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TEC 8300 Manual - Tempco Electric Heater Corporation

1. 8 Chapter 2 Installation 2 Unpacking seedi reso crate 15 2 2 Mountilg srece reie rasa Hae hee 15 2 3 Wiring Precautions 15 2 4 Power Wiring v bee Sennen dee neces 16 2 5 Sensor Installation Guidelines 16 2 6 Thermocouple Input Wiring 16 2 7 RTD Input Wiring 17 2 8 Linear DC Input Wiring 17 2 9 CT Heater Current Input Wiring 18 2 10 Event Input 19 2 11 Output 1 Wittig iioii rrt Rees 20 2 12 Output 2 21 2 13 Alarm 1 Wiring 22 2 14 Alarm 2 Wiring 22 2 15 RS 485 iii bes eraot eig a REF HE 23 2 16 5 232 os ieu Re EREMO RR ERR Rs 23 2 17 Analog Retransmission 24 2 18 Programming Port 24 Chapter 3 Programming Basic Functions 3 l Input I tette ta 25 3 2 OUT OUT2 Types 26 3 3 Configuring User Menu 26 3 4 Heat Only Control 26 3 5 Cool Only Control eie 27 3 6 Heat Cool Control 28 3 7 Dwell Tim t uii esercito retta usss 29 3 8 Process Alarms 29 3 9 Deviation Alarms
2. 2 Tx2 0 COM 46 4 9 Analog Retransmission Analog retransmission is available for Setup Menu model number TEC 8300 XXXXXXN where N 3 4 or 5 See ordering code in Fumi FUNC section 1 2 ann COMM Setup Aor nj AOFN Select FULL for FUNC in the setup menu AOLO Select a correct output signal for COMM which should be accordant with the retransmission option used Five types of Terminals retransmission output are available These 13 4 20mA 0 20 0 5 1 5 and 0 10V There are eight types of parameters AO that can be retransmitted according to the analog function AOFN selected These are PVI PV2 PVI PV2 2 SV MV2 and PV SV Refer to table 1 4 for a complete description Select a value for AOLO corresponding to output zero and select a value for AOHI corresponding to output SPAN How to determine output signal AOLO and AOHI are set to map to output signal low SL e g 4mA and output signal high SH e g 20mA respectively The analog output signal AOS corresponding to an arbitrary value of parameter AOV is determined by the following curve Output Signal SH AOS SL Parameter Value AOLO AOV AOHI SH SL Formula AOS SL AOV AOLO ormula AOS SL AOV AOLO lt AS AOV AOLO aos 51 9 SH SL Figure 4 6 Conversion Curve for Retransm
3. 30 3 10 Deviation Band Alarms 31 3 11 Heater Break Alarm 32 3 12 Loop Break 32 3 13 Sensor Break Alarm 33 3 I4 SP Range the 33 3 15 PVI Shift here PS 33 3 16 Failure Transfer 34 3 17 Bumpless 35 3 9 pick sents teenie sess EUR RA 36 3 19 Auto tUhIng escas echte Ew ots 36 3 20 Manual Tuning 38 3 21 Signal Conditioner DC Power Supply 40 3 22 Manual Control eise er en 40 3 23 Display Mode 41 3 24 Heater Current Monitoring 41 3 25 Reload Default Values 41 NOTE It is strongly recommended that a process should incorporate a LIMIT CONTROL like TEC 910 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system Information in this user s manual is subject to change without notice Copyright O 2013 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
4. indicates output 2 on time Now you can use the up and down keys to adjust the percentage values for H or C The controller performs open loop control as long as it stays in manual control mode The H value is exported to output 1 OUT1 and C value is exported to output 2 provided that OUT2 is performing cooling function 1 OUT2 selects COOL Exception If OUTI is configured as ON OFF control 1 e PB1 0 if PB1 is assigned or PB2 0 if PB2 is assigned by event input the controller will not perform manual control mode Exiting Manual Control Press keys the and the controller will revert to its previous operating mode may be a failure mode or normal control mode 40 3 23 Display Mode Operation Press v several times until 4 52 display appears on the display Then press co 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 4 and f H _ shows the percentage value for output 1 and r _ _ shows the percentage value for output 2 on the lower display while the upper display shows the current process value PVHI PVLO show the historical extreme maximum or minimum values of the process o
5. 5 5 Heat Cool Control Figure 5 7 Heat Cool Control Example An injection mold is required to be controlled at Injection Mold 120 C to ensure a consistent quality for the parts An oil Plastics 120 C pipe is buried in the mold Since plastics are injected at a higher temperature e g 250 C the circulation oil needs to be cooled as its temperature rises Here is an example at right PID heat cool is used for the example at right To achieve this set the following parameters in the setup menu FUNC BASC 18 0 seconds INI PT DN OIFT 0 0 INIU C OUT2 COOL DPI 1 DP O2TY 4 20 OUTI REVR O2FT BPLS OITY RELY 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 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 t wu OR Oil Tank Pump Freezer 51 5 6 Ramp and Dwell Example 1 Temperature cycling chambe
6. EF 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 nA LG mA Input 1 Gain Calibration Coefficient Low 199 9 High 199 9 V2G UAT Voltage Input 2 Gain Calibration Coefficient Low 199 9 High 199 9 sic1 5 G Point 1 Signal Value of Special Sensor Low 19999 High 45536 IND1 1 d Point 1 Indication Value of Special Sensor Low 19999 High 45536 SIG2 5 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 SIG3 5 53 Point Signal Value of Special Sensor Low 19999 High 45536 IND3 1 nd3 Point Indication Value of Special Sensor Low 19999 High 45536 sic4 1 GH Point 4 Signal Value of Special Sensor Low 19999 High 45536 INDA nd Point 4 Indication Value of Special Sensor Low 19999 High 45536 aa sic5 6 G5 Point 5 Signal Value of Special Sensor Low 19999 High 45536 5 nd Point 5 Indication Value of Special Sensor Low 19999 High 45536 SIG6 5 565 Point 6 Signal Value of Special Sensor Low 19999 High 45536 IND6 I Point 6 Indication Value of Special Sensor Low 19999 High 45536 107 5 11 Point 7 Signal Value of Special Sensor Low 19999 High 45536 1 nd Point 7 Indication Value of Special Sensor Lo
7. set point MV1 MV2 PV SV deviation value Output Signal 420mA 0 20 0 1V 0 5V 1 5 0 10V Resolution 15 bits Accuracy 0 05 of span 0 0025 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 99 994 Isolation Breakdown Voltage 1000VAC min Integral linearity error 0 00595 of span Temperature effect 0 002596 of span C Saturation low 0mA or 0V Saturation high 22 2mA or 5 55V 11 1V min Linear output range 0 22 2 0 20 or 4 20mA 0 5 55V 0 5V 1 5V 0 11 1V 0 10V User Interface Dual 4 digit LED displays Upper 0 4 10mm lower 0 3 8mm Keypad 3 keys Programming port For automatic setup calibration and testing Communication port Connection to PC for supervisory control Control Mode Output 1 Reverse heating or direct cooling action Output 2 PID cooling control cooling P band 1 255 of PB ON OFF 0 1 100 0 F hysteresis control P band 0 P or PD 0 100 095 offset adjustment PID Fuzzy logic modified Proportional band 0 1 900 0 F Integral time 0 1000 seconds Derivative time 0 360 0 seconds Cycle time 0 1 100 0 seconds Manual control Heat MV1 and cool MV2 Auto tuning Cold start and warm start Self tuning Select NONE or YES Failure mode Auto transfer to manual mode while sensor break or A D co
8. vEC 8300 Adjust SP here it is 1 00 to control the difference between PV1 and PV2 Choose P1 2 for PVMD the PV display will show the difference value PVI 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 53 5 9 Dual Set Point PID The TEC 8300 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 Set the following parameters in the setup menu FUNC FULL AIFN AIMD NORM EIFN PID2 PVMD PV1 SPMD MINR 2 Adjust the following parameters in the user menu AISP 800 C 1 1 0 C PL1 100 RAMP According to the process requirement SP1 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 TD1 PB2 TI2 and TD2 directly according to previous records to eliminate the auto tuning sequenc
9. Deviation band alarm 2 Setup OUT2 A2EN A2MD Adjust SP1 A2DV Trigger levels SP1A2DV s Indicates an Alarm Condition 1 1 105 105 105 ON 105 OFF 105 Figure 3 13 100 100 100 100 100 Normal Deviation 95 OFF 95 95 95 95 Band Alarm DB LO A1MD LTCH SP1 100 A1DV 5 Process Process proceeds _ 105 105 105 105 105 105 Figure 3 14 100 pe p 100 100 dad 05 ONc 95 Latching Deviation Band Alarm DB HI A1MD HOLD SP1 100 A1DV 5 Process proceeds xi d O 1 1 105 105 105 105 105 105 Figure 3 15 100 E E 100 100 Holding Deviation 95 95 ON I 95 Alarm DB HI A1MD LT HO SP1 100 A1DV 5 Process proceeds 105 105 105 105 105 105 100 100 100 i 100 100 Figure 3 16 95 95 95 95 Latching Holding j J Deviation Band Alarm j 3 11 Heater Break Alarm A current transformer Part No TEC99999 should be installed to detect the heater current if a heater break alarm 1s required The CT signal is sent to input 2 and the PV2 will indicate the heater current in 0 1amp resolution The range of the current transformer is 0 to 50 0amp For more detailed descriptions about heater current monitoring please see section 3 24 Heater break alarm 1 IN2 CT 2 1 AIMD NORM 0 1 Adjust AISP Trigger level AISP
10. 1999 Hg 1999 199 9 Reference Voltage 1 REF1 EF Calibration Coefficient for Low 199 9 High 199 9 RTD 1 Calibration Serial Resistance 1 Mode SR1 Srl Coefficient for Low 199 9 High 199 9 Menu IB mA Input 1 Gain Calibration _ uar Voltage Input 2 Gain Calibration Coefficient 1999 High 199 9 mA Input 2 Gain Calibration eB PVHI Bead Maximum Value of Low 19999 High 45536 PVLO Historical Minimum Value of 19999 High 45536 DIESE Current 2 Value Low High 100 00 masm umu IN1 Process Value ow 19999 High 45536 gm Display Menu Current Proportional Band 500 0 C Moo GJET old Junction Compensation Low 40 00 C High 0000 Current Process Rate Value Low 16383 High 16383 PVRH 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 200 C 250 C Range of A1SP IN1 IN2 Range Low 184P 328 F 148 F 20 020 455 d EERS 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 19999 same as range of m 45536 If PVMD Range of SP2 sam
11. 50 3 C Allow at least 20 minutes to warm up The calibrator source is set at 0 00 C with internal compensation mode Perform step 1 as stated on the previous page then press the scroll key until the display shows Press the up or down keys until a value of 0 0 is obtained Press the scroll key for at least 3 seconds The display will blink for a moment until a new value is obtained If the display didn t blink or 1f the obtained value is equal to 199 9 or 199 9 then calibration failed This setup 1s performed in a high temperature chamber therefore it 1s recommended to use a computer to perform the procedures Step 11N Perform step 1 as stated on the previous page then press the scroll key until the display shows s Press the up and down keys until a value of 0 1 is obtained Press the scroll key for at least 3 seconds The display will blink for a moment until the new value 0 0 is obtained Otherwise calibration failed Caution It is not recommended to use step 11N since the cold junction gain is not able to achieve the rated accuracy using this step Final step Step 12 Set the DIP switch to your desired position refer to section 1 3 Automatic calibration procedures The programming port see section 2 18 of the TEC 8300 can be used for automatic calibration The equipment required for automatic calibration is available upon request 58 Chapter 7 Error Codes and Troubleshooting This proced
12. A cost effective solution 1 The system is very noisy 2 The pressure changes very rapidly 3 The pump characteristics are ultra nonlinear with respect to its speed 4 The pump can t generate any more pressure if its speed is lower than half of its rating speed 5 An ordinary pump may slowly lose pressure even if the valves are completely closed Obviously a conventional controller can t fulfill the conditions mentioned above Only the superior noise rejection capability in addition to the fast sampling rate possessed by the TEC 8300 can handle such an application To achieve this set the following parameters in the setup menu FUNC FULL EIFN NONE Key menu PVMD PVI SPMD FILT 0 5 SP2F SELF NONE REFC SPMD PUMP SP2 SP2F DEVI and program the following parameters in the user menu Pump control features 1 Minimum oscillation of SP2 a negative value Rees 5 added to SP1 to 2 Rapidly stabilized obtain the set point for the idle state Since the pump can t produce any more pressure at lower speeds the pump may not stop running even if the pressure has reached the set point If this happens the pump will be overly worn and waste additional power To avoid this the TEC 8300 provides a reference constant REFC in the user menu If PUMP is selected for SPMD the controller will periodically test the process by using this reference constant after the pressure has reached its set point If the test shows t
13. Chapter 4 Full Function Page No Programming 4 1 Event ee alee geste acs 43 4 2 Second Set Point 43 4 3 Second PID sa 44 4 4 Ramp and Dwell 44 4 5 Remote Set 45 4 6 Differential 45 4 7 Output Power Limits 46 4 8 Data Communication 46 4 9 Analog Retransmission 47 4 10 Digital Filter 47 4 11 Sleep Mode i ir iisi pex terr ERES 47 4 12 Pump Control 48 4 13 Remote Lockout 48 Chapter 5 Applications 5 1 Pump Pressure Control 49 5 2 Variable Period Full Wave SSR VPFW SSR 49 5 3 Heat Only 50 5 4 Cool Only 1 51 5 5 Heat Cool 51 5 6 Ramp and Dwell 52 5 7 Remote Set 53 5 8 Differential Control 53 5 9 Dual Set Point PID 54 3 10 8 455 542 bs ped dona dee eed eee eee S 55 9 11 RS 2832 56 5 12 pun cases p os 56 Chapter 6 Calibration 57 Chapter 7 Error Codes and
14. 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 Technical questions and troubleshooting help is available from Tempco When calling or writing please give as much background information on the application or process as possible E mail techsupport tempco com Phone 630 350 2252 800 323 6859 TEMPCO s Visionary 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 DA TEMPCO Electric Heater Corporation 607 N Central Avenue Wood Dale IL 60191 1452 USA ac Tel 630 350 2252 Toll Free 800 323 6859 8 Fax 630 350 0232 E mail info tempco com Committed to Excellence Web www tempco com Copyright 2013 All Rights Reserved 72
15. the second PID set PB2 TI2 and TD2 will be used to replace and TD1 for control SP P2 If chosen SP2 PB2 TI2 and TD2 will replace SP1 PB1 and TDI for control x SPP 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 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 OI 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 t
16. unavailable for other inputs Sensor break responding time Within 4 seconds for TC RTD and mV inputs 0 1 second for 4 20mA and 1 5V inputs Characteristics E ERES 148 F to 1652 P e o 2 C BEES 26 ER to27mA 0 05 7050 1 3Vt011 5V 0 0596 302 Input 2 Resolution 18 bits Sampling rate 1 66x second Maximum rating 2VDC minimum 12VDC maximum Temperature effect 3 0uV C for mA input 1 5uV C for all other inputs Common mode rejection ratio CMRR 120dB Sensor break detection Below 1mA for 4 20mA input below 0 25V for 1 5V input unavailable for other inputs Sensor break responding time 0 5 seconds Characteristics Accuracy 2 TEC99999 0 50 0 A of Reading 0 2 A 0 8V input current 1 3V 711 5V 0 05 302 KQ Input 3 event input Logic low 10V minimum 0 8V maximum Logic high 2V minimum 10V maximum External pull down resistance 400KW maximum External pull up resistance 1 5MW minimum Functions select second set point and or PID reset alarm 1 and or alarm 2 disable output 1 and or output 2 remote lockout Output 1 Output 2 Relay rating 2A 240 VAC life cycles 200 000 for resistive load Pulsed voltage source voltage 5V current limiting resist ance 66W Input Impedance 302 KQ Linear output characteristics Zero Span Load Type Tolerance Tolerance
17. ww ISP atom mw Aide oud Lew SP SER ew Rede _ AAP oFSE O O opere _ ue SH FL 0 2 D Er Fr r 098 nr 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 in Notation Format Notation Format d c L MA2G 71 A 6 Warranty WARRANTY RETURNS Tempco Electric Heater Corporation is pleased to offer No product returns can be accepted without a completed Return suggestions on the use of its products However Tempco makes Material Authorization RMA form no warranties or representations of any sort regarding the fitness for use or the application of its products by the Purchaser The TECHNICAL SUPPORT selection application or use of Tempco products is the Purchaser s responsibility No claims will be allowed for any damages or losses whether direct indirect incidental special or consequential Specifications are subject to change without notice In addition Tempco reserves the right to make changes without notification to the Purchaser to materials or processing that do not affect compliance with any applicable specification TEC Temperature Controllers are warranted to be free from defects in material and workmanship for two 2 years after delivery to the first purchaser for use Tempco s sole
18. 0 1V linear voltage input 0 5V linear voltage input 1 5V linear voltage input I 0 10V linear voltage input pow rage E NEN NE 2 Pu dP IN2 Decimal Point Selection Same as DP1 IN2L 1 n amp L IN2 Low Scale Value Low 19999 High 45536 IN2H 1 ACH IN2 High Scale Value Low 19999 High 45536 ou Reverse heating control action Zx OUT1 Output 1 Function Direct cooling control action 0 1 11 Relay output Solid state relay drive output Solid state relay output Output 1 Signal Type 211 4 20 mA current module 10 Table 1 4 Parameter Description page 4 of 7 Contained Basic Parameter Display Parameter Range Default Function Notation Format Description Value 0 20 mA current module 0 1V voltage module O1TY IE Output 1 Signal 0 5V voltage module 1 5V voltage module 0 10V voltage module ga CYC1 CYC 1 output 1 Cycle Time Low 0 1 High 100 0 sec Select bumpless transfer or 0 0 100 0 o 1 Failure Transfer 96 to continue output 1 control function as the oce unit fails power starts or manual mode starts Output 2 no function OUT2 oub g Output 2 Function L PID cooling control DC power supply module installed v O2TY o2ty y Output 2 Signal Type Output 2 Signal Type Signal Type Same as O1TY ra CYC2 Output 2 Cycle Time Low 0 1 High 100
19. 0 sec Select BPLS bumpless transfer or 0 0 100 0 O2FT Output 2 Failure Transfer to continue output 2 control function as the ode unit fails power starts or manual mode starts A N o es Ea ES nua ne No alarm function ti r Dwell timer action dEH Deviation high alarm dEL Deviation low alarm Deviation band out of band alarm Deviation band in band alarm py IN1 process value high alarm 131 process value low alarm Al Alarm 1 Function IN2 process value high alarm IN2 process value low alarm 10 p IN2 process value high n alarm WP fap IN1 o or IN2 process value low alarm 12 1 1 IN2 difference process value d PTS high alarm P 13 d 1 1 IN2 difference process value Lun low alarm 14 Loop break alarm 15 Sensor break A D fails 4 Normal alarm action l Latching alarm action A1MD ind Alarm 1 Operation Mode Hold alarm action Latching amp Hold action 11 Table 1 4 Parameter Description page 5 of 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value Alarm 1 Failure Transfer 0 oF F Alarm output OFF if sensor fails IFE Mode 1 mr Alarm output ON if sensor fails Alarm 2 Function Same as A1FN 2 A2MD Read d Aad 2 Operation Mode SameasAiMD SameasAiMD A1MD 0 A2FT ACFE Aa 2 Fail
20. 1 Heater 2 Figure 2 11 CT Input Wiring for Single Phase Heater Heater 3 Contactor Heater Supply Current Transformer 99999 19 9 Mains Supply 1 2 CHS DIN Rail CT Signal Input Contactor Three Phase Heater Power 19 9 Mains supply 66666031 Signal Input TEC99999 Out TEC99999 Out 1 2 Figure 2 12 CT Input Wiring for Three Phase Heater Make sure that the total current through TEC99999 does not exceed 100A rms 18 2 10 Event Input wiring The event input can accept a switch signal as well as an open collector signal The event input function EIFN is activated when the switch is closed or an open collector or a logic signal is pulled down ls 5 Ss IF 169 169 E IP Also refer to section 4 1 for event input functions Leal Le M 2 L lt lt 25 1 Sit 2 2 3 3 4 EY 4 5 S5 6 6 7 9 7 8 8 9 9 9 L I II CH e e Open Collector Input Switch Input Figure 2 13 Event Input Wiring 19 2 11 Output 1 Wiring Figure 2 14 Output 1 Wiring Max 2A Resistive 120V 240V o Mains Supply Relay Output Direct Drive o 120V 240V Mains Supply 4 Minimum Load 10 K ohms 10 o Three Heater
21. 1 0 5V 0 10V 5 Retransmit 0 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 4 20mA 0 20mA drive SSR 5V 30mA Input 3 Event Input El 4 Isolated 1 5V 0 5V 3 Isolated 4 20mA 0 9 Special Order 5 solated 0 10V 4 Isolated 1 5V 0 5V 6 Triac Output 5 Isolated 0 10V 1A 240VAC SSR 6 Triac Output 1A 240VAC SSR Example 9 Special order 7 Isolated 20V 25mA DC TEC 8300 4111101 Output Power Supply 8 Isolated 12V 40 mA DC e 90 264 operating voltage e Input Standard Input e Output 1 Relay Output 2 Relay Alarm 1 Form C Relay e RS 485 Communication Interface Accessories TEC99014 RS 232 interface cable 2M 99999 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 Isola
22. 37 3 20 Manual Tuning In certain applications very few when using both self tuning and auto tuning to tune a process proves inadequate for the control requirements you can try manual tuning Connect the controller to the process and perform the procedures according to the flow chart shown in the following diagram Figure 3 23 Manual Tuning Procedure Use initial PID values to control the process Wait and Examine the Process steady state reached Yes Does the process oscillate Wait and Examine the Process steady state reached Does the process oscillate Yes 1 Flag 0 Flag 2 1 1 0 5 1 1 Wait and Examine the Process Is steady state reached Yes 1 Oscillating period gt Tu Load new PID values 1 7 PBu 1 TI1 0 3 Note The final PID values can t be zero If PBu 0 then set PB1 1 If Tu lt 1 sec then set Tl1 1 sec the process oscillate 1 6PB1 PB1 0 8 1 1 The above procedure may take a long time before reaching a new steady state since the P band was changed This is particularly true for a slow process As a result the above manual tuning procedures will take from minutes to hours to obtain optimal PID values 38 3 20 Manual Tuning continued The PBu is called the ultimate P band and the period of oscillation T
23. Master Set the following parameters in the setup menu For the master unit For the slave units FUNC FULL FUNC FULL COMM 1 5V IN2 1 5V AOLO 0 C IN2L 0 C AOHI 300 C IN2H 300 C PVMD PV1 PVMD PVI SPMD SP1 2 SPMD PV2 If a voltage signal such as in the above example is sent to slave units the slave inputs should be connected in parallel If a current signal e g 4 20mA is sent to slave units the slave inputs should be connected in series Current retransmission is widely used because it can transmit over a longer distance without voltage drop Note AOHI and IN2H should be set with values higher than the set point range used 5 8 Differential Control In certain applications it is desirable to control a second process so that its process value always deviates from the first process value by a constant amount Water tank is 5 12 meters in height and the level in water tank 2 needs to be maintained at 1 meter lower than the tank 1 level Set the following parameters in the setup menu FUNC FULL IN1 INIL INIH According to sensor 1 signal IN1U PU 2 DP IN2 IN2L IN2H According to sensor 2 signal IN2U PU DP2 2 DP OUTI REVR OITY 4 20 PVMD P1 2 SPMD SP1 2 Figure 5 13 Differential Control Example From Controller Output Water Tank 1 Level Sensor 1 4 20 mA Valve Control Water Tank 2 Level Sensor 2 4 12M Height Outlet
24. TIMR for AIFN or A2FN OFST been enabled in case of TI1 0 is used to adjust the control offset manual reset Adjust CYCI according to the output 1 type OITY Generally CYC1 0 5 2 seconds for SSRD and SSR CYC1 10 20 seconds for relay output CYCI is ignored if linear output is selected for O1HY is hidden if PBI is not equal to 0 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 by 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 Setup P OUTI 0 CYCI if RELAY SSRD or SSR is selected for OITY Adjust SP1 OFST TIME f enabled PB1 0 TDI coincide with set point Using the P control set to 0 the auto tuning and self tuning are disabled Refer to section 3 21 manual tuning for the adjustment of and TDI 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 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 other Setup Cool Control OUTI functions for cool only ON OFF control cool only P PD co
25. as any time nr Unit minute the set point is changed Choose or LHe Unit hour MINR or HRR for SPMD and the unit will perform the ramping function The ramp rate is programmed by using RAMP which is found in the user menu Adjust S crt RAMP Example without dwell timer Select MINR for SPMD 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 A2EN is set for TIMR The timer is programmed by using TIME which is in the user menu The timer starts to count
26. 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 ALIEN 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 starts to count The TIME value can still be corrected without disturbing 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 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 44 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 AIEN and A2FN E 31 simultaneously or an error code will result Error code Ramp and dwell A ramp may be accompanied with a dwell timer to control the process Here is an example Example with ramp and dwell Select HRR for SPMD PU for IN1U and set RAMP 60 Select TIMR for A2EN 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 Ti
27. if required for input 1 Step 4 Set the DIP switch for voltage DIP Switch Position input Press the scroll key until the ON display shows iG Send a BEBE 0 10V Input 10V 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 Perform both steps 5 and 6 to calibrate RTD function if required for input 1 Step 5 Set the DIP switch for RTD input Press the scroll key until the display shows F i Send 100 ohms signal to terminals 18 19 and 20 using to the connection shown below Figure 6 1 RTD Calibration 18 100 ohms a TEC 8300 Step 6 Press the scroll key and the display will show 5 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 and REF 1 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 Perform step 7 to calibrate mA function if required for input 1 Step 7 Set the DIP switch for mA input Press the scroll key until the display shows 5H if Send a 20mA signal to terminals 19 and 20 with the correct polarity Press the scroll key for at least 3 seconds Th
28. 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 MV PV PROCESS Fuzzy Rule Language informationy Figure 1 1 Fuzzy PID System Block F Inf re rmm eoe PID Fuzzy Control has been proven to be an efficient method to improve the control stability as shown by the comparison curves at left M Digital information f the temperature difference is large and the temperature rate is large then AMV is large If the temperature difference is large and the temperature rate is small then AMV is small value MV 1 2 Ordering Code rec ssoo ood oa 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 R S N L 2A 240VAC 9 Special order 2A 240VAC o RS 232 9 Special order 3 Retransmit 4 20mA RTD PT100 DIN PT100 JIS 0 20mA Current 4 20mA 0 20 mA 4 Retransmit 1 5V Voltage 0 1V 0 5V 1 5V Output
29. loop break alarm since loop break alarm will not perform the holding function even if it is set for holding or latching holding mode See section 3 8 for descriptions of these alarm modes Loop break conditions are detected during a time interval of 2TI1 double the integral time but 120 seconds maximum Hence the loop break alarm doesn t respond as quickly as it occurs If the process value doesn t increase or decrease while the control variable MV1 has reached its maximum or minimum value within the detecting time interval a loop break alarm if configured will be activated Figure 3 18 Loop Break Sources Heater E Sensor Switching Device Controller Loop Break Sources Sensor Controller Heater Switchit Loop break alarm if configured occurs when any following conditions happen Input sensor is disconnected or broken Input sensor is shorted Input sensor is defective 1 2 3 4 Input sensor is installed outside isolated from the process 5 Controller fails A D converter damaged 6 Heater or chiller valve pump motor etc breaks or fails or is uninstalled 7 Switching device used to drive heater is open or shorted 32 3 13 Sensor Break Alarm Alarm 1 or alarm 2 can be configured as a sensor break alarm by selecting SENB for 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 A D fa
30. to suit the specific application TEC 8300 is powered by 11 26VAC VDC or 90 264VAC supply incorporating dual 2 amp control relays output and dual 2 amp alarm relays output as standard Alternative output options include SSR drive triac 4 20mA and 0 10 volts TEC 8300 is fully programmable for PT100 thermocouple types J K T E B R S 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 8300 to control fast processes such as pressure and flow Self tuning is incorporated Self tuning can be used to optimize the control parameters as soon as undesired control results are observed Unlike auto tuning self tuning will produce less disturbance to the process during tuning and can be used at any time Digital communications formats RS 485 RS 232 or 4 20mA retransmission are available as an additional option These options allow the TEC 8300 to be integrated with supervisory control systems and software or alternatively to drive remote displays chart recorders or data loggers PID control when properly tuned PID Fuzzy control Digital Temperature Fuzzy Control 7 Advantage output Warm Up Load Disturbance Time 1 information The function of Fuzzy The Fuzzy Rule may Logic 15 to adjust work like this parameters internally in order to make manipulati
31. 0 Time Note The filter is available only for PV1 and is performed for the displayed value only The controller is designed to use an unfiltered signal for control even if the filter is applied A lagged filtered signal if used for control may produce an unstable process 4 11 Sleep Mode To enter sleep mode Set FUNC for FULL to pro vide full function Select YES for SLEP to enable sleep mode Press a v for 3 seconds Sleep mode features Shut off display Shut off outputs Green power Replaces power switch the unit will now enter sleep Setup menu mode FUNC FULL SLEP YES During sleep mode 1 All displays are shut off except a decimal point which is lit periodically 2 All outputs and alarms are shut off To exit sleep mode 1 Press to leave the sleep mode 2 Disconnect the power the sleep function can be used in place of a power switch to reduce the system cost Default SLEP NONE sleep mode is disabled Note If sleep mode is not required by your system NONE should be selected for SLEP to disable sleep mode 47 4 12 Pump Control Pump control function is one of the unique features of the TEC 8300 Using this function the pressure in a process can be excellently controlled The pressure in a process is commonly generated by a pump driven by a variable speed motor The complete system has the following characteristics which affect control behavior PUMP
32. 00 k O J Figure 1 4 Front Panel Description 45536 will be displayed by Table 1 3 Dis play Form of Characters m M J 5536 C D y Indicates Abstract Characters 1 4 Keys and Displays continued Figure 1 5 Display Sequence of Initial Message PV oF ofc sv All segments of display and omi outa am ana indicators are left off for 0 5 101 TEC 8300 PV OF IBBBE All segments of display and AMAP indicators are lit for 2 seconds GJ GJ 8300 Program Code PV OF orc Display Ange code of the aaO 333 product for 2 5 seconds a am The left diagram shows program vJ no 3 for TEC 8300 with version 39 Program Version Program No xEC 8300 Display Date Code and Serial Date Code 1 number for 2 5 seconds 189 The left diagram shows Year 2001 LL E Month May 5 Date 22nd and e Serial number 192 This means that LJ CJ the product is the 192nd unit Date 31st produced on May 22nd 2001 Month December Note that the month code A stands for Year 2001 TA October B stands for November and TEC stands for December Display the used hours for 2 5 1550 seconds The left diagram shows that the SMe unit has been used for 23456 2 hours since production TEC 8300
33. 1 Power starts within 2 5 seconds 2 Failure mode is activated 3 Manual mode is activated 4 Calibration mode is activated When bumpless transfer is configured the correct control variable is applied immediately as power is recovered and the disturbance is small During sensor breaks the controller continues to control by using its previous value If the load doesn t change the process will remain stable If the load changes the process may run away Therefore you should not rely on bumpless transfer for extended periods of time For fail safe reasons an additional alarm should be used to announce to the operator when the system fails For example a sensor break alarm if configured will switch to failure state and tell the operator to use manual control or take proper security action when the system enters failure mode WARNING After the system fails never depend on bumpless transfer for a long time or it might cause the system to run away 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 P
34. 1 5 Menu Overview Sv vet Menu Press for 3 seconds to enter the auto tuning mode Display 9 d F Mode FILE for 3 seconds To execute the default setting program 3 EJ 9 9 9 L i Calibration Mode 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 P P P D PJ P BI P P P PJ BI ce AJ eJ 2 ce AJ 1 52 for 3 seconds 5 A D P P P PJ PJ PJ P P PJ P P P 9 PJ P P P PJ EJ EJ E9 9 9 2 9 9 9 9 9 9 9 9 9 Home Screen The menu will revert to PV SV display after keyboard is kept untouched for 2 minutes except Display Mode Menu and Manual Mode Menu However the menu can revert to PV SV display at any time by pressing and z S EJ 9 9 9 B B fg 9 E
35. 2 seconds N 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 PB1 is about half to two times the range of the pressure sensor 95 Increasing FILT filter can further reduce the oscillation amplitude But a value of FILT higher than 5 seconds is not recommended A typical value for FILT is 0 5 or 1 4 Close the valves and observe whether the controller can shut off the pump each time The value of REFC should be adjusted as little as possible so that the controller can shut off the pump each time when all the valves are closed A typical value for REFC is between 3 and 5 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 18 about 0 50K g cmz Nn Remote Lockout 1 Connect external switch to terminal and 16 2 Set LOCK for EIFN 3 Lock all parameters 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 te
36. 20 0 C AOHI 30 0 C AOLO 40 0 AOHI 60 0 INI PTDN IN1 0 1V according to humidity sensor INIU C INIU PU DP1 1 DP DP1 1 DP Retransmission Application RH PV OF SP1 50 0 DF oc eti SP1L 40 0 sv 25 SP1H 60 0 sv BB GJ GJ GJ GJ 13 Chart Recorder 1 20 30 C 2 40 50 SPIL and SP1H are used to limit the adjustment range of the set point 56 Chapter 6 Calibration Do not proceed through this section unless there is a definite need to recalibrate the controller If you do recalibrate all previous calibration data will be lost Do not attempt recalibration unless you have the appropriate calibration equipment If the calibration data is lost you will need to return the controller to your supplier who may charge you a service fee to recalibrate the controller Entering calibration mode will break the control loop Make sure that the system is ready to enter calibration mode Equipment needed for calibration 1 A high accuracy calibrator Fluke 5520A calibrator recom mended with the following functions 0 100mV millivolt source with 0 005 accuracy 0 10V voltage source with 0 005 accuracy 0 20 current source with 0 005 accuracy 0 300 ohm resistant source with 0 005 accuracy 2 A test chamber providing 25 C 50 C temperature range The calibration procedures described in the f
37. 3 PVI shift 4 Softstart RAMP 14 Programmable SP1 range 5 Remote set point 15 Heat cool control 6 Complex process value 16 Hardware lockout 7 Output power limit 17 Self tune 8 Digital communication 18 Auto tune 9 Analog retransmission 19 ON OFF P PD PI PID 10 Power shut off sleep mode 11 Digital filter 12 Pump control control 20 User defined menu SEL 21 Manual control 22 Display mode 13 Remote lockout 23 Reload default values 24 Isolated DC Power supply then you can use basic mode 3 1 Input 1 Press Ly to enter setup mode Press 9 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 TC T TC IN1 E TC B R TC S TC N TC L TC RTD PT DN PT JS Linear 4 20 0 20 0 1 V 0 5 1 5 0 10 Default J TC if F is selected K TC if C is selected IN1U Selects the process unit for Input 1 Range C F PU process unit If the unit is neither C nor F then PU is selected Default C or F IN1U DP1 Selects the location of the decimal point for most not all process related parameters Range T C and RTD NO DP 1 DP DP1 Linear NO DP 1 DP 2 DP 3 DP 1 Default 1 DP IN1L Selects the low scale value for Linear type IN1L input 1 Hidden
38. 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 K E Consideration should be given to pre vent unauthorized personnel from gaining access to the power terminals such as leak proof anti vibration antiseptic etc Standard sensor limits of error are 4 F 2 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 se
39. 7 2 for some probable causes and actions Table 7 1 Error Codes and Corrective Actions 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 1 and SPMD and SV can t use the same value for normal control Illegal setup values used P1 2 or P2 1 is used for Check and correct setup values of PVMD and SPMD PVMD while PV1 or PV2 is used 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 2 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 PB p TI 0 and OUT1 PB2 0 and TI or TI2 20 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 INTU 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 Illega
40. 8300 Order a TEC 8300 with standard input 4 20mA output 1 20V DC output 2 for sensor power Set the following parameters in the setup menu FUNC FULL OUT1 REVR SELF NONE COMM optional OITY 4 20 SLEP NONE INI 4 20 0 SPMD PUMP INIU PU OUT2 DCPS SPIL 5 00 DPI 2 DP optional SP1H 15 00 INIL 0 EIFN NONE SP2F DEVI IN1H 20 00 PVMD PVI IN2 NONE FILT 1 Key menu SPMD Adjust the following parameters SP2F in the user menu ios ATSP optional 1 3 TDI 0 2 Refer to section PBI 10 00 SP2 0 50 4 12 for more PL1 100 details 5 2 Variable Period Full Wave SSR VPFW SSR VPFW SSR is a variable period full wave solid state relay It can provide a zero cross output with superior controllability compared to a conventional SSR with a fixed time base The block diagram of VPFW SSR is shown as follows Figure 5 2 Block Diagram of VPFW SSR AC AC Input Outpu Pulsed Voltage Control Input NOTES 1 The VPFW SSR can be used to drive resistant load and some types of inductance load such as relay contactor magnetic switch solenoid valve etc However it can not drive motor and capacitance load 2 Only AC power can supply VPFW SSR otherwise it will not operate properly Unlike a conventional SSR the VPFW SSR always gives the output an even number of half cycles full wave as shown in the following diagram Figure 5 3 VPFW SSR vs Conventiona
41. 9013 TEC99003 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 90 264VAC To Power To PC 24 Chapter 3 Programming Basic Functions This unit provides a useful parameter FUNC which can be used to select the function complexity level before setup If Basic Mode FUNC BASC is selected for a simple application then the following functions are ignored and deleted from the full function menu RAMP SP2 PB2 TI2 TD2 PL1 PL2 COMM PROT ADDR BAUD DATA PARI STOP AOFN AOLO AOHI IN2 IN2U DP2 IN2L IN2H EIFN PVMD FILT SLEP SPMD and SP2F Basic Mode capabilities 1 Input 1 thermocouple RTD volt mA 2 Input 2 CT for heater break detection 3 Output 1 heating or cooling relay SSR SSRD volt mA 4 Output 2 cooling relay SSR SSRD volt mA DC power supply 5 Alarm 1 relay for deviation deviation band process heater break loop break sensor break latch hold or normal alarm 6 Alarm 2 relay for deviation deviation band process heater break loop break sensor break latch hold or normal alarm 7 Dwell timer If you don t need 8 Heater break alarm 9 Loop break alarm 10 Sensor break alarm l Second setpoint 11 Failure transfer 2 Second PID 12 Bumpless transfer 3 Event input 1
42. Capacity Linear Output Resolution 15 bits Output regulation 0 01 for full load change Output settling time 0 1 second stable to 99 994 Isolation breakdown voltage 1000VAC Temperature effect 0 002595 of SPAN C 63 Triac SSR Output Rating 1A 240VAC Inrush Current 20A for 1 cycle Min Load Current 50mA rms Max Off state Leakage 3mA rms Max On state Voltage 1 5V rms Insulation Resistance 1000Mohms min at 500VDC Dielectric Strength 2500VAC for 1 minute DC voltage supply characteristics installed at output 2 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 PV2 high low alarm PV1 or PV2 high low alarm PVI PV2 high low alarm Loop break alarm Sensor break alarm Alarm mode Normal latching hold latching hold Dwell timer 0 6553 5 minutes Data Communication Interface RS 232 1 unit RS 485 up to 247 units Protocol Modbus protocol RTU mode Address 1 247 Baud Rate 0 3 38 4Kbits sec Data Bits 7 or 8 bits Parity Bit None even or odd Stop Bit 1 or 2 bits Communication Buffer 50 bytes Analog Retransmission Functions PV1 PV2 PV1 PV2 2
43. Drive o 120V 240V Mains Supply m m 8 Q Three Phase Delta Breaker Relay Output Heater Contactor to Drive Load Contactor 2 15 RS 485 Figure 2 18 RS 485 Wiring RS 485 to RS 232 network adapter TEC99001 or TEC99002 RS 232 aun 5 2 me 2 16 RS 232 Figure 2 19 RS 232 Wiring V 1 E91 C9 9 RS 232 port T m 4 Max 247 units can be linked L CC94 1 Terminator 220 0 5W Figure 2 21 Configuration of RS 232 Cable Female DB 9 1 DCD TEC 8300 2 RD 3 TD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI To DTE PC RS 232 Port 23 2 17 Analog Retransmission Figure 2 22 Analog Retransmission Wiring Indicators Indicators PLC s Recorders lt Recorders Data loggers Data loggers Inverters etc Load Inverters etc The total effective resistance of parallel loads should be greater than 10K Ohms Retransmit Current Retransmit Voltage Figure 2 23 Programming Port Wiring See Figure 1 3 in Section 1 3 to find the programming port location Programmer connector and ATE connector inserted here Access hole on the bottom view 9
44. El No Eisg Power Three Phase Delta Breaker Heater Contactor Load Relay or Triac SSR Output to Drive Contactor Linear Voltage Max 1A 240V 120V 240 4 Mains Supply Mains Supply Internal Circuit cc c Un 1 I 30mA 5V Pulsed 33 31 Voltage 33 4 _ uQ OV 7 Pulsed Voltage to Drive SSR Triac SSR Output Direct Drive 20 2 12 Output 2 Wiring Figure 2 16 Alarm 1 Wiring Max 2A Resistive 120V 240V o Mains Supply o 120V 240V o Mains Supply No Fuse Three Phase Delta Breaker Heater Contactor Load Relay Output to Drive Contactor 21 Figure 2 17 Alarm 2 Wiring Max 2A Resistive 120 240 Mains Supply Relay Output Direct Drive o 120V 240V Mains Supply Three Phase Delta Breaker Relay Output Heater Contactor to Drive Load Contactor 2 13 Alarm 1 Wiring Figure 2 16 Alarm 1 Wiring Max 2A Resistive 120V 240V o Mains Supply c m o N o Relay Output Direct Drive o 120V 240V o Mains Supply No Fuse Three Phase Breaker 1 2 10 0 Three 14 w m Heater 0 0 9 Power H 7 8 e Relay Output to Drive Contactor 22 2 14 Alarm 2 Wiring Figure 2 17 Alarm 2 Wiring Max 2A Resistive Load 120V 240V Mains Supply I 2 T 5 IIG 7 8 9 Relay Output Direct
45. Figure 1 6 System Mode Priority Manual Mode Failure Mode Low Request Calibration Mode Request Auto tuning Mode Calibration mode auto tuning mode and normal control mode are in the same priority level Sleep mode is in the highest priority level System Modes Sleep mode See section 4 11 Manual mode See section 3 23 Failure mode See section 3 17 Calibration mode See chapter 6 Auto tuning mode See section 3 20 Normal control mode See section 3 24 3 26 4 1 Request Normal Control Mode 1 7 Parameter Description Table 1 4 Parameter Description page 1 of 7 Contained Basic Parameter Display Parameter Range Default Function Notation Format Description Value TIME Dwell Time High 6553 5 minutes icum Iu V stas Hm Lon D 1955 en NNNM orst Offset Value for control 0 High 100 0 ere rc Q MER 0 High S000 200 0 SHIF PV1 Shift offset Value Low 360 0 ore High 360 0 F EA T ee tena T a NE em fame E mem BEES Ta t 1 ON OFF Control 55 6 C PAY Hysteresis sii Low ii High 100 0 F 2 A1HY LR iH stress Control of Alarm 1 Low 0 1 High 18 52 A2HY RPH Hysteresis Control of Alarm 2 Low icd 08 TA m2 Output 2 Power Limit Low High 100 Basic Function Mode FUNC Function Complexity Level 1 1 Full Function Mode No communic
46. ID values will be stored in and TDI or PB2 TI2 and TD2 as determined by the event input conditions See section 4 1 When self tuning is completed the value of SELF will change from YES to NONE to disable the self tuning function When self tuning is enabled the control variables are tuned slowly so that the disturbance to the process is less than auto tuning Usually self tuning will perform successfully with no need to apply additional auto tuning Exceptions Self tuning will be disabled as soon as one of the following conditions occurs NONE is selected for SELF The controller is used for on off control PB 0 The controller is used for manual reset TI 0 The controller is in a loop break condition The controller is in failure mode e g sensor break The controller is in manual control mode Q Q 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 m 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 tun
47. IFT If or A2FN are configured for dwell timer TIMR the alarm will not perform failure transfer 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 MV2 to continue control Without Bumpless Transfer PV gt 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 Bumpless transfer setup 1 OIFT BPLS 2 O2FT BPLS Bumpless transfer occurs as
48. Instruction Manual TEC 8300 Self Tune Fuzzy PID Process Temperature Controller Agency Approvals w Electric Heater Corporation a 607 Central Avenue Wood Dale IL 60191 1452 USA gt Tel 630 350 2252 Toll Free 800 323 6859 Map EC Fax 630 350 0232 E mail info tempco com Serving Industry Since 1972 Web www tempco com Manual TEC 8300 Revision 11 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 Using the Manual Installers isses sane seen awa es Read Chapters 1 2 e Basic Function Read Chapters 1 3 5 e Enhanced Function User Read Chapters 1 3 4 5 e System Read All Chapters expert Serius nics PRESE Read Page 10 Chapter 1 Overview Page No 1 1 Features xcd rte Rep e Rs 1 1 2 Ordering Code ich emcee yaa pasaq 2 1 3 Programming Port DIP Switch 3 1 4 Keys and Displays 4 1 3 Menu OvervieW i es bid ovens E ee eee RET FP 6 1 6 System Modes 7 1 7 Parameter Description
49. J 9 9 9 EJ 9 9 9 9 EJ 9 9 EJ 9 EJ 9 9 9 9 f 9 g E PJ 9 PJ P 9 PJ P PJ PJ 9 P P PJ P PJ PJ P P PJ P P PJ P PJ 9 PJ P P PJ P 9 09 PJ P 9 PJ P P PJ P PJ P PJ PJ 9 PJ P 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 to SEL5 contained at the bottom of setup menu 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 Priority High No Sleep Mode
50. OFST or if TI2 is used for control depends on Event input and EIFN selection but 2 0 and 2 0 REFC Exists if SPMD selects PUMP SHIF Exists unconditionally PB1 Exists if PB1 0 CPB DB Exists if OUT2 select COOL SP2 Exists if EIFN selects SP2 or SPP2 or if SPMD selects PUMP PB2 Exists if EIFN selects PID2 or SPP2 Exists if EIFN selects PID2 or SPP2 provided that PB2 0 2 If 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 A1FN selects DEHI DELO PV1H PV1L PV2H PV2L P12H P12L D12H or D12L A2HY Exists if 2 selects DELO PV1H PV1L PV2H PV2L P12H P12L D12H or D12L If or SPP2 is selected for EIFN then PL1 exists if PB1 0 or PB2 lt 0 If PID2 or SPP2 is not selected for EIFN then PL1 exists if PB1 0 Exists if OUT2 selects COOL 65 Menu Existence Conditions Table Page 2 of 3 parameter Existence Conditions Notation FUNG 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 MV1 and MV2 Exists unconditionally X Exists if IN1selects 4 20 0 20 0 1 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 5
51. 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 a On Off Control ON OFF Control PID Control Cold Start Auto tunin Begins z 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 me If auto tuning begins near the set point warm start the unit skips the warm up cycle and enters the waiting cycle Afterward the procedures are the same as described for cold start Auto Tuning Error If auto tuning fails an ATER message will appear on the upper display in the following cases If PB exceeds 9000 9000 PU 900 0 F or 500 0 C if TI exceeds 1000 seconds if the set point is changed during the auto tuning procedure or if the event input state is changed so that the set point value is changed Solutions to 1 Try auto tuning again 2 Don t change the set point value during the auto tuning procedure 3 Don t change the event input state during the auto tuning procedure 4 Use manual tuning instead of auto tuning See section 3 20 5 Touch any key to reset message
52. Troubleshooting 59 Chapter 8 Specifications 63 Appendix 1 Menu Existence Conditions 65 A 2 Factory Menu Description 68 A 5 aleae bet pan p RA gor 70 A 6 Wartanty cu ett Get wasqa ET TEES 72 i NOTES Chapter1 Overview Valuable Fuzzy plus PID 1 1 Features High accuracy 18 bit input Unique A D microprocessor based High accuracy 15 bit output control D A Automatic programming Fast input sample rate 5 Differential control times second Auto tune function Two function complexity levels Self tune function Sleep mode function Soft start ramp and dwell Pump control timer TEC 8300 Fuzzy Logic plus PID microprocessor based controller incorporates a bright easy to read 4 digit LED display which indicates the process value Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time with the minimum of overshoot during power up or external load disturbance The units are housed in a 1 8 DIN case measuring 48mm x 96mm with 65mm behind panel depth The units feature three touch keys to select the various control and input parameters Using a unique function you can put up to five parameters at the front of the user menu by using SEL1 to SEL5 found in the setup menu This is particularly useful to OEM s as it Is easy to configure the menu
53. V or 0 10 Exists unconditionally Exists if OUT2 selects COOL 66 Menu Existence Conditions Table Page 3 of 3 Parameter Existence Conditions Exists unconditionally Exists if A1FN selects DELO DBHI DBLO PV1H PV1L PV2H PV2L P12H P12L D12H D12L LB or SENB Exists if ATFN is not NONE Exists unconditionally Exists if A2FN selects DELO DBHI DBLO PV1H PV1L PV2H PV2L P12H P12L D12H D12L LB or SENB Exists unconditionally 67 A 2 Factory Menu Description d Parameter Description Range Eror Current Error Code Low O0 High 40 PRoo Prob Cope Contains Program Low o High 15 99 MODE nadE Contains Lockout Status Code and Current System Low 0 High 3 5 CMND And Command Password Low 0 High 65535 JOB Job Job Password Low 0 High 65535 DRIF d Warm up Drift Calibration Factor Low 5 0 C High 5 0 ADO AdO Zero Calibration Coefficient Low 360 High 360 m ADG Hd 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 CIJEL Low Temperature Calibration Low 5 00 High 40 00 C __ CJG L JL Cold Junction Gain Calibration Coefficient Low 199 9 High 199 9
54. ZAIHY Setup Heater break alarm 2 IN2 CT A2FN PV2 L A2MD NORM A2HY 0 1 Adjust A2SP Trigger level 25 2 Setup Limitations 1 Linear output can t use heater break alarm 2 CYCI should use 1 second or longer to detect heater current reliably Example A furnace uses two 2KW heaters connected in parallel to warm up the process The line voltage is 220V and the rating current for each heater is 9 09A If we want to detect any one heater break set 18 13 0 0 1 AIFN PV2 L AIMD NORM then No heater breaks 1 heater breaks 2 heaters breaks 1 1 XX Alarm XX Alarm 20 30 20 30 20 30 10 40 10 40 10 40 0 50 0 50 0 50 Figure 3 17 Heater Break Alarm 3 12 Loop Break Alarm Select LB for AIFN if alarm 1 1s required to act as a loop break alarm Similarly if alarm 2 is required to act as a loop break alarm then set OUT2 to AL2 and A2EN to LB TIME AISP AIDV and are hidden if alarm 1 is configured as a loop break alarm Similarly TIME A2SP A2DV and A2HY are hidden if alarm 2 is configured as a loop break alarm Loop break alarm 1 Setup AIFN LB AIMD NORM LTCH Loop break alarm 2 Setup OUT2 AL2 A2FN LB A2MD NORM LTCH One of four kinds of alarm modes can be selected for alarm 1 and alarm 2 These are normal alarm latching alarm holding alarm and latching holding alarm However the holding mode and latching holding mode are not recommended for
55. al 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 9 32 max 7 0 mm Figure 2 2 1 8 min LL Lead Termination 3 2 mm TT Spade Connector for 6 Stud 90 264 VAC 1 11 47 63Hz 2 ALARM 2 15 VA 9 O 1 12 13 Yt 1 4 14 5 fa 15 OP2 IN2 CT 16 Ono 16 O INS 7 17 P ALARM 1 8 1 8 FR 9 Sno 1 B All relay contacts Resistive 2A 240VAC Figure 2 3 Rear Terminal Connections 15 2 4 Power Wiring The controller is supplied to operate at 11 26VAC VDC or 90 264VAC Check that the installation voltage corresponds to the power rating indicated on the product label before connecting power to the controller Fuse This equipment is designed for installation in an enclosure which provides adequate protection against electrical shock The enclosure must be connected to earth ground __ 2 24 Local requirements regarding electrical installation should be rigidly observed FA 2
56. all parameters are unlocked Figure 1 3 Access Hole Overview Rear Terminal Access Hole Panel The programming port is used to connect to TEC99003 for automatic programming TEC99013 programming cable also required 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 SELI 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 K Press and release quickly to increase the value of parameter 4 Piney Press and hold to accelerate increment speed Down Ke Press and release quickly to decrease the value of parameter X id y Press and hold to accelerate decrement speed Press 2 for at least 3 seconds Enter Key Press for at least 6 seconds Start Record Key Scroll Key Scrolls through the parameters in order Allows access to more parameters on user menu also used to enter manual mode auto tune mode default setting mode and to save calibration data during calibratio
57. at 150 C for 30 minutes and then stay unpowered for another batch A TEC 8300 equipped with dwell timer is used for this purpose The system diagram is shown as follows Figure 5 5 Heat Control Example Set SP1 150 0 TIME 30 0 Timer ALM1 To achieve this function set the following parameters in the setup menu FUNC BASC basic function INI K_TC INIU C DP1 1 DP OUTI REVR OITY RELY 18 0 OIFT 0 0 TIMR AIFT ON SELF NONE Auto tuning is performed at 150 C for a new oven 50 5 4 Cool Only Control A TEC 8300 is used to control a refrigerator with the temperature below 09 To avoid set point adjustment beyond the desired range SP1L is set at 10 C and SPIH is set at O C Because the temperature is lower than the ambient a cooling action is required so select DIRT for OUTI Since output 1 is used to drive a magnetic contactor select RELY for OITY Because small temperature oscillation is tolerable use ON OFF control to reduce the over all cost To achieve ON OFF control is set to zero and is set at 0 1 C Figure 5 6 Cooling Control Example Refrigerator Setup Summary FUNC BASC IN1 PT DN IN1U C DP1 1 DP OUT1 DIRT O1TY RELY Mains SP1L 10 C Supply SP1H 0 18 DF User Menu EM PB1 0 O1HY 0 1 C vC En Out Out2 Alm Alm2 L4 8300
58. ation function RS 485 interface 3 RS 232 interface 4 20 analog retransmission output an COMM Lonn Communication Interface Ir 0 20 analog retransmission output 0 1V analog retransmission output 0 5V analog retransmission output 1 5V analog retransmission output 0 10V analog retransmission output PROT COMM Protocol Selection Modbus protocol RTU mode Table 1 4 Parameter Description page 2 of 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value La ADDR Addr Addross Assignment of Digital High 255 0 3 Kbits s baud rate 0 6 Kbits s baud rate 42 1 2 Kbits s baud rate 1 2 4 Kbits s baud rate irj 4 8 Kbits s baud rate bHug Baud Rate of Digital COMM 11 9 6Kbits s baud rate 117171 14 4 Kbits s baud rate 12 19 2 Kbits s baud rate Coo 28 8 Kbits s baud rate 1 38 4 Kbits s baud rate JA A Data Bit count of Digital I f data bits COMM 1 LE 8 data bits ort Even parity PAr Parity Bit of Digital COMM Odd parity No parity bit Stop Bit Count of Digital I One stop bit 5toP p 9 COMM Setup LE Two stop bits Menu Retransmit IN1 process value Retransmit IN2 process value Retransmit 131 2 difference process value Retransmit IN2 IN1 difference process value Ha Fr Output Function Retransmit set point value Retransmit output 1 manipulation
59. ctive 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 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 61 NOTES 62 Chapter 8 Specifications Power 90 264 47 63Hz 15 maximum 11 26 VAC VDC 15VA 7W maximum Input 1 resolution 18 bits Sampling rate 5x second Maximum rating 2VDC minimum 12VDC maximum 1 minute for mA input Temperature effect 1 5uV C for all inputs except mA input 3 0uV C for mA input Sensor lead resistance effect T C 0 2uV ohm 3 wire RTD 2 6 C ohm of resistance difference of two leads 2 wire RTD 2 6 C ohm of resistance sum of two leads Common mode rejection ratio CMRR 120dB Normal mode rejection ratio NMRR 55dB Sensor break detection Sensor open for RTD and mV inputs below 1mA for 4 20mA input below 0 25V for 1 5V input
60. d 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 AI1HY 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 alarm latching alarm holding alarm and latching holding alarm See section 3 8 for descriptions of these alarm modes Examples 909909909909900909900990990009900090990090900000990900099000090909090990990090999 DE HI NORM SP1 100 A1DV 10 A1HY 4 Process Process proceeds x 112 112 ON 112 108 108 108 100 100 100 DE HI A1MD SP1 100 A1DV 10 A1HY 4 Process Process proceeds X 112 112 ON 112 108 108 108 100 100 100 Process Process proceeds p 100 92 88 112 108 100 112 108 100 A1HY DE LO A1MD HOLD SP1 100 A1DV 10 A1HY 4 2 Types of deviation alarms DE HI DE LO Deviation alarm 1 Setup AIFN AIMD Adjust SP1 AIDV AIHY Trigger levels SPI AIDV AIHY Deviation alarm 2 Setup OUT2 A2EN A2MD Adjust SP1 A2DV A2HY Trigger levels SP1 A2DV A2HY e0000090920009090090099099009999009999 Mx Indicates an Alarm Condition 108 OFF i68 Figure 3 9 Normal Deviation Alarm Figur
61. d is measured by of PB with a range of 1 255 Initially set 100 for CPB and examine the cooling effect If the cooling action should be enhanced then decrease CPB if the cooling action is too strong then increase CPB The value of CPB is related to PB and its value remains unchanged throughout the self tuning and 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 DB Programming Adjustment of DB is dependent on the system requirements If a higher positive value of DB greater dead band is used unwanted cooling action can be avoided but an excessive overshoot over the set point 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 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 28 3 7 Dwell Timer Alarm 1 or alarm 2 can be configured as dwell timer by selecting Error Code TIMR for AIEN or A2EN but not both otherwise Er07 will appear As the dwell timer is configured the parameter TIME is used for dwell time adjustment Th
62. ding Alarm A1MD LT HO A latching holding alarm performs both holding and latching function Although the descriptions in the examples below are based on alarm 1 the same conditions can be applied to alarm 2 A1SP 200 A1HY 10 0 Process proceeds 1 A1FN PV1 H 904 l p 205 205 oN 205 205 205 195 195 195 195 orr 195 Figure 3 5 Normal Process Alarm A1SP 200 A1HY 10 0 P rocess proceeds A1MD LTCH A1FN PV1 H ae 205 205 ON 205 205 205 195 195 195 195 195 Figure 3 6 Latching Process Alarm A1SP 200 AIHY 10 0 SP1 210 Process proceeds A1MD HOLD A1FN PV1 L Me INTER E Qc d 1 210 210 210 210 205 205 205 205 OFF 205 195 195 195 gt 195 195 Figure 3 7 Holding Process Alarm A1HY 10 0 SP1 210 Process proceeds A1MD LT HO A1FN PV1 L xc xc 210 210 210 210 205 205 205 205 205 195 195 195 ON 195 195 Figure 3 8 Latching Holding Process Alarm 29 3 9 Deviation Alarm A deviation alarm alerts the user when the process deviates too far from the set point The user can enter a positive or negative deviation value A1DV A2DV for alarm 1 and alarm 2 A hysteresis value A1HY or A2HY can be selected to avoid interference problems in a noisy environment Normally 1 an
63. e 95 The circuit diagram and its temperature profile are shown as follows Figure 5 14 Dual PID Furnace AC power To Furnace Heater Heater Power Input Alarm 1 controls Event input Figure 5 15 Dual PID Crossover TA Process Value Use PID 1 PID Crossover Value Use PID 2 Time Example 2 Dual set point PID A heat treating furnace is required to harden the mold at a high temperature 1000 C for 30 minutes then the mold is cooled down with a programmable ramp 20 C minute to a lower set point 200 C Use the dual set point PID and ramp dwell functions for this application Set the following parameters in the setup menu FUNC FULL TIMR EIFN SP P2 PVMD PV1 SPMD MINR 2 Adjust the following parameters in the user menu TIME 30 0 minutes RAMP 20 0 C minute SP1 1000 C SP2 200 C PL1 100 Set the proper values for TDI PB2 2 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 95 The circuit diagram is the same as shown in figure 5 14 The temperature profile is shown below Figure 5 16 Dual Set Point PID Profile G 30 40 minutes minutes 2001 Use SP1 PID1 es Use SP2 PID2 Time Minutes 54 5 10 RS 485 A tile making plant has five production lines Each production
64. e 3 10 100 Latching Deviation Alarm 1 r 100 100 92 OFF 92 Figure 3 11 Holding Deviation Alarm b d P s vs D 88 ON A1HY DE LO A1MD LT HO SP1 100 A1DV 10 1 4 Process Process proceeds E 55 P 88 ON D FPE 00 l is I 100 92 88 Figure 3 12 Latching Holding Deviation Alarm 3 10 Deviation Band Alarm A deviation band alarm presets two reference levels relative to set point Two types of deviation band alarm can be configured for alarm 1 and alarm 2 These are deviation band high alarm AIFN or 2 select DB HI and deviation band low alarm AIFN or A2FN select DB LO and AIHY are hidden if alarm 1 is selected as a deviation band alarm Similarly A2SP and A2HY are hidden if alarm 2 is selected as a deviation band alarm The trigger level for deviation band alarm moves with the set point For alarm 1 the trigger level SP1 A1DV For alarm 2 the trigger level SP1 A2DV One of four alarm modes can be selected for alarm 1 and alarm 2 These are normal alarm latching alarm holding alarm and latching holding alarm See section 3 8 for descriptions of these alarm modes A1MD NORM SP1 100 A1DV 5 Process proceeds 2 types of deviation band alarms DB HI DB LO Deviation band alarm 1 Setup AIMD Adjust SP1 Trigger level SPI AIDV
65. e as range of IN1 IN2 Exception If any of A1SP 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 equipment must be switched off and isolated Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair Component replacement and internal adjustments must be made by a qualified maintenance person only To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture Do not use this instrument in areas under hazardous con ditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed 122 F 2 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If there is any damage due to transit report the damage and file a claim with the carrier Write down the model number and serial number for future reference when corresponding with our service center The serial number S N is labeled on the box and the housing of the controller 2 2 Mounting Make the panel cutout to fit the dimensions shown in figure 2 1 Remove both mounting clamps and insert the contro
66. e as set point 47 Use hour ramp rate as set point SPMD 5 gd Set point Mode Selection Use IN1 process value as set point e Use IN2 process value as set point Selected for pump control Lv SP1L SP IL 5 1 Low Scale Value Low 19999 High 45536 2 k pe 1000 0 C Lx PPM SP IH B is mM 0 Ht t iy Set point 2 SP2 is an actual value aM SP2F 5PgF Format of set point 2 Value set point 2 SP2 is a deviation Z No parameter put ahead Parameter TIME put ahead 1 Parameter A1SP put ahead io Parameter put ahead Parameter A2SP put ahead Parameter A2DV put ahead Parameter RAMP put ahead Setup Parameter OFST put ahead Menu Zx SEL1 SEL Select 1st Parameter r Er Parameter REFC put ahead E Parameter SHIF put ahead Parameter PB1 put ahead Parameter put ahead Parameter TD1 put ahead L Parameter CPB put ahead Parameter DB put ahead Parameter SP2 put ahead 2 Parameter PB2 put ahead Parameter TI2 put ahead Parameter TD2 put ahead RR D Gain Calibration W alibration u I Voltage Input 1 Gain 199 9 High 199 9 Cold Junction Low CJTL JEL Temperature Calibration 5 00 C High 40 00 Coefficient 13 Table 1 4 Parameter Description page 7 of 7 Contained Basic Parameter Display Parameter Flange Default E EA Format Description EN Cold Junction Gain 30 Calibration Coefficient Low
67. e 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 DIP Switch Position 0 LII RTD Input 1 2 3 4 Press the scroll key for at least 3 seconds The display will blink for a moment if it does not calibration failed DIP Switch Position ON mA Input 1 2 3 4 Perform step 8 to calibrate voltage as well as CT function if required for input 2 Manual calibration procedures continued next page 57 Manual calibration procedures continued Step 8 Press the scroll key until the display shows 2 Send a 10V signal to terminals 15 and 16 with the correct polarity Press the scroll key for at least 3 seconds The display will blink for a moment until a new value is obtained If the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then calibration failed Perform step 9 to calibrate mA function if required for input 2 Step 9 Press the scroll key until the display shows 5820 Send a 20mA signal to terminals 15 and 16 with the correct polarity Press the scroll key for at least 3 seconds The display will blink for a moment until a new value is obtained If the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then calibration failed Perform step 10 to calibrate offset of cold junction compensati
68. e dwell time is measured in minute ranging from 0 to 6553 5 minutes Once the process reaches the set point the dwell timer starts to count from zero until time out The timer relay will remain unchanged until time out The dwell timer operation is shown as following diagram If alarm 1 is configured as dwell timer AISP AIDV AIHY and A1MD are hidden The case is the same for alarm 2 Example Set AIFN TIMR or A2FN TIMR but not both Adjust TIME in minutes AIMD if AIFN TIMR or A2MD if A2FN TIMR is ignored in this case 3 8 Process Alarms A process alarm sets an absolute trigger level or temperature When the process could be PV 2 or PV1 PV2 exceeds 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 PVI H PVI L PV2 H PV2 L P1 2 H P1 2 L D1 2 H D1 2 L When PV1 H or PVI L is selected the alarm examines the PV1 value When PV2 H or PV2 L is selected the alarm examines the PV2 value When P1 2 H or P1 2 L is selected the alarm occurs if the PV1 or PV2 value exceeds the trigger level When D1 2 H or D1 2 L is selected the alarm occurs if the PV1 PV2 difference value exceeds the trigger level The trigger level is determined by AISP Alarm 1 set point and AIHY Alarm 1 hysteresis value in User Menu for alarm 1 The hysteresis value is int
69. g diagram Figure 5 10 Bread Baking Oven AC Relay 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 minutes 80 ep ee 30 C new batch 5 45 Cooling Time down minutes Figure 5 11 Temperature Profile of Baking Oven 52 5 7 Remote Set Point An on line multiple zone oven is used to dry paint Since heat demand varies at different positions in the production line multiple zones with individual controls should be used to ensure a consistent temperature profile If you order a TEC 8300 with a retransmission unit for the master controller and retransmit its set point to input 2 on the rest of the slave controllers each zone will be synchronized with the same temperature Here 1s an example Figure 5 12 Remote Set Point Application To Control To Control To Control To Control Zone 1 Heater Zone 2 Heater Zone 3 Heater Zone 4 Heater OUT1 OUT1 OUT1 180 180 sv 180 Out Out2 Alm Alm2 4 C sv 1 8300 TEC 8300 Slave Slave Slave
70. hat the pressure is still consumed by the process the controller will continue to supply appropriate power to the pump If the test shows that the pressure is not consumed by the process the controller will gradually decrease the power to the pump until the pump stops running When this happens the controller enters an idle state The idle state will use a lower set point which is obtained by adding SP2 to SP1 until the pressure falls below this set point The idle state 1s provided for the purpose of preventing the pump from been restarted too frequently The value of SP2 should be negative to ensure that the controller functions correctly REFC reference constant 3 Guaranteed pump stop 4 Programmable pump stopping interval The pump functions are summarized as follows 1 If the process is demanding material 1 loses pressure the controller will precisely control the pressure at the set point 2 If the process no longer consumes material the controller will shut off the pump for as long as possible 3 The controller will restart the pump to control the pressure at the set point as soon as the material is demanded again while the pressure falls below a predetermined value i e SP 14 SP2 Programming guide Perform auto tuning to the system under such conditions that the material i e pressure is exhausted at typical rate A typical value for is about 10Kg cm is about 1 second TD1 is about 0
71. hidden parameters for the specific application are also deleted from the SEL selection Example selects TIMR selects DE HI PB1 10 0 SELI selects TIME SEL2 selects A2 DV SEL3 selects OFST SEL4 selects PB1 SELS selects NONE Now the upper display scrolling becomes 3 4 Heat Only Control Heat Only ON OFF Control Select REVR for OUTI set PBI to 0 SPI is used to adjust set point value O1HY is used to adjust dead band for ON OFF Setup ON OFF control TIME is used to adjust the dwell timer enabled by selecting OUTI TIMR for A1FN or A2FN Output 0 1 hysteresis OIHY is enabled io the case of PB1 0 The heat only Adjust ie 1 TIME on off control function is shown in if enabled the diagram at right The ON OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest If ON OFF control is set 1 0 TDI OFST CPB and PL1 will be hidden and have no function to the system The manual mode auto tuning self tuning and bumpless transfer will be disabled too 26 SP1 O1HY 2 SP1 SP1 O1HY 2 Time Figure 3 2 Heat Only ON OFF Control 3 4 Heat Only Control continued next page 3 4 Heat Only Control continued Heat only P or PD control Select REVR for OUTI set to 0 SPI is used to adjust set point value TIME is used to adjust the dwell timer enabled by selecting
72. if T C RTD type 15 selected for INI IN1H Selects the high scale value for Linear type IN1H input 1 Hidden if T C or RTD type is selected for INI How to use IN1L and IN1H If 4 20mA is selected for SL specifies the input signal low 1 4mA SH specifies the input signal high 1 20mA 5 specifies the current input signal value and the conversion curve of the process value is shown as follows process value Figure 3 1 A Conversion Curve for Linear Type 1 gt I Process Value PV1 T r I IML 7 a input signal SL S SH 5 SL Formula PV1 INIL INIH INIL SH SL Example If a 4 20mA current loop pressure transducer with range 0 15 kg cm2 is connected to input 1 then perform the following setup 4 20 INIL 0 0 INIU PU INIH 15 0 DP1 1 DP Of course you may select another value for to alter the resolution 25 3 2 OUT1 and OUT2 Types O1TY Selects the signal type for Output 1 O1TY 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 0 20 0 1V 0 5V 1 5 1 5 linear voltage output 0 10 0 10V linear voltage output 4 20mA linear current output 0 20 linear current output 0 1 linea
73. il 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 or TI2 dependent on the selection see section 4 1 then it enters a learning cycle The double integral time is introduced to allow the process to reach a stable state Before the learning cycle the unit performs a pre tune function with PID control While in the learning cycle the unit performs a post tune function with an ON OFF control The learning cycle is used to test the characteristics of the process The data is measured and used to determine the optimal PID values At the end of the two successive ON OFF cycles the PID values are obtained and automatically stored in the nonvolatile memory Once the auto tuning procedures are completed the process display will cease to flash and the unit will revert to PID control using its new PID values 36 3 19 Auto tuning continued
74. ilure also creates a sensor break alarm TIME AISP AIDV and A1HY are hidden if alarm 1 is configured as a sensor break alarm Similarly TIME A2SP A2DV and A2HY are hidden if alarm 2 is configured as a sensor break alarm One of four kinds of alarm modes can be selected for sensor break alarm These are normal alarm latching alarm holding alarm and latching holding alarm However the holding alarm and latching holding alarm are not recommended for sensor break alarm since sensor break alarm will not perform the holding function even if it 1s set for holding or latching holding mode See section 3 8 for the descriptions of these alarm modes 3 14 SP1 Range SPIL SP1 low limit value and SP1H SP1 high limit value in the setup menu are used to confine the adjustment range of SP1 Example A freezer is working in its normal temperature range 10 C to 15 C In order to avoid an abnormal set point SP1L and SP1H are set with the following values SPIL 15 C SP1H 10 C Now SP1 can only be adjusted within the range of 10 C to 15 C 3 15 PV1 Shift In certain applications it is desirable to shift the controller display value from its actual value This can easily be accomplished by using the PV1 shift function Press the scroll key to bring up the parameter SHIF The value you adjust here either positive or negative will be added to the actual value The SHIF function will alter PV1 only Here is an example A process
75. ing 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 Initial 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 if 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 PBIZPB2 18 0 F 1 12 100 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 or PB2 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 unt
76. irst PID set is selected event input is not applied during auto tuning procedure the PID values will be stored in PB1 and TD1 Similarly if the second PID set is selected event input is applied while PID2 or SP P2 is selected for EIFN during auto tuning the PID values will be stored in PB2 TI2 and TD2 as soon as auto tuning is completed Application 1 programmed by the set point Choose 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 is activated The alarm output is connected to the event Apply signal to 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 TI1 and TD1 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
77. is equipped with a heater a sensor and a subject to be warmed up Due to the design and position of the components in the system the sensor could not be placed any closer to the part Thermal gradient different temperature is common and necessary to an extent in any thermal system for heat to be transferred from one point to another If the difference between the sensor and the subject is 35 C and the desired temperature at the subject to be heated is 200 C the controlling value or the temperature at the sensor should be 235 C You should input 35 C so as to subtract 35 C from the actual process display This in turn will cause the controller to energize the load and bring the process display up to the set point value Figure 3 20 PV1 Shift Application Subject Subject Heater Heat Transfer Heater Heat Transfer lt Sensor C C ICE LLL oa mm 200 200 35 temperature difference is observed SHIF 0 Adjust SHIF SHIF 35 C Supply more heat 33 Sensor Break Alarm 1 Setup AIFN SENB A1MD NORM LTCH Hidden TIME AISP AIDV AIHY Sensor Break Alarm 2 Setup OUT2 AL2 A2FN SENB A2MD NORM LTCH Hidden TIME A2SP A2DV A2HY Setup SPIL SPIH Figure 3 19 SP1 Range IN 1H or sensor range high SP1H s SP1L IN1L or sensor range low Subject Heater Heat Transfer D
78. isplay is stable SHIF 35 C SV 3 16 Failure Transfer The controller will enter failure mode if one of the following conditions occurs 1 SB1E occurs due to input 1 sensor break or input 1 current below 1mA if 4 20mA is selected or input 1 voltage below 0 25V if 1 5V is selected if 2 or P2 1 is selected for PVMD or PV is selected for SPMD 2 SB2E occurs due to input 2 sensor break or input 2 current below 1mA if 4 20mA is selected or input 2 voltage below 0 25V if 1 5V is selected if PV2 1 2 or P2 1 is selected for PVMD or PV2 is selected for SPMD 3 ADER occurs if the A D converter of the controller fails Output 1 and output 2 will perform the failure transfer function as one of the following conditions occurs l 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 Failure mode occurs as 1 SBIE 2 SB2E 3 ADER Failure Transfer of output 1 and output 2 occur 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 occur as Failure mode is activated Failure Transfer Setup 1 OIFT 2 O2FT 3 AIFT 4 2 1 If output 1 is configured as proportional control PB1 0 and BPLS i
79. ission Notes The setup values used for AOHI and AOLO NOTES must not be equal otherwise incorrect values will occur However AOHI can be set either higher lower than AOLO If AOHI gt AOLO AOHI is set higher than AOLO it could Direct result in a direct conversion If AOHI is set conversion lower than AOLO it could result in a AOHI AOLO reverse conversion Reverse conversion Example A control uses 4 20 analog output to retransmit the difference value between input 1 and input 2 PVI PV2 It is required that if the difference value is 100 4mA will be exported and if the difference value is 100 20mA will be exported Make the following setup for TEC 8300 INIU PU DP1 NODP IN2U PU DP2 NODP FUNC FULL COMM 4 20 AOFN P 1 2 AOLO 100 AOHI 100 4 10 Digital Filter value is too unstable to be read programmable low pass filter FILI incorporated in the TEC 8300 can be used to improve this This is a first order filter with the time constant specified by the FILT parameter which is in the setup menu The default value of FILT Is set at 0 5 seconds before shipping Adjust FILT to change the time constant from 0 to 60 seconds 0 seconds means no filter is applied to the input signal The filter is characterized by the following diagram Figure 4 7 Filter Characteristics PV1 Filter is used to stabilize the process display FILT 0 yam FILT 3
80. l SSR VPFW SSR Control Input Conventional SSR Power Input ff f MM Gower ty ff The VPFW switches the load without DC current minimizing the harmonic current and stress on the load This prolongs the load life Since the duty cycle i e output power level of the control input is small the off period will be extended to keep the output resolution such that the conversion error is minimized As low as 0 1 timing error can be achieved Hence VPFW SSR is particularly suitable for smoother control 5 2 Variable Period Full Wave SSR continued next page 49 5 2 Variable Period Full Wave SSR continued The advantages of VPFW SSR over conventional SSR are summarized in the following table Table 5 1 Function Comparison between Conventional SSR and VPFW SSR Functions VPFWSSR Conventional SSR Timing Error cycle time Control Achievement Excellent Life Output 1 and output 2 of the TEC 8300 can be connected to the VPFW SSR directly provided that a pulsed voltage drive output is ordered Load Heater Here is an example Figure 5 4 VPFW SSR Application Example TEC 8300 PV OF nuc BBBB OUT1 REVR BBBB O1TY SSRD out ote Ami Ang CYC1 1 0 sec 4 OUT2 COOL O2TY SSRD CYC2 1 0 sec TEC 8300 AC Power Three phase VPFW SSR s are also available upon request 5 3 Heat Only Control An oven is designed to dry the products
81. l setup values used OUT2 select AL2 but Check and correct setup values of OUT2 and A2FN OUT2 r UU AEN 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 ATFN and A2FN Dwell selected for both ATFN and A2FN timer can only be properly used for single alarm output T Correct the communication software to meet the protocol Communication error register address out of range Don t issue an over range register address to the slave 12 E iel Communication error access a non existent parameter Don t issue a non existent parameter to the slave ler 24 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 ertor ofitange to 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 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 EEPROM can t be written correctly Return to factory for repair Input 2 IN2 sensor break or input 2 current below 1 mA 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 in
82. le PVRL is a negative value NOTE The controller will not revert to its PV SV display from display mode unless you press the v keys 41 3 24 Heater Current Monitoring TEC99999 a current transformer Accessory installed should be equipped to measure TEC99999 the heater current Select CT for IN2 The input 2 signal Setup conditioner measures the heater IN2 CT current while the heater is powered and the current value ere u 2 will remain unchanged while the heater is unpowered The PV2 will indicate the heater current For information on how to read Limitations PV2 value please referto section 1 Linear output type can t 3 24 be used NOTES 2 CYCI or CYC2 should be set for 1 second or If the heater to be measured 1s longer to detect heater controlled by output 1 then current reliably should be set for 1 second Only full wave AC or longer and OITY should use current san be detected RELY SSRD or SSR Similarly if the heater to be measured is controlled by output 2 CYC2 should be set for 1 second or longer and O2TY should use RELY SSRD or SSR to provide an adequate time for the A to D converter to measure the signal Since CT94 1 can detect a full wave AC current only a DC or half wave AC current can t be measured or CYC221 second 3 25 Reload Default Values The default values listed in table 1 4 are stored in the memory when the product leaves the fact
83. line is equipped with 16 TEC 8300 units to control the temperature for the kiln They want to program the controllers and monitor the process from the control room to improve quality and productivity A cost effective solution for the above application would be to use 80 TEC 8300 units plus a TEC99002 smart network adapter and DAQ PC based software for this purpose The system 1s installed as shown in the following diagram Terminator 220 ohms 0 5W TX2 Figure 5 17 RS 485 Applications Setup Enter setup mode to configure each TEC 8300 Choose FULL for FUNC 485 for COMM RTU for PROT and select a different address ADDR for each unit Use the same values of BAUD DATA PARI and STOP for the TEC 8300 s TEC99002 and DAQ Software Also refer to section 2 15 and section 4 8 Taking advantage of DAQ software the operator can monitor the process on the PC screen program the set point as well as other control parameters such as PID values download the ramp and soak profile to the controllers execute the manual control or trigger auto tuning etc and print out reports as required The historical data can be saved in the floppy drive hard drive or on a CD for permanent storage Setup menu FUNC COMM PROT ADDR BAUD DATA PARI STOP Control Room DAQ Software TEC99002 Twisted pair wire
84. ller 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 Panel Cutout 92 mm 7 mm Figure 2 1 IN1 V 65mm com 10 20 5 9 B Mounting Dimensions 2 3 Wiring Precautions Before wiring check the label to verify the correct model number and options Switch off the power while checking Care must be taken to ensure that the maximum voltage ratings specified on the label are not exceeded 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 the unit Verify that the ratings of the output devices and the inputs as specified in chapter 8 are not exceeded Electrical power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes This electric
85. ly 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 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 SP1 is set at 300 C and SP2 is set at 80 C Choose ACTU for SP2F After 6 00PM the timer output is closed The event input function will then select SP2 80 C to control the process Format of SP2 Value SP2F choose Actual Value or Deviation Value Refer to section 4 1 for more descriptions about SP2F function 43 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 f
86. max distance 1 Km 55 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 8300 to control the temperature of the solution being tested He is particularly interested in generating a test report containing the relationship between the concentration and temperature For a single unit application it is adequate to order a TEC 8300 with RS 232 communication and DAQ software Using the BC Net software the temperature data can be viewed and stored in a file The user can program the temperature as well as other control parameters such as PID values He can set up the controller download a ramp and soak profile execute manual control or auto tuning procedure etc The results can be printed out or stored in a file for future reference Refer to section 2 16 for installation and section 4 8 for setup procedure Figure 5 18 SP1 25 0 SP1L 20 0 SP1H 30 0 5 12 Retransmit An air conditioned room uses two TEC 8300 units to control the temperature and humidity The temperature and humidity must be recorded on a chart recorder The preferred ranges for these two parameters are 20 C to 30 C and 40 RH to 60 RH The recorder inputs accept a 0 5V signal To achieve this set the following parameters in the setup menu UNIT 1 UNIT 2 FUNC FULL FUNC FULL COM 0 5V COMM 0 5V AOFN PV1 AOFN PV1 AOLO
87. me 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 PV1 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 input 2 is used for the process signal input If PV2 is selected for SPMD the remote set point signal is sent to input 2 and input 1 is used for the process signal To achieve this set the following parameters in the setup menu Setup FUNC FULL SPMDzPV2 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 PV1 IN1 IN1U 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 to accept remote set point FUNC FULL INI INIU INIL INIH 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 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 Er i Note 2 If PV1 PV2 is selected for SPMD a signal loss will result in the con
88. mits 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 selected 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 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 MV1 H 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 no
89. n procedure Resets historical values of PVHI and PVLO and start to record the peak process value Press Reverse Scroll Key Scrolls through the parameters in reverse order during menu scrolling Press Mode Key Selects the operation mode in sequence Press 4 Ly Sleep Key for at least 3 seconds DF nm m Mz UN Co NY LI BBB Output 1 Indicator R a n Out Out2 1 Alm2 9 v Alarm 1 Indicator Alarm 2 Indicator TM 1 T Output 2 Indicator Resets the front panel display to normal display mode also used to leave Press Reset Key the specific mode execution to end auto tune and manual control execution and to quit sleep mode The controller enters sleep mode if the sleep function SLEP is enabled select YES How to display a 5 digit number Process Unit Indicator For a number with decimal point the Upper Display display will be shifted one digit right to display process value 199 99 will be displayed by 199 9 menu symbol and error code etc 4553 6 will be displayed by 4553 Lower Display to display set point value For a number without decimal point parameter value or control the display will be divided into two output value etc alternating phases 19999 will be displayed by 3 Buttons for ease of control setup and set point adjustment d g g g g 83
90. n the upper display The historical extreme values are saved in a nonvolatile memory even when it is unpowered Press for at least 6 seconds to reset both the historical values PVHI and PVLO and begin to record new peak process values MV1 MV2 show the process value on the upper display and shows the percentage control value for output 1 while PVHI i ___ shows the percentage control value SET for output 2 PVLO DV shows the difference value between MV1 1H process and set point ie PV SV This value is used to control output 1 and output 2 PV1 shows the process value of input 1 on DV the upper display PV1 PV2 shows the process value of input 2 on PV2 pus the upper display PB shows the current proportional band PB value used for control shows the current integral time used for TD control c CJCT TD shows the current derivative time used for control Since the controller 1s performing PVR FUZZY control the values of PB TI and TD may change from time to time PVRH CJCT shows the temperature at the cold junction measured in C independent of the unit used PVR Shows the changing rate of the process in C or F or PU per minute It may be negative 1f the process is going down PVRH PVRL The maximum and minimum changing rate of the process since power up as measured in C or F or PU per minute PVRH is a positive value whi
91. 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 T Dead band O1HY Time Figure 3 3 Cool Only ON OFF Control Refer to section 3 5 in which similar descriptions for heat only control can be applied to cool only control 27 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 Control Modes ON OFF ALM1 OUT1 or REVR NONE ALM1 or of DIRT NONE ALM1 OUT1 or x ALM2 ALM1 OUT1 or REVR NONE ALM2 OUT2 X Not Applicable x x x x 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 1s recommended to use PID control for the heat cool control to produce a stable and zero offset process value Other Setup Required O1TY CYC1 O2TY CYC2 A2SP A2DV and O2TY are set in accordance with the types of OUTI and OUT2 installed and CYC2 are selected according to the output 1 type and output 2 type O2TY Generally select 0 5 2 seconds for CYC1 if SSRD or SSR 15 used for O1 TY Select 10 20 seconds if relay is used for OITY is ign
92. nsor except by proper selection and replacement Figure 2 4 Power Supply Connections 2 6 Thermocouple Input Wiring The thermocouple input connections are shown in figure 2 5 The correct type of thermocouple extension lead wire or compensating cable must be used for the entire distance between the controller and the thermocouple ensuring that the correct polarity is maintained throughout Joints in the cable should be avoided if possible A r3 SS ra 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 DIP The color codes used on the thermocouple extension leads are shown in table 2 1 Switch Table 2 1 Thermocouple Cable Color Codes Thermocouple Cable British American German French Figure 2 5 Type Material BS ASTM DIN NFE Thermocouple Copper Cu white blue red yellow Input Wiring T Constantan blue red brown blue Cu Ni blue blue brown blue Iron Fe yellow white red yellow J Constantan blue red blue black Cu black black blue black Nickel Chromium Ni Cr brown yellow re ye Nickel Aluminum i Due a gue dena Ni AI red yellow green yellow R Pt 13 Rh Pt Been red yellow S Pt 10 Rh Pt ue n white green green white g
93. ntrol and cool only PID control are the same as the descriptions in section 3 5 for heat only control except that the output variable and action for the cool control is inverse to the heat control such as the following diagram shows Heat only PID control Selecting REVR for SP1 is used to adjust set point value TIME is used to adjust the dwell timer enabled by selecting TIMR for or A2FN and should not be zero Adjust CYCI according to the output 1 type Generally CYC1 0 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 TI1 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 8300 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 SP1 01HY 2 SP1 T T 1 N1T 77 1 7 SP1 O1HY 2 Setup PID OUTI if RELAY SSRD or SSR is selected for OI TY SELF NONE or YES Adjust SP1 TIME if enabled PB1 z0 TI1 0 41 Auto tuning Used for
94. nverter damage Sleep mode Enable or disable Ramping control 0 900 0 F minute or 0 900 0 F hour ramp rate Power limit 0 100 output 1 and output 2 Pump pressure control Sophisticated functions provided Remote set point Programmable range for voltage or cur rent input Differential control Control PV1 PV2 at set point Digital Filter Function First order Time constant 0 0 2 0 5 1 2 5 10 20 30 60 seconds programmable Environmental and Physical Operating temperature 10 C to 50 C Storage temperature 40 C to 60 C Humidity 0 to 90 RH non condensing Insulation resistance 20Mohms min at 500VDC Dielectric strength 2000VAC 50 60Hz for 1 minute Vibration resistance 10 55Hz 10m s for 2 hours Shock resistance 200m s 20g Moldings Flame retardant polycarbonate Dimensions 48mm W X96mm H X80mm D 65mm depth behind panel Weight 220 grams Approval Standards Safety UL873 11th edition 1994 CSA C22 2 No 24 93 EN61010 1 IEC1010 1 Protective class IP 20 housing and terminals with protective covers EMC EN61326 A 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 2 selects DELO DBHI or DBLO RAMP Exists if SPMD selects MINR or HRR Exists if TI1 is used for control depends on Event input and EIFN selection but 1 0 and
95. o 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 in the 9P2F 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 will 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 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 EIFN 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 required to be heated to a higher temperature as soon as its Setup pressure exceeds a certain limit Set SPMD SP1 2 EIFN SP2 or SP P2 if the second PID choose SP2 or SPP required for the higher temperature too The pressure gauge is switched ON as it senses a higher App
96. ollowing section are step by step manual procedures Manual calibration procedures Perform step 1 to enter calibration mode Step 1 Set the lockout DIP switch to the unlocked condition both switches 3 and 4 are off Press both scroll and down keys and release them quickly The operation mode menu will appear on the display Repeat this 1 several times aud ERES e 4 on the display Press the scroll key for at least 3 seconds The display will show and the unit will enter calibration mode Output 1 and output 2 use their failure transfer values to control Perform step 2 to calibrate zero for the A to D converter and step 3 to calibrate the gain for the A to D converter The DIP switch should be set for T C input Step 2 Short terminals 19 and 20 then press the scroll key for at least 3 seconds The display will blink for a moment until a new value is obtained If the display didn t blink or if the obtained value is equal to 360 or 360 then calibration failed DIP Switch Position Input 1 2 9 24 Step 3 Press the scroll key until the display shows Adi Send 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 Perform step 4 to calibrate the voltage function
97. on if required Set the DIP switch for T C input Step 10 Set up the equipment according to the following diagram to calibrate the cold junction compensation Note that a K type thermocouple must be used DIP Switch Position f B a TC Input 3 4 K 5520A Calibrator TEC 8300 K TC K Stay at least 20 minutes in still air at room temperature 25 3 C Figure 6 2 Cold Junction Calibration Setup The 5520A calibrator is configured for K type thermocouple output with internal compensation Send a 0 00 C signal to the unit under calibration The unit under calibration is powered in a still air room with a temperature of 25 3 C Allow at least 20 minutes to warm up The DIP switch is located at the TC input Perform step 1 as stated above then press the scroll key until the display shows Press the up and down keys until a value of 0 00 is obtained Press the scroll key at least 3 seconds The display will blink for a moment until a new value is obtained If the display didn t blink or if the obtained value is equal to 5 00 or 40 00 then calibration failed Perform step 11 to calibrate the gain of cold junction compensation if required If a test chamber for calibration is not available perform step 11N to use a nominal value for the cold junction gain Step 11 Set up the equipment the same as in step 10 The unit under calibration 1s powered in a still air room with a temperature of
98. on of more flexible and adaptive to various processes Sensor break alarm and bumpless transfer RS 485 RS 232 communication Programmable inputs thermocouple RTD mA VDC Analog input for remote set point and CT Event input for changing function and set point Analog retransmission Signal conditioner DC power supply A wide variety of output modules available Safety UL CSA IECIO10 1 EMC CE EN61326 Programmable digital filter Hardware lockout and remote lockout protection Loop break alarm Heater break alarm Two different methods can be used to program the TEC 8300 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 tuning the process Unfortunately many systems are too complex to describe precisely in numerical terms In addition these systems may be variable from time to time In order to overcome the imperfections of PID control Fuzzy Technology was introduced What is Fuzzy Control It works
99. ored 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 AIFN or A2MD NORM or A2HY 0 1 PB120 TI1 0 TD120 and set appropriate values for and CYCI Heat PID Cool PID set OUTI REVR OUT2 COOL 100 DB 4 0 PB10 TI120 TD10 and set appropriate values for OITY CYCI O2TY CYC2 If you have no idea about a new process then use the self tuning program to optimize the PID values by selecting YES for SELF to enable the self tuning program See section 3 18 for a description of the self tuning program You can use the auto tuning program for the new process or directly set the appropriate Heat Cool Uses Uses OUT2 O1HY OFST TD1 ALM1 or OUT1 DIRT NONE ALM2 REVR COOL m Adjust to meet process requirements Setup Values ATMD A1HY or or A2FN A2MD A2HY DE HI or ORM PV1 H DE LO or PV1 L r i DE LO x x or NORM PV1 L DE HI x x or NORM PV1 H DE HI x x or NORM PV1 H fx values for TI1 and TD1 according to the historical records for the repeated systems If the control behavior is still inadequate then use manual tuning to improve the control See section 3 20 for more information on manual tuning add ef ef ud x x 40 5 40 0 Programming The cooling proportional ban
100. ory 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 v several times until FILE 0 appears Then press C default file The upper display will show F Use the up and down keys to select 0 or 1 If C units FILE 1 are required select 0 for FILE and if F units oF default file 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 NOTES 42 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 TI1 and TD1 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
101. put 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 Hz E Ato D converter or related component s malfunction Return to factory for repair 60 Table 7 2 Common Failure Causes and Corrective Actions Symptom Probable Causes Corrective Actions No power to instrument Check power line connections 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 Displ i irecti s 5 down scale as process warms 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 defe
102. r A chamber is used to test the temperature cycling effect on personal computers An external cycle timer is used to control the event input for switching the set point The products under test are required to stay at 60 C for 1 hour and 10 C for 30 minutes The transition interval between the high and low temperatures is required to be 5 minutes Make the following setup EIFN SP P2 TIMR OUTI REVR relay output OUT2 COOL 4 20mA output SPMD MINR INIU C DPI 1 DP The circuit diagram and its temperature profile are shown below Figure 5 8 A Temperature Cycling Chamber Chamber Freezer RTD Heater TIME 60 0 minutes SP1 60 0 SP2 10 0 C CPB 100 TEC 8300 RAMP 14 0 C minute Figure 5 9 Temperature Profile of Chamber 60 minutes 60 minutes 60 C 60 C 30 35 5 minutes BILL 65 minutes minutes The TEC 8300 provides a 4 20mA signal to control the speed of the inverter SP P2 is chosen for EIFN in order to create a dual PID control You can perform auto tuning twice at SP1 and SP2 for the initial setup for the dual PID values Refer to sections 3 19 and 4 3 Example 2 Programmable bread baking oven Bread is baked in batches A ramp is incorporated to control the thermal gradient to suit for making the bread A dwell timer is used to shut off the oven power and announce this to the baker The system is configured as shown in the followin
103. r voltage output 0 5V linear voltage output 3 3 Configuring User Menu Most conventional controllers are designed with a fixed order in which the parameters scroll The TEC 8300 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 SEL4 and change SEL2 Selects the 2nd most significant parameter for view and change SEL2 SEL3 Selects the 3rd most significant parameter for view and change SEL3 SEL4 Selects the 4th most significant parameter for view and change SELS Selects the 5th most significant parameter for n vlew and change Range NONE TIME ALSP Al DV A2 SP SEL5 A2 DV RAMP OFST REFC SHIF PB1 5 TDI C PB DB SP2 PB2 TD TD2 O2TY Selects the signal type for Output 2 O2TY The selection should be consistent with the output 2 module installed The available output 2 signal types are the same as for OITY 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 20 may be 20 21mA However this deviation will not degrade the control performance at all When using the up and down keys to select the parameters you may not see all of the above parameters The number of visible parameters is dependent on the setup condition The
104. re 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 Three line Transmitter or sensor Bridge Type Sensor Set OUT2 g P5 pc Power Supply Caution To avoid damage don t use a DC power supply beyond its current rating Purchase one with the correct voltage to suit your external devices See the ordering code in section 1 2 3 22 Manual Control Manual control may be used for the following purposes 1 To test the process characteristics to obtain a step response as well as an impulse response and use these data for tuning a controller 2 To use manual control instead of a closed loop control if the sensor fails or the controller s A D converter fails NOTE that bumpless transfer can not be used for an extended time See section 3 17 3 In certain applications it is desirable to supply a process with a constant demand Operation Press and release v until 4384 Means hand control appears on the display Press for 3 seconds The upper display will begin to flash and the lower display will show z The controller is now in manual control MV1 38 4 for OUTI or heating Means MV2 7 63 for mode QUT or cooling Pressing co will cause the lower display to show fF __ and H alternately where H _ indicates output 1 on time f
105. reen Pt 30 Rh_ Use m pes Use Pt 696Rh Copper Wire grey grey Copper Wire Color of Overall Sheath 16 2 7 RTD Input Wiring The RTD connections are shown in figure 2 6 with the compensating lead 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 equal in length Led Lex RY SP Lu KS For the purpose of accuracy a two wire RTD should be avoided if possible A 0 4ohm lead DIP resistance in a two wire RTD will produce 1 C Switch temperature error 1 2 3 4 5 6 7 8 9 eI o Three wire RTD Two wire RTD Figure 2 6 RTD Input Wiring 1 2 3 4 2 8 Linear DC Input Wiring i DC linear voltage and linear current connections for input 1 are shown in figure 2 7 and figure 2 8 DIP DC linear voltage and linear current connections for input 2 are shown in i figure 2 9 and figure 2 10 Switch 1 5V 0 10V g g 10 Figure 2 7 Input 1 Linear Voltage Wiring 1 2 4 4 5 6 7 DIP al 4 9 0 20 or Switch 0 4 20mA 0 1 0 5V 1 5V 0 10V Figure 2 8 Input 1 Linear Current Wiring 20 Figure 2 9 0 20mA or 4 20mA Input 2 Linear Voltage Wiring Figure 2 10 Input 2 Linear Current Wiring 17 2 9 CT Heater Current Input Wiring Heater
106. rminals 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 external switch is closed When the switch is left open the lockout condition is determined by internal DIP switch hardware lockout see section 1 3 Hardware lockout Can be used only during initial setup Remote lockout Can be used any time 48 Chapter 5 Applications 5 1 Pump Pressure Control Regulated water supply systems are widely used in residential areas water plants chemical plants electrical plants semiconductor plants etc By taking advantage of its PUMP function the TEC 8300 can be used to create an economical yet versatile solution for these applications Here is an example Figure 5 1 Water Supply System TEC 8300 PV nc Iran 5 LLLI LI Kg cm 1000 Pressure Reservoir 4 Pressure Sensor xEC 8300 OUT2 DC20V 4 20 mA K Water Motor Pump 30 Inverter t Water The water pressure in this example must be controlled at 10Kg cm To achieve this the following devices are used for this example Inverter To supply a variable frequency AC voltage to the motor Motor A 3 0 induction motor Pump Any appropriate economical type of pump Pressure Sensor A three wire or two wire type of pressure transducer with a 0 20Kg cm range Pressure Reservoir Provides smoother pressure for the system TEC
107. roduced to avoid interference action of alarm in a noisy environment Normally can be set with a minimum 0 1 value 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 ATMD HOLD A holding alarm prevents an alarm from powering up The alarm is enabled only when the process reaches the set point value may be SP1 or SP2 see section 4 1 event Time l Time Timer starts Figure 3 4 Dwell Timer Function 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 A ISP AIHY Process Alarm 2 Setup OUT2 A2FN A2MD Adjust A2SP A2HY Trigger level A2SP A2HY Reset Latching alarm 1 Power off 2 Apply event input in accordance with proper selection of EIFN input Afterwards the alarm performs the same function as a normal alarm Latching Hol
108. s selected for OIFT then output 1 will perform bumpless transfer Thereafter the previous averaging value of will be used for controlling output 1 2 If output 1 is configured as proportional control PB1 0 and a value of 0 to 100 0 is set for OIFT then output 1 will perform failure transfer Thereafter the value of will be used for controlling output 1 3 If output 1 is configured as ON OFF control PB1 0 then output 1 will be driven OFF if OIFN selects REVR and be driven ON if O1FN selects DIRT 34 Output 2 failure transfer if activated will perform 1 If OUT2 selects COOL 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 OUT2 selects COOL and a value of 0 to 100 0 is set for O2FT then output 2 will perform failure transfer Thereafter the value of 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 1 Alarm 2 failure transfer is activated as the controller enters failure mode Thereafter alarm 2 will transfer to the ON or OFF state preset by A2FT Exception If AIFN or A2FN are configured for loop break LB alarm or sensor break SENB alarm alarm 1 or alarm 2 will be switched to ON state independent of the setting of A
109. t 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 485 standard PC can t support an RS 485 port network adapter such as 99001 or PROT RTU TEC99927 must be used to convert RS 485 to RS 232 for a PC if RS 485 is required 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 required or 232 if RS 232 is required Select 9 TXI i e Modbus protocol RTU mode for PROT Set individual addresses for any units that TX 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
110. ted RS 232 interface module TEC 102 104 Isolated 4 20mA 0 20maA retransmission module TEC 102 105 Isolated 1 5 0 5 retransmission module TEC 102 106 Isolated 0 10 retransmission module Output Power Supply 9 Isolated 5V 80mA DC Output Power Supply A Special order Range set by front keyboard Need to order accessory TEC99999 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 DAQ software converts 255 channels of RS 485 or RS 422 to RS 232 network 1 3 Programming Port and DIP Switch DIP Switch Table 1 1 DIP Switch Configuration 1 2 3 4 TC RTD mV Input 1 0 1 0 5V 1 5V 0 10V m Select 0 20 mA 4 20 mA All parameters are Unlocked Only SP1 SEL1 SEL5 are unlocked m Lockout Only SP1 is unlocked m All Parameters are locked Factory Default Setting m 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
111. troller reverting to manual mode with 0 output 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 INIL IN1H are set according to input 1 signal IN2 IN2L IN2H are set according to input 2 signal INIU IN2U DP2 are set according to input 1 and input 2 signal PVMD PI 2 or P2 1 SPMD SPI 2 The response of PV2 will be parallel to PV1 as shown in the following diagram Setup PVMD PI 2 or PVMD P2 1 SPMD SPI 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 PV1 value if P2 1 is chosen for PVMD If you need PV1 or PV2 to be displayed instead of PV you can use the display mode to select PV1 or PV2 to be viewed See section 3 23 Error messages If P1 2 or P2 1 is selected for PVMD while Error or PV2 is selected for SPMD an Er tia 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 tS error code will appear 45 4 7 Output Power Li
112. u is called the ultimate period in the flow chart in figure 3 23 When this occurs the process is said to be in a critical steady state figure 3 24 shows an example of a critical steady state Figure 3 24 Critical Steady State If PB PBu the process sustains to oscillate Time If the control performance using above tuning is still unsatisfactory the following ADJUSTMENT SEQUENCE SYMPTOM SOLUTION rules can be applied for further adjustment of PID values 1 Proportional Band P PB1 and or PB2 Slow Response Decrease PB1 or PB2 High overshoot or Oscillations Increase PB1 or PB2 2 Integral Time 1 and or TI2 Slow Response Decrease or TI2 Instability or Oscillations Increase or TI2 3 Derivative Time D TD1 and or TD2 Slow Response or em Decrease TD1 or TD2 Oscillations High Overshoot Increase TD1 or TD2 Figure 3 25 shows the effects of PID adjustment on process response P action PV PB too low Set point PB too high I action TI too hi PV Set point TI too low Perfect h Time 39 Table 3 2 PID Adjustment Guide Figure 3 25 Effects of PID Adjustment D action PV TD too low Perfect Set point TD too high Time 3 21 Signal Conditioner DC Power Supply Three types of isolated DC power supplies are available to supply an external transmitter or sensor These a
113. ure Transfer Same as A1FT 1 Event input no function 5 SP2 activated to replace SP1 PB2 TI2 TD2 activated to replace PB1 TD1 SP2 PB2 TI2 TD2 activated to replace SP1 PB1 TD1 1 Reset alarm 1 output EIFN Event Input Function 5 Snc Reset alarm 2 output 1 1 Reset alarm 1 amp alarm 2 f Disable Output 1 4 Disable Output 2 2 Disable Output 1 amp Output 2 l mg H Lock All Parameters Use PV1 as process value Use PV2 as process value PVMD nd PV Mode Selection Use PV1_ PV2 difference as 0 process value Use PV2_ PV1 difference as process value O second time constant E Filter Damping Time IL Constant of PV 60 seconds time constant Self Tuning Function Selftune function disabled ELF Selection Self tune function enabled Sleep mode Function Sleep mode function disabled SLE Selection 5 Sleep mode function enabled 0 2 second time constant C3 C3 0 5 second time constant 1 second time constant 2 seconds time constant 5 seconds time constant 10 seconds time constant 20 seconds time constant 30 seconds time constant C3 C3 C3 C3 unm nu eu uy Pu 12 Table 1 4 Parameter Description page 6 of 7 Contained Basic Parameter Display Parameter Rang Default Function Notation Format Description Value Use SP1 or SP2 depends on EIFN as set point 7 Use minute ramp rat
114. ure requires access to the circuitry of a unit under live power Accidental contact with line voltage is possible Only qualified personnel should perform these procedures Potentially lethal voltages are present Troubleshooting procedures 1 If an error message is displayed refer to table 7 1 to see what caused it and what action to take to correct the problem 2 Check each point listed below Experience has proven that many control problems are caused by a defective instrument Line wires are improperly connected No voltage between line terminals ncorrect voltage between line terminals Connections to terminals are open missing or loose Thermocouple is open at tip Thermocouple lead is broken Shorted thermocouple leads Short across terminals Open or shorted heater circuit Open coil in external contactor Burned out line fuses Burned out relay inside control Defective solid state relays Defective line switches Burned out contactor Defective circuit breakers 59 If the points listed on the above chart have been checked and the controller still does not function properly it 1s 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 Refer to table
115. value 4 Retransmit output 2 manipulation value Retransmit deviation PV SV Value AOLO 018199 Output Low Scale Low 19999 High 45536 AOHI Hot Analog Output High Scale Low 19999 High 45536 EL J type thermocouple ee type thermocouple _ EL T type thermocouple _ E D E type thermocouple 1 n IN1 Sensor Type Selection _ EL B type thermocouple e r R type thermocouple LF S type thermocouple Table 1 4 Parameter Description page 3 of 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value N type thermocouple L type thermocouple PT 100 ohms DIN curve 185 PT 100 ohms JIS curve ZLI 4 20mA linear current input IN1 Sensor Type Selection 0 20 mA linear current input 0 1V linear Voltage input lt 0 5V linear Voltage input 1 5V linear Voltage input 0 10V linear Voltage input Special defined sensor curve Degree C unit Zx IN1U 1 m lu IN1 Unit Selection Degree F unit Process unit 1 No decimal point 1 decimal digit Zx IN1 Decimal Point Selection 2 decimal digits Setup 8 decimal digits Menu i n IL IN1 Low Low Scale Value Value Low 19999 High 45536 n iH 1 High Scale Value 1 High Scale Value Value Low 19999 High 45536 IN2 no function Current transformer input 4 20 mA linear current input 0 20 mA linear current input IN2 Signal Type Selection
116. w 19999 High 45536 siG8 5 LB Point 8 Signal Value of Special Sensor Low 19999 High 45536 IND8 1 nd Point 8 Indication Value of Special Sensor Low 19999 High 45536 SiG9 6 59 Point 9 Signal Value of Special Sensor Low 19999 High 45536 IND9 nd Point 9 Indication Value of Special Sensor Low 19999 High 45536 LYPE Signal of Special Sensor Low 0 High 3 DATE Manufacturing Date of Product Low 0 High 3719 NO Serial Number of Product Low 1 High 999 These parameters are available only if SPEC is selected for IN1 68 2 Parameter Description Range 2 HOUR Hor Working Hour Value Low 0 High 65535 Hours HRLO Hr L g Fractional Hour Value Low O0 High 0 9 Hour ERR1 Er r Historical Error Record 1 Low 0 High FFFF 0 ERR2 Historical Error Record 2 Low 0 High FFFF 0 DELI ASCII Input Delimiter Low 0000 High 007F 000A BPL1 b PL OUT1 Bumpless Transfer Value Low 0 High 100 00 96 BPL2 hPL 2 OUT2 Bumpless Transfer Value Low 0 High 100 00 96 _ CJCL L JEL Sense Voltage of Cold Junction Calibration Low Low 31 680 High 40 320 mV 69 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 in Notation Format in Notation Format wm me

TEC 8300 Manual - Tempco Electric Heater Corporation

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