the parameter symbol except and age value for output 1 and shows the percentage value for output 2 on the lower display while the upper display shows the current process value.

PVHI/PVLO show the historical extreme

(maximum or minimum) values of the process on the 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.

MV1/MV2 show the process value on the

upper display and shows the percentage control value for output 1, while

shows the percentage control value

for output 2.

DV 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 on

the upper display.

PV2 shows the process value of input 2 on

the upper display.

PB shows the current proportional band

value used for control.

TI shows the current integral time used for

control.

TD shows the current derivative time used

for control. Since the controller is performing FUZZY control, the values of PB, TI, and TD may change from time to time.

CJCT shows the temperature at the cold

junction, measured in °C independent of the unit used.

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 The maximum and mini-

mum changing rate of the process since power up, as measured in °C (or °F or PU) per minute. PVRH is a positive value while PVRL is a negative value.

NOTE

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

shows the percent-

3–24 Heater Current Monitoring

TEC99999, a current transformer, should 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 Table

1.4 under PVMD to use as a process value or SPMD to use as a setpoint.

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.

Accessory installed:

CT94-1

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.

3–25 Reload Default Values

The default values listed in table 1.4 are stored in the memory when the product leaves the factory. In 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.

CAUTION

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

FILE 0

°C default file

FILE 1

°F default file

Page 45

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. Three types of signal, relay or switch contacts, open collector pull low, and TTL logic level can be used to switch the event input.

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

NONE: Event input no function

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: If chosen, the SP2 will replace

the role of SP1 for control.

PID2: If chosen, the second PID set

PB2, TI2, and TD2 will be used to replace PB1, TI1, and TD1 for control.

SP.P2: If chosen, SP2, PB2, TI2, and

TD2 will replace SP1, PB1, TI1, and TD1 for control.

NOTE: If the second PID set is chosen during auto-tuning and/or self-tuning procedures, the new PID values will be stored in PB2, TI2, and TD2.

RS.A1: Resets alarm 1 as the event

input is activated. However, if the alarm 1 condition is still existent, alarm 1 will be retriggered when the event input is released.

RS.A2: Resets alarm 2 as the event

input is activated. However, if the alarm 2 condition is still existent, alarm 2 will be retriggered when the event input is released.

R.A1.2: Resets both alarm 1 and alarm

2 as the event input is activated. However, if 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: Disables output 1 as the event input is activated. The out-

put 1 control variable MV1 is cleared to zero.

D.O2: Disables output 2 as the event input is activated. The out-

put 2 control variable MV2 is cleared to zero.

D.O1.2: Disables both output 1 and output 2 by clearing MV1

and MV2 values as soon as the event input is activated.

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: All parameters are locked to prevent them from being

changed. See section 4-13 for more details.

Terminals:

Event input +

Event input –

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

SP2F Function: Defines the format of SP2 value. If ACTU is

selected for SP2F 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.

SP2F=Format of SP2 value

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

Modification from RS-232 to event input:

Because of the limited number of pins, pin 14 is used for both event input and RS-232. If you want to change function of the TEC-9300 from RS-232 to event input, you must modify jumper JP22 on the terminal board by opening jumper J1 and shorting jumper J2. Refer to section 2-16 for the location of jumper JP22.

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 14 and pin 13). The signal applied to the event input may come from a timer, a PLC, an alarm relay, a manual switch or other devices. Select SP2 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.

Application 1: A process

is required to be heated to a higher temperature as 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: An oven is required to be heated to 300°C

from 8:00AM to 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.

Apply Signal To

Event input +

Event input –

Setup

EIFN choose SP2 or SP.P2

Availability

SPMD choose

or or

Format of SP2 Value

SP2F choose

Actual Value

or Deviation Value

Page 46

4–3 Second PID Set

In certain applications the characteristics of a process are strongly related to its process value. The TEC9300 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.

Apply Signal To

Event input +

Event input –

Setup

EIFN choose PID2 or SP.P2

Application 1: programmed by the set point

Choose SP.P2 for EIFN then both set point and PID values will be switched to another 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.

EIFN=SP.P2

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. The alarm 1 output is connected to the event input, so the PID values will change from PB1, TI1, and TD1 to PB2, TI2, and TD2.

Refer to section 5-9 for more details.

EIFN=PID2

Alarm output controls the event input

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:

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. When 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 timer before time out. Example: 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.

Note: When the ramp function is used, the lower display will show the current ramping value. However, it will revert to show the set point value as soon as the up or down key is pressed for adjustment. The ramping value is initiated as the process value either at power up or when RAMP and/or the set point are changed. Setting RAMP to zero means no ramp function at all.

Dwell

The dwell timer can be used

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.

4–4 Ramp and Dwell, continued next page…

Page 47

4–4 Ramp and Dwell, continued…

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. Set E1 for SP2. 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.

4–5 Remote Set Point

Selecting PV1 or PV2 for SPMD will enable the TEC9300 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: Use Input 2 to accept remote set point

FUNC=FULL IN2, IN2U, DP2, IN2L, IN2H, are set according to remote sig-

nal. PVMD=PV1 IN1, IN1U, DP1, are set according to the process signal IN1L, IN1H if available, are set according to the process signal

Setup

FUNC = FULL SPMD = PV2, PVMD = PV1

SPMD = PV1, PVMD = PV2

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 fol-

lowing diagram at right 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 the PV2 to be displayed instead of PV, you can use the display mode to select PV1 or PV2 to be viewed. See section 3-23.

Setup

PVMD=P1-2

or PVMD=P2-1

SPMD=SP1.2

SPMD=PV2

Case 2: Use Input 1 to accept remote set point

FUNC=FULL IN1, IN1U, DP1, IN1L, IN1H, are set according to remote sig-

nal. 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

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-9300 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 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.

Page 48

4–7 Output Power Limits

In certain systems the heater (or cooler) is overdesigned 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. If the controller is used for ON-OFF control, then both PL1 and PL2 are 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:

NOTE:

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

PL1 PL2

4–8 Data Communication

Two types of interfaces are available for data communication. These are the RS-485 and RS232 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 TEC99001) has to be used to convert RS-485 to RS-232 for a PC if RS-485 is required for data communication. Up to 247 RS-485 units can be connected to one RS-232 port; therefore a PC with four comm ports can communicate with 988 units.

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-9300 is con-

figured for RS-232 communication, the EI (event input) is disconnected internally. The unit can no longer perform event input function (EIFN).

When you attach an RS-232 module (TEC-102-103) to the connectors on the CPU board, you also need to modify jumper JP22 according to section 2-16. If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable should be modified for the proper operation of RS-232 communications according to section 2-16.

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

TX1

TX2

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

TX1

TX2

COM

Page 49

4–9 Analog Retransmission

FILT

Analog retransmission is available for model number TEC-9300-XXXXXN 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 map to 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.

Terminals

AO+

AO–

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-9300 can be used to improve this. This is a first order filter with the time constant specified by the FILT parameter which is in the setup menu. The default value of FILT is set at 0.5 seconds before shipping. Adjust FILT to change the time constant from 0 to 60 seconds. 0 seconds means no filter is applied to the input signal. The filter is characterized by the following diagram.

FILT

Filter is used to stabilize the process display.

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.

NOTES

AOHI ≠ AOLO AOHI > AOLO:

Direct

conversion

AOHI < AOLO: 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 exported, and if the difference value is 100, 20mA will be exported. Make the following setup for TEC-9300:

IN1U=PU, DP1=NODP, IN2U=PU, DP2=NODP, FUNC=FULL, COMM=4-20, AOFN=P1-2, AOLO (low side of scale) =-100, AOHI (high side of scale)=100

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.

4–11 Sleep Mode

To enter sleep mode: Set FUNC for FULL to pro-

vide 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: SLEP=NONE, sleep mode is disabled.

Note: If sleep mode is not required by your system, NONE

should be selected for SLEP to disable sleep mode.

Sleep mode features:

Shut off display Shut off outputs Green power Replaces power switch

Setup menu

FUNC = FULL SLEP = YES

Page 50

4–12 Pump Control

Pump control function is one of the unique features of the TEC-9300. 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-9300 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

Key menu

SPMD SP2F REFC SP2

PUMP:

A cost effective solution

the set point as soon as the material is demanded again while the pressure falls below a predetermined value (i.e., SP1+SP2).

Programming guide:

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.

and program the following parameters in the user menu: 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-9300 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 been 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

Pump control features:

1. Minimum oscillation of pressure

2. Rapidly stabilized

3. Guaranteed pump stop

4. Programmable pump stopping interval

4–13 Remote Lockout

The parameters can be locked to prevent them from being changed by using either hardware lockout (see section 1-3), remote lockout, or both. If you need the parameters to be locked by using an external switch (remote lockout function), then connect a switch to terminals 13 and 14 (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: Can be used only during initial setup. Remote lockout: Can be used any time.

Remote Lockout:

1. Connect external switch to terminal and .

2. Set LOCK for EIFN

3. Lock all parameters

1413

Page 51

Chapter 5 Applications

Figure 5.2 Block Diagram of VPFW SSR

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-9300 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: To supply a variable frequency AC voltage to the

motor.

Motor: A 3-Ø induction motor. Pump: Any appropriate economical type of pump. Pressure Sensor: A three-wire or two-wire type of pressure

transducer with a 0–20Kg/cm≈ range.

Pressure Reservoir: Provides smoother pressure for the

system.

TEC-9300: Order a TEC-9300 with standard input, 4–20mA

output 1, 20V DC output 2 for sensor power.

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

Adjust the following parameters in the user menu:

A1SP: optional

REFC = 3

PB1 = 10.00

OUT1 = REVR O1TY = 4-20 O1FT = 0 OUT2 = DCPS A1FN: optional EIFN = NONE PVMD = PV1 FILT = 1

TI1 = 1 TD1 = 0.2

SP2 = -0.50

PL1 = 100

SELF = NONE SLEP = NONE

SPMD = PUMP

SP1L = 5.00 SP1H = 15.00

SP2F = DEVI

Key menu:

SPMD

SP2F

REFC

SP2

Refer to section 4-12 for more details.

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:

NOTES:

1. The VPFW SSR can be used to drive a resistant load and some types of inductance loads such as relay, contactor, magnetic switch, solenoid valve, etc. However, it can not drive a motor or capacitance load.

2. Only AC power can supply VPFW SSR, otherwise it will not operate properly.

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.

Page 52

5–2 Variable Period Full Wave SSR, continued…

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

Output 1 and output 2 of the TEC-9300 can be connected to the VPFW SSR directly provided that a pulsed voltage drive output is ordered.

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 TEC-9300 equipped with dwell timer is used for this purpose. The system diagram is shown as follows:

Here is an example:

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 = BPLS

A1FN = TIMR

A1FT = ON SELF = NONE

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

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

Page 53

5–4 Cool Only Control

A TEC-9300 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 overall cost. To achieve ON-OFF control, PB1 is set to zero and O1HY is set at 0.1°C.

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 at right:

PID heat-cool is used for the example at right.

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

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 3-19.

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.

CYC1 = 18.0 (seconds) O1FT = BPLS OUT2 = COOL O2TY = 4–20 O2FT = BPLS SELF = STAR

Key menu

FUNC IN1 IN1U DP1 OUT1 O1TY CYC1 O1FT OUT2 O2TY O2FT SELF SP1 CPB DB

Page 54

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:

The TEC-9300 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 3-19 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.

Terminal

, use

Form B Relay

Order a form B relay for alarm 1. 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 55

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 TEC-9300 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 at right:

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

5–8 Differential Control

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 IN2U = PU DP2 = 2-DP OUT1 = REVR O1TY = 4–20 PVMD = P1-2 SPMD = SP1.2

If a voltage signal (such as in the above example) is sent to slave units, the slave inputs should be connected in parallel. If a current signal (e.g., 4–20mA) is sent to slave units, the slave inputs should be connected in series. Current retransmission is widely used because it can transmit over a longer distance without voltage drop.

Note: AOHI and IN2H should be set with values higher than the set

point range used.

Adjust SP (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 3-23. The diagram at right indicates PV2 instead of PV.

Page 56

5–9 Dual Set Point/PID

The TEC-9300 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.

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:

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

Page 57

5–10 RS-485

A tile making plant has five production lines. Each production line is equipped with 16 TEC-9300 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-9300 units plus a Smart Network Adapter (Part Number TEC99003) and DAQ (Part Number TEC99923) PCbased software for this purpose.

The system is installed as shown in the following diagram.

Setup

Enter setup mode to configure each TEC-

9300. 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-9300’s, Smart Network Adapter and DAQ Software. Also refer to section 2-15 and section 4-8.

Taking advantage of DAQ 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 58

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-9300 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 TEC9300 with RS-232 communication and DAQ (Part Number TEC99923) software. Using the DAQ 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.

5–12 Retransmit

An air-conditioned room uses two TEC-9300 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 59

Chapter 6 Calibration

Do not proceed through this section unless there is a defi-

nite 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 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 3

Press the scroll key until the display shows 60mV signal to terminals 12 and 13 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.

Send a

Step 4

Set the DIP switch for voltage input. Press the scroll key until the display shows . Send a 10V signal to terminals 12 and 13 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 18, 19, and 20 using to the connection shown below:

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 12 and 13, 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.

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 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.

Change

Step 7

Set the DIP switch for mA input. Press the scroll key until the display shows . Send a 20mA signal to terminals 12 and 13 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.

Manual calibration procedures, continued next page…

Page 60

Manual calibration procedures, continued…

Step 8

Press the scroll key until the display shows . Send a 10V signal to terminals 15 and 16 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 mA function ( if required ) for input

Step 9

Press the scroll key until the display shows . Send a 20mA signal to terminals 15 and 16 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 10 to calibrate offset of cold junction compensation, if required. Set the DIP switch for T/C input.

Step 10

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

Step 11

Set up the equipment the same as in step 10. 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 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.

Press the up and down keys until a

Step 11N

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: It is not recommended to use step 11N, since the

cold junction gain is not able to achieve the rated accuracy using this step.

• Final step

Step 12

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

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 stillair 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 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.

• Perform step 11 to calibrate the gain of cold junction compensation if required. If a test chamber for calibration is not available, perform step 11N to use a nominal value for the cold junction gain.

Press the up and down keys until a value

Automatic calibration procedures

The programming port (see section 2-18) of the TEC-9300 can be used for automatic calibration.

The equipment required for automatic calibration is available upon request.

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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 and not the controller

• Incorrect settings

• 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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NOTES

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Chapter 8 Specifications

Power

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

Input 1 resolution: 18 bits Sampling rate: 5x/second Maximum rating: -2VDC minimum, 12VDC maximum

(1 minute for mA input)

Temperature effect: ±1.5uV/°C for all inputs except mA

input ±3.0uV/°C for mA input

Sensor lead resistance effect:

T/C: 0.2uV/ohm 3-wire RTD: 2.6°C/ohm of resistance difference of two leads 2-wire RTD: 2.6°C/ohm of resistance sum of two leads

Common mode rejection ratio (CMRR): 120dB Normal mode rejection ratio (NMRR): 55dB Sensor break detection:

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

Input 2 Resolution:

18 bits

Sampling rate: 1.66 times/second Maximum rating: -2VDC minimum, 12VDC maximum Temperature effect: ±3.0uV/°C for mA input ±1.5uV/°C

for all other inputs

Common mode rejection ratio (CMRR): 120dB Sensor break detection: Below 1mA for 4–20mA input,

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

Sensor break responding time: 0.5 seconds

Characteristics:

Input 3 (event input) Logic low:

-10V minimum, 0.8V maximum.

Logic high: 2V minimum, 10V maximum External pull-down resistance: 400KΩ maximum External pull-up resistance: 1.5MΩ minimum Functions: select second set point and/or PID, reset alarm 1

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

Output 1/Output 2 Relay rating:

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

Pulsed voltage: source voltage 5V, current limiting resist-

ance 66Ω.

Linear output characteristics:

Linear Output Resolution:

15 bits

Output regulation: 0.01% for full load change Output settling time: 0.1 second (stable to 99.9%) Isolation breakdown voltage: 1000VAC Temperature effect: ±0.0025% of SPAN/°C

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Triac (SSR) Output Rating:

1A/240VAC

Inrush Current: 20A for 1 cycle Min. Load Current: 50mA rms Max. Off-state Leakage: 3mA rms Max. On-state Voltage: 1.5V rms Insulation Resistance: 1000Mohms min. at 500VDC Dielectric Strength: 2500VAC for 1 minute

DC voltage supply characteristics

(installed at output 2)

Alarm 1/Alarm 2 Alarm 1 relay:

Form A or Form B, max. rating 2A/240VAC, 100,000 life cycles for resistive load.

Alarm 2 relay: Form A, max. rating 2A/240VAC, 200,000 life

cycles for resistive load.

Alarm functions: •Dwell timer, •Deviation high/low alarm,

•Deviation band high/low alarm, •PV1 high/low alarm,

•PV2 high/low alarm, •PV1-PV2 high/low alarm,

•Loop break alarm, •Sensor break alarm.

Alarm mode: Normal, latching, hold, latching/hold. Dwell timer: 0–6553.5 minutes

Data Communication Interface:

RS-232 (1 unit), RS-485 (up to 247 units)

Protocol: Modbus protocol RTU mode Address: 1–247 Baud Rate: 0.3~38.4Kbits/sec Data Bits: 7 or 8 bits Parity Bit: None, even or odd Stop Bit: 1 or 2 bits Communication Buffer: 50 bytes

Analog Retransmission Functions:

PV1, PV2, PV1-PV2, PV2-PV1, set point, MV1, MV2, PV-SV deviation value

Output Signal: 4–20mA, 0–20mA, 0–1V, 0–5V, 1–5V, 0–10V Resolution: 15 bits Accuracy: ±0.05% of span ±0.0025%/°C Load Resistance: 0–500ohms (for current output)

10Kohms minimum (for voltage output)

Output Regulation: 0.01% for full load change Output Settling Time: 0.1 sec. (stable to 99.9%) Isolation Breakdown Voltage: 1000VAC min. Integral linearity error: ±0.005% of span Temperature effect: ±0.0025% of span/°C Saturation low: 0mA (or 0V) Saturation high: 22.2mA (or 5.55V, 11.1V min.) Linear output range:

0–22.2mA(0–20mA or 4–20mA), 0–5.55V (0–5V, 1–5V), 0–11.1V (0–10V)

User Interface Dual 4-digit LED displays:

Upper 0.4" (10mm), lower

0.3" (8mm)

Keypad: 3 keys Programming port: For automatic setup, calibration, and

testing

Communication port: Connection to PC for supervisory

control

Control Mode Output 1:

Reverse (heating) or direct (cooling) action

Output 2: PID cooling control, cooling P band 1~255% of PB ON-OFF: 0.1–100.0(°F) hysteresis control (P band=0) P or PD: 0–100.0% offset adjustment PID: Fuzzy logic modified

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

Cycle time: 0.1–100.0 seconds Manual control: Heat (MV1) and cool (MV2) Auto-tuning: Cold start and warm start Self-tuning: Select NONE or YES Failure mode: Auto-transfer to manual mode while sensor

break or A-D converter damage

Sleep mode: Enable or disable Ramping control: 0–900.0°F/minute or 0–900.0°F/hour

ramp rate

Power limit: 0–100% output 1 and output 2 Pump/pressure control: Sophisticated functions provided Remote set point: Programmable range for voltage or cur-

rent input

Differential control: Control PV1-PV2 at set point

Digital Filter Function:

First order

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

programmable

Environmental and Physical Operating temperature:

-10°C to 50°C

Storage temperature: -40°C to 60°C Humidity: 0 to 90% RH (non-condensing) Insulation resistance: 20Mohms min. (at 500VDC) Dielectric strength: 2000VAC, 50/60Hz for 1 minute Vibration resistance: 10–55Hz, 10m/s for 2 hours Shock resistance: 200m/s (20g) Moldings: Flame retardant polycarbonate Dimensions: 50.7mm(W) × 50.7mm(H) × 88.0mm(D),

75.0mm depth behind panel

Weight: 150 grams

Approval Standards Safety:

UL873 (11th edition, 1994), CSA C22.2 No. 24-93, EN61010-1 (IEC1010-1)

Protective class: NEMA 4X (IP 65) front panel, indoor

use, IP 20 housing and terminals.

EMC: EN61326

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Chapter 9 Modbus Communications

This chapter specifies the Modbus Communications protocol as RS-232 or RS-485 interface module is installed. Only RTU mode is supported. Data is transmitted as eight-bit binary bytes with 1 start bit, 1 stop bit and optional parity checking (None, Even or Odd). Baud rate may be set to 2400, 4800, 9600, 14400, 19200, 28800 and 38400.

9-1 Functions Supported

Only function 03, 06 and 16 are available for this series of controllers. The message formats for each function are described as follows:

Function 03: Read Holding Registers Query: (from Master) Response: (from Slave)

Slave address (0-255) Function code (3) Starting address of register Hi (0) Byte count Starting address of register Lo Data 1 Hi

(0-79, 128-131) Data 1 Lo No. of words Hi (0) Data 2 Hi No. of words Lo (1-79) Data 2 Lo CRC16 Hi • CRC16 Lo •

•

CRC16 Hi

CRC16 Lo

Function 06: Preset Single Register Query: (from Master) Response: (from slave)

Slave address (0-255) Function code (6) Register address Hi (0) Register address Lo (0-79, 128-131) Data Hi Data Lo CRC16 Hi CRC16 Lo

Function 16: Preset Multiple Registers Query: ( from master ) Response: (from slave)

Slave address (0-255) Function code (16) Starting address of register Hi (0) Starting address of register Lo (0-79, 128-131) No. of words Hi (0) No. of words Lo (1-79) Byte count (2-158) CRC16 Hi Data 1 Hi CRC16 Lo Data 1 Lo Data 2 Hi Data 2 Lo

•

CRC16 Hi CRC16 Lo

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9-2 Exception Responses

If the controller receives a message which contains a corrupted character (parity check error, framing error, etc.), or if the CRC16 check fails, the controller ignores the message. However, if the controller receives a syntactically correct message which contains an illegal value, it will send an exception response, consisting of five bytes as follows:

slave address +offset function code + exception code + CRC16 Hi +CRC16 Lo

Where the offset function code is obtained by adding the function code with 128 (ie. function 3 becomes H'83), and the exception code is equal to the value contained in the following table:

Exemption Code Name Cause

1 Bad Function Code Function code is not supported by the controller

2 Illegal data address Register address out of range

a read-only or protected data

3 Illegal data value

Data value out of range or attempt to write

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9-3 Parameter Table

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P= 100.0

RC 16

9-3 Communication Examples

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A–1 Menu Existence Conditions

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A–2 Factory Menu Description

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A–3 Glossary

Absolute zero: The lowest theoretical temperature. At absolute zero, a body would have no molecular motion of heat energy. Absolute zero is the zero point on the Rankine and Kelvin scales. (-273.15°C or -

459.67°F) AC: Alternating Current; an electric current that reverses direction at

regularly occurring intervals.

Accuracy

Calibration accuracy: The potential error of a device compared to

a physical constant or agency standard. Control accuracy: Maintaining a process at the desired setting. The

errors or combination of errors in the entire system including the sensor, control, power, load and design inefficiencies affect control accuracy.

Display accuracy: The amount of potential error between a measured value and the control’s displayed value.

Set point accuracy: The potential error between a measured value and the control setting.

Alarm: A control condition or function, indicating that the process is a predetermined amount above or below the set point.

Alpha (α): The average percent change in resistance per degree of a pure metal resistance device between 0° and 100°C. Usually designated by the Greek letter alpha, α with units of ohm/ohm/°C. The common alpha for a platinum RTD is 0.00385ohm/ohm/°C.

Ambient compensation: The design of an instrument such that changes in ambient temperature do not affect the readings of the instrument.

Ambient temperature: The average or mean temperature of the surrounding air which comes in contact with the equipment and instruments under test.

Ampere (amp):A unit used to define the rate of flow of electricity (current) in a circuit; units are one coulomb (6.25 x 10 ond.

Analog indication: A meter with graduated scale and a pointer that moves to indicate process condition.

Analog output: A voltage or current signal that is a continuous function of the measure parameter.

Analog set point: Potentiometer adjustment of the control setting. ANSI: American National Standards Institute Anti-reset windup: This is a feature in a three-mode PID controller

which prevents the integral (auto reset) circuit from functioning when the temperature is outside the proportional band.

ASME: American Society of Mechanical Engineers. ASTM: American Society for Testing and Materials. Automatic reset (Integral): The integral function of a control that

automatically compensates for the difference between the set point and the actual process temperature. A signal moves the proportional band up or down to correct for the droop or offset error.

Automatic tuning (of control parameters): A control that calculates the optimum PID parameters with a built-in software algorithm to eliminate manual tuning efforts.

AWG: American Wire Gauge. Bandwidth: A symmetrical region around the set point in which propor-

tional control occurs. Baud rate: In serial communications, the rate of information transfer in

bits per second.

electrons) per sec-

Blackbody: A theoretical object that radiates the maximum amount of energy at a given temperature, and absorbs all the energy incident upon it. A blackbody is not necessarily black. (The name blackbody was chosen because the color black is defined as the total absorption of light [energy].)

Boiling point: The temperature at which a substance in the liquid phase transforms to the gaseous phase; commonly refers to the boiling point of water which is 100°C (212°F) at sea level.

Btu: British Thermal Unit. The quantity of thermal energy required to raise one pound of water 1°F at or near its maximum density (39.1°F).

Bumpless transfer: The smooth, automatic transition from automatic control (closed loop) to manual control (open loop). The control output is maintained during the transfer.

Burst proportioning: A fast-cycling output form on a time proportioning controller (typically adjustable from .2 to 4 seconds) used in conjunction with a solid state relay to prolong the life of heaters by minimizing thermal stress.

Calender-van Dusen equation: An equation that defines the resistance-temperature value of any pure metal that takes the form of R

(1+AT+BT2) for values between the ice point (0°C) and the freez-

T=Ro

ing point of antimony (630.7°C) and the form RT=Ro[1+AT+BT2+C(T-

100)T2] between the oxygen point (-183.0°C) and the ice point (0°C). Calibration: The process of adjusting an instrument so that the indica-

tion is accurate compared to the actual value. Calorie: The quantity of thermal energy required to raise one gram of

water 1°C at 15°C. Cascade: Control in which the output of a secondary or inner control

loop is the set point for a primary or outer loop. The primary loop, in turn, determines the control action.

CE: A mark that designates compliance with European Union (EU) requirements for products sold in Europe.

Celsius: (Centigrade) A temperature scale with 0°C defined as the ice point and 100°C as the boiling point of water at sea level.

cfm: The volumetric flow rate of a liquid or gas in cubic feet per minute. Chatter: The rapid cycling on and off of a relay in a control process due

to insufficient bandwidth in the controller. Closed loop control: A control system in which process temperature

changes are detected by a sensor. The feedback from the sensor allows the control to make adjustments for accurate system regulation.

Cold junction compensation: A temperature sensitive device that prevents changes in the ambient temperature from affecting the cold junction of a thermocouple.

Common mode rejection ratio: The ability of an instrument to reject interference from a common voltage at the input terminals with relation to ground. Expressed in dB (decibels).

Control loop: The basic control loop of any automatic control system consists of:

1. variable (process)

2. sensor

3. error detector (of control)

4. control

5. final control element (relay, SSR, SCR)

6. temperature indication

Control mode: The method in which the control restores the system temperature to set point. On/Off, proportional, and PID are the most common control modes.

CT: Current Transformer

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Current proportioning: A 4–20 milliamp (typical) current output which provides a current proportional to the amount of control required.

Current transformer: A transformer, intended for measuring purposes, designed to generate a current at its secondary winding which is proportional to the current at the primary winding.

Cycle time: The time, usually expressed in seconds, for a controller to complete one on/off cycle.

Data logging: Recording a process variable over an extended period of time.

DC: Direct Current; An electric current flowing in one direction and constant in value.

Dead band: 1. For chart recorders: the minimum change of input signal required to cause a deflection in the pen position. 2. For temperature controllers: the temperature band where heat is turned off upon rising temperature and turned on upon falling temperature expressed in degrees. The area where no heating (or cooling) takes place.

Default parameters: The parameters, or programmed instructions, permanently stored in microprocessor software to provide a data base.

Derivative: (see Rate) Deviation: The difference between the value of the controlled variable

and the value at which it is being controlled. Deviation alarm: An offset value that follows the set point. If the set

point is 350°F and the deviation alarm value is +20°F, the alarm value would be 350°F plus 20°F (or 370°F), See Process alarm.

Dielectric strength: An amount of voltage that an insulating material can withstand before an electrical breakdown occurs.

Differential: In an on/off control, the temperature difference, expressed in degrees, between where the control switches off and the control switches on.

Differential control:A controller can control one process in relation to the difference of a second process.

DIN: Deutsche Industrial Norms. A German agency that sets engineering and dimensional standards that now has worldwide recognition.

Drift: A change in a value over a long period due to changes in factors such as ambient temperature, time, or line voltage.

Droop: In time proportioning controls, the difference in temperature between the set point and where the system temperature stabilizes. Corrected by automatic or manual reset.

Dual output: The primary output will regulate the process temperature. A secondary output will be utilized for process cooling or as an alarm.

Duty cycle: Percentage of “load ON time” relative to total cycle time. Efficiency: The amount of useful output versus energy input. Electrical interference: Electrical noise induced upon the signal

wires that obscures the wanted information signal. Electromagnetic Compatibility (EMC): A system that meets three

requirements: 1. it does not cause interference with other systems, 2. it is not susceptible to emissions from other systems and 3. it does not cause interference with itself.

Electromagnetic Interference (EMI): An electrical and magnetic noise which can be generated when switching inductive devices, lightning, radio wave radiation, electrostatic discharge, etc.

emf: Electromotive force. A rise in (electrical) potential energy. The principal unit is the volt.

Emissivity: The ratio of energy emitted by an object to the energy emitted by a blackbody at the same temperature. The emissivity of an object depends upon its material and surface texture; a polished metal surface can have an emissivity around 0.2, and a piece of wood can have an emissivity around 0.95.

Endothermic: Absorbs heat. A process is said to be endothermic when it absorbs heat.

Error: The difference between the correct or desired value and the actual reading or value taken.

Event input: A programmable On/Off input used to signal peripheral equipment or a process.

Event output: A programmable On/Off output used to signal peripheral equipment or a process.

Exothermic: Gives off heat. A process is said to be exothermic when it releases heat.

Fahrenheit: A temperature scale with 32°F defined as the ice point and 212°F as the boiling point of water at sea level.

Filter: A low pass filter designed to minimize display fluctuations. Flow rate: speed or velocity of fluid movement. FM: Factory Mutual Research Corp. An organization which sets indus-

trial safety standards.

FM-approved: An instrument that meets a specific set of specifications established by Factory Mutual Research Corp.

Form A: Single Pole Single Throw relay that only utilizes the N.O. and common contacts. These contacts close when the relay coil is energized. The contacts open when power is removed from the control.

Form B: Single Pole Single Throw relay that only utilizes the N.C. and common contacts. These contacts will open when the relay coil is energized. The contacts will close when power is removed from the control.

Form C: Single Pole Double Throw. Utilizes the N.O., N.C. and common contacts. The user has the option of wiring for a Form A or Form B contact. Refer to the Form A and Form B above for more information.

fpm: Flow velocity in feet per minute. fps: Flow velocity in feet per second. Freezing point: The temperature at which the substance goes from the

liquid phase to the solid phase. Frequency: The number or event occurrences or cycles over a specified

period of time. Fuse: A device that interrupts power in a circuit when an overload

occurs. Fuzzy logic: An artificial intelligence technique that allows control

decisions to be made upon approximate or incomplete information. Fuzzy logic is a continuous decision making function that can prevent initial overshoot and set point differentials.

Gain: The amount of amplification used in an electrical circuit. GIGA: The prefix for one billion (G). gph: The volumetric flow rate in gallons per hour. gpm: The volumetric flow rate in gallons per minute. Ground: 1. The electrical neutral line having the same potential as the

surrounding earth. 2. The negative side of dc power supply. 3. Reference point for an electrical system.

Grounded junction: A thermocouple junction in which the sheath and conductors are welded together forming a completely sealed integrated junction.

Heat: Thermal energy expressed in Calories, Btu’s or Joules. Heat of fusion: The amount of energy required to change one pound of

a material from a solid to a liquid without an increase in temperature. Expressed in Btu/lb.

Heat of vaporization: The amount of energy required to change one pound of a material from a liquid to a vapor without an increase in temperature. Expressed in Btu/lb.

Heat sink: 1. Thermodynamic. A body which can absorb thermal energy. 2 Practical. A finned piece of metal used to dissipate the heat of solid state components mounted on it.

Heat transfer: The process of thermal energy flowing from a body of high energy to a body of low energy. Means of transfer are: conduction, the two bodies are in contact; convection, a form of conduction where the two bodies in contact are of different phases, i.e; solid and gas; radiation, all bodies emit infrared radiation

Heat treating: A process for treating metals where heating to a specific temperature and cooling at a specific rate changes the properties of the metal.

Hertz (Hz): Unit in which frequency is expressed. Synonymous with cycles per second.

Hi-Pot test: To apply a high voltage to an electrical conductor to test the surrounding insulation.

Hysteresis: In ON/OFF control, the temperature change necessary to change the output from full ON to full OFF.

Hunting: Oscillation or fluctuation of process temperature between set point and process variable.

IAE: Integrated absolute error Ice point: The temperature at which pure water freezes. 0°C, 32°F,

273.16K.

IE: Integrated error Impedance: The total opposition in a circuit to the flow of electrical

current. Measured in ohms and represented by “Z”. Infrared: Or radiation is the exchange of energy by electromagnetic

waves. The infrared spectrum extends from the deep red end of the visible spectrum to the microwave region of the radio spectrum. The portion adjacent to the visible spectrum is of importance to heating. Radiant heat transfer can be very efficient in directing energy from the heat source to an object.

Integral: (see Automatic Reset). Interchangeability error: A measurement error that can occur if two

or more probes are used to make the same measurement. It is caused by a slight variation in characteristics of different probes.

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Intrinsically safe: An instrument which will not produce any spark or thermal effects under normal or abnormal conditions that will ignite a specified gas mixture.

IPTS-68: International Practical Temperature Scale of 1968. Fixed points in thermometry set by the 1968 General Conference of Weights and Measures.

ISA: Instrument Society of America. ISE: Integrated squared error Isolation: Electrical separation Isothermal: A process or area that maintains a constant temperature. ITS-90: International Temperature Scale of 1990 Joule: The basic unit of thermal energy. 1 Joule equals 1 ampere passed

through a resistance of 1ohm for 1 second. Junction: A thermocouple junction is the point at which two alloys are

joined. A typical thermocouple circuit would have a measuring and a reference junction.

Kelvin: The unit of absolute or thermodynamic temperature scale. Zero Kelvin is absolute zero, where all molecular activity stops. No “°” symbol is used. 0°C=273.15K; 100°C=373.15K.

Kilo: The prefix for one thousand (K). Kilowatt (kw): 1000 watts or 3412Btu per hour. Lag: 1. A time delay between the output of a signal and the response of the

instrument to which the signal is sent. 2. A time relationship between two waveforms where a fixed reference point on one wave occurs after the same point of the reference wave.

Least Significant Digit (LSD): The digit farthest to the right in a display.

Linearity: The deviation of an instrument’s response from a straight line.

Load: The electrical demand of a process expressed as power (watts), current (amps) or resistance (ohms).

Manual reset: The adjustment on a proportional control which shifts the proportional band in relation to the set point to eliminate droop of offset errors.

Maximum operating temperature: The maximum temperature at which an instrument or sensor can be safely operated.

Maximum power rating: The maximum power in watts that a device can safely handle.

Reference junction: The cold junction in a thermocouple circuit which is held at a stable known temperature. The standard reference temperature is 0°C (32°F); however, other temperatures can be used.

Relay (mechanical): An electromechanical device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other.

Relay (solid state): A solid state switching device which completes or interrupts a circuit electrically with no moving parts.

Repeatability: The ability of a probe or instrument to give the same output or reading under repeated identical conditions.

Resistance: The resistance to the flow of electric current measured in ohms (Ω). For a conductor, resistance is a function of diameter, resistivity (an intrinsic property of the material), and length.

Resolution sensitivity: The amount of temperature change that must occur before the control actuates. It may be expressed in temperature or as a percentage of the control’s scale.

Response time (Time constant): The time required by a sensor to reach 63.2% of a step change in temperature under a specified set of conditions. Five time constants are required for the sensor to stabilize at

99.3% of the step change value. Retransmit output: Analog output scaled to the process or the set

point value.

RFI: Radio frequency interference. RS232 or RS485 output signal: A serial interface suitable for con-

nection between a digital control and a personal computer, a host computer, or a printer.

RTD: A temperature sensing probe of finely wound platinum wire that displays a linear resistance change for a corresponding temperature change. The resistance increases as the temperature rises. A base resistance of 100ohms at 32°F is the industry (DIN) standard.

Saturation temperature: The boiling temperature of a liquid at the existing pressure.

SCFM: Volumetric flow rate in cubic feet per minute at 60°F (15°C) and standard atmospheric pressure.

SCR: Silicone Controlled Rectifier Secondary standard: A standard of unit measurement derived from a

primary standard.

Sensitivity: The minimum change in input signal to which an instrument can respond.

Set point: Control setting to achieve or maintain temperature. Sheath thermocouple: A thermocouple made out of mineral-insulated

thermocouple cable which has another metal sheath. Shield: Material surrounding a conductor(s) to prevent electrostatic or

EMI from external sources. Slide wire feedback: A potentiometer that varies the resistance to

control a valve position. Soak: To raise the temperature of a metal object in a heated environment

to produce a metallurgical change. Soft start: Reduces voltage on initial start-up which reduces power to

the heaters. If heater has accumulated moisture internally during a shut down, soft start will allow heater to dry before full voltage is applied so as to extend heater life.

Solid State Relay (SSR): A solid state switching device which completes or breaks a circuit electrically with no moving parts.

Measuring junction: The thermocouple junction referred to as the hot junction that is used to measure an unknown temperature.

Mechanical relay: An electromechanical device that completes or breaks a circuit by opening or closing electrical contacts.

Mega: The prefix for one million (M). Melting point: The temperature at which a substance transforms from

a solid phase to a liquid phase.

Micro: The prefix for one millionth. Microamp: 10 Micron: 10

-6

amps (one millionth of an amp).

-6

meters (one millionth of a meter).

Microprocessor: The central processing unit (CPU) that performs the logic operations in a micro-computer system. The microprocessor in a process or instrument control decodes instructions from the stored program, performs algorithmic and logic functions, and produces signals and commands.

Milli: The prefix for one thousandth. Milliamp: 10 Millivolt: 10

-3

amps (one thousandth of an amp).

-3

volts (one thousandth of a volt).

NEC: National Electrical Code NEMA: National Electrical Manufacturer’s Association NEMA 4X: A front panel rating designating the control as washdown

capable and corrosion resistant. NIST: National Institute of Standards and Technology, United States

Department of Commerce.

Noise: Undesirable electrical interference on the signal wires. Noise suppression: A device used to reduce electrical interference. Normal-mode rejection ratio: The ability of an instrument to reject

interference, usually of line frequency (50–60Hz), across its input terminals.

NPT: National Pipe Thread. Offset: The difference in temperature between the set point and the

actual process temperature. Also referred to as droop.

ohm: The unit of electric resistance. On/off controller: A controller whose action is fully on or fully off. Open Loop Control: A control system with no sensing feedback. Overshoot: Excursion of temperature above the set point. Phase: A time-based relationship between a periodic function and a ref-

erence. In electricity, it is expressed in angular degrees to describe the voltage or current relationship of two alternating waveforms.

Phase proportioning: A form of temperature control where the power supplied to the process is controlled by limiting the phase angle of the line voltage.

PID: Three mode temperature control — proportional, integral, (automatic reset), derivative(rate).

Polarity: In electricity, the quality of having two oppositely charged poles, one positive and one negative.

Potentiometer: 1. A variable resistor often used to control a circuit. 2. A balancing bridge used to measure voltage.

Primary standard (NBS): The standard reference units and physical constants maintained by the National Bureau of Standards upon which all measurement units in the United States are based.

Process alarm: A fixed alarm or secondary set point value independent of the primary set point. Should a process value exceed this value, an alarm condition would register.

Process variable: The parameter being controlled or measured such as temperature, relative humidity, flow, level, pressure, etc.

Proportional band: A temperature band in degrees within which a control’s proportioning function is active.

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Proportional control mode: When process temperature approaches

set point and enters the proportional band, the output is switched on and off at the established cycle time. The change in power to the load provides a throttling action which results in less temperature overshoot.

Ramp: A programmed rise or fail in temperature at a constant rate. Range: An area between two limits in which a measurement or control

action takes place. Typically expressed in upper and lower limits. Rankine (°R): An absolute temperature scale based upon the Fahrenheit

scale with 180° between the ice point and boiling point of water.

459.69°R=0°F. Rate (derivative): A control function that measures the rate of increase

or decrease of the system temperature and brings the control into an accelerated proportioning action. This mode prevents an overshoot condition at initial heat-up and with system disturbances.

Rate time: The interval over which the system temperature is sampled for the derivative function.

Span: The difference between the upper and lower limits of a range expressed in the same units as the range.

Specific gravity: The ratio of mass of any material to the mass of the same volume of pure water at 4°C.

Specific Heat: The ratio of thermal energy required to raise the temperature of a particle 1 degree to the thermal energy required to raise an equal mass of water 1 degree.

SSR: Solid state relay (see relay, solid state). Stability: The ability of an instrument or sensor to maintain a constant

output when a constant input is applied. Surge current: A current of short duration occurring when power is

initially applied to capacitive or resistive loads, usually lasting no more than several cycles.

Temperature gradient: The range of temperature variations at various physical locations throughout a thermal system.

Tera: The prefix for one trillion (T). Thermal expansion: An increase in size due to an increase in temper-

ature expressed in units of an increase in length or increase in size per degree, i.e., inches/inch/degree C.

Thermal lag: The time delay in the distribution of heat throughout a thermal system.

Thermal system: A regulated environment consisting of a heat source, heat transfer medium, sensing device and a process variable control instrument.

Thermistor: A temperature sensing probe made of a mixture of metal oxides and encapsulated in epoxy or glass. A large change in resistance is exhibited proportional to a change in temperature. The resistance usually decreases as temperature rises.

Thermocouple: A temperature sensing probe consisting of the junction of two dissimilar metals which has a millivolt output proportional to the difference in temperature between the “hot” junction and the lead wires (cold junction).

Thermocouple break protection: Fail-safe operation that assures output shutdown upon an open thermocouple condition.

Thermowell: A closed-end tube designed to protect temperature sensors from harsh environments, high pressure, and flows. They can be installed into a system by pipe thread or welded flange and are usually made of corrosion-resistant metal or ceramic material depending upon the application.

Transducer: A device which converts the parameter being measured into another form which is its output. For example, a thermocouple transforms heat into a millivolt output.

Transmitter (two-wire): A device which is used to transmit temperature data from either a thermocouple or RTD via a two-wire current loop. The loop has an external power supply and the transmitter acts as a variable resistor with respect to its input signal.

Triac: A solid state switching device used to switch alternating current wave forms.

Triple point (water): The thermodynamic state where all three phases, solid, liquid, and gas may all be present in equilibrium. The triple point of water is at .01°C.

TTL: Transistor-to-transistor logic. A form of solid state logic which uses only transistors to form the logic gates.

UL: Underwriters Laboratories, Inc. An independent laboratory that establishes standards for commercial and industrial products.

Ultraviolet: That portion of the electromagnetic spectrum below blue light (380 nanometers).

Undershoot: Excursion of temperature below set point. Ungrounded junction: A thermocouple junction fully insulated from

the sheath.

Viscosity: The inherent resistance of a substance to flow Volt: The (electrical) potential difference between two points in a circuit.

The fundamental unit is derived as work per unit charge —(V=W/Q). One volt is the potential difference required to move one coulomb of charge between two points in a circuit while using one joule of energy.

Voltage: An electrical potential which is measured in volts. VPFW SSR: A type of Solid State Relay with Variable Period and Full

Wave switching characteristics. Wattage: A measurement of electrical power. In a resistive circuit,

W=VI (see Ohms Law formulas). Working standard: A standard of unit measurement calibrated from

either a primary or secondary standard which is used to calibrate other devices or make comparison measurements.

Zero voltage switching: The making or breaking of a circuit timed such that the transition occurs when the voltage waveform crosses zero voltage; typically it is only found in solid state switching devices.

Page 89

A–4 Memo

he following table as a master copy for your settings.

Page 90

Page 91

A–5 Warranty

WARRANTY

Tempco Electric Heater Corporation is pleased to offer suggestions on the use of its products. However, Tempco makes no warranties or representations of any sort regarding the fitness for use, or the application of its products by the Purchaser. The selection, application, or use of Tempco products is the Purchaser's responsibility. No claims will be allowed for any damages or losses, whether direct, indirect, incidental, special, or consequential. Specifications are subject to change without notice. In addition, Tempco reserves the right to make changes– without notification to the Purchaser–to materials or processing that do not affect compliance with any applicable specification. TEC Temperature Controllers are warranted to be free from defects in material and workmanship for two (2) years after delivery to the first purchaser for use. Tempco's sole responsibility under this warranty, at Tempco's option, is limited to replacement or repair, free of charge, or refund of purchase price within the warranty period specified. This warranty does not apply to damage resulting from transportation, alteration, misuse, or abuse.

RETURNS

No product returns can be accepted without a completed Return Material Authorization (RMA) form.

TECHNICAL SUPPORT

Technical questions and troubleshooting help is available from Tempco. When calling or writing please give as much background information on the application or process as possible.

E-mail: [email protected] Phone: 630-350-2252

800-323-6859

Note: Information in this manual was deemed correct at the time of printing. The policy of Tempco is one of continuous development and product improvement, and we reserve the right to modify specifications and designs without prior notice. Not responsible for typographical errors.

Page 92

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