TCUCOVR.
TCUCOVR(wip).QXD 10/20/03 2:28 PM Page 2 INTRODUCTION The Temperature Control Unit (TCU) is a multi-purpose series of industrial control products that are field-programmable for solving various applications. This series of products is built around the concept that the end user has the capability to program different personalities and functions into the unit in order to adapt to different indication and control requirements.
Table of Contents GENERAL DESCRIPTION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1 SAFETY SUMMARY · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2 INSTALLATION & CONNECTIONS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3 Installation Environment · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Configuration Of Parameters · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Parameter Entry · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Normal Display Mode · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Modifying A Secondary Display Parameter From The Front Panel · · · · · · · · · · · · · · · · · · · · · · · UNPROTECT
Lower Display Lockouts (SP, OP, HCur, IN-2, dEv, UdSP) · · · · · · · · · · · · · · · · · · · · · · · · · Protected Mode Lockouts (Code, PID, PID2, rtbS & AL) · · · · · · · · · · · · · · · · · · · · · · · · · · · Hidden Mode Lockouts (ALrS, trnF, tUNE and SPSL) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Alarm Module (4-AL) (Optional) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Alarm Action (Act1, Act2) · · · · · · · · · · · · · · · · · · · ·
Valve Position Deadband (VPdb) (Position Mode) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 39 Valve Fail Time Alarm (VFAL) (Position Mode) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 39 Valve Motor Open Time And Valve Motor Close Time (VOPt, VCLt) (Velocity mode) · · · · · · 39 Valve Minimum On Time (VONt)(Velocity Mode) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 39 Factory Service Operations Module (9-FS) · · · · · · · · · · · · · · · · · ·
External Cascade Control · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Internal Cascade Control · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · PID CONTROL · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Proportional Band · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
Calibration · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Configure Step 9 - Factory Service Operations (9-Fs) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Millivolt Calibration (Cal) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Thermocouple Cold Junction Calibration (CJC) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · RTD Ohms Calibrati
GENERAL DESCRIPTION The optional Heater Current Monitor serves as a digital ammeter for heater current monitoring. Used with current transformer accessory (CT005001), this display is integrated within the controller. An alarm event output can be programmed to signal when the heater or heater control devices have failed, before damage to process material occurs. The Heater Break Alarm triggers under two conditions: 1.
The optional RS485 multi-drop serial communication interface provides two-way communication between a TCU unit and other compatible equipment such as a printer, a programmable controller, or a host computer. In multi-point applications the address number of each unit on the line can be programmed from zero to ninety nine. Up to thirty-two units can be installed on a single pair of wires. The Setpoint value, % Output Power, Setpoint Ramp Rate, etc.
INSTALLATION & CONNECTIONS Installation Environment NEMA 4X/IP65 Unit Installation The unit should be installed in a location that does not exceed the maximum operating temperature and provides good air circulation. Placing the unit near devices that generate excessive heat should be avoided. Continuous exposure to direct sunlight may accelerate the aging process of the bezel. The bezel should be cleaned only with a soft cloth and neutral soap product. Do NOT use solvents.
Figure 1, Panel Installation & Removal 4
Unit Removal Procedure To remove a NEMA 4X/IP65 or standard unit from the panel, first unscrew and remove the panel latch screws. Insert flat blade screwdrivers between the latch and the case on the top and bottom of the unit, so that the latches disengage from the grooves in the case. Push the unit through the panel from the rear.
Typical Connections Output Modules The main control, optional Alarm, optional Cooling output and optional Valve Position control output sockets must be fitted with the appropriate output module. Output modules are shipped separately and must be installed by the user. Output Module Restrictions With some models, the Alarm outputs and Valve Position outputs share the same common terminal. When using these models, the same type of output modules are usually installed in these positions.
Figure 5, Triac Module Triac: Type: Isolated, Zero Crossing Detection. Rating: Voltage: 120/240 VAC. Max. Load Current: 1 amp @ 35°C 0.75 amp @ 50°C Min. Load Current: 10 mA Off State Leakage Current: 7 mA maximum @ 60 Hz Operating Frequency: 20 to 400 Hz Protection: Internal Transient Snubber, Fused. Select Input Sensor Type The input sensor type (Thermocouple or RTD) must be selected by an internal hardware jumper to match the programmed input sensor type.
5. In extremely high EMI environments, the use of external EMI suppression devices, such as ferrite suppression cores, is effective. Install them on Signal and Control cables as close to the unit as possible. Loop the cable through the core several times or use multiple cores on each cable for additional protection. Install line filters on the power input cable to the unit to suppress power line interference. Install them near the power entry point of the enclosure.
Signal Wiring When connecting the thermocouple or RTD leads, be certain that the connections are clean and tight, refer to Figures 7 and 8 for terminal connections. If the thermocouple probe cannot be connected directly to the controller, thermocouple wire or thermocouple extension-grade wire must be used to extend the connection points (copper wire does not work). Always refer to the thermocouple manufacturer’s recommendations for mounting, temperature range, shielding, etc.
Valve Positioner Wiring Units with Valve Positioner option have three output connections for controlling the valve motor and three input connections for slidewire feedback. The valve motor output connects to terminals labeled “Valve Position Outputs”, terminals 1, 2 and 3. See Figure 9, Valve Positioner Wiring for more details. Terminal 1 is the Valve motor supply common. Terminal 2 is the Valve Close or CW output. Terminal 3 is the Valve Open or CCW output.
AC Power Wiring Primary AC power is connected to the separate two position terminal block labeled AC. To reduce the chance of noise spikes entering the AC line and affecting the controller, an AC feed separate from that of the load should be used to power the controller. Be certain that the AC power to the controller is relatively “clean” and within the -15%, +10% variation limit.
FRONT PANEL DESCRIPTION The front panel bezel material is flame and scratch resistant, tinted plastic. An optional NEMA 4X/IP65 bezel version is available that meets NEMA 4 X/IP65 requirements, when properly installed. There are two 4-digit LED displays, a red upper Main Display and a lower green Secondary Display. There are up to six annunciators depending on options installed, with red b acklighting, that illuminate to inform the operator of the controller and output status.
OPERATION OVERVIEW Controller Power-up D) Use values based on control loop experience, calculated values or values from a similar process. If the controller is a replacement, the PID settings from the unit being replaced may be used as good initial values. Be sure to consider any differences in the units and the PID settings when replacing. The PID settings may be fine tuned by using the techniques outlined in the PID Control section.
Remote And Local Setpoint Operation The controller setpoint mode can be switched between Local Setpoint operation and Remote Setpoint operation. In the Hidden Function Mode, the “SPSL” parameter allows the operator to select the desired setpoint operating mode. To allow front panel switching between setpoint modes, program the setpoint select parameter (SPSL) to “Enbl” in the Lockout Module.
Operation and configuration of the controller is divided into five distinct operational/programming modes to simplify the operation of the controller: Normal Display Mode, Unprotected Parameter Mode, Protected Parameter Mode, Hidden Function Mode, and Configuration Parameter Modules. See Figure 12, Operational/Programming Modes. Configuration Of Parameters As supplied from the factory, the controller parameters have been programmed to the values listed in the Programming Quick Reference Tables.
Parameter Entry Normal Display Mode The PAR button is used to select the desired parameter. To modify the parameter setting use the UP and DOWN buttons. Press PAR to enter the new value. The controller progresses to the next parameter. In a Configuration Parameter Module, pressing the DSP button causes the new value to be rejected, the controller displays “End”, and returns to the Normal Display Mode.
UNPROTECTED PARAMETER MODE Unprotected Parameter Mode Reference Table The Unprotected Parameter Mode is accessed by pressing the PAR button from the normal display mode with program disable inactive. In this mode, the operator has access to the list of the most commonly modified controller parameters. At the end of the list, a configuration “access point” allows the operator to enter the configuration parameter modules. These modules allow access to the fundamental set-up parameters of the controller.
Display Parameter dt-2 Derivative Time #2 (Secondary) SP-2 Internal Cascade Directed Setpoint Remote Setpoint ratio multiplier Remote Setpoint bias offset Alarm 1 Value rtio bIAS AL-1 AL-2 Alarm 2 Value CNFP Configuration Access Point Range and Description/ Units (Factory Comments Setting Value) 0 to 9999 sec. 0 is off. This parameter does not (0) appear if proportional band #2 = 0.0%. Second Analog Input models only. -999 to 9999 Second Analog Input models (N/A) only. Read only parameter. 0.
PROTECTED PARAMETER MODE module, access to the unprotected parameter mode and hence, the configuration parameter modules is possible. The controller returns to the normal display mode if the unprotected mode and configuration modules cannot be accessed. This mode cannot be accessed if all parameters are locked out in Configuration Module 3. The Protected Parameter Mode is accessed from the normal display mode by pressing the PAR button with program disable active.
Front Panel Program Disable Models With Program Disable There are several ways to limit the programming of parameters from the front panel buttons. The settings of the parameters in the Lockout Module, the code number entered, and the state and/or function programmed for the User Input (Terminal #7) affect front panel access. It is possible to have the program disable function on versions with the User Input, even if the User Input is not programmed for program disable (PLOC), by the use of a code number.
HIDDEN FUNCTION MODE Hidden Function Mode Reference Table The Hidden Function Mode is only accessible from the normal display mode by pressing and holding the PAR button for three seconds. These functions must be unlocked in Configuration Module #3. Factory settings are locked. In this mode, these controller functions can be performed.
CONFIGURATION PARAMETER MODULES Temperature Scale (SCAL) Select either degrees Fahrenheit (F) or degrees Celsius (C). If changed, be sure to check All parameters. Accessible from the unprotected parameter mode, the configuration parameter modules allow the operator access to the controller’s fundamental set-up parameters. There are nine possible configuration stages that can be accessed.
Setpoint Ramp Rate (SPrP) The setpoint can be programmed to ramp independent of the controller’s display resolution. The setpoint ramp rate can reduce thermal shock to the process, reduce temperature overshoot on start-up or setpoint changes, or ramp the process at a controlled rate. SPrP - 0.1 to 999.9 degrees/minute A ramp value of zero disables setpoint ramping. If the optional user input is programmed for setpoint ramp, it affects the enabling and disabling of setpoint ramping (See User Input, page 24).
SPSL - Select Local or Remote Setpoint. On models equipped with Second Analog Input, configured as Remote Setpoint, a negative transition engages Remote Setpoint operation and a positive transition engages Local Setpoint operation. Select the controller output response to the Local/Remote transfer operation (bumpless, tracking, etc) by the setpoint transfer parameter (SPtr).
Output Power Limits (OPLO & OPHI) Enter the safe output power limits for the process. These parameters may also be used to limit the minimum and maximum controller power due to process disturbances or setpoint changes, to reduce overshoots by limiting the process approach level.
Auto-Tune Dampening Code (tcod) Prior to invoking Auto-Tune, the dampening code should be set to achieve the desired dampening level under PID control. After Auto-tune is complete, changes to “tcod” parameter have no effect until Auto-tune is re-started. When set to 0, this yields the fastest process response with possible overshoot. A setting of 4 yields the slowest response with the least amount of overshoot. Dampening codes of 0 or 1 are recommended for most thermal processes.
Linear DC Analog Output (ANAS, ANLO, ANHI, ANdb, ANUt) (Optional) The Linear DC output can be programmed to transmit one of the following controller parameters: Example: Chart Record Process Display Value (0 to 10 VDC): The process range is 300-700. Programming 300 for ANLO (0 VDC value) and 700 for ANHI (10 VDC value) yields full scale deflection for a chart recorder (0 to 10 VDC). The 0 to 10 VDC output is assigned to transmit the input reading (ANAS = INP).
The code number allows access to the unprotected mode. To enter the unprotected mode from the protected mode, the code number entered must match the code number entered here. See Front Panel Program Disable, page 12, for a description of the various program access levels. Lockouts Module (3-LC) The controller can be programmed to limit operator access to various parameters, control modes, and display contents.
Second Analog Input Alarm On models equipped with the Second Analog Input, the alarm(s) may be configured to monitor the second input reading in addition to the main input. Refer to the corresponding alarm operation figures for operation modes. Note that deviation and band alarm modes are only valid for Internal Cascade operation. Alarm Module (4-AL) (Optional) The controller may be optionally fitted with the dual alarm option (AL1 and AL2). Some models are equipped only with a single alarm (AL1).
The alarm triggers under the two following conditions: 1. The valve slidewire feedback position does not match the controller output power (within the valve position deadband) after the valve fail time has expired. The alarm indicates that the valve cannot be properly positioned due to a malfunction of the valve or valve positioner. 2. The slidewire feedback signal is broken or out of range. In this case, the valve position controller cannot position the valve.
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Alarm Standby Delay (Stb1, Stb2) The alarm(s) may be independently configured to exhibit a power-on, standby delay which suppresses the alarm output from turning “ON” until the temperature first stabilizes outside the alarm region. After this condition is satisfied, the alarm standby delay is canceled and the alarm triggers normally, until the next controller power-on. Figure 17, Alarm Standby Delay Sequence depicts a typical operation sequence.
Heat-Cool Overlap/Deadband (db-2) This parameter defines the area in which both heating and cooling are active (negative value) or the deadband area between the bands (positive value). The parameter units are degrees or tenth’s of degrees (depending on system resolution). If a heat/cool overlap is specified, the displayed percent output power is the sum of the heat power (OP1) and the cool power (OP2).
Serial Communications Module (6-SC) (Optional) When communicating with a TCU unit via the serial port, the data formats of both units must be identical. A print operation occurs when the user input, programmed for the print request function is activated, when a “P” command is sent via the serial communications port, or after the time expires for the automatic print rate, if enabled. Serial communication is covered in detail in RS485 Serial Communications, page 48.
Operation mode (OPEr) The Second Analog Input must be configured for either Remote Setpoint Operation or Internal Cascade Operation (single controller cascade). Print Options (PoPt) Selecting YES for the print options allows the operator to scroll through the available options using the PAR button. The up and down arrow keys toggle between “yes” and “no” with “yes” enabling the option to be printed when a print function occurs.
Square Root Linearization (root) (Cont’d) As a result of the scaling and square root linearization, the following represents the readings at various inputs: Delta P (PSI) 0.00 15.63 31.25 62.50 125.00 187.50 250.00 312.50 375.00 437.50 500.00 Transmitter (mA) 4.00 4.50 5.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00 Before programming the indicator, organize all the data for the programming steps to avoid confusion.
Local/Remote Setpoint Transfer Modes (SPtr) When switching from/to Local or Remote Setpoint, the response of the controller can be programmed to act in a variety of ways. These responses apply to changes in setpoint mode from the controller’s front panel, User Input or Serial communications. The table summarizes the responses for Setpoint transfer operation: SPtr parameter nor Auto trAC Local to Remote - Output may bump. - No output bump. Process error eliminated at rate of integral action.
Valve Position 1 And Valve Position 2 (VPS1, VPS2) (Cont’d) 3) Measure the resistance of the open and closed positions and divide by the total slidewire resistance to yield percentage values. Directly key-in the percentage values. Valve Motor Open Time And Valve Motor Close Time (VOPt, VCLt) (Velocity mode) For velocity mode control, the valve motor open transit time (VOPt) and valve motor close transit time (VCLt) must be known. In many cases, these transit times differ from the valve specification.
Reference Table: Configuration Parameter Module Configure Module 1 - Input Parameters (1-IN) SCAL Temperature Scale Range and Units (Factory Setting Value) tc-t - Type T TC tc-E - Type E TC tc-J - Type J TC tc-k - Type K TC tc-r - Type R TC tc-S - Type S TC tc-b - Type b TC tc-N - Type N TC LIN - Linear mV display r385 - 385 curve RTD r392 - 392 curve RTD rLIN - Linear ohms display (tc-J) °F/°C ( °F) dCPt Temperature resolution 0 or 0.
Configure Module 2 - Output Parameters (2-OP) Display Parameter CYCt Cycle time OPAC Control Action OPLO OPHI OPFL Range and Units (Factory Setting Value) 0 to 250 seconds (2) drct - cooling rEv - heating (rev) Output power lower 0% to 100%, OP1 limit range (0) -100% to 100%, OP1 & OP2 (-100) Output power 0% to 100%, OP1 upper limit range (100) -100% to 100% OP1 & OP2 (100) Sensor fail power 0% to 100%, OP1 preset -100% to 100%, OP1 & OP2 (0) OPdP Output power dampening (filtering) time 0 to 25
Configure Module 3 - Lockout Parameters (3-LC) Display Parameter SP Setpoint access OP Output power access Range and Units (Factory Setting Value) LOC - lockout rED - read only Ent - enter (Ent) LOC - lockout rED - read only Ent - enter (Ent) dEv Deviation LOC - lockout rEd - read only (rEd) IN-2 Second Analog input LOC - lockout rEd - read only (rEd) Hcur Heater Current UdSP Units display Code Access code PId PID values enable PId2 Secondary PID values enable LOC - lockout rEd - read
Configure Module 4 - Alarms (4-AL) Unit returns to configuration access point if alarm(s) are not installed.
Configure Module 5 - Cooling Parameters (5-O2) Unit returns to configuration access point if cooling option is not installed. Display CYC2 GAN2 db-2 Range and Units (Factory Setting Value) Cooling output cycle 0 to 250 sec time (2) Relative cooling 0.0 to 10.0 gain (1.0) Parameter Heating/cooling overlap-deadband -999 to 9999 (0) Description/ Comments 0 turns OP2 off. 0.0 places cooling output into ON/OFF control mode and db-2 becomes hysteresis value. Positive value is deadband.
Configure Module 6 - Serial Communications (6-SC) Unit returns to configuration access point if RS485 serial option is not installed. Display bAUd PArb Add Abr PrAt PoPt INP SEt OPr Pdb INt dEr AL1 AL2 Parameter Baud rate Range and Units (Factory Setting Value) 300 to 9600 (1200) Description/ Comments Display Baud rate of unit must match connected equipment. Parity bit odd, even, no parity Parity of unit must (odd) match other equipment.
Configure Module 7 - Second Analog Input (7-2N) Configure Module 8 - Valve Positioner (8-VP) Unit returns to configuration access point if Second Analog Input option is not installed. Unit returns to configuration access point if Valve Positioner option is not installed.
Configure Module 9 - Factory Service Operations (9-FS) Display Code Range and Units (Factory Setting Value) Enter factory service 48 - Calibrate function code. instrument 66 - Reset parameters to factory settings Parameter Description/ Comments Refer to Calibration Section for details.
RS485 SERIAL COMMUNICATIONS INTERFACE Before serial communication can take place, the unit must be programmed to the same baud rate and parity as the connected equipment. In addition, the loop address number and print options should be known. When used with a terminal or host computer and only one unit is employed, an address of zero may be used to eliminate the requirement for the address specifier when sending a command.
Sending Commands And Data (Cont’d) VALUE IDENTIFIER A B C D E F G H I J K L M O Q S Temperature Display Value Setpoint Output Power Proportional Band Integral Time Derivative Time Alarm 1 Alarm 2 Deviation Output Power Offset Setpoint Ramp Rate Cooling Relative Gain Cooling Deadband Remote Setpoint Ratio Remote Setpoint Bias Controller Mode U Setpoint Mode W X Y Z AA BB Output status* Secondary Proportional Band Secondary Integral Time Secondary Derivative Time Second Input Reading Remote Setpoint Read
The following procedure should be used when constructing a command string. 1. The first two to three characters of the command string must consist of the Address Command (N) and the address number of the unit (0-99). If the unit address is zero, the address command and number need not be sent. 2. The next character in the command string is the command that the unit is to perform (P, R, T, C, or V). 3. A Value Identifier is next if it pertains to the command.
1 TMP 500F100 - 200 msec Mnemonics Sent 1 SET 525F100 - 200 msec 1 PWR 20%100 - 200 msec Receiving Data Data is transmitted from the TCU when a “T” Transmit Value or a “P” Transmit Print Options command is sent to the unit via the serial port. Data is also transmitted when the User Input, programmed for the Print Request function, is activated. The print rate feature allows the selected print options to be transmitted at a programmable rate over the serial port.
A print-out from a TCU unit with an address of 1 and all print options selected is shown below: 1 TMP 500F 1 SET 525F 1 PWR 20.0% 1 PBD 4.0% 1 INT 120S 1 DER 30S 1 AL1 600F 1 AL2 475F 1 DEV -25F 1 OFP 0.0% 1 RMP 0.0R 1 CRG 1.0G 1 CDB OF 1 OSt 1001 1 RAt 1.000R 1 BIAS 0U 1 Pb2 4.0% 1 It2 120S 1 dt2 30S 1 IN2 100.0U 1 RSP 0U 1 SP2 0.0U 1 HCr 50.0A Note: If the cooling option is installed, AL2 is not printed or functional.
Terminal Emulation Program For IBM® PC REM “FOR THIS PROGRAM TO WORK THE ”RS-485" CARD SHOULD BE SET-UP AS COM2" 2 REM “ALSO THE CARD SHOULD USE ”RTS" FOR HANDSHAKING" 3 REM “THE TCU UNIT SHOULD BE SET-UP FOR 9600 BAUD, AND ODD PARITY” 4 TXEMPTY = &H60 5 LSR = &H2FD: REM “COMM2 LINE STATUS REGISTER” 6 MCR = &H2FC: REM “COMM2 MODEM CONTROL REGISTER” 10 CLS : CLOSE : 20 OPEN “COM2:9600,0,7,1" FOR RANDOM AS #1 30 ON TIMER(1) GOSUB 300 40 A$ = INKEY$: IF A$ < > “ ” THEN GOTO 1000: REM “CHECK FOR KEYBOARD INPUT
Terminal Emulation Program For IBM® PC (Cont’d) Serial Connections When wiring the terminal block at the rear of the unit, refer to the label with the terminal description for installing each wire in its proper location. It is recommended that shielded (screened) cable be used f o r serial communications. This unit meets the EMC specifications using Alpha #2404 cable or equivalent.
* Terminal numbers are model dependent. Consult label on controller case for description. ** Some models do not have TX EN. This is an output used in conjunction with interface converter model GCM422, to convert RS485 to 20 mA current loop. One or several TCU units can be connected to an RLC model DMPC printer using an optional RLC GCM422 converter module. Figure 25 shows the wiring for a single and a multiple hook-up to the printer.
Connecting To A Host Terminal Six TCU units are used to control a process in a plant. The TCU units are located at the proper location to optimize the process. A communication line is run to an industrial computer located in the production office. Figure 26, Connecting To A Host Terminal, shows the line connection. Each TCU is programmed for a different address and all are programmed for the same baud rate and parity as the computer.
HEATER CURRENT MONITOR OPTION This option allows monitoring of heater element current controlled by the TCU via the main output OP1. The actual heater current is viewed in the lower display. This is useful in determining how much the heater element has aged, if the element open circuited or if the element has a ground fault. A Heater Break Alarm can be programmed to signal the event before process damage occurs (See Alarm Action, page 29).
VALVE POSITION OPTION water temperature by controlling the position of the valve. Given the time constant of the process is 60 seconds, the Valve Update Time (VUdt) of the controller is set at five seconds to reduce valve activity. Adding Valve Update Time to the valve motor transit time (20 seconds), the valve fail time is set at 50 seconds [2 * (20+5)] to alert for a valve fail condition. The valve position hysteresis is set at 2.
Example: Steam is used to heat water by passing it through a heat exchanger. Variations in inlet water temperature, steam pressure, hot water demand, etc., all contribute to the need for closed loop control. The steam pressure is controlled by a TCU with Valve Positioner option. The TCU maintains constant hot water temperature by controlling the position of the valve. No slidewire feedback is used.
SECOND ANALOG INPUT OPTION Temperature Remote Setpoint Slave Control Example: Multiple TCUs are used to regulate the temperature zones of a continuous drying oven. To reduce thermal shock to the product, the setpoint levels of incoming zone controllers are low, while the other controllers have setpoints that are increasingly ramped up to the ideal drying temperature. The TCUs are slave controllers that have Remote Setpoint with unique bias values to implement the ramp in setpoint values of the drying oven.
External Cascade Control External Cascade Control involves the use of two controllers, one of which has a Remote Setpoint Input. The outer loop controller (Primary controller) directs the setpoint of the inner loop controller (Secondary controller) through the linear DC 4-20 mA output. The Secondary controller has a Second Analog Input option configured as a Remote Setpoint (RSP) in order to receive the directed setpoint. See Figure 29, for more details.
Internal Cascade Control The Internal Cascade control mode of the TCU embodies the function of two Cascade controllers into a single unit. In all other respects, Internal Cascade yields the same control flexibility and control quality as External Cascade. In Internal Cascade, the Primary loop provides an internal setpoint for the Secondary loop. The Primary loop output power (0-100%) is scaled internally by the “DSP1” and “DSP2” scaling parameters to yield the Secondary (directed) setpoint.
PID CONTROL Proportional Band Integral Time Proportional band is defined as the “band” of temperature the process changes to cause the percent output power to change from 0% to 100%. The band may or may not be centered about the setpoint value depending upon the steady state requirements of the process. The band is shifted by manual offset or integral action (automatic reset) to maintain zero error. Proportional band is expressed as percent of input sensor range.
Derivative Time Output Power Offset (Manual Reset) Derivative time is defined as the time, in seconds, in which the output due to proportional action alone equals the output due to derivative action with a ramping process error. As long as a ramping error exists, the derivative action is “repeated” by proportional action every derivative time. The units of derivative time are seconds per repeat.
PID Adjustments (Cont’d) Figure 35, Process Response Extremes 65
ON/OFF CONTROL The controller operates in the ON/OFF control mode by setting the proportional band = 0.0%. The ON/OFF control hysteresis band (CHYS) parameter eliminates output chatter around setpoint. For heat/cool systems, the cooling output can also be used in the ON/OFF control by setting the relative gain = 0.0 (GAN2). Additionally, the heat/cool parameter (db-2) determines the amount of operational deadband or overlap between the two outputs.
ON/OFF and PID control can be used for the heat and cool outputs in several combinations. The following lists the valid control modes: OP1 & OP2 VALID CONTROL MODES MANUAL MODE OP1 OP1 OP2 OUTPUT POWER STATE MODE MODE RANGE PID — 0% to +100% OP1-TP ON/OFF — 100 OP1-ON PrOP = 0.0 Any other setting OP1-OFF PID PID -100% to +100% OP1-TP PID ON/OFF 0% to +100% OP1-TP (GAN2=0.0) -100% to 0% OP1-TP ON/OFF ON/OFF +100% OP1-ON (PrOP=0.0) (GAN2=0.
AUTO-TUNE Auto-Tune is a user initiated function in which the controller automatically determines the PID settings based upon the process characteristics. During Auto-tune, the controller temporarily causes the system to oscillate by cycling the output power from 0 to 100%. The nature of these oscillations determines the settings of the controller’s parameters. Figure 40, Auto-Tune Operation dampening code may be set to yield the response characteristics shown in Figure 39, Dampening Code.
As shown in the Auto-Tune Operation Figure 40, Auto-Tune cycles the process at a control point 3/4 of the distance between the current process temperature (at the instant Auto-Tune is started) and the temperature setpoint. The 3/4 control point was selected to reduce the chance of temperature overshoot at setpoint when Auto-Tuning at start-up. If Auto-Tuning from setpoint and temperature overshoot is unacceptable, temporarily lower the setpoint by an amount of the temperature oscillation and then Auto-Tune.
The following additional parameters are calculated and set as a result of Auto-Tuning of the secondary: Secondary Proportional Band (Pb-2) Secondary Integral Time (It-2) Secondary Derivative Time (dt-2) Secondary Output Power Dampening (OPd2) Auto-Tuning of the secondary presents two different control points at which the controller cycles power. In Automatic mode of operation, the secondary control point is the setpoint directed by the primary at the instant Auto-Tune is started.
APPENDIX “A” - Application Examples Plastics Extruder Application Several TCU controllers are employed to control the temperature of a plastics extruder. Each TCU controls a heating element and a cooling water solenoid to maintain each extruder zone at the desired temperature. The heater current monitor of the TCU is used for early detection of heater element failure. The linear DC output is used to retransmit the process temperature to a control computer for data logging purposes.
Temperature Control Programming Example A TCU is used to control the temperature of cooking kettles at a food processing facility. The 4-20 mA linear DC output is used to control a steam valve which provides the heat to the kettles. The following is a list of the process requirements and the subsequent parameter values keyed-in to the controller. Configure Output CYCt 0 OPAC rEv OPLO 0% OPHI 70% Process Requirements Output: Linear DC 4-20 mA.
APPENDIX “B” - SPECIFICATIONS AND DIMENSIONS 1. DISPLAY: Dual 4-digit Upper Temperature Display: 0.4" (10.2 mm) high red LED Lower Auxiliary Display: 0.3" (7.6 mm) high green LED Display Messages (Model dependent): “OLOL” “ULUL” “OPEN” “SHrt” “....” “-...” “SLid” “VALV” - Appears Appears Appears Appears Appears Appears Appears Appears when when when when when when when when 2. POWER: Switch selectable 115/230 VAC (+10%, -15%) no observable line variation effect, 48-62 Hz, 10 VA.
Protection: Input overload 120 VAC for 30 seconds. 6. THERMOCOUPLE: Types: T, E, J, K, R, S, B, N, Linear mV Input Impedance: 20 MW all types Lead resistance effect: 20 mV/350W Cold junction compensation: Less than 1°C error over 0 - 50°C ambient temperature range. Disabled for Linear mV type. Resolution: 1 °C/F all types, or 0.1°C/F for T, E, J, K and N only. 7. RTD: 2, 3 or 4 wire, 100W platinum, alpha = 0.00385 (DIN 43760), alpha = 0.003916 Excitation: 0.175 mA Resolution: 1 or 0.
9. OUTPUT MODULES [Optional] (For All Output Channels): Relay: Type: Form-C (Form-A with some models. See Ordering Information) Rating: 5 Amps @ 120/240 VAC or 28 VDC (resistive load), 1/8 HP @ 120 VAC (inductive load) Life Expectancy: 100,000 cycles at maximum load rating. (Decreasing load and/or increasing cycle time, increases life expectancy). Logic/SSR Drive: Can drive multiple SSR Power Units.
18. ALARMS (Optional): Hardware: Plug-in, replaceable output module Modes: Absolute high acting Absolute low acting Deviation high acting Deviation low acting Inside band acting Heater break. Valve fail Second Analog Input monitoring Reset Action: Programmable; automatic or latched Standby Mode: Programmable; enable or disable Hysteresis: Programmable Probe Break Action: Upscale Annunciator: LED backlight for “AL1”, “AL2”, (Alarm #2 not available with cooling output or motorized valve position option.) 19.
22. CONNECTION: Jaw-type terminal block Wire Range: 12-30 AWG copper wire Torque: 5-7 inch-lbs (56-79 N-cm) 23. CONSTRUCTION: NEMA 2 for standard models. Front Panel: Flame and scratch resistant tinted plastic Case: High impact black plastic. (Mounting collar included) NEMA 4X/IP65 model only: Sealed bezel utilizing two captive mounting screws (panel gasket included). This unit is rated for NEMA 4X/IP65 indoor use. Installation Category II, Pollution Degree 2 24. WEIGHT: 1.3 lbs (0.6 kgs) 21.
APPENDIX “C” - TROUBLESHOOTING The majority of problems can be traced to improper connections or incorrect set-up parameters. Be sure all connections are clean and tight, that the correct output module is fitted, and that the set-up parameters are correct. For further technical assistance, contact technical support at the numbers listed on the back cover of the instruction manual. Problems Possible Cause Remedies NO DISPLAY 1. Power off 2. Voltage selector switch in the wrong position. 3.
Problems Possible Cause Remedies “OLOL” IN DISPLAY 1. Temperature exceeds range of input probe. 2. Excessive positive probe temperature. 3. Loss of set-up parameters. 1. Temperature below range of input probe. 2. Excessive negative probe temperature. 3. Loss of set-up parameters. 1. RTD probe shorted. 1. Change to input sensor with a higher temperature range. 2. Reduce temperature. 3. Check set-up. 1. Change to input sensor with lower bottom range. 2. Increase temperature. 3. Check set-up parameters.
Output Leakage Current The AL1 and AL2/OP2 outputs of the TCU have an RC Network (Snubber) on the Normally Open contacts. High energy noise spikes are generated whenever current through an inductive load (such as motors, solenoids or relay coils) is interrupted. This noise may interfere with the unit doing the switching and other nearby equipment causing erratic operation and accelerate relay contact wear.
APPENDIX “D” - MANUAL TUNING Open Loop Step Response Method The Open Loop Step Response Method is a tuning procedure that does not induce process oscillations. This method involves making a step change to the process and observing the process reaction. A strip paper recorder or other high resolution data logging equipment is required for this procedure. This procedure requires that all disturbances to the process are minimized because the data is influenced by these disturbances.
Closed Loop Cycling Method An alternative to auto-tuning is manual tuning. This tuning method induces oscillations into the process in the same way as the controller’s auto-tune function. If oscillations are not acceptable, the open-loop tuning method can be used. The following is a manual tuning procedure for determination of the PID control constants. 1. Connect a chart recorder to log temperature and set the paper speed appropriate for the process. 2. Set the controller to automatic (auto) control mode.
APPENDIX “E” - CALIBRATION Calibration Check RTD Ohms Reading The instrument has been fully calibrated at the factory for all thermocouple and RTD types. If the unit appears to be indicating or controlling incorrectly, see Troubleshooting, page 78, before attempting this procedure. If the controller is suspected of reading incorrectly, the instrument may be checked for indication accuracy without disturbing the factory calibration.
Configure Step 9 - Factory Service Operations (9-Fs) Second Input Check The Second Input Check applies to those models that have the Second Analog Input (Remote Setpoint), Heater Current Monitor and Valve Positioner options. Different signals are required for each option. Display Parameter Code Enter factor service function code CAL Millivolt Calibration 48 yes/no Heater Current Monitor Check 1. Apply signals over the range of 0 to 100 mA AC, 60 Hz to the terminals labeled CT.
Millivolt Calibration (Cal) Connect precision millivolt source with an accuracy of 0.01% to terminals (+) #9 and (-) #10. Place the input sensor select jumper in the TC position. Display StP1 StP2 StP3 StP4 StP5 StP6 StP7 StP- Parameter 0.0 mV step 9.00 mV step 18.0 mV step 27.0 mV step 36.0 mV step 45.0 mV step 54.0 mV step Pause Display Parameter Cold Junction CJF or CJC Temperature Description/Comments Apply 0.0 mV, wait 10 seconds, press PAR. Apply 9.0 mV, wait 10 seconds, press PAR. Apply 18.
Analog Output Calibration (ANCL) (Cont’d) Heater Current Monitor Connect precision AC milliampere source (0.1% accuracy) to rear terminals labeled Second Analog Input, CT+ And CT-. 0 to 10 VDC Press PAR until ANCL appears in the display. Connect a precision voltmeter (0.1% accuracy) to rear terminals (+) #11 and (-) #12. Display Parameter ANC1 Analog output 0 VDC code value ANC2 Analog output 10 VDC code value Display StP1 StP2 StP3 StP4 StP5 Description/Comments Observe voltage reading. If 0.
APPENDIX “F”- USER PARAMETER VALUE CHART UNIT NUMBER MNEMONIC SP OPOF OP ProP Intt dErt Pb-2 It-2 dt-2 rtio bIAS AL-1 AL-2 PARAMETER Temperature Setpoint Output Power Offset Output Power Proportional Band Integral Time Derivative Time Proportional Band #2 (secondary) Integral Time #2 (secondary) Derivative Time #2 (secondary) Remote Setpoint Ratio Remote Setpoint Bias Alarm 1 Alarm 2 CONFIGURE OUTPUT MNEMONIC CYCt OPAC OPLO USER SETTING OPHI OPFL OPdP CHYS tcod ANAS ANLO ANHI ANdb ANut CONFIGURE INPUT
CONFIGURE LOCKOUTS MNEMONIC SP OP dEv HCur IN-2 UdSP Code PID PID2 rtbs AL ALrS SPSL trnF tUNE PARAMETER Access Setpoint Access Output Power Access Deviation Display Access Heater Current Display Access Second Analog Input Display Access Display Units Access Code Number Access Primary PID Values Access Secondary PID Values Access Ratio and Bias Values Access Alarm(s) Values Enable Reset Alarm(s) Enable Local/Remote Setpoint Selection Enable Auto/Man Transfer Enable Auto-tune CONFIGURE SERIAL COMMUNICATION
CONFIGURE SECOND ANALOG INPUT MNEMONIC OPEr root dPt2 dSP1 INP1 dSP2 INP2 SPtr OPd2 PARAMETER Second Input Operating Mode Second Input Square Root Linearization Second Input Decimal Point Position Second Input, Display Scale Point 1 Second Input, Input Scale Point 1 Second Input, Display Scale Point 2 Second Input, Input Scale Point 2 Local/Remote Setpoint Select Action Secondary PID Output Power Dampening CONTROLLER OPERATING MODE USER SETTING Local or Remote Setpoint Automatic or Manual Auto-tune Invok
APPENDIX “G” ORDERING INFORMATION MODELS WITHOUT SECOND INPUT OPTIONS (STANDARD) NEMA 4 to 20 mA 0 to 10 VDC ALARM COOLING RS485 PART NUMBER 4X/IP65 ANALOG ANALOG OUTPUTS OUTPUT COM 115/230 VAC BEZEL OUTPUT OUTPUT NO NO NO NO NO NO TCU00000 NO NO NO 2 NO NO TCU00001 NO NO NO 1 YES NO TCU00002 NO YES NO 2 NO NO TCU01001 NO YES NO 2 NO YES TCU01004 NO YES NO 1 YES YES TCU01005 YES NO NO NO NO NO TCU10000 YES NO NO 2 NO NO TCU10001 YES NO NO 1 YES NO TCU10002 YES YES NO 2 NO NO TCU11001 YES YES NO 1 YES NO TCU
SECOND ANALOG INPUT MODELS NEMA 4 to 20 mA 0 to 10 VDC ALARM COOLING RS485 PART NUMBER 4X/IP65 ANALOG ANALOG OUTPUTS OUTPUT COM 115/230 VAC BEZEL OUTPUT OUTPUT YES NO NO 2 NO YES TCU10104 YES YES NO 2 NO NO TCU11108 YES NO YES 2 NO NO TCU12108 These models have dual alarm outputs, or single alarm with cooling outputs, with shared common terminals (Form A Type). As a result, these outputs should be fitted with the same type of output module. The main output (OP1) may be fitted with any type of output module.
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LIMITED WARRANTY The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to two years from the date of shipment, provided the products have been stored, handled, installed, and used under proper conditions. The Company’s liability under this limited warranty shall extend only to the repair or replacement of a defective product, at The Company’s option.
TCU/IM - N 02/13 DRAWING NO. LP0235 Red Lion Controls Headquarters 20 Willow Springs Circle York PA 17406 Tel +1 (717) 767-6511 Fax +1 (717) 764-0839 Red Lion Controls Europe Softwareweg 9 NL - 3821 BN Amersfoort Tel +31 (0) 334 723 225 Fax +31 (0) 334 893 793 Red Lion Controls India 201-B, 2nd Floor, Park Centra Opp 32 Mile Stone, Sector-30 Gurgaon-122002 Haryana, India Tel +91 984 487 0503 Red Lion Controls China Unit 302, XinAn Plaza Building 13, No.99 Tianzhou Road ShangHai, P.R.
