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User Manual - Tempco Electric Heater Corporation

1. 13 Retransmission Output Chart Recorder SM 20 30 C 2 40 50 Figure 5 18 Retransmission Application 61 NOTES 62 Chapter 6 Calibration Do not proceed through this section unless there is a defi nite need to recalibrate the controller If you do recali brate all previous calibration data will be lost Do not attempt recalibration unless you have the appropriate calibration eguip ment 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 Manual Calibration Procedures lt Perform step 1 to enter calibration mode STEP 1 Set the lockout DIP switch to the unlocked condition both switches 3 and 4 are off Press both scroll and down keys and release them quickly The operation mode menu will appear on the display Repeat this operation several times until appears on the display Press the scroll key for at least 3 seconds The display will show foi and the unit will enter calibration mode Output 1 and output 2 use their failure transfer values to control lt 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 19 and 20 t
2. RS 232 PC based software for this purpose The system is in stalled as shown in the diagram at right Figure 5 17 RS 485 Applications Twisted pair wire max distance 1 Km 60 5 10 RS 485 continued Setup menu Setup FUNC Enter setup mode to configure each TEC 4300 Choose FULL for FUNC 485 for COMM RTU COMM for PROT and select a different address ADDR for each unit Use the same values of BAUD PROT DATA PARI and STOP for the TEC 4300 s TEC99002 and TEC99923 Also refer to section 2 15 and section 4 8 ADDR Taking advantage of DAQ software the operator can monitor the process on the PC screen BAUD program the set point as well as other control parameters such as PID values download the ramp DATA and soak profile to the controllers execute the manual control or trigger auto tuning etc and PARI print out reports as required The historical data can be saved in the floppy drive hard drive or STOP on a CD for permanent storage 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 4300 to control the temperature of the solution being tested He is particularly interested in generating a test report containing the relationship between the concen
3. Color of overall sheath 16 2 7 RTD Input Wiring Figure 2 6 The RTD connections are shown in figure 2 6 with the compensating lead RTD Input Wiring connected to terminal 19 For two wire RTD inputs terminals 19 and 20 should be linked A three wire RTD offers the capability of lead resistance compensation provided that the three leads are the same gauge and egual in length RTD For the purpose of accuracy a two wire RTD should be avoided if possible A 0 4ohm lead resistance in two wire RTD will produce 1 C temperature error DIP Switch Three wire RTD 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 Figure 2 7 Input 1 Linear Voltage Wiring DC linear voltage and linear current connections for input 2 are shown in figure 2 9 and figure 2 10 0 1V 0 5V 1 5V 0 10 DIP Switch 0000000000 00000000000000000e0o00 0 20MA or DIP Switch 42005 Figure 2 8 Input 1 Linear Current Wiring 0 1V 0 5V 1 5V 0 10V Figure 2 9 Input 2 Linear Voltage Wiring 0 20mA or 4 20mA Figure 2 10 Input 2 Linear Current Wiring 17 2 9 CT Heater Current Input Wiring Heater 1 Heater 2 Heater 3 Figure 2 11 Contactor CT Input Wiring for Single Phase Heater not to exceed 50A Heater Supply Current Transformer SIS TEC99999 1 2 Mains Supply DIN Rail CT Si
4. 50 4 5 Remote Set Point 0 0 0 0 nnen 51 4 6 Differential Control ua sossun 51 4 7 Output Power Limits 52 4 8 Data Communication 52 4 9 Analog Retransmission 23 4 10 Digital Filter ecce sees er RR 53 4 11 Sleep Mode 0 0 00 eee 53 4 12 Pump Control soolon 54 4 13 Remote Lockout 0 0 0 0 e ee ee eee 54 Chapter 5 Applications 5 1 Pump Pressure Control 55 5 3 Heat Only 56 5 4 Cool Only Control 56 5 5 Heat Cool Control 0 0 0 0 puasa eee 57 5 6 Ramp and Dwell lt 57 5 7 Remote Set Point 58 5 8 Differential Control 0 00 et ragi 59 5 9 Dual Set Point PID 59 SSI0 RS 485 Bs ieee gid ost he ER E ac EA wag bns sores 60 5 11 RS2232 Ed TRUE ous 61 5 12 Retransmit vaa sv mud ERRARE eras 61 Chapter 6 Calibration 63 Chapter 7 Error Codes and Troubleshooting 65 Chapter 8 Specifications 67 Appendix 1 Menu Existence Conditions 69 2 Factory Menu Description 72 AS Memo cs dares eoe Qu dae Dr ep ues 74 AGO W rk nty 44er toe RE a TI NOTES Chapter 1 Overview 1 1 Features
5. Three Line Bridge Type a Transmitter Sensor or Sensor a SIS S 3 22 Manual Control Manual control may be used for the following purposes Exception 1 To test the process characteristics to obtain a step response as If OUTI is configured as ON OFF control i e PB1 0 if PBI is well as an impulse response and use these data for tuning a assigned or PB2 0 if PB2 is assigned by event input the controller controller will never perform manual control mode 2 To use manual control instead of a closed loop control if the sensor fails or the controller s A D converter fails Exiting Manual Control Press 4 keys the and the controller will revert to its previous 3 In certain applications it is desirable to supply a process with operating mode may be a failure mode or normal control mode a constant demand Operation Press Y until eee hand control appears on the display Press for seconds then the upper display will begin to flash and the lower display will show H_ The controller is now in manual control mode Press the lower Means display will show and H alternately where MV 1 38 4 for OUTI or heating indicates output 1 or heating control variable value f MV1 and indicates output 2 or cooling control Means variable value MV2 Now you can use the up and down keys to MV2 7 63 for OUT or cooling adjust the percentag
6. Figure 5 6 Cooling Control Example 56 5 5 Heat Cool Control An injection mold is reguired to be controlled at 120 C to ensure a consistent guality for the parts An oil pipe is buried in the mold Since plastics are injected at a higher temperature e g 250 C the circulation oil needs to be cooled as its temperature rises Here is an example PID heat cool is used for the example at right To achieve this set the following parameters in the setup menu FUNC BASC IN1 PT DN IN1U C DP1 1 DP OUTI REVR OITY RELY CYC1 18 0 seconds O1FT 0 0 OUT2 COOL O2TY 4 20 O2FT BPLS SELF STAR 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 Key menu FUNC INI INIU DPI OUTI OITY CYCI OIFT OUT2 O2TY O2FT SELF SP1 CPB DB 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 5 6 Ramp and Dwell Example 1 Temperature cycling chamber A c
7. High accuracy 18 bit input A D Sleep mode function Heater break alarm a Unigue High accuracy 15 bit output D A Soft start ramp and dwell timer Sensor break alarm Valuable Fast input sample rate 5 times second Programmable inputs thermocouple and pem Two function complexity levels RTD mA VDC a User menu configurable Analog input for remote set point and RS 485 RS 232 communication CT Analog retransmission Pump control V Fuzzy plus PID microprocessor based Event input for changing function and Signal conditioner DC power supply control set point A wide variety of output modules Automatic programming Programmable digital filter available Differential control Hardware lockout and remote lockout Safety UL CSA IEC1010 1 MN protection EMC CE EN61326 Auto tune function Loop break alarm Self tune function TEC 4300 Fuzzy Logic plus PID microprocessor based controller incorporates a bright easy to read 4 digit The function of Fuzzy Logic is LED display which indicates the process value Fuzzy Logic technology enables a process to reach a to adjust PID parameters predetermined set point in the shortest time with the minimum of overshoot during power up or externalload internally in order to make disturbance The units are housed in a 1 4 DIN case measuring 96mm x 96mm with 53mm behind paneldepth manipulation of output value The units feature three to
8. INIL are set according to input 1 signal IN2 IN2L IN2H are set according to input 2 signal INIU DPI IN2U DP2 are set according to input and input 2 signal PVMD P1 2 or P2 1 SPMD SPI 2 The response of PV2 will be parallel to PV1 as shown in the following diagram Setup PVMD P1 2 or PVMD P2 1 SPMD SP1 2 PV PV1 PV2 PV PV1 PV2 or PV2 PV1 Set point SP1 or SP2 Set point Time Figure 4 4 Relation between PV1 and PV2 for a Differential Control The PV display will indicate PV1 PV2 value if P1 2 is chosen for PVMD or PV2 PVI value if P2 1 is chosen for PVMD If you need PV1 or PV2 to be displayed instead of PV you can use the display mode to select PV1 or PV2 to be viewed See section 3 23 Error messages If P1 2 or P2 1 is selected for PVMD while Error PV1 or PV2 is selected for SPMD an Err message 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 INIUZIN2U DP1 DP2 otherwise an Er iS error code will appear 4 7 Output Power Limits MV1 In certain systems the heater or cooler is over powered such that the process is too heavily heated or cooled To avoid an excessive 100 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 s
9. 4 20mA 0 20mA Isolated 1 5V 0 5v Isolated 0 10V drive SSR 5V 30mA Isolated 4 20mA 0 20mA Isolated 1 5V 0 5v 9 Special Order Triac Output 1 240VAC SSR Special order O Example TEC 4300 4111101 e 90 264 operating voltage Input Standard Input e Output 1 Relay e Output 2 Relay Alarm 1 Form C Relay e RS 485 Communication Interface Accessories TEC99999 0 50amp AC current transformer TEC 101 101 Isolated 4 20mA 0 20mA analog output module TEC 101 114 Isolated 1 5V 0 5V analog output module TEC 101 115 Isolated 0 10V analog output module TEC 101 109 Isolated 1A 240VAC triac output module SSR TEC 101 111 Isolated 20V 25mA DC output power supply TEC 101 112 Isolated 12V 40mA DC output power supply TEC 101 113 Isolated 5V 80mA DC output power supply TEC 102 101 Isolated RS 485 interface module TEC 102 103 Isolated RS 232 interface module TEC 102 104 Isolated 4 20mA 0 20mA retransmission module TEC 102 105 Isolated 1 5V 0 5V retransmission module TEC 102 106 Isolated 0 10V retransmission module TEC99014 RS 232 interface cable 2M TEC99927 Modbus to USB converter Isolated 0 10V Triac Output 1A 240VAC SSR Isolated 20V 25mA DC Output Power Supply 8 Isolated 12V 40 mA DC Output Power Supply Isolated 5V 80mA DC Output Power Supply DL amp O A Spe
10. BPL2 bPLg OUT2 Bumpless Transfer Value Low 0 High 100 00 CJCL L JEL Sense Voltage of Cold Junction Calibration Low Low 31 680 High 40 320 mV 73 Use the following table as a master copy for your settings Use the following table as a master copy for your settings page 1 of 2 Display Your setting Display Your setting Format i Format Contained Parameter Notation Mm J Mm m Un n U ma I I ri 325 T zn ni D I S D S JI Pp O ET n D n UN mi m un zn Ti a oO Mm aA r nm r Q a nag nr RN ru uc O1HY p IH m E LE A1HY A2H lt zn n X uc 0 50 r ir n c 3 r1 ERE Setup FUNC Use the following table as a master copy for your settings page 2 of 2 Contained Parameter Display Your setting Contained Parameter Display Your setting Notation Format in Notation Format ri AdB ADG Ado 75 NOTES 76 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
11. e A1MD HOLD A1FN PV1 L 1 210 210 210 21 205 205 205 205 205 OFF 205 195 195 195 195 ON 195 195 Figure 3 7 Holding Process Alarm A1SP 200 A1HY 10 0 SP1 210 Process proceeds A1MD LT HO A1FN PV1 L TT Xy Xr 210 210 210 210 205 205 205 205 205 205 195 195 195 195 ON I 195 195 Figure 3 8 Latching Holding Process Alarm 36 3 9 Deviation Alarm 2 Types of A deviation alarm alerts the user when the process deviates too far from the set point Deviation Alarms The user can enter a positive or negative deviation value A1DV A2DV for alarm 1 i and alarm 2 A hysteresis value or 2 can be selected to avoid interference DE HI DE LO problems in a noisy environment Normally AIHY 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 AISP 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 Deviation alarm 1 Setup AIFN AIMD Adjust SP1 AIDV AIHY Trigger levels SP1 AIDV A1HY alarm latching alarm holding alarm and latching holding alarm See section 3 8 for Deviation alarm 2 descriptions of these alarm modes Setup OUT2
12. 32 F 32 F same as range of ae nan EET BS 89 88 ERES RS J Y J Table 1 7 Range Determination for A2SP Linear V mA If A2FN PV1 H PV1 L PV2 H PV2 L or SPEC Range of A2SP same as range of If PVMD Range of SP2 same as range of Exception If any of ATSP A2SP or SP2 is configured with respect to CT input its adjustment range is unlimited 14 Chapter 2 Installation Dangerous voltage capable of causing death can be present in this instrument Before installation or beginning any troubleshooting procedures the power to all eguipment must be switched off and isolated Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair Component replacement and internal adjustments must be made by a qualified maintenance person only To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture Do not use this instrument in areas under hazardous conditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified in chapter 8 2 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If there is any damage due to transit report the damage and file a claim with the carrier Write down the model number
13. 8 Types of Process Alarms PVI H PVI L PV2 H PV2 L P1 2 H P1 2 L D1 2 H D1 2 L Process Alarm 1 Setup AIFN AIMD Adjust AISP AIHY Trigger level AISP fiA1HY Process Alarm 2 that absolute trigger level an alarm occurs A process alarm is independent from the set point Adjust AIFN Alarm 1 function in the setup menu One of eight functions can be selected for process alarm These are PV1 H PVI L PV2 H Setup OUT2 A2FN A2MD PV2 L P1 2 H P1 2 L Adjust A2SP A2HY D1 2 H D1 2 L Trigger level A2SP fi A2HY When PVI H or PV1 L is selected the Reset Latching alarm alarm examines the 1 Power off PV1 value When PV2 H or PV2 L is 2 Apply event input in accordance lected th l with proper selection of EIFN examines 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 Examples A1SP 200 AIHY 10 0 p A1MD NORM A1FN PV1 H Pt 205 205 gt 205 205 205 195 195 195 195 orp 195 Figure 3 5 Normal Process Alarm e A1SP 200 A1HY 10 0 r d A1MD LTCH A1FN PV1 H 90885 Ao E Nv Nv x 1 v 7 1 v 205 205 ON 205 205 205 195 195 195 195 195 Figure 3 6 Latching Process Alarm Although the above descriptions are based on alarm 1 the same cond
14. AIMD 2 is selected as a deviation band alarm The trigger level for deviation band alarm Adjust SP1 AIDV 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 and alarm 2 These are normal alarm latching alarm holding alarm and Deviation band alarm 2 latching holding alarm See section 3 8 for descriptions of these alarm modes Setup OUT2 A2FN A2MD Adjust SP1 A2DV Trigger level SP14A1DV Examples Trigger level SP1 A2DV DB HI A1MD NORM SP1 100 A1DV 5 x indicates an Alarm Condition Process proceeds ale slp X QD 105 105 105 ON 105 OFF 105 Figure 3 13 100 100 100 100 100 Normal Deviation 95 OFF 95 95 95 95 Band Alarm A1FN DB LO A1MD LTCH SP1 100 A1DV 5 Process proceeds m Me T T T 105 105 105 105 105 105 Figure 3 14 100 100 100 100 100 ee 2i Latching Deviation 95 ON 95 95 Band Alarm A1FN A1MD HOLD SP1 100 A1DV 5 Process proceeds Ay 1 1 105 105 105 105 OFF 105 105 Figure 3 15 E 100 100 Holding Deviation 95 ON 95 Band Alarm DB HI A1MD LT HO SP1 100 A1DV 5 Process Process proceeds N 105 105 105 ON 105 105 k u E 100 95 38 l ly Tr l TN Nx is 1 is a Figure 3 16 o5 Latching Holding Deviation Band Alarm 07
15. 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 43 3 19 Auto tuning continued PV Set Point PV Set Point Auto tuning Auto tuning Begins Complete Warm up Waiting Cycle Cycle Learning Cycle New PID Cycle gt 2 Integral Time Pre tune Stage Figure 3 22 Auto Tuning Procedure Post tune Stage lt vy v On Off Control ON OFF Control PID Control 1 Time Cold Start Auto tunin Begins Auto tuning Pre tune Stage Complete Waiting Cycle Learning Cycle New PID Cycle 2 Integral Time Pre tune Stage Post tune Stage gt PID Control ON OFF Control PID Control 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 sta
16. C for INIU 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 ramping up or down by 10 C minute PV 200 C 100 C 30 C Time minutes 0 17 30 40 Figure 4 1 RAMP Function 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 event input Dwell The dwell timer can be used A1FN or A2FN Choose separately or in conjunction with a ramp If AIFN is set for TIMR E nr TIMER alarm will act as a dwell timer djust Similarly alarm 2 will act as a dwell Sing 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 AIFN F for INIU and set TIME 30 0 SP1 is set to 400 F initially and corrected to 200 F before the process reaches 200 F As the process reaches the set point i e 200 F the timer
17. 0 005 accuracy 0 20mA current source with 0 005 accuracy 0 300 ohm resistant source with 0 005 accuracy 2 A test chamber providing 25 C 50 C temperature range 3 A switching network SW6400 optional for automatic calibration 4 A calibration fixture equipped with programming units optional for automatic calibration Step 5 Set the DIP switch for RTD input Press the scroll key until the display DIP Switch Position shows EF 1 Send a 100 ohms signal to terminals 18 19 and 20 ON RTD Input 122 2952 using to the connection shown below Press the scroll key for at least 3 seconds The dis NE ain TEC 4300 play will blink for a 20 moment if it does not cal Figure 6 1 RTD Calibration ibration failed Step 6 Press the scroll key and the display will show 5 J Change the ohm s value to 300 ohms Press the scroll key for at least 3 seconds The display will blink for a moment while values are obtained for SR1 and REF last step If the display didn t blink or if any value obtained for SR1 or REFI is equal to 199 9 or 199 9 then calibration failed lt Perform step 7 to calibrate mA function if required for input 1 Step 7 DIP Switch Position Set the DIP switch for mA input Press y the scroll key until the display shows B B mA Input Send a 20mA signal to terminals 19 and 20 with the correct polarity Press the scroll key for at least 3 seconds The display will bli
18. 36 0 High 36 0 Set point 2 See Table 1 5 1 8 Q0 OF Proportional Band 2 Value Low High 18 09 W 2 Integral Time 2 Value Low 0 High 1000 sec 100 2 Derivative Time 2 Value Low 0 High 360 0 sec 25 0 D2 O1HY o THY Output 1 ON OFF Control 55 6 C I U rm de un a E a o nu nr a Hysteresis L 0 1 High 100 07F 0 OW I Low 01 Mon S d Low 0 Hoh gory r Basic Function Mode v FUNC E unk Function Complexity Level bASL 1 Full Function Mode No communication function RS 485 interface RS 232 interface 4 20 mA analog retransmission output Mon COMM Conn Communication Interface 0 20 mA analog retransmission output 0 1V analog retransmission 7 output 0 5V analog retransmission output 1 5V analog retransmission output 0 10V analog retransmission output PROT COMM Protocol Selection 0 uy Modbus protocol RTU mode o 1 4 Parameter Description page 2 of 7 Notation Format Description Value 0 3 Kbits s baud rate 0 6 Kbits s baud rate 1 2 Kbits s baud rate 2 4 Kbits s baud rate 4 8 Kbits s baud rate Rud Baud Rate of Digital COMM jin 9 6 Kbits s baud rate 14 4 Kbits s baud rate 19 2 Kbits s baud rate 28 8 Kbits s baud rate 38 4 Kbits s baud rate Data Bit count of Digital 7 data bits COMM L E 8databits 190 j n Even parity Parity Bit of Digital COMM Odd parity No parity bit Stop Bit Count of
19. A2FN A2MD Adjust SP1 A2DV A2HY Examples Trigger levels SP1 A2DV A2HY 1 Mas A1FN DE HI A1MD NORM SP1 100 A1DV 10 A1HY 4 XX Indicates an Alarm Condition Process proceeds Lrocess proceeds gt X X 112 112 ON 112 112 112 108 108 108 108 OFF 108 N 100 100 100 100 100 Figure 3 9 Normal Deviation Alarm A1FN DE HI A1MD LTCH SP1 100 A1DV 10 A1HY 4 Process proceeds p x x Xe 112 112 ON 102 112 112 108 108 108 108 Figure 3 10 100 100 100 100 100 Latching Deviation Alarm A1HY DE LO A1MD HOLD SP1 100 A1DV 10 A1HY 4 Process proceeds xc xc 100 100 19 n 100 100 100 92 92 92 92 OFF 1 9 Figure 3 11 88 88 88 ONL 88 88 88 Holding Deviation Alarm A1HY DE LO A1MD LT HO SP1 100 A1DV 10 A1HY 4 Process Process proceeds p x xc E n ie 100 S 92 88 ON 388 37 1 TN Figure 3 12 S Latching Holding 88 Deviation Alarm 3 10 Deviation Band Alarm 2 types of A deviation band alarm presets two reference levels relative to set point Two types Deviation Band Alarms of deviation band alarm can be configured for alarm 1 and alarm 2 These are DB HI DB LO deviation band high alarm A1FN or A2FN select DB HI and deviation band low xs I alarm A1FN or A2FN select DB LO A1SP and A1HY are hidden if alarm 1 is Deviation band alarm 1 selected as a deviation band alarm Similarly A2SP and A2HY are hidden if alarm Setup AIFN
20. DEVI 55 5 3 Heat Only Control Set An oven is designed to dry the products at SP1 150 0 150 C for 30 minutes and then stay TIME 30 0 unpowered for another batch A TEC 4300 eguipped with dwell timer is used for this purpose The system diagram is ow shown at right a E To achieve this function set the following parameters in the setup menu Alm2 FUNC BASC basic function sEC 4300 IN1 K_TC INIU C DP1 1 DP OUTI REVR OITY RELY CYC1 18 0 O1FT 0 0 A1FN TIMR A1FT ON SELF NONE Auto tuning is performed at 150 C Timer ALM1 Fiaure 5 5 Heat Control Example 5 4 Cool Only Control A TEC 4300 is used to control a refrigerator with Refrigerator the temperature below 0 C To avoid set point Setup Summary adjustment beyond the desired range SPIL is set FUNC BASC at 10 C and SPIH is set at 0 C Because the _ IN1 PT DN temperature is lower than the ambient a cooling action is reguired so select DIRT for OUTI IN1U C Since output 1 is used to drive a magnetic DP1 1 DP contactor select RELY for OITY Because a small OUT1 DIRT temperature oscillation is tolerable use ON OFF _ control to reduce the over all cost To achieve O1Ty RELY ON OFF control 1 is set to zero and 1 is SP1L 10 C set at 0 1 C SP1H 0 C Mains User Menu Supply PB1 0 C O1HY 0 1 C PV in _ J Li a U E TEC 4300 4 v
21. Figure 2 5 The thermocouple input connections are shown in figure 2 5 The correct type of m02 Thermocouple thermocouple extension lead wire or compensating cable must be used for the entire LEM Input Wiring 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 sas on the thermocouple Thermocouple Cable British American German French extension leads are Type Material BS ASTM DIN NFE shown in table 2 1 white blue red yellow Copper Cu T Constantan Cu Ni blue red brown blue blue blue brown blue Iron Fe yellow white red yellow J Constantan Cu Ni blue red blue black black black blue black Nickel Chromium f brown yellow red yellow K Ni Cr N blue red green purple padamu ag yellow green yellow Ni Al Y 9 R Pt 13 Rh Pt AE va k yellow S Pt 1096Rh Pt blue re W i e green green green white green Pt 30 Rh Use grey red Use B Pt 6 Rh Copper red grey Copper Wire grey grey Wire Table 2 1 Thermocouple Cable Color Codes
22. 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 current 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 Storage temperature 40 C to 60 Humidity 0 to 9096 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 96mm W X96mm H X65mm D 55mm depth behind panel Weight 255 grams Approval Standards Safety UL873 11th edition 1994 CSA C222 No 24 93 EN61010 1 IEC1010 1 Protective class IP 20 housing and terminals with protective covers EMC EN61326 68 1 Menu Existence Conditions Menu Existence Conditions Table Page 1 of 3 A2SP Exists if A2FN selects PV1H PV1L PV2H PV2L P12H P12L D12H or D12L A2DV Exists if A2FN selects DEHI D
23. Indication Value of Special Sensor Low 19999 High 45536 SIG6 5 DB Point 6 Signal Value of Special Sensor Low 19999 High 45536 IND6 1 ngB Point 6 Indication Value of Special Sensor Low 19999 High 45536 SIG7 G L 1 Point 7 Signal Value of Special Sensor Low 19999 High 45536 IND7 1 nid 1 Point 7 Indication Value of Special Sensor Low 19999 High 45536 108 5 LB Point 8 Signal Value of Special Sensor Low 19999 High 45536 IND8 n gE Point 8 Indication Value of Special Sensor Low 19999 High 45536 sic9 5 59 Point 9 Signal Value of Special Sensor Low 19999 High 45536 IND9 149 Point 9 Indication Value of Special Sensor Low 19999 High 45536 LE Signal Type of Special Sensor Low 0 High 3 DATE GALE Manufacturing Date of Product Low 0 High 3719 __ Serial Number of Product Low 1 High 999 These parameters are available only if SPEC is selected for IN1 72 A 2 Factory Menu Description continued N Heel Parameter Description Range ie HOUR Hour Working Hour Value Low O High 65535 Hours HRLO Helo Fractional Hour Value Low 0 High 0 9 Hour ERR1 Err Historical Error Record 1 Low 0 High FFFF 0 ERR2 Err 2 Historical Error Record 2 Low 0 High FFFF 0 DELI dEL ASCII Input Delimiter Low 0000 High 007F 000A BPL1 hPL OUT Bumpless Transfer Value Low 0 High 100 00 96
24. be maintained at 80 C Use a programmable 24 hour cycle timer for this nm nc purpose The timer output is used to control the event input Set SPMD SP1 2 and EIFN SP2 or Her or SP P2 if the second PID is required to be used for the second set point SPI 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 Format of SP2 Value SP2F choose Actual Value or Deviation Value Refer to section 4 1 for more descriptions about SP2F function 49 4 3 Second PID Set In certain applications the characteristics of a process are strongly related to its process value The TEC 4300 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 TH and TDI 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
25. 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 PID Fuzzy control Warm Up Load Disturbance Time 1 2 Ordering Code 4300 O O L L Power Input 1 2 3 4 5 6 7 4 90 264 VAC 50 60 HZ 5 11 26 VAC or VDC 9 Special Order Signal Input Alarm 1 Alarm 2 Communications 1 Standard Input 0 None 0 None 0 None 1 Form C Relay 1 Relay 1 RS 485 Input 1 Universal Input Thermocouple J K T E B 2A 240VAC 2A 240VAC o ng 232 R S N L 9 Special order 9 Special order 3 Retransmit 4 20mA S m RTD PT100 DIN PT100 JIS 0 20 Current 4 20mA 0 20 mA 4 x p x Voltage 0 1V 0 5V 1 5V Output 1 I 0 10V 5 Retransmit O 10V Input 2 CT and Analog Input 0 None Output 2 9 Special order CT 0 50 Amp AC Current 1 Relay 2A 240VAC Transformer 2 Pulsed voltage to 0 None Analog Input 4 20 mA drive SSR 5V 30mA 1 Relay 2A 240VAC 3 Isolated 2 Pulsed voltage to 0 20mA 0 1V 0 5V 1 5V 0 10V Input 3 Event Input EI
26. 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 INI INIL INIH According to sensor 1 signal IN1U PU DP1 2 DP IN2 IN2L IN2H According to sensor 2 signal IN2U PU DP2 2 DP OUTI REVR OITY 4 20 PVMD P1 2 SPMD SPI 2 Adjust SPl 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 above diagram indicates PV2 instead of PV 5 9 Dual Set Point PID The TEC 4300 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 AIFNZPVIH A1MD NORM EIFN PID2 PVMD PV1 SPMD MINR 2 Adjust the followi
27. process heater 12 Bumpless transfer 13 Remote lockout break loop break 13 PV1 shift 24 Isolated DC Power supply then you can use basic mode 3 1 Input 1 Press Y 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 PTJS ni Linear 4 20 0 20 0 1V 0 5V 1 5V 0 10 Default J TC if F is selected K TC if C is selected IN1U Selects the process unit for Input 1 Range F PU process unit If the unit is neither nor F then PU is selected Default C or F DP1 Selects the location of the decimal point for most not all process related parameters DP1 Range T C and RTD NO DP 1 DP Linear NO DP 1 DP 2 DP 3 DP Default 1 DP IN1L Selects the low scale value for Linear type input 1 IN1L Hidden if T C or RTD type is selected for IN1 IN1H Selects the high scale value for Linear type input 1 IN1H Hidden if T C or RTD type is selected for IN1 How to use IN1L and IN1H If 4 20mA is selected for IN1 SL specifies the input signal low i e 4mA SH process value Figure 3 1 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 a
28. special or conseguential 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 77 RETURNS No product returns can be accepted without a completed Return Material Authorization RMA form TECHNICAL SUPPORT Technical guestions 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 techsupport tempco com Phone 630 350 2252 800 323 6859 Complete Your Thermal Loop System With Over 100 000 Various Items Available from Stock Electric Heating Elements Videographic Data Recorders Thermocouples and RTD Assemblies Temperature Measurement SCR Power Controls Current Indicators Solid State Relays Thermocouple and Power Lead Wire Mechanical Relays Wiring Accessories TEMPCO s Visionar
29. taking advantage of its PUMP function a O F the TEC 4300 can be used to create an n sv nn Amt wars economical yet versatile solution for these applications Here is an example u Pressure Reservoir The water pressure in this example must be controlled at 10Kg cm To achieve this the following devices are used for this example Pressure 2j A Y Sensor TEC 4300 Inverter To supply a variable freguency AC voltage to the motor OUTI IN1 E ES Motor A 3 induction motor 4 20 4 20 mA Water Pump Any appropriate economical type of NS Spee pump Control Pump Motor Pressure Sensor A three wire or two wire 30 type of pressure transducer with a 0 20Kg cm AC range Pressure Reservoir Provides smoother pressure for the system TEC 4300 Order a TEC 4300 with standard Inverter input 4 20mA output 1 20V DC output 2 for sensor power uis Figure 5 1 A Water Supply System Set the following parameters Adjust the following parameters in the setup menu in the user menu FUNC FULL AISP optional COMM optional REFC 3 IN1 4 20 PB1 10 00 IN1U PU TI121 DP1 2 DP TD1 0 2 IN1L 0 SP2 0 50 IN1H 20 00 PL1 100 IN2 NONE Refer to section 4 12 for more details OUTIZREVR OITY 4 20 0 OUT2 DCPS A1FN optional EIFNZNONE PVMD PV1 FILT 1 SELF NONE SLEP NONE SPMD PUMP SP1L 5 00 SP1H 15 00 SP2F
30. 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 3 18 Self tuning Self tuning provides an alternate option for tuning the controller It is activated when YES is selected for SELF When self tuning is used 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 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 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 NONE is selected for SELF The controller is used for on off control PB 0 The controller is used for manual reset T1 0 The controller is in a loop break condition The controller is in failure mode e g sensor break The con
31. 0 21 328 to 1652 PT100 210 C to 700 C Gn art 82 PT100 200 C to 600 C Us o xv ov 10 108 V oam ero OV 8mVto70mV 0 05 Linear Output 13V to 11 5V 0 05 302 KQ 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 67 Specifications continued 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 500 Dielectric Strength 2500VAC for 1 minute DC voltage supply characteristics installed at output 2 Ripple Isolation Voltage Barrier 0 15 V 0 05 Vp p 500 VAC Alarm 1 Alarm 2 Alarm 1 relay Form C rating 2A 240VAC 200 000 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 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 AKbits sec Data Bits 7 or 8 bits Parity Bit None even or odd Stop Bit 1 or2 bits Communic
32. 1 0 E 5 K gt VA Figure 2 16 Alarm 1 Wiring rA L Imr 120V 240V Mains Supply Pl ead Kia a Three Phase No Fuse Delta Contactor Breaker Heater Load Relay Output to Drive Contactor 24 2 14 Alarm 2 Wiring Max 2A Resistive o 120V 240V o Mains Supply Relay Output Direct Drive Figure 2 17 Alarm 2 Wiring 120V 240V o Mains Supply Three Phase No Fuse Delta Contactor Breaker Heater Load Relay Output to Drive Contactor 25 2 15 RS 485 5 lt GA GOH had FA 2 had rA 121 K G ra had 2 L6H lt E IEA 25 had 21 ra ATA 25 K ES K i Twisted Pair Wire KN S SIS y 55d ss K IFI Ll lt R FS L rz H EY gt IS 4 Z FS JN 4 EN RI T K r TIES s iks rN SA 52 1 SI lt HIS S S RS e s RS TY 3 R SN C34 ES TS rS s R S C34 K RS 485 to RS 232 network adaptor TEC99001 or TEC99927 RS 232 TX1 Max 247 units can be linked Terminator 220 ohms 0 5W 26 Figure 2 18 RS 485 Wiring EN 2 16 RS 232 Figure 2 19 9 pin RS 232 Wiring RS 232 port TEC99014 If you use a conventional 9 pin
33. 2 or P2 1 is used for Check and correct setup values of PVMD and SPMD PME while PN SET C Hon for SPMD Dependent Difference of PV1 and PV2 can t be used for PV while PV1 values used for PV and SV will create incorrect result or PV2 is used for SV of control Illegal setup values used Before COOL is used for Check and correct setup values of OUT2 PB1 PB2 TI1 OUT2 DIRT cooling action has already been used for TI2 and OUT1 IF OUT2 is required for cooling control the OUT1 or PID mode is not used for OUT1 that is PB1 or control should use PID mode 2 9 and OUT1 2 0 and TI1 or TI22 0 should use reverse mode heating action otherwise don t use OUT2 for cooling control Illegal setup values been used unequal IN1U and IN2U or Check and correct setup values of IN1U IN2U DP1 DP2 unequal DP1 and DP2 while P1 2 or P2 1 is used for PVMD PVMD SPMD A1FN or A2FN Same unit and decimal point or PV1 or PV2 is used for SPMD or P1 2 H P1 2 L D1 2 H should be used if both PV1 and PV2 are used for PV SV or D1 2 L are used for A1FN or A2FN alarm 1 or alarm 2 Illegal setup values used OUT2 select AL2 but Check and correct setup values of OUT2 and A2FN OUT2 A2FN select NONE will not perform alarm function if A2FN select NONE 7 Illegal setup values used Dwell timer TIMR is Check and correct setup values of A1FN and A2FN Dwell selected for both A1FN and A2FN timer can only be properly used for single alar
34. 2 to continue control Without Bumpless Transfer PV lt Power interrupted T Sensor break Set point Large deviation Time Since the hardware and software need time to be initialized the control is abnormal as the power is recovered and results in a large disturbance to the process During the sensor breaks the process loses power With Bumpless Transfer PV Power interrupted Sensor break Set point Load varies Small deviation Time Figure 3 21 Benefits of Bumpless Transfer 42 Bumpless transfer setup 1 OIFT BPLS 2 O2FT BPLS Bumpless transfer occurs as 1 Power starts within 2 5 seconds 2 Failure mode is activated 3 Manual mode is activated 4 Calibration mode is activated When bumpless transfer is configured the correct control variable is applied immediately as power is recovered and the disturbance is small During sensor breaks the controller continues to control by using its previous value If the load doesn t change the process will remain stable If the load changes the process may run away Therefore you should not rely on bumpless transfer for extended periods of time For fail safe reasons an additional alarm should be used to announce to the operator when the system fails For example a sensor break alarm if configured will switch to failure state and tell the operator to use manual control or take proper security action
35. 20 0 1V 0 5V 1 5V or 0 10 Exists if FUNC selects FULL Exists if IN2 selects 4 20 0 20 0 1V 0 5V 1 5V or 0 10 Exists unconditionally Exists if OUT2 selects COOL 70 Menu Existence Conditions Table Page 3 of 3 Parameter hin Existence Conditions Notation A1FN Exists unconditionally A1MD Exists if A1FN selects DEHI DELO DBHI DBLO PV1H PV1L PV2H PV2L P12H P12L D12H D12L LB or SENB A2FN Exists if ATFN is not NONE Exists unconditionally Exists if A2FN selects DEHI DELO DBHI DBLO PV1H PV1L PV2H PV2L P12H P12L D12H D12L LB or SENB A2FT Exists if A2FN is not NONE EIFN PVMD Exists if FUNC selects FULL FILT SELF Exists unconditionally SLEP Exists if FUNC selects FULL SPMD SP1L Exists unconditionally SP1H SP2F Exists if EIFN selects SP2 or SPP2 or if SPMD selects PUMP Exists unconditionally 71 A 2 Factory Menu Description Mis Mii Parameter Description Range pii EROR Eror Current Error Code Low 0 High 40 PROG Prat r T contains Pogan Low 0 Hg 1599 MODE nadE foo Lockout Status Code and Current System Low 0 High 3 5 __ CMND nnd Command Password Low 0 High 65535 JOB Job Job Password Low O High 65535 DRIF d___ Warm up Drift Calibration Factor Low 5 0 High 5 0 ADO Ald D Z
36. 3 11 Heater Break Alarm A current transformer Part Number TEC99999 should be installed to detect the heater current if a heater break alarm is reguired The CT signal is sent to input 2 Heater break alarm 1 Setup IN2 CT and the PV2 will indicate the heater current in 0 lamp resolution The range of the A1FN PV2 L current transformer is 0 to 50 0amp For more detailed descriptions about heater AIMD NORM current monitoring please see section 3 24 AIHY 0 1 Examples Adjust AISP nda T VUES A furnace uses two 2KW heaters connected in parallel to warm up the process The line voltage Heater break alarm 2 is 220V and the rating current for each heater is 9 09A If we want to detect any one heater break Setup IN2 CT set AISP 13 0A AIHY 0 1 AIFN PV2 L AIMD NORM then up N A2FN PV2 L No heater breaks 1 heater breaks 2 heaters breaks A2MD NORM Mo vo A2HY 0 1 XX Alarm X Alarm Figure 3 17 2 Heater Break Alarm Adjust A2SP 20 30 20 30 20 30 Trigger level A2SP A2HY 10 40 10 40 10 40 Limitations 1 Linear output can t use heater break alarm 2 CYCI should use 1 second or longer to detect heater current reliably o a o o a O o a 3 12 Loop Break Alarm Loop Break alarm Select LB for A1FN 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 set OUT2 to AL2 and A1FN to LB TIME A1SP AIDV and A1HY are hidden if alarm 1 is configured as a
37. Burned out line fuses Troubleshooting procedures 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 Refer to table 7 2 for some probable causes and actions 1 If an error message is displayed refer to table 7 1 to see what caused it and what action to take to correct the problem 2 Check each point listed below Experience has proven that many control problems are caused by a defective instrument Line wires are improperly connected No voltage between line terminals Incorrect voltage between line terminals Connections to terminals are open missing or loose Thermocouple is open at tip Thermocouple lead is broken Shorted thermocouple leads Table 7 1 Error Codes and Corrective Actions bol Error Description Corrective Action Illegal setup values been used PV1 is used for both PVMD Check and correct setup values of PVMD and SPMD PV and SPMD and SV can t use the same value for normal control setup values used P1
38. C OR oA 9c ORG A The flow chart shows a complete listing of all parameters For actual application the number of available parameters depends on setup conditions and should be less than that shown in the flow chart See Appendix A 1 for the existence conditions of each parameter You can select at most 5 parameters put in front of the user menu by using SEL1 SEL5contained at the bottom of setupmenu 1 6 System Modes The controller performs closed loop control in its normal control mode condition The controller will maintain its normal control mode when you are operating the user menu setup menu or display mode reloading default values or applying event input signals Under certain conditions the normal control mode will transfer to an exception mode The exception modes include sleep mode manual mode failure mode calibration mode and auto tuning mode All of these modes perform in an open loop control except auto tuning mode which performs ON OFF plus PID closed loop control The mode transfer is governed by the priority conditions A lower priority mode can not alter a higher priority mode as shown in figure 1 6 System Modes Sleep mode See section 4 11 Manual mode See section 3 23 Failure mode See section 3 17 Calibration mode See chapter 6 Auto tuning mode See section 3 20 Normal control mode Se
39. Digital I One stop bit EN COMM Two stop bits Retransmit IN1 process value Retransmit IN2 process value Retransmit IN1 IN2 difference process value I Retransmit IN2 IN1 difference process value Analog Output Function Retransmit set point value Retransmit output 1 manipulation value Retransmit output 2 manipulation value Retransmit deviation PV SV Value ADLO Haba 01252 Output Low Seal Low 19999 High 45536 AHI AoH nalog Output High Scale Low 19999 High 45536 17 thermocouple type thermocouple EL T type thermocouple E type thermocoup IN1 Sensor Type Selection type thermocoup iR type thermocoup rss type thermocoupi Table 1 4 Contained in Setup Menu Parameter Description page 3 of 7 Basic Display Parameter Function Notation Format in iL in IH IN1 Sensor Type Selection N IN1 Unit Selection IN1 Low Scale Value Low 19999 IN1 High Scale Value Low 19999 3 3 m a Py m IE C3 c3 rr IN2 Signal Type Selection Ca C3 C3 wm un E3 7 IN2 Unit Selection Same as IN1U i n amp u IN2L nb IN2H Output L Signal Type IN2 High Scale Value Low 19999 Output 1 Function Lorre N type thermocouple L type thermocouple PT 100 ohms DIN curve PT 100 ohms JIS curve 4 20 mA linear current input 0 20 mA linea
40. ELO DBHI or DBLO Exists if SPMD selects MINR or HRR Exists if TI1 is used for control depends on Event input and EIFN selection but Tl12 0 and OFST PB120 or if TI2 is used for control depends on Event input and EIFN selection but TI2 0 and PB2 0 REFC Exists if SPMD selects PUMP SHIF Exists unconditionally PB1 TH Exists if PB1 0 TD1 CPB DB Exists if OUT2 select COOL Exists if EIFN selects SP2 or SPP2 or if SPMD selects PUMP Exists if EIFN selects PID2 or SPP2 Exists if EIFN selects PID2 or SPP2 provided that PB2 0 O1HY If PID2 or SPP2 is selected for EIFN then O1HY exists if PB1 0 or PB2 0 If PID2 or SPP2 is not selected for EIFN then O1HY exists if PB1 0 A1HY Exists if ATFN selects DEHI DELO PV1H PV1L PV2H PV2L P12H P12L D12H or D12L A2HY Exists if A2FN selects DEHI DELO PV1H PV1L PV2H PV2L P12H P12L D12H or D12L PL1 If PID2 or SPP2 is selected for EIFN then PL1 exists if PB1 0 or 2 0 If PID2 or SPP2 is not selected for EIFN then PL1 exists if PB1 0 Exists if OUT2 selects COOL TI2 TD2 69 Menu Existence Conditions Table Page 2 of 3 E Existence Conditions Notation FUNC Exists unconditionally COMM Exists if FUNC selects FULL Exists if COMM selects 485 or 232 Exists if COMM selects 4 20 0 20 0 1V 0 5V 1 5V or 0 10 Exists if COMM selects 4 20 0 20 0 1V 0 5V 1 5V or 0 10 and AOFN is not MV1 and MV2 Exists unconditionally Exists if IN1selects 4 20 0
41. FF Alarm output OFF if sensor fails A1FT A IFL Mode on Alarm output ON if sensor fails ma A2FN Alarm 2 Function Same as A1FN 2 A2MD Ez Haad 2 Operation Mode Same as A1MD x 2 par 2 Failure Transfer Same as A1FT par Event input no function SP2 activated to replace SP1 2 2 TD2 activated to replace PB1 TH TD1 SP2 PB2 TI2 TD2 activated to N replace SP1 PB1 TI1 TD1 Resetalarm 1 output EIFN Event Input Function 7 Reset alarm 2 output ri wc Reset alarm 1 amp alarm 2 j 4 Disable Output 1 j Disable Output 2 i Disable Output 1 amp Output 2 Lock All Parameters O second time constant 0 2 second time constant C 0 5 second time constant 1 second time constant Filter Damping Time 2 seconds time constant Fi LE Constant of PV 5 seconds time constant 10 seconds time constant nuo Ca Ca C3 Ca 20 seconds time constant 30 seconds time constant 60 seconds time constant SHE SEI Self Tuning Function Self tune function disabled SELF i Selection Self tune function enabled SLEP SLE Sleep mode Function Sleep mode function disabled Selection Use PV1 as process value Use PV2 as process value PVMD PYAd PV Mode Selection Use PV1_ PV2 difference as process value Use PV2_ PV1 difference as process value LI 2 Sleep mode function enabled 12 Table 1 4 Parameter Description page 6 of 7 C
42. 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 TD 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 If you don t need 1 Input 1 sensor break latch 14 Programmable SP1 1 Second setpoint thermocouple RTD hold or normal alarm range 2 Second PID volt mA 6 Alarm 2 relay for 15 Heat cool control 3 Event input 2 Input 2 CT for heater deviation deviation 16 Hardware lockout break detection band process heater 17 Self t 4 Soft start RAMP 3 Output 1 heating or break loop break 5 Remote set point cooling relay SSR sensor break latch Autotune 6 Complex process value SSRD volt mA hold or normal alarm 19 ON OFF P PD PI 7 Output power limit 4 Output 2 cooling Dwell timer D JHN 8 Digital communication relay SSR SSRD Heater break alarm 20 User defined menu 9 Anal m SEL nalog retransmission volt mA DC power Loop break alarm supply Mos 21 Manual control 10 Power shut off sleep mode Sensor break alarm 11 Dieital fil 5 Alarm 1 relay for 5 22 Display mode Digital filter deviation deviation 11 Failure transfer 12 Pump control 23 Reload default values P band
43. RS 232 cable instead of TEC99014 the cable must be modified according to the following circuit diagram To DTE PC RS 232 Port 1 DCD TEC 4300 kea 3TD Figure 2 21 4 DTR Configuration of 5 GND RS 232 Cable 6 DSR 7 RTS 8 CTS 9 RI Female DB 9 27 2 17 Analog Retransmission Indicators PLC s Recorders Data loggers Inverters etc The total effective resistance of serial loads can t exceed 500 ohms Retransmit Current Figure 2 22 Analog Retransmission Wiring Indicators Load PLC s Recorders Data loggers Inverters etc 1 5V 0 5V al is X O Olo O oc c The total effective resistance of parallel loads should be greater than 10K Ohms Retransmit Voltage 28 2 18 Programming Port See figure 1 3 in section 1 3 to find the programming port location See Figure 1 3 in Section 1 3 to find the programming port location Programmer connector and ATE connector inserted here Figure 2 23 Programming Port Wiring Access hole on the bottom view lt TEC99013 TEC99003 90 264VAC To Power To PC NOTE The programming port is used for off line automatic setup and testing procedures only Don t attempt to make any connection to these jumpers when the unit is used for a normal control purpose 29 NOTES 30 Chapter 3 Programming Basic Functions This unit provides a useful parameter
44. TI2 and TD2 4 RS AI RS A1 Resets alarm 1 as the event input is activated However if the alarm 1 condition is still existent alarm 5 RS A2 will be retriggered when the event input is released 6 RAI12 RS A2 Resets alarm 2 as the event input is activated However if the alarm 2 condition is still existent alarm 7 DOI 2 will be retriggered when the event input is released 8 DO2 R A1 2 Resets both alarm 1 and alarm 2 as the event input is activated However if alarm 1 and or alarm 2 9 D OI2 are still existent alarm 1 and or alarm 2 will be triggered again when the event input is released 10 LOCK 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 D O2 Disables output 2 as the event input is activated D O1 2 Disables both output 1 and output 2 as soon as the event input is activated When any of D O1 D O2 or D O1 2 are selected for EIEN 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 SP2F Function Defines the format of SP2 value If ACTU is selected for SP2F inthe SP2F Format of SP2 value setup menu the event input function will use the SP2 value for its second set point If DEVI ACTU SP2 is an actual value is selected for SP2F the SP1 value wi
45. User s Manual TEC 4300 Self Tune Fuzzy PID Process Temperature Controller GTA TEMPCO Electric Heater Corporation 607 N Central Avenue Wood Dale IL 60191 1452 USA Oe S Tel 630 350 2252 e Toll Free 800 323 6859 Fr SLECTRN coge Fax 630 350 0232 e E mail info tempco com Committed to Excellence Web www tempco com Manual TEC 4300 Revision 10 2013 NOTES Warning Symbol A 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 Information in this user s manual is subject to change without notice Using the Manual e InstalletS Read Chapter 1 2 e Basic Function Read Chapters 1 3 5 e Enhanced Function User Read Chapters 1 3 4 5 e System Read Chapters Expert SERRA Ee Read Page 10 Copyright O 2003 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 1 Overvi
46. ation 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 Oma 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 PV2 high low alarm PV1 or PV2 high low alarm PV1 PV2 high low alarm Loop break alarm Sensor break alarm User Interface Dual 4 digit LED displays Upper 0 55 14mm lower 0 4 10mm 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 0 100 096 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
47. brator K TC K 2 Stay at least 20 minutes in still air at room temperature 25 3 C Figure 6 2 Cold Junction Calibration Setup The 5520 calibrator is configured for K type thermocouple output with internal compensation Send a 0 00 C signal to the unit under calibration The unit under calibration is powered in a still air room with a temperature of 25 3 C Allow at least 20 minutes to warm up The DIP switch is located at the TC input Perform step 1 as stated above then press the scroll key until the display shows ZE Press the up and down keys until a value of 0 00 is obtained Press the scroll key at least 3 seconds The display will blink for a moment until a new value is obtained If the display didn t blink or if the obtained value is egual to 5 00 or 40 00 then calibration failed lt Perform step 11 to calibrate the gain of cold junction compensation if required If a test chamber for calibration is not available perform step 10N to use a nominal value for the cold junction gain Step 11 Set up the eguipment the same as in step 10 The unit under calibration is powered in a still air room with a temperature of 50 3 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 ii Press the up and down keys until a value of 0 0 is obtained Press the scroll k
48. cial order Range set by front keyboard Need to order accessory 99999 if Heater Break detection is required Related Products TEC99001 Smart network adapter for third party software converts 255 channels of RS 485 or RS 422 to RS 232 network TEC99002 Smart network adapter for DAO software converts 255 channels of RS 485 or RS 422 to RS 232 network TEC99923 DAO software for data acquisition and control 1 3 Programming Port and DIP Switch Table 1 1 DIP Switch Configuration Figure 1 3 Access Hole Overview DIP Switch TC RTD mV Input 1 Select 0 1V 0 5V 1 5V 0 10V 0 20 mA 4 20 mA All parameters are Unlocked Only SP1 SEL1 SEL5 are unlocked Lockout Only SP1 is unlocked All Parameters are locked E O EO BE Factory Default Setting The programming port is used for off line automatic setup and testing procedures only Do not attempt to make any connection to these pins when the unit is being used for normal control purposes When the unit leaves the factory the DIP switch is set so that TC and RTD are selected for input 1 and all parameters are unlocked unless a different configuration is specified J 0FF 112134 Rear m Terminal E E r Access Hole The programming port is used to connect to TEC99003 for automatic programming TEC99013 pro
49. completed Application 1 programmed by the set point Choose SP P2 for EIFN 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 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 AIFN NORM for AIMD 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 Apply signal to O Event input Event input Setup EIFN choose PID2 or SP P2 EIFN SP P2 EIFN PID2 Alarm output controls the input so the PID values will change from PB1 TII and TDI to PB2 TI2 and TD2 Refer to section 5 9 for more details 4 4 Ramp and Dwell Ramp The ramping function is performed SPMD Choose during power up as well as any time Ai nr Unit minute the set point is changed Choose or Hege Unit hour MINR or HRR for SPMD and the unit will perform the ramping function The rate is programmed by using RAMP which is found in the user menu Adjust O crt RAMP Example without dwell timer Select MINR for SPMD
50. configured as proportional control PB1 0 and BPLS is selected for OIFT then output 1 will perform bumpless transfer Thereafter the previous averaging value of 1 will be used for controlling output 1 2 If output 1 is configured as proportional control PB1 0 and a value of 0 to 100 096 is set for OIFT 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 PB120 then output 1 will be driven OFF if O1EN selects REVR and be driven ON if O1EN selects DIRT Output 2 failure transfer if activated will perform 1 If COOL is selected for OUT2 and BPLS is selected for OIFT then output 2 will perform bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 2 If COOL is selected for OUT2 and a value of 0 to 100 0 96 is set for O2FT then output 2 will perform failure transfer Thereafter the value of OIFT 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 AIFT Exception If AIFN 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 AIFT If AIFN is configured for dwell timer TIMR alarm 1 will not perform failure transfer Alarm 2 failure transfer is activa
51. ction as the unit fails power starts or manual mode starts 0 ren Output 2 no function VA OUT2 outo Output2 Function 1 0 PID cooling control r DC power supply module 3 gL installed Output 2 Signal Same as O1TY CYC2 Output 2 Cycle Time Low 0 1 High 100 0 sec N Select BPLS bumpless transfer or 0 0 100 0 O2FT ert Output 2 Failure Transfer 96 to continue output 2 control function as the OL Mode z unit fails power starts manual mode starts lt S d 0 none No alarm function 1 Ei Ar Dwelltimer action 2 JEH Deviation high alarm dEL p Deviation low alarm 4 dk Deviation band out of band alarm 5 dhl Deviation band in band alarm 6 py IH IN1 process value high alarm V ASEN BP Alarm 1 Function 7 PY IN1 process value low alarm 8 PU PH IN2 process value high alarm 9 PU IN2 process value low alarm 10 P AH IN1 or IN2 process value high 11 12 IN1 or IN2 process value low alarm wd IPH process value 13 d H e L difference process value 14 L h Loop break alarm 15 SEnb Sensor break or A D fails Normal alarm action Latching alarm action Zx A1MD H ind Alarm 1 Operation Mode Hold alarm action Latching amp Hold action Table 1 4 Parameter Description page 5 of 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value Lr i i Alarm 4 Paiute Transfer 0
52. ctions correctly Pump control features 1 Minimum oscillation of pressure 2 Rapidly stabilized Guaranteed pump stop 4 Programmable pump stopping interval 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 loses pressure the controller will shut off the pump for as long as possible 3 The controller will restart the pump to control the pressure at the set point as soon as the pressure falls below a predetermined value i e SP1 SP2 Programming guide 1 Perform auto tuning to the system under such conditions that pressure is exhausted at typical rate A typical value for PB1 is about 10Kg cm TII is about 1 second TDI is about 0 2 seconds 2 If the process oscillates around the set point after auto tuning then increase until the process can be stabilized at the set point The typical value of 1 is about half to two times the range of the pressure sensor W Increasing FILT filter can further reduce the oscillation amplitude on the display 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
53. e heater is powered and the current value will remain unchanged while the heater is unpowered PV2 will indicate the heater current For information on how to read PV2 value please refer to section 3 23 NOTES If the heater to be measured is controlled by output 1 then CYCI should be set for 1 second or longer and OITY 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 adeguate 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 TEC99999 Setup IN2 CT OITY or O2TY RELY SSRD or SSR CYC2 1 second Limitations 1 Linear output type can t be used 2 CYCI 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 On certain occasions it is desirable to retain these values after the parameter values have been changed Here is a convenient way to reload the default values Operation Press Y several times until FILE 0 default file FILE 1 default file Elec appears Then press 2 The upper display will show Use the up a
54. e section 3 24 3 26 4 1 Priority High Sleep Mode Figure 1 6 System Mode Priority Manual Mode Failure Mode Low Request Request Request Calibration Auto tuning Normal Mode Mode Control Mode Calibration mode auto tuning mode and normal control mode are in the same priority level Sleep mode is in the highest priority level 1 7 Parameter Description Table 1 4 Parameter Description page 1 of 7 Display Parameter Range Default Format Description Value e 100 0 m e OK o Dwell Time Low High 6553 5 minutes ISP Alarm 1 Set point See Table 1 5 1 6 AOT POA 200 0 C 200 0 C 10 0 C gt Alarm 1 Deviation Value Low 360 0F 9 360 0 18 0 F 100 0 Alarm 2 Set point See Table 1 5 1 7 212 0 F 200 0 C High 200 0 C 10 0 360 0 360 0 18 0 ia 500 0 C RAMP Ramp Rate Low 0 High 900 0 F oo OFST aF 5L Value for P control Low 0 High 400 0 Ref Constant f inh REFC PRETI EE ail Low 0 60 200 0 C 5 200 0 SH PV1 Shift offset Value Low 360 0 F High 360 0 F i 200 0 10 0 C PB1 Proportional Band 1 Value Low 0 High 900 07F 18 0 F TM Integral Time 1 Value Low 0 High 1000 sec 100 Derivative Time 1 Value Low 0 High 360 0 sec OW 1 cooling Proportional Band L High 255 100 Heating Cooling Dead Band nh Negative Vales Overlap Low
55. e unit Verify that the ratings of the output devices and the inputs as specified in chapter 8 are not exceeded Electrical power in industrial environments 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 we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the controller This wire is a twisted pair construction with foil wrap and drain wire The drain wire is to be attached to ground at one end only 15 SSI Figure 2 2 Lead Termination 90 264 VAC gt 47 63 Hz 15 VA OP1 2 Alarm 1 COM Figure 2 3 Alarm 2 AO TX1 AO TX2 2 RTD Rear Terminal Connection Diagram 2 4 Power Wiring The controller is supplied to operate at 11 26 VAC VDC or 90 264 Check that the installation voltage corresponds to the power rating indicated on the product label before connecting power to the controller Fuse 0 5 90 264 VAC or o p 11 26 VAC VDC This equipment is designed for installation in an enclosure which provides adequate protection against electrical shock The enclosure must be connected to earth ground Figure 2 4 Local requirements regarding electrical installation should be rigidly Power Supply Connections observed Consideration should be given to prevent unaut
56. e value between process and set point i e PV SV This value is used to control output 1 and output 2 PH PV1 shows the process value of input 1 on PVLO P gt upper display Ma B PV2 shows the process value of input 2 on the MV2 upper display PB shows the current proportional band value DV 22 used for control PV1 Bui shows the current integral time used for PV2 pus control PB Fb TD shows the current derivative time used for control TI t Since the controller is performing fuzzy control the values of PB TI and TD may TD L dj change from time to time CJCT CJCT shows the temperature at the cold junction measured in independent of the PVR Per unit used Pura PVR Shows the changing rate of the process in PVRH Pe C or F or PU per minute It may be negative PVRL F 1 if the process is going down PVRH PVRL The maximum and mini mum changing rate of the process since power up as measured in 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 4 v keys 3 24 Heater Current Monitoring TEC99999 a current transformer should be eguipped to measure the heater current Select CT for IN2 The input 2 signal conditioner measures the heater current while th
57. e 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 COOL is selected for OUT2 46 3 23 Display Mode Operation Press Y several times until display appears on the upper display Then press to enter display mode You can select more parameters to view by pressing Or pressing 4 to 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 Z H4 _ _ shows the percentage 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 minimum values of the process on the upper display The show the historical extreme maximum or 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 to record new peak process values MV1 MV2 show the process value on the upper display and H shows the percentage control value for output 1 while E _ 2 shows the percentage control value for output 2 DV shows the differenc
58. elected PLI 5096 for OUT2 then PL2 is hidden If the controller is used for ON PL2 OFF control then both PL1 and PL2 are hidden Operation Press for seconds then press 9 several times to reach PL1 and PL2 PL1 and PL2 are adjusted by using the up and down keys with range of 0 100 MV2 Example OUT2 COOL PB1 10 0 C CPB 50 PL1 50 PL2 80 100 Output 1 and output 2 will act as the following curves 80 NOTE The adjustment range of and MV2 C for manual control and or failure transfer are not limited by PL1 and PL2 I 5 C OUT2 Figure 4 5 Power Limit Function 4 8 Data Communication Two types of interfaces are available for data communication These are the RS 485 and RS 232 interfaces Since RS 485 uses a differential architecture to drive and sense signal instead of a single ended architecture which RS 232 uses RS 485 is less sensitive to RS 485 Benefits Long distance Multiple units noise and more suitable for communication over longer distances RS 485 can RS 232 Benefits communicate without error over a distance of 1km while RS 232 is not recommended Direct connection to a PC for distances over 20 meters RS 485 Setup Using a PC for data communication is the most economical method The signal is FUNC FULL transmitted and received through the PC communication port generally RS 232 Since COMM 485 a standard PC can t support an RS 485 port a network adapte
59. ensor break detection 0 2 A Sensor open for TC RTD and mV inputs below 1mA for 0 8V MA 3mA 27mA 0 05 7050 input current V 4 20mA input below 0 25V for 1 5V input unavailable for 1 3V 11 5V 0 05 302 KQ other inputs Sensor break responding time Within 4 seconds for TC RTD and mV inputs 0 1 second for 4 20mA 1 5V inputs Input 3 event input Characteristics Logic low 10V minimum 0 8V maximum Logic high 2V minimum 10V maximum Accuracy Input s i Type Range External pull down resistance 400K W maximum External pull up resistance 1 5MW minimum J 120 C to 1000 C 2 22 MO N 184 F to 1832 F Functions select second set point and or PID reset alarm 1 200 C to 1370 and or alarm 2 disable output 1 and or output 2 328 F to 2498 F remote lockout 250 C to 400 KH aa Output 1 Output 2 E xg ES 148 F to 1652 F Relay rating 2A 240 VAC life cycles 200 000 for resistive 0 C to 1820 C iin DoF 200 C to 2 2 MQ Pulsed voltage source voltage 5V current limiting 32 F to 3308 82020 resistance 66W 0 C to 1767 8 C Rm AINE NN 32 F to 3214 F Linear output characteristics Garr 3212 we pze Tolerance Tolerance Capacity 9 250 C to 1300 C 418 F to 2372 F ZAMS 4 20mA 3 8 4mA 20 21mA 5002 max L 200009005 22Mo 0 20 2
60. ero Calibration Coefficient Low 360 High 360 ADG Ald Ato D Gain Calibration Coefficient Low 199 9 High 199 9 V1G U ID Voltage Input 1 Gain Calibration Coefficient Low 199 9 High 199 9 CJTL CIEL ide naon Low Temperature Calibration Low 5 00 C High 40 00 C CJG JL Cold Junction Gain Calibration Coefficient Low 199 9 High 199 9 REF1 Reference Voltage 1 Calibration Coefficient for RTD 1 Low 199 9 High 199 9 SR1 Sr Serial Resistance 1 Calibration Coefficient for RTD 1 Low 199 9 High 199 9 MA1G mH IL mA Input 1 Gain Calibration Coefficient Low 199 9 High 199 9 V2G Ug Voltage Input 2 Gain Calibration Coefficient Low 199 9 High 199 9 sic1 G L Point 1 Signal Value of Special Sensor Low 19999 High 45536 IND1 1 nd Point 1 Indication Value of Special Sensor Low 19999 High 45536 SIG2 5 Go Point 2 Signal Value of Special Sensor Low 19999 High 45536 IND2 1 nde Point 2 Indication Value of Special Sensor Low 19999 High 45536 sic3 5 G4 Point 3 Signal Value of Special Sensor Low 19999 High 45536 IND3 1 ng3 Point Indication Value of Special Sensor Low 19999 High 45536 SIG4 G GH Point 4 Signal Value of Special Sensor Low 19999 High 45536 IND4 1 mg Point 4 Indication Value of Special Sensor Low 19999 High 45536 58165 5 55 Point 5 Signal Value of Special Sensor Low 19999 High 45536 IND5 n g5 Point 5
61. ershoot over the set point will occur If a lower negative value of DB greater overlap is used an excessive overshoot over the set point can be minimized but an unwanted cooling action will occur It is adjustable in the range 36 0 to 36 0 of PBI or PB2 if PB2 is selected A negative DB value shows an overlap area over which both outputs are active A positive DB value shows a dead band area over which neither output is active 34 3 7 Dwell Timer Alarm 1 or alarm 2 can be configured as dwell timer by selecting Error Code TIMR for AIFN 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 minutes ranging from 0 to 6553 5 minutes Once the process reaches the set point the dwell timer starts to count from zero until timed out The timer relay will remain unchanged until time out The dwell timer operation is shown as diagram at right If alarm 1 is configured as dwell timer AISP AIDV AIHY and AIMD are hidden A1 or A2 The case is the same for alarm 2 Time Example Set AIFN TIMR or A2EN TIMR but not both Adjust TIME in minutes AIMD if AIFN TIMR A2MD if A2FN TIMR is ignored in this case Timer starts Figure 3 4 Dwell Timer Function 35 3 8 Process Alarms A process alarm sets an absolute trigger level or temperature When the process could be PV1 PV 2 or PVI PV2 exceeds
62. es spece eR Re 32 3 3 Configuring User 32 3 4 Heat Only Control isss 00 0 0 eee eee 33 3 5 Cool Only Control iso ses ay akan eo 33 3 6 Heat Cool Control 34 3 7 Dwell Diet oles s mk 35 3 8 Process Alarms esee 36 3 9 Deviation Alarms 37 3 10 Deviation Band Alarms 38 3 11 Heater Break Alarm 39 3 12 Loop Break Alarm 39 3 13 Sensor Break Alarm 40 3 14 SPI Range i ae peace eis ek gare qusun esta lea 40 3 15 PVL Shift lure da ed nU ene 40 3 16 Failure Transfer esee eere 41 3 17 Bumpless Transfer 42 3 18 Self tummg u uluya SERRE m r er n 43 3 19 AUto tuning cee ek mh Rs 43 3 20 Manual Tuning sees 45 3 21 Signal Conditioner DC Power Supply 46 CONTENTS Page No Chapter 3 continued 3 22 Manual Control ecer uu eese saldo s 46 3 23 Display Mode er en 47 3 24 Heater Current Monitoring 47 3 25 Reload Default Values 47 Chapter 4 Full Function Programming 4 Event Input i usos ERE OKE 49 4 2 Second Set Point 49 4 3 Second PID Set zu uu ss s suysu on dhe wand nia Reg 50 4 4 Ramp and Dwell
63. ew 121 Features ee RR er Rer Ree 1 1 2 Ordering Code ccce juon mia emere 2 1 3 Programming Port and DIP Switch 3 1 4 Keys and Displays 4 1 5 Menu OVEIVIEW Se tees SE 6 1 6 System Modes 7 1 7 Parameter Description 8 Chapter2 Installation 2 Unpacking 262 929 rr Re Go hee pa 15 2 2 MOUNTINE eei oet Ear IRR pte and 15 2 3 Wiring Precautions uu usyay uska anan u eee 15 2 4 Power Wiring 4 2 22 saman iiiu ares 16 2 5 Sensor Installation Guidelines 16 2 6 Thermocouple Input Wiring 16 2 7 RTD Input Wiring 2 2 aswa wasaqa 17 2 8 Linear DC Input Wiring 17 2 9 CT Heater Current Input Wiring 18 2 10 Event Input wiring ookoo eene 19 2 11 Output 1 Wiring 0 ee eee 20 2 12 Output 2 Wiring sers uu 22 2 13 Alarm 1 Wiring 24 2 14 Alarm 2 Wiring ciseau a i 25 2 15 RS 485 yea ne hu ep RADI E 26 2 16 RS 232 aetu pasa OE RR DEBERE eR re s 27 2 17 Analog Retransmission 28 2 18 Programming Port 2 3 22 29 Chapter 3 Programming Basic Functions Sel Input 1 eere re aee E Her 31 3 2 0UT1 and OUTI Typ
64. ey 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 egual to 199 9 or 199 9 then calibration failed This setup is performed in a high temperature chamber therefore it is recommended to use a computer to perform the procedures Step 11N Perform step 1 as stated above then press the scroll key until the display shows 5 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 lt Final step Step 12 Set the DIP switch to your desired position refer to section 1 3 Automatic calibration procedures The programming port see section 2 18 of the TEC 4300 can be used for automatic calibration The eguipment reguired for automatic calibration is available upon reguest 64 Chapter 7 Error Codes and Troubleshooting This procedure reguires access to the circuitry of a unit Short across terminals under live power Accidental contact with line voltage is Open or shorted heater circuit possible Only qualified personnel should perform these Open coil in external contactor procedures Potentially lethal voltages are present
65. f PB2 The control result is unsatisfactory TD TD2 assigned 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 seconds Of course you can use other reasonable values for PID before tuning according to your previous experiences But don t use a zero value for PB1 and TII 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 v 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 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 Auto tune function advantage Consistent tuning results can be obtained As the process reaches the set point value the unit enters a waiting cycle The waiting cycle elapses for a double integral time TII 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
66. gnal Input CD C D Figure 2 12 CT Input Wiring for Contactor Three Phase Heater not to exceed 100A Three Phase Heater Power 66666931 CT Signal Input TEC99999 TEC99999 Out 1 2 Make sure that the total current through TEC99999 does not exceed 100A rms in a 3 Phase system 18 2 10 Event Input wiring Figure 2 13 oF Event Input Wiring Open Collector Input Switch Input 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 19 2 11 Output 1 Wiring Max 2A Resistive 120V 240V Mains Supply u kani a SS L 1 Figure 2 14 Output 1 Wiring r S S i m L id bagel SI m LJ gt 471 3 221 E221 Ie 35 SP 1 zA T K s s RS 3 tr HE 521 1 Relay Output Direct Drive 120V 240V Mains Supply Heater 070 0 Power Three Phase No Fuse Relay or Triac SSR Delta Contactor Breaker Output to Drive Heater Contactor Load 120V 240V Mains Supply 39115 30 mA 5V Pulsed Voltage to Drive SSR 25 624 lt L lt zr EH k ad S HEH lt 20 2 11 Output 1 Wiring continued 0 20mA 4 20mA Maxi
67. gramming cable also reguired 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 SELI SELS 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 1 4 Keys and Displays The unit is programmed by using the three keys on the front panel The available key functions are listed in the following table Table 1 2 Keypad Operation TOUCHKEYS FUNCTION DESCRIPTION Up Ke Press and release guickly to increase the value of parameter Press and hold to accelerate increment speed Down Ke Press and release quickly to decrease the value of parameter y Press and hold to accelerate decrement speed lt Scroll Key Scrolls through the parameters in order Allows access to more parameters on user menu also used to enter manual bs Enter Key mode auto tune mode default setting mode and to save calibration data for at least a seconds during calibration procedure Press Start Record Key Resets historical values of PVHI and PVLO and start to record the peak process for at least 6 seconds value Reverse Scroll Key Scrolls through the parameters in reverse order during menu scrolling Mode Key Selects the operation mode i
68. hamber 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 OUTI REVR relay output OUT2 COOL 4 20mA output SPMD MINR INIU C DP1 1 DP The circuit diagram and its temperature profile are shown at right Plastics Freezer Injection Mold 120 C o Alm2 TEC 4300 O Figure 5 7 Heat Cool Control Example Chamber Freezer C72 TIME 60 0 minutes SP1 60 0 C SP2 10 0 CPB 100 96 RAMP 14 0 C minute AC Relay TEC 4300 Figure 5 8 A Temperature Cycling Chamber 57 5 6 Ramp and Dwell continued The TEC 4300 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 a
69. hen press DIP Switch Position the scroll key for at least 3 seconds The display will blink for a moment A A A T C Input until a new value is obtained If the display didn t blink or if the obtained value is equal to 360 or 360 then calibration failed STEP 3 Press the scroll key until the display shows Fat Send a 60mV signal to terminals 19 and 20 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 lt Perform step 4 to calibrate the voltage function if required for input 1 STEP 4 Set the DIP switch for voltage input Press the scroll key until the display ar DIP Switch Position ON shows i Send a 10V signal to N d N B 0 10V Input terminals 19 and 20 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 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
70. horized 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
71. ignal for id SX AOHI which should be accordant with retransmission option used Five types of retransmission output are available These are 4 20mA 0 20mA 0 5 1 5V and 3 AO 0 10V There are eight types of parameters a AO 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 14 for a complete description Select a value for AOLO corresponding to output zero and select a value for AOHI corresponding to output SPAN Terminals 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 Output Signal SH AOS SL Parameter Value AOLO AOV AOHI SH SL AOHI AOLO AOHI AOLO SH SL Figure 4 6 Conversion Curve for Retransmission Formula AOS SL AOV AOLO AOV AOLO AOS SL Notes The setup values used for AOHI and AOLO NOTES must not be equal otherwise incorrect AOHIZAOLO values will occur However AOHI can be AOHI gt AOLO set either higher or lower than AOLO If Direct conversion AOHl is set higher than AOLO it will result AOHI lt AOLO in a direct conversion If AOHI is set lower than AOLO it will result in a reverse conversion Reverse conversion Example A control
72. igned with a fixed order in which the parameters scroll The TEC 4300 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 SEL 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 TDI C PB DB SP2 PB2 TD TD2 When using the up and down keys to select the parameters you may not see all of the above parameters The number of visible parameters is dependent on the setup condition The hidden parameters for the specific application are also deleted from the SEL selection Example AIEN selects TIMR selects DE HI PB1 10 TI1 0 SELI selects TIME SEL2 selects A2 DV SEL3 selects OFST SEL4 selects PB1 SELS selects NONE Now the upper display scrolling becomes 32 SEL1 un r n tl Ep N un m r nu n Fa E w un rm r ER m m au un Fm rile uy SI 3 4 Heat Only Control Heat Only ON OFF Control Select REVR for OUTI set PB1 to 0 SPI is used to adjust set point value OIHY is used to adjust dead band for ON OFF contr
73. itions can be applied to alarm 2 00000000000000000000000000000000000000000000000000000000000000000 alarm occurs if the PV1 PV2 difference value exceeds the trigger level The trigger level is determined by AISP Alarm 1 set point and AIHY 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 AIHY can be set with a minimum 0 1 value AIDV 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 SPI or SP2 see section 4 1 event input Afterwards the alarm performs the same function as a normal alarm Latching Holding Alarm A1MD LT HO A latching holding alarm performs both holding and latching function 000900000000000000000000000000000000000000000090900000009 A1SP 200 A1HY 210 0 SP1 210 Process proceeds
74. l OFF control cool only P PD control and cool only PID control are the same as the descriptions in section 3 5 for DUTT 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 SP1 01HY 2 SP1 Dead band O1HY SP1 O1HY 2 5 I I Ti OUT1 Action I I Time Figure 3 3 Cool Only ON OFF Control 33 I I I Time I Time Figure 3 2 Heat Only ON OFF Control Setup P OUTI rEt 20 CYCI if RELAY SSRD or SSR is selected for OITY Adjust SP1 OFST TIME if enabled 00 TDI Setup PID OUTI OITY CYCI if RELAY SSRD or SSR is selected for OITY SELF NONE or YES Adjust SP1 TIME if enabled PB1 00 TII 90 Tdl 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 Refer to section 3 4 in which similar descriptions for heat only control can be applied to cool only control 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 Table 3 1 Heat Cool Control Setup Setup Values A1FN A1MD A1HY or or or OUT1 OUT2 O1HY OFST PB1 TD1 CPB A2FN A2MD A2HY x
75. l stability as shown by the comparison curves below disturbance to the process during tuning and can be used at any time M Wt MEME Figure 1 1 Digital communications formats RS 485 RS 232 or 4 20mA retransmission uzzy Fuzzy PID System are available as an additional option These options allow the TEC 4300 to be N integrated with supervisory control systems and software alternatively to drive remote displays e E al inference Digital igita igita chart recorders or data loggers information 77 rates r S Detuzzitier information Two different methods can be used to program the TEC 4300 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 RS 485 or RS 232 COMM port For nearly a hundred years PID control has been used and has proven to be an efficient controlling method by many industries yet PID has difficulty dealing with some sophisticated systems such as second and higher order systems long time lag systems during set point change and or load disturbance circumstances etc The PID principle is based on a mathematical model which is obtained by PID control with properly tuned PID parameters 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 Temperature imperfections of PID
76. la vfer CON 2 19993 indicates Abstract Characters n nc Outi o O F Out2 SV n Alm2 TEC 4300 n Outi Out2 Alm1 030 Alm2 TEC 4300 Out2 2 438 Alm2 TEC 4300 4 v Outi Out2 Almi n Alm2 TEC 4300 2 4 v Figure 1 5 Display Sequence of Initial Message All segments of display and indicators are left off for 0 5 second All segments of display and indicators are lit for 2 seconds Display program code of the product for 2 5 seconds The left diagram shows program no 4 for TEC 4300 with version 39 Display Date Code and Serial number for 2 5 seconds The left diagram shows Year 2001 Month May 5 Date 22nd and Serial number 192 This means that the product is the 192nd unit produced on May 22nd 2001 Note that the month code A stands for October B stands for November and C stands for December Display the used hours for 2 5 seconds The left diagram shows that the unit has been used for 23456 2 hours since production Program Code LI LILA LI Program Version Program No Date Code od JI 1 Date 31st Month December Year 2001 ir LL 1 5 Menu Overview User Menu Hand Manual for 3 seconds Con
77. ll be added to SP2 The sum of SP1 and SP2 SP1 SP2 DEVI SP2 is a deviation value 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 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 17 and pin 16 The signal O Event input applied to the event input may come from a timer a PLC an alarm relay a manual switch or other Event input device Select SP2 for which is in the setup menu This is available only when SPI 2 MIN R or HR R is used for SPMD Application 1 A process is reguired to be heated to a higher temperature as soon as its Setup pressure exceeds a certain limit Set SPMD SP1 2 EIFN SP2 or 2 if the second PID is choose SP2 or SPP required for the higher temperature too The pressure gauge is switched ON as it senses a higher Apply Signal To pressure Connect the output contacts of the pressure gauge to the event input SPI is set for a Availability normal temperature and SP2 is set for a higher temperature Choose ACTU for SP2F SPMD choose Application 2 An oven is required to be heated to 300 C from 8 00AM to 6 00PM After gr ie 6 00PM it should
78. 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 The holding mode and latching holding mode are not recommended for loop break alarm since the 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 Setup AIFN LB AIMD NORM LTCH Loop break alarm 2 Setup OUT2 AL2 A2FN LB A2MD NORM LTCH respond as guickly as it occurs If the process value doesn t increase or decrease by the time 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 if config Heater ured occurs when any fol lowing conditions happen 1 Input sensor is discon nected or broken Switching Device 2 Input sensor is shorted 3 Input sensor is defective 4 Input sensor is installed Controller outside isolated from the process 5 Controller fails A D converter damaged ps 6 Heater or chiller valve pump motor etc breaks fails
79. lternately you can use the auto tuning program for the new process or manually ALM1 or OUT1 DIRT NONE X ALM2 ale ME OUT1 OUT2 REVR COOL nnn w Adjust to meet process requirements DE HI x X x or NORM PV1 H DE LO x or NORM PV1 L DE LO 40 x x or NORM PV1 L DE HI x or NORM x PV1 H DE HI 40 5 x or NORM x PV1 H set the appropriate values for PB1 TI1 and TDI according to the historical records 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 0 0 0 0 0 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 decrease CPB If the cooling action is too strong increase CPB The value of CPB is related to PB and its value remains unchanged throughout the self tuning and auto tuning procedures Adjustment of CPB is related to the cooling media used If air is used as the cooling medium set CPB at 100 If oil is used as the cooling medium set CPB at 125 If water is used as the cooling medium set CPB at 250 Adjust as necessary 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 ov
80. m output N Correct the communication software to meet the protocol n Een Communication error register address out of range Don t issue an over range register address to the slave 12 Er 12 Communication error access a non existent parameter Don t issue a non existent parameter to the slave 14 ler iy Communication error attempt to write a read only data Don t write a read only data or a protected data to the slave 15 er 45 error Write vallis which IS out of range fo Don t write an over range data to the slave register 1 The PID values obtained after auto tuning procedure are out of range Retry auto tuning b 2 Don t change set point value during auto tuning procedure Fail to perform auto tuning function 3 Don t change Event input state during auto tuning procedure 4 Use manual tuning instead of auto tuning 29 EEPE EEPROM can t be written correctly Return to factory for repair Input 2 IN2 sensor break or input 2 current below 1 mA 38 if 4 20 mA is selected or input 2 voltage below 0 25V if Replace input 2 sensor 1 5V is selected Input 1 IN1 sensor break or input 1 current below 1 mA if 4 20 mA is selected or input 1 voltage below 0 25V if Replace input 1 sensor 1 5V is selected EXLES A to D converter or related component s malfunction Return to factory for repair Troubleshooting continued Table 7 2 Common Failure Causes and Corrective Actions Symptom Probable Causes Cor
81. mp 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 1000 PVMD PV1 SPMD MINR 2 Adjust the following parameters in the user menu TIME 30 0 minutes 200r sda ea maaan RAMP 20 0 C minute Use SP1 PID1 EM Use SP2 PID2 SP1 1000 C Time Minutes 5 2 200 Figure 5 16 Dual Set Point PID Profile PL1 100 3 Set the proper values for PB1 TII 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 above A tile making plant has five production t 1 t 2 16 lines Each produc tion line is eguipped e TOON 2 with 16 TEC 4300 8888 z 8886 B 8888 units to control the H888 18888 8866 temperature for the kiln They want to program the con Control Room trollers and monitor the process from the control room to TEC99923 improve guality and productivity A cost effective solution for the above applica tion would be to use 80 TEC 4300 units plus a TEC99001 smart network adap TEC99001 ter and TEC99923 TEC 4300 TEC 4300 TEC 4300
82. mum Load 500 Ohms Linear Current 0 1V 0 5V 1 5V 0 10V Mimimum Load 10K Ohms A E m TN SO Ki K N _ ra lt ra Ta s i ESSE RI RS RS 62 EN Linear Voltage 4 BS Max 1A 240V 120V 240V Mains Supply Triac SSR Output Direct Drive 21 2 12 Output 2 Wiring Max 2A Resistive 120V 240V Mains Supply Figure 2 15 Output 2 Wiring NI KN SUS IE T SS Relay Output Direct Drive Yi N 120V 240V Mains Supply o o Three 5 o Phase Heater 0 0 Power Three Phase No Fuse Relay or Triac SSR Delta Contactor Breaker Output to Drive Heater Contactor Load 120V 240V Mains Supply I IT T 3 30 mA 5V Iz Pulsed Voltage E N 4 31 Pulsed Voltage to Drive SSR all S T E 2 12 Output 2 Wiring continued Maximum Load 500 Ohms 0 20mA Linear Current 0 1V 0 5V 1 5V 0 10V Mimimum Load 10K Ohms S SY N 24 4 Linear Voltage L Led H H RI S Ai gt e R 1A 240V 120V 240V Mains Supply Triac SSR Output Direct Drive Hoa lt T c Lo IN gt 23 2 13 Alarm 1 Wiring Max 2A Resistive 120V 240V Mains Supply e Relay Output Direct Drive LJ rA H C9
83. n sequence Resets the front panel display to normal display mode also used to leave Reset Key the specific mode execution to end auto tune and manual control execution and to quit sleep mode Press A v Sleep Key The controller enters sleep mode if the sleep function SLEP is enabled for at least 3 seconds select YES How to display a 5 digit number For a number with decimal point the Upper Display to display process value display will be shifted one digit right menu symbol and error code etc 199 99 will be displayed by 199 9 4553 6 will be displayed by 4553 P Output 1 Indicator nmn Process Unit Indicator N 2 Indicator s OI FOE Fora number without decimal point oua the display will be divided into two gue T D sv B BB H Lower Display alternating phases icat n EL LI f arm Z Indicator Alm2 to display set point value 19999 will be displayed by parameter value or control output value etc N a v H 3 Buttons for ease of control 1 J 3233 setup and set point adjustment vEC 4300 Figure 1 4 FrontPanel Description 45536 will be displayed by 15536 CN Table 1 3 Display Form of Characters 12 5 5 b F F J J Ola T E Y U C E G K d P p TIME 9999 will be displayed by li
84. nd 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 take note of any parameters PID values alarm setpoints ect 47 NOTES 48 Chapter 4 Full Function Programming 4 1 Event Input Refer to section 2 10 for wiring an event input Terminals The event input accepts a digital type signal Three types of signal relay or switch contacts open collector pull 0 Event input low and TTL logic level can be used to switch the event input 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 TII and TDI for PID control and EIFN SPI or other values determined by SPMD for the set point 0 NONE SP2 If chosen the SP2 will replace the role of SP1 for control SP2 PID2 If chosen the second PID set PB2 TI2 and TD2 will be used to replace TI1 and TD1 for control SP P2 If chosen SP2 PB2 TI2 and TD2 will replace SP1 PB1 TI1 and TDI for control 3 appi NOTE If the second PID set is chosen during auto tuning and or self tuning procedures the new PID values SP will be stored in PB2
85. ng parameters in the user menu A1SP 800 C 1 0 PL1 100 RAMP According to the process reguirement SPI According to the process requirement 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 PBI1 TII TD1 PB2 TI2 and TD2 directly according to previous records to eliminate the auto tuning sequence ioe The circuit diagram and its temperature profile are shown at right From Controller Output Water Tank 1 Level Sensor 1 Figure 5 13 Differential Control Example Outlet SV 1 00 4 20 mA Valve Control Output Water PV1 5 12 Tank 2 T dion OUT1 Sensor 2 gt PV a n Height TEC 4300 Outlet AC power S N ESE SN rz RYH S s K E To Furnace TA Heater S R E S lt Jl ESH ESH a X Heater Power Input Alarm 1 controls Figure 5 14 Dual PID Furnace Event input o Process Value Use PID 1 800 _ PID Crossover Value Use PID 2 Figure 5 15 Dual PID Crossover Time 59 5 9 Dual Set Point PID continued Example 2 Dual set point PID A heat treating furnace is reguired to harden the mold at a high temperature 1000 C for 30 minutes then the mold is cooled down with a programmable ra
86. nk 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 lt Perform step 8 to calibrate voltage as well as CT function if required for input 2 Calibration Continued On Next Page 63 Manual calibration procedures continued Step 8 Press the scroll key until the display shows fi 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 lt Perform step 9 to calibrate mA function if required for input 2 Step 9 Press the scroll key until the display shows 5822 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 lt 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 DIP Switch Position following diagram to calibrate the cold PA junction compensation Note that a K A A A T C Input type thermocouple must be used K 5520A Cali
87. nnounce this to the baker The system is configured as shown in the diagram at right 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 A1FN TIMR Time 40 0 minutes SPMD MINR RAMP 30 0 C min 40 PV minutes 40 180 C putes N 180 C S 30 C min ES Restart a new batch Cooling Time down minutes Figure 5 11 Temperature Profile of Baking Oven 30 5 45 To Control 5 7 Remote Set Point An on line multiple zone oven is Zone 1 Heater used to dry paint Since heat demand OUT 60 minutes 60 minutes 60 60 30 5 minutes minutes 65 minutes 35 minutes Figure 5 9 Temperature Profile of Chamber AC Relay Figure 5 10 a Bread Baking Oven To Control Zone 4 Heater To Control Zone 3 Heater To Control Zone 2 Heater OUT1 OUT1 OUT1 varies at different positions in the production line multiple zones with individual controls should be used to ensure a consistent temperature pro a file If you order a TEC 4300 with a i retransmission unit for the master zzca
88. oint Using the P control TII set to 0 the auto tuning and self tuning are disabled Refer to section 3 21 manual tuning for the adjustment of PB1 and TD1 Manual reset adjust OFST is not practical because the load may change from time to time and often need to adjust OFST repeatedly The PID control can avoid this situation Heat only PID control Selecting REVR for OUTI SPI is used to adjust set point value TIME is used to adjust the dwell timer enabled by selecting TIMR for AIEN or A2EN PBI and TII should not be zero Adjust CYC1 according to the output 1 type OITY Generally CYC120 5 2 seconds for SSRD and SSR CYC1 10 20 seconds for relay output CYCI is ignored if linear output is selected for OITY 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 TII and TDI 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 TEC 4300 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 3 5 Cool Only Control ON OFF control P PD control and PID control can be used for cool control Set OUTI to DIRT direct action The other functions for cool only ON Setup Cool Contro
89. ol Output 1 hysteresis O1HY is enabled in the case of PB1 0 The heat only on off control function is shown in the following diagram The ON OFF control may introduce excessive process oscillation PV even if hysteresis is minimized to the smallest If ON OFF control is Setup ON OFF OUTI PB1 20 Adjust SP1 OIHY set 1 e PB1 0 TDI CYC1 CPB and PL1 will be hidden and have no function The manual mode auto tuning self SP1 01HY 2 tuning and bumpless transfer will be disabled too SP1 Dead band O1HY Heat only P or PD control Select REVR for OUTI set TII to 0 SP1 O1HY 2 SPI is used to adjust set point value TIME is used to adjust the dwell timer enabled by selecting TIMR for 1 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 OITY 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 OITY 1 is hidden if PBI is not equal to 0 OFF 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 p
90. ontained Basic Parameter Display Parameter Rang in Function Notation Format Description I SPMD Set point Mode Selection JN i E SP1L SP1 Low Scale Value Low 1999 SP4H SP 8 High Scale Value Low 19999 o Alku 1 dE E SP2F 5PgF Format of set point 2 Value Select 1st Parameter Setup Menu y SEL1 EL Default Value Use SP1 or SP2 depends on EIFN as set point Use minute ramp rate as set point Use hour ramp rate as set point Use IN1 process value as set point Use IN2 process value as set point Selected for pump control High 45536 0 32 0 1000 0 1832 0 F High 45536 set point 2 SP2 is an actual value Set point 2 SP2 is a deviation value No parameter put ahead Parameter TIME put ahead Parameter A1SP put ahead Parameter A1DV put ahead Parameter A2SP put ahead Parameter A2DV put ahead Parameter RAMP put ahead Parameter OFST put ahead Parameter REFC put ahead Parameter SHIF put ahead Parameter PB1 put ahead Parameter 1 put ahead Parameter TD1 put ahead Parameter CPB put ahead Parameter DB put ahead Parameter SP2 put ahead Parameter PB2 put ahead Parameter TI2 put ahead Parameter TD2 put ahead 18 SEL2 Select 2nd Parameter Same as SEL1 SEL4 Select 4th Parameter Same as SEL1 SEL5 Select 5th Parameter Same as SEL1 U 1 Voltage Input 1 Gain Calibration Coefficient za Cold Junction Low r fel LICL I L 1 L SEL3 Select 3rd Paramete
91. or is uninstalled 7 Switching device used to drive heater is open or shorted 39 Sensor Loop Break Sources Sensor Controller Heater Switching Device Figure 3 18 Loop Break Sources 3 13 Sensor Break Alarm Alarm 1 or alarm 2 can be configured as a sensor break alarm by selecting SENB for AIFN or A2FN The sensor break alarm is activated as soon as failure mode occurs Refer to section 3 16 for failure mode conditions Note that Sensor Break Alarm 1 Setup AIFNZSENB A1MD NORM LTCH A D failure also creates a sensor break alarm TIME A1SP AIDV and A1HY are Hidden TIME A1SP AIDV hidden if alarm 1 is configured as a sensor break alarm Similarly TIME A2SP A2DV and 2 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 Sensor Break Alarm 2 normal alarm latching alarm holding alarm and latching holding alarm Setup OUT2 AL2 However the holding alarm and latching holding alarm are not recommended A2FN SENB since the sensor break alarm will not perform the holding function even if it is set A2MD NORM LICH for holding or latching holding mode See section 3 8 for the descriptions of these Hidden TIME A2SP A2DV alarm modes A2HY 3 14 SP1 Range SPIL SPI low limit value and SPIH SPI IN1H hiati high limit value in the setup menu are used to Setup SPIL SPIH or sensor range high confine the adj
92. procedure carefully Incorrect setup values 6 No heat or output Suppress arcing contacts in system to Electromagnetic interference EMI or eliminate high voltage spike sources Radio Frequency interference RFI Separate sensor and controller wiring from EEPROM defective dirty power lines ground heaters Replace EEPROM 9 Display blinks entered values change by themselves 66 Chapter 8 Specifications Power Input 2 90 264VAC 47 63Hz 15VA 7W maximum Resolution 18 bits 11 26 VAC VDC 15VA 7W maximum N Sampling rate 1 66x second Input 1 resolution 18 bit N iu Maximum rating 2VDC minimum 12VDC maximum Sampling rate 5x d 9 Temperature effect 3 0uV C for mA input Maximum rating 2VDC minimum 12VDC maximum 1 50 for all other inputs EN Common mode rejection ratio CMRR 120dB Temperature effect 1 5uV C for all input N HA o mpm Sensor break detection Below 1mA for 4 20mA input 3 0uV C for mA input below 0 25V for 1 5V input unavailable for other inputs Sensor lead resistance effect Sensor break responding time 0 5 seconds T C 0 2uV ohm Characteristics 3 wire RTD 2 6 C ohm of resistance difference of two leads Wi 26 i Accuracy Input 2 wire RTD 2 6 C ohm of resistance sum of two leads Type Range 25 Impedance Common mode rejection ratio CMRR 120dB m Normal mode rejection ratio NMRR 55dB TEC99999 of Reading 302 KO S
93. r such as TEC99001 or PROT RTU TEC99927 must be used to convert RS 485 to RS 232 for a PC if RS 485 is reguired ADDR Address for data communication Up to 247 RS 485 units can be connected to one RS 232 port BAUD Baud Rate therefore a PC with four comm ports can communicate with 988 units DATA Data Bit Count PARI Parity Bit Setup STOP Stop Bit Count Enter the setup menu RS 485 T inal Select FULL full function for FUNC Select 485 for COMM if RS 485 is reguired or 232 if RS 232 is reguired Select RTU O TXI i e Modbus protocol RTU mode for PROT Set individual addresses for any units that O TX2 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 RS 232 Setup conditions FUNC FULL If you use a conventional 9 pin RS 232 cable instead of TEC99014 the cable COMM 232 should be modified for the proper operation of RS 232 communications PROT RTU according to section 2 16 ADDR Address BAUD Baud Rate DATA Data Bit Count PARI Parity Bit STOP Stop Bit Count RS 232 Terminals 3 TX1 3 0 COM 52 4 9 Analog Retransmission Analog retransmission is available for model Setup Menu number TEC 4300 XXXXXXN where N 3 4 or 5 See ordering code in section 1 2 Funi FUNC Set Lann COMM Hoa AOFN Select FULL for FUNC in the setup menu AOLO ncc Select a correct output s
94. r Same as SEL1 I L I L Calibration Mode Menu Lo Low 199 9 High 199 9 Temperature Calibration Low 5 00 C High 40 00 Coefficient tes Table 1 4 Parameter Description page 7 of 7 Contained Basic Parameter Display Parameter Range Default Function Format Description Value Cold Junction Gain Calibration Coefficient 199 9 High 199 9 Reference Voltage 1 N Calibration Coefficient for Low 199 9 High 199 9 Calibration Serial Resistance 1 Mode Calibration Coefficient for Low 199 9 High 199 9 RTD 1 mA Input 1 Gain Calibration High 1999 Voltage Input 2 Gain N Calibration Coefficient High 199 9 mA Input 2 Gain Calibration inh uH Menu HETI ih U ae Deviation PV SV 12600 High 12600 IN1 Process Value Low 19999 High 45536 Display Mode IN2 Process Value Low 19999 High 45536 Menu Proportional Band Low High 2000 k Current Integral Time Value High 4000 sec Current Derivative Time High 1440 sec old N tion C ti o N em Current Process Rate Value 16383 High 16383 EFA PVRH PUH Maximum Process Rate Value Low 16383 High 16383 PVRL Minimum Process Rate Value Low 16383 High 16383 Table 1 5 Input IN1 or IN2 Range Table 1 6 Range Determination for A1SP Input Type 1 120 200 C 250 100C oc oc Range of ATSP IN1 IN2 Range Low 328 F 418 F 148 F 32 F
95. r current input 0 1V linear Voltage input 0 5V linear Voltage input 1 5V linear Voltage input 0 10V linear Voltage input Special defined sensor curve Degree C unit Degree F unit Process unit No decimal point 1 decimal digit 2 decimal digits 3 decimal digits High 45536 High 45536 IN2 no function Current transformer input 4 20 mA linear current input 0 20 mA linear current input 0 1V linear voltage input 0 5V linear voltage input 1 5V linear voltage input 0 10V linear voltage input IN2 Decimal Point Selection Same as DP1 IN2 Low Scale Value Low 19999 High 45536 High 45536 Reverse heating control action Direct cooling control action Relay output Solid state relay drive output Solid state relay output 4 20 mA current module Parameter Default Description Value 2 Table 1 4 Parameter Description page 4 of 7 Contained Basic Parameter Display Parameter Default in Function Notation Format Description Value 0 20 mA current module O1TY o EY Output 1 Signal Type I D C3 C3 C3 n 0 1V voltage module un un Ca EC iC Ca 0 5V voltage module N 1 5V voltage module Co 0 10V voltage module VA CYC1 EYE 1 Output 1 Cycle Time Low 0 1 High 100 0 sec i I Select BPLS bumpless transfer or 0 0 100 0 4 O1FT o IFE 1 Failure Transfer 96 to continue output 1 control fun
96. rature at the c sensor should be 235 C You should input 35 C so as to subtract 35 C from the actual process display 35 C temperature Adjust SHIF Display is stable This in turn will cause difference is observed SHIF 35 C SHIF 35 C the controller to SHIF 0 Supply more heat PV SV energize the load and bring the process Figure 3 20 display up to the set PV1 Shift Application point value 200 200 235 C 40 3 16 Failure Transfer The controller will enter failure mode if one of the following conditions 1 SB1E occurs due to input 1 sensor break or input 1 current below 1mA if 4 20 is selected or input 1 voltage below 0 25V if 1 5V is selected 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 3 ADER occurs if the A D converter of the controller fails Output 1 and output 2 will perform the failure transfer function if one of the following conditions occurs 1 During power starts within 2 5 seconds 2 The controller enters failure mode 3 The controller enters manual mode 4 The controller enters calibration mode Output 1 failure transfer if activated will perform 1 If output 1 is
97. rective Actions e No power to instrument Check power line connections 1 LED s will not light Power supply defective Replace power supply board 2 Some segments of the display or LED display or LED lamp defective Replace LED display or LED lamp LED lamps not lit or lit erroneously Related LED driver defective Replace the related transistor or IC chip Analog portion or A D converter defective Replace related components or board 3 Display Unstable Thermocouple RTD or sensor defective Check thermocouple RTD or sensor Intermittent connection of sensor wiring Check sensor wiring connections Wrong sensor or thermocouple type wrong Check sensor or thermocouple type and if input mode selected proper input mode was selected Analog portion of A D converter defective Replace related components or board k P ul s ai Reversed input wiring of sensor Check and correct 4 Considerable error in temperature indication No heater power output incorrect output Check output wiring and output device device used Replace output device Output device defective Replace output fuse Open fuse outside of the instrument 7 Heat or output stays on but indicator Output device shorted or power service Check and replace reads normal shorted CPU or EEPROM non volatile memory Check and replace 8 Control abnormal or operation incorrect defective Key switch defective Read the setup
98. roportional Band values i PB1 and or PB2 overshoot 5 Increase PB1 or PB2 Oscillations Slow Response Decrease TI1 or TI2 2 Integral Time 1 W TI1 and or TI2 Instability id Increase TI1 or TI2 Oscillations Slow Response or 3 Derivative Time D Oscillations Decrease TON COP TD2 TD1 and or TD2 High Overshoot Increase TD1 or TD2 P action Figure 3 25 shows the effects of PID PV PB too low adjustment on process response Set point Figure 3 25 Effects of PID Adjustment PB too high I action P action TI too high PV g PV TD too low Perfect Set point Set point Perfect TI too low TD too high 45 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 Figure 3 26 DC Power Supply Applications Two Line Transmitter SS SY Ll ES e L onl ouT2 g PS DC Power Supply S eR L 1 Caution To avoid damage don t use a DC power supply rN R 5 L2 RS S5 t3 N beyond its current rating Purchase one with the correct voltage to suit your external devices See the ordering code in section 1 2
99. rt Auto Tuning Error If auto tuning fails an ATER message will appear on the upper display in the following cases f 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 44 3 20 Manual Tuning In certain applications very few when using both self tuning and auto tuning to tune a process proves inadeguate for the control reguirements you can try manual tuning Connect the controller to the process and perform the procedures according to the following diagram Table 3 2 PID Adjustment Guide optimal PID values The manual tuning procedure may take a long time before reaching a new steady state since the P band was changed This is particularly true for a slow process As a result the above manual tuning procedures will take from minutes to hours to obtain If the control performance using above tuning ADJUSTMENT SEQUENCE SYMPTOM SOLUTION still E I spi a i Slow Response Decrease PB1 or PB2 f applied for further adjustment o 1 P
100. s follows Conversion Curve for Linear Type i 15 INHH 4 Example If a 4 20mA current loop pressure transducer with range 0 15 Process Value kg cmz is connected to input 1 then perform the following setup PV1 INI24 20 INIL 0 0 INIU PU INIH 15 0 DPI1 1 DP dicas e des Of course you may select another value for DP to alter the resolution NIL m input signal Formula PV1 INIL INIH INIL zc SL S 31 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 5 linear voltage output 0 10 0 10V linear voltage output 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 OITY 1 O2TY actu 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 3 3 Configuring User Menu Most conventional controllers are des
101. serial number and date code for future reference when corresponding with our service center The serial number S N and date code D C are labeled on the box and the housing of the controller 92 mm 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 Figure 2 1 Mounting Dimensions Panel Cutout Before wiring check the label to verify the correct model number and options Switch off the power while checking Care must be taken to ensure that the maximum voltage ratings specified on the label are not exceeded t is recommended that the power source for these units be protected by fuses or circuit breakers rated at the minimum value possible All units should be installed inside a suitably grounded metal enclosure to prevent live parts from being accessible to human hands and metal tools All wiring must conform to the appropriate standards of good practice and local codes and regulations Wiring must be suitable for the voltage current and temperature ratings of the system Beware not to over tighten the terminal screws Unused control terminals should not be used as jumper points as they may be internally connected causing damage to th
102. so n go o PV L IBD L IBD PV PV PV IBD IBD SL z IOL amp 190 amp Ta D JON 5 N iBU a IB Alm2 Alm2 Alm2 go n go a TEC 4300 TEC 4300 TEC 4300 controller and retransmit its set point to input 2 on the rest of the a LA Uv SSS DST ST slave controllers each zone will be synchronized with the same temper 14 13 16 15 16 15 16 115 ature At right is an example Set the following parameters in the Master Slave Slave Slave setup menu Figure 5 12 Remote Set Point Application For the For the Master unit Slave Units If a voltage signal such as in the above example is sent to slave units the slave inputs should FUNC FULL FUNC FULL be connected in parallel If a current signal e g 4 20mA is sent to slave units the slave COMM 1 5V IN2 1 5V inputs should be connected in series Current retransmission is widely used because it can AOLO 0 C IN2L 0 C transmit over a longer distance without voltage drop AOHI 300 C IN2H 300 C Note AOHI and IN2H should be set with values higher than the set point range used PVMD PV1 PVMD PV1 SPMD SP1 2 SPMD PV2 58 5 8 Differential Control In certain applications it is desirable to control a second process so that its process value always
103. starts to count The TIME value can still be corrected without disturbing the the timer before time out TIME is changed to 40 0 28 minutes after the process has reached its set point The behavior of the process value and alarm 1 are shown below SP1 changed to 200 F PV reaches set point changed to 40 0 28 PV minutes 200 F Alarm 1 ON Alarm 1 OFF Time minutes 40 minutes Figure 4 2 Dwell Timer 50 4 4 Ramp and Dwell continued 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 AIFN and A2FN simultaneously or an error code will result Ramp and dwell A ramp may be accompanied with a dwell timer to control the process Here is an example Example with ramp and dwell Select HRR for SPMD PU for INIU and set RAMP 60 Select TIMR for A2FN and set TIME 20 0 When power is applied the process value starts at 0 SP1 30 and SP2 40 The timer output is used to control event input G er Error code mat we Time minutes 0 30 50 60 Alarm 2 ON Alarm 2 OFF Figure 4 3 Ramp Accompanied with a Dwell Timer 4 5 Remote Set Point Selecting PV 1 or PV2 for SPMD will enable the TEC 4300 to accept a remote set point signal If is selected for SPMD the remote set point signal is sent to input 1 and inp
104. ted 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 41 Failure mode occurs as 1 SBIE 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 OIFT 2 O2FT 3 AIFT 4 A2FT 3 17 Bumpless Transfer The bumpless transfer function is available for output 1 and output 2 provided that OUT2 is configured as COOL Bumpless transfer is enabled by selecting BPLS for OIFT 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 MV
105. tration and temperature For a single unit application it is adequate to order a TEC 4300 with RS 232 communication and TEC99923 software Using the TEC99923 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 RH An air conditioned room uses two Sp4 25 0 SP1 50 0 TEC 4300 units to control the temper Sp4 20 0 5 JC mye SP1L 40 0 2 5 F ature and humidity The temperature sp4H 30 0 2 L ALI SP1H 60 0 ER LI jo and humidity must be recorded on a 2 s g 5 ri nos E AA chart recorder The preferred ranges Ani JA for these two parameters 20 to 30 and 40 RH to 60 RH The xEC 4300 sEC4300 recorder inputs accept a 0 5V signal 4 v 4 v 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 INIU C IN1U PU DP1 1 DP DP1 1 DP SPIL and SP1H are used to limit the adjustment range of the set point
106. trol Mode Auto Tuning Mode Press for 3 seconds to enter the auto tuning mode Display Mode Default Setting N Mode for 3 seconds To execute the default setting program Calibration Mode A Apply these modes will break the control loop and change some of the previous setting data Make sure that if the system is allowable to use these modes gt PJ P P PJ 9 P PJ P PJ P PJ PJ 6 lt o 3 c 9 PII 1 2 B AAA NANNA mimim m Krimin Bop c ORE C OR OA OA 9C cS A eA C OA DR C BA ce A C ce A OA c C A ce A e ZJ X A 9c OR OR C oA oA Eg C oA oA EC DE EJ we OR oA ce oA C OR OR oA C A ORE 9c ORE C 9 C eA Gc SR Home Screen mec aw The menu will revert to C oa PV SV display after keyboard 9 C OA is kept untouched for 2 minutes except Display Ec EE Mode Menu and Manual C aw Mode Menu However the oA menu can revert to PV SV Ec ES EJ display at any time by C JA N Gc a pressing 9c cS G
107. troller is in manual control mode AN Q Pp The controller is in sleep mode 8 The controller is being calibrated If self tuning is enabled auto tuning can still be used any time Self tuning will use the auto tuning results for its initial values Benefits of Self tuning 1 Unlike auto tuning self tuning will produce less 1 disturbance to the process 2 Unlike auto tuning self Selects tuning doesn t change the Di 1 isable Self tunin control mode during the tuning period It performs PID control Self tune Menu always or Enable Self tuning 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 Default SELF NONE Operation The parameter SELF is contained in the setup menu Refer to section 1 5 to find SELF for initiating self tuning 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 nitial setup for a new process Applicable conditions 1 0 TI12 0 if PB1 TI1 TD1 assigned The set point is changed substantially from the previous auto tuning value PB220 TI240 i
108. uch keys to select the various control and input parameters Using a unique function to various processes MV more flexible and adaptive you can put up to five parameters at the front of the user menu by using SELI to SELS found in the setup menu The Fuzzy Rule may work like This is particularly useful to OEM s as it is easy to configure the menu to suit the specific application this TEC 4300 is powered by 11 26VAC VDC or 90 264VAC supply incorporating dual 2 amp control relays output and dual 2 amp alarm relays PID FUZZY CONTROL large then DMV is large If the temperature difference is large and the temperature rate is output as standard Alternative output options include SSR drive triac If the temperature difference is 4 20mA and 0 10 volts TEC 4300 is fully programmable for PT100 MV PV large and the temperature rate is thermocouple types J K T E B 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 4300 to control fast processes such as pressure and flow Self tuning is incorporated Self tuning can be used to optimize the control parameters as soon as undesired control results are observed Unlike auto tuning self tuning will produce less efficient method small then DMV is small PID Fuzzy Control has been proven to be an to improve the contro
109. uses a 4 20mA analog output to retransmit the difference value between input 1 and input 2 PV1 PV2 It is reguired 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 4300 IN1U PU DP1 NODP IN2U PU FUNC FULL COMM 4 20 AOFN P1 2 AOLO 100 AOHI 100 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 4300 can be used to improve this This is a first order filter with the time constant specified by the FILT parameter in the setup menu The default value of FILT is set at 0 5 seconds Adjust FILT to change the time constant from 0 to 60 seconds 0 seconds means no filter is applied to the input signal The filter is characterized by the following diagram Menu FILT Filter is used to stabilize the process display PV1 FILT 0 1 sec FILT 30 1 sec Time Figure 4 7 Filter Characteristics 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 4 11 Sleep Mode To enter sleep mode Set FUNC for FULL to provide full function Select YES for SLEP to enable sleep mode Press Y for 3 seconds the unit will now enter sleep mode Sleep mode features Shut off display Shut off o
110. ustment range of SPI Example SA SP1L 3 2 ss KDE Example A freezer is working in its normal temperature range 10 C to 15 C In order to avoid an abnormal set point SPIL and SPIH are set with the following values SPIL 15 C SPIH 10 C Figure 3 19 SP1 Range Now SPI can only be adjusted within the range of 10 C to 15 C IN1L or sensor range low 3 15 PV1 Shift In certain applications it is desirable to shift the controller display value from its actual value This can be easily accomplished by using the PV1 shift function Press the scroll key to bring up the parameter SHIF The value you adjust here either pos itive 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 compo nents 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 Subject Heater Subject Heater Subject teater system for heat to be transferred from one Heat Heat Heat point to another If the diff b h Transfer Transfer Transfer ifference between the 165 C 165 C 200 C lt sensor and the subject is 35 C and the desired temperature at the subject to be heated is 200 C the Sens r Sens r i Sens r 1 controlling value or i N the tempe
111. ut 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 Setup FUNC FULL SPMD PV2 PVMD PV1 Or SPMD PV1 PVMD PV2 Case 1 Use Input 2 to accept remote set point FUNC FULL IN2 IN2U DP2 IN2L IN2H are set according to remote signal PVMD PV 1 IN1 INIU DPI are set according to the process signal INIL IN1H if available are set according to the process signal SPMD PV2 Case 2 Use Input 1 to accept remote set point FUNC FULL IN1 IN1U DP1 INIL IN1H are set according to remote signal PVMD PV2 IN2 IN2U DP2 are set according to the process signal IN2L IN2H if available are set according to the process signal SPMD PV 1 Note 1 If PV1 is chosen for both SPMD and PVMD an i C 4 error code will appear If PV2 is chosen for both SPMD and PVMD an error code will appear In either case the TEC 4300 will not control properly Error message Note 2 If PV1 PV2 is selected for SPMD a signal loss will result in the controller reverting to manual mode with 0 output 51 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
112. utputs Green power During sleep mode Replaces power switch 1 All displays are shut off except a decimal point which is lit periodically Setup menu FUNC FULL SLEP YES 2 All outputs and alarms are shut off To exit sleep mode 1 Press 4 Y 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 53 4 12 Pump Control Pump control function is one of the unique features of the TEC 4300 Using this function the pressure in a process can be excel lently controlled The pressure in a process is commonly generated by a pump driven by a variable speed motor The complete system has the following characteris tics 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 PUMP A cost effective solution 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 b
113. w x x Cool Control Modes Uses Heat Uses ALM1 OUT1 or REVR NONE x ALM2 ALM1 or ALM2 OUT1 DIRT NONE ALM1 OUT1 or REVR NONE ALM2 om Rc OUTI or REVR NONE ALM2 X Not Applicable 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 OITY CYCI O2TY CYC2 A2SP A2DV OITY and O2TY are set in accordance with the types of OUTI and OUT installed CYC1 and CYC2 are selected according to the output 1 type OITY and output 2 type O2TY Generally select 0 5 2 seconds for CYC1 if SSRD or SSR is used for OI T Y Select 10 20 seconds if relay is used for OITY and CYCI is ignored if linear output is used Similar conditions are applied to CYC2 selection Examples Heat PID Cool ON OFF Set OUTI REVR AIFN or A2FN PV1 H AIEN or A2MD NORM or A2HY 0 1 PB120 TI1z0 TD120 and set appropriate values for OITY and CYCI Heat PID Cool PID set OUTIZREVR OUT2 COOL CPB 100 DB 4 0 PB140 TI1z0 TD170 and set appropriate values for OITY CYCI O2TY CYC2 If this is a new process then use the self tuning program to optimize the PID values by selecting YES for SELF See section 3 18 for a description of the self tuning program A
114. when all the valves are closed A typical value for REFC is between 3 and 5 5 An ordinary pump may slowly lose pressure even if the valves are completely closed Adjust SP2 according to the rule that a more negative value of SP2 will allow the pump to be shut off for a longer time when the valves are closed A typical value for SP2 is about 0 50Kg cm An example for pump control is given in section 5 1 4 13 Remote Lockout The parameters can be locked to prevent them from being changed by using either hardware lockout 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 17 and 16 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 event input is closed When the event input is left open the lockout condition is determined by internal DIP switches 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 9 and A 2 Set LOCK for EIFN 3 Lock all parameters 54 Chapter 5 Applications 5 1 Pump Pressure Control Regulated water supply systems are widely TEC 4300 used in residential areas water plants chemical PV plants electrical plants semiconductor plants oat He Kg cm etc By
115. y Solutions The Electric Heating Element Temperature Controls and Temperature Sensors Handbook REQUEST YOUR FREE 960 PAGE COPY TODAY Call 800 323 6859 or E mail info tempco com Specify Print Edition CD ROM or Both lt Serving Industry Since 1972 Experience the Advantages of our Diverse and Innovative Products DA TEMPCO Electric Heater Corporation 607 N Central Avenue Wood Dale IL 60191 1452 USA ese lt Tel 630 350 2252 e Toll Free 800 323 6859 conse Fax 630 350 0232 e E mail info tempco com Committed to Excellence www tempco com Copyright 2013 All Rights Reserved
116. y the TEC 4300 can handle such an application To achieve this set the following parameters in the setup menu FUNC FULL EIFNZNONE PVMD PV1 SELF NONE SPMD PUMP SP2F DEVI and program the following parameters in the user menu REFC reference constant SP2 a negative value added to SPI to obtain the set point for the idle state Since the pump can t pro duce any more pressure at lower speeds the pump may not stop run ning 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 4300 provides a ref erence 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 con troller enters an idle state The idle state will use a lower set point which is obtained by adding SP2 to SPI 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 fun

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