Tempco tec-220 Manuale utente
Instruction Manual
TEC-220 and TEC-920
Auto-Tune Fuzzy / PID Process
Temperature Controller
Agency Approvals
Manual EC-220/920 Revision 9/2016
EMPCO Electric Heater Corporation
607 N. Central Avenue • Wood Dale, IL 60191-1452 USA
el: 630-350-2252 • oll Free: 800-323-6859
Fax: 630-350-0232 • E-mail: [email protected]
Web: www.tempco.com
Serving Industry Since 1972
OTES
Warning Symbol
This symbol calls attention to an operating procedure, practice, or
the like which, if not correctly performed or adhered to, could
result in personal injury or damage to or destruction of part or all
of the product and system. Do not proceed beyond a warning sym-
bol until the indicated conditions are fully understood and met.
Using the Manual
Installers . . . . . . . . . . . . . . . . . . . . . . . . . . . Read Chapter 1, 2
System Designer . . . . . . . . . . . . . . . . . . . . . Read All Chapters
Expert User . . . . . . . . . . . . . . . . . . . . . . . . . Read Page 11
N TE:
It is strongly recommended that a process should incorpo-
rate 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 © 2010, Tempco Electric Heater Corporation, all
rights reserved. No part of this publication may be reproduced,
transmitted, transcribed or stored in a retrieval system, or trans-
lated into any language in any form by any means without the
written permission of Tempco Electric Heater Corporation.
Contents
age No.
Chapter 1 verview
1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2 Ordering Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-3 Programming Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4 Keys and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5 Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6 Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 2 Installation
2-1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3 Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-4 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-5 Sensor Installation Guidelines . . . . . . . . . . . . . . . . . . . 8
2-6 Sensor Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-7 Control Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-8 Alarm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-9 Data Communication . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 3 Programming
3-1 Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-2 Signal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-3 Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-4 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-5 Configuring the Display . . . . . . . . . . . . . . . . . . . . . . . 14
3-6 Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-7 Dwell Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-8 PV Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-9 Digital ilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-10 ailure Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-11 Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-12 Manual tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-13 Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-14 Data communication. . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-15 Process Variable (PV) Retransmission. . . . . . . . . . . . 17
Chapter 4 Applications
4-1 Heat Only Control With Dwell Timer . . . . . . . . . . . . . 19
4-2 Cool Only Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-3 Heat-Cool Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 5 Calibration . . . . . . . . . . . . . . . . . . 21
Chapter 6 Specifications . . . . . . . . . . . . . 23
Chapter 7 Modbus Communications
7-1 unctions Supported . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-2 Exception Responses . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-3 Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-4 Data Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-5 Communication Examples . . . . . . . . . . . . . . . . . . . . . . 29
Appendix
A-1 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A-2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figures & Tables
age No.
igure 1.1 uzzy Control Advantage. . . . . . . . . . . . . . . . . . 1
igure 1.2 Programming Port Overview . . . . . . . . . . . . . . . 2
igure 1.3 ront Panel Description . . . . . . . . . . . . . . . . . . 3
igure 1.4 Display in Initial Stage. . . . . . . . . . . . . . . . . . . . 3
igure 2.1 Mounting Dimensions and Panel Cutout . . . . . . 7
igure 2.2 Lead Termination for TEC-920 . . . . . . . . . . . . . 7
igure 2.3 Lead Termination for TEC-220 . . . . . . . . . . . . . 7
igure 2.4 Rear Terminal Connection for TEC-220 . . . . . . 8
igure 2.5 Rear Terminal Connection for TEC-920 . . . . . . 8
igure 2.6 Power Supply Connections . . . . . . . . . . . . . . . . 8
igure 2.7 Sensor Input Wiring . . . . . . . . . . . . . . . . . . . . . 8
igure 2.8 Output 1 Relay or Triac (SSR) to
Drive Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
igure 2.9 Output 1 Relay or Triac (SSR) to
Drive Contactor . . . . . . . . . . . . . . . . . . . . . . . . . 8
igure 2.10 Output 1 Pulsed Voltage to Drive SSR . . . . . . 9
igure 2.11 Output 1 Linear Current. . . . . . . . . . . . . . . . . . 9
igure 2.12 Output 1 Linear Voltage. . . . . . . . . . . . . . . . . . 9
igure 2.13 Output 2 Relay or Triac (SSR) to
Drive Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
igure 2.14 Output 2 Relay or Triac (SSR) to
Drive Contactor . . . . . . . . . . . . . . . . . . . . . . . . 9
igure 2.15 Output 2 Pulsed Voltage to Drive SSR . . . . . . 9
igure 2.16 Output 2 Linear Current. . . . . . . . . . . . . . . . . . 9
igure 2.17 Output 2 Linear Voltage . . . . . . . . . . . . . . . . . 9
igure 2.18 Alarm Output to Drive Load . . . . . . . . . . . . . 10
igure 2.19 Alarm Output to Drive Contactor . . . . . . . . . . 10
igure 2.20 RS-485 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 10
igure 2.21 RS-232 Wiring . . . . . . . . . . . . . . . . . . . . . . . . 10
igure 2.22 Configuration of RS-232 Cable . . . . . . . . . . . 10
igure 3.1 Conversion Curve for Linear Type
Process Value . . . . . . . . . . . . . . . . . . . . . . . . . . 11
igure 3.2 Heat Only ON-O Control . . . . . . . . . . . . . . . 12
igure 3.3 Output 2 Deviation High Alarm . . . . . . . . . . . . 13
igure 3.4 Output 2 Process Low Alarm . . . . . . . . . . . . . . 13
igure 3.5 RAMP unction . . . . . . . . . . . . . . . . . . . . . . . . 14
igure 3.6 Dwell Timer unction . . . . . . . . . . . . . . . . . . . . 14
igure 3.7 PV Shift Application . . . . . . . . . . . . . . . . . . . . . 15
igure 3.8 ilter Characteristics . . . . . . . . . . . . . . . . . . . . . 15
igure 3.9 Effects of PID Adjustment . . . . . . . . . . . . . . . . 16
igure 4.1 Heat Control Example. . . . . . . . . . . . . . . . . . . . 19
igure 4.2 Cooling Control Example . . . . . . . . . . . . . . . . . 19
igure 4.3 Heat-Cool Control Example . . . . . . . . . . . . . . . 20
igure 5.1 RTD Calibration . . . . . . . . . . . . . . . . . . . . . . . . 21
igure 5.2 Cold Junction Calibration Setup . . . . . . . . . . . . 22
Table 1.1 Display orm of Characters . . . . . . . . . . . . . . . . 3
Table 3.1 Heat-Cool Control Setup Value . . . . . . . . . . . . . 11
Table 3.2 PID Adjustment Guide . . . . . . . . . . . . . . . . . . . . 16
Table A.1 Error Codes and Corrective Actions . . . . . . . . . 30
Appendix
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Returns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
OTES
1–1 General
Tempco’s TEC-220 and TEC-920 uzzy Logic plus PID micro-
processor-based controllers incorporate a bright easy to read 4-
digit LED display indicating process value or set point. uzzy
Logic technology enables a process to reach a predetermined set
point in the shortest time with a minimum of overshoot during
power-up or external load disturbances.
The TEC-220 is a 1/32 DIN size panel mount controller. The
TEC-920 is a 1/16 DIN size panel mount controller. These units
are powered by 11–26 or 90–250 VDC/VAC 50/60 Hz supply,
incorporating a 2 Amp control relay output as a standard. The
second output can be used as a cooling control, an alarm or a
dwell timer. Either output can use a triac, 5V logic output, linear
current or linear voltage to drive an external device. There are six
types of alarms or a dwell timer that can be configured for the
second output. The units are fully programmable for PT100 RTD
and thermocouple types J, K, T, E, B, R, S, N, and L with no need
to modify the unit. The input signal is digitized by using an 18-
bit A to D converter. Its fast sampling rate allows the unit to con-
trol fast processes.
Digital communications RS-485 is available for the TEC-220 or
TEC-920. RS-232 is available for the TEC-220 only. These
options allow the units to be integrated with supervisory control
systems and software.
A programming port is available for automatic configuration,
without the need to access the keys on the front panel.
By using proprietary uzzy modified PID technology, the con-
trol loop will minimize overshoot and undershoot in a short time.
The following diagram is a comparison of results with and with-
out uzzy technology.
1
Chapter 1 verview
High accuracy
This series is manufactured with custom
designed ASIC (Application Specific
Integrated Circuit) technology which
contains an 18-bit A to D converter for
high resolution measurement (true 0.1°
resolution for thermocouple and RTD)
and a 15-bit D to A converter for linear
current or voltage control output. The
ASIC technology provides improved
operating performance, low cost,
enhanced reliability, and higher density.
Fast sampling rate
The sampling rate of the input A to D
converter is 5 times/second. The fast
sampling rate allows this series to control
fast processes.
Fuzzy control
The function of uzzy control is to adjust
PID parameters from time to time in
order to make manipulation of the output
value more flexible and adaptive to vari-
ous processes. The result is to enable a
process to reach a predetermined set
point in the shortest time with the mini-
mum of overshoot and undershoot during
power-up or external load disturbance.
Digital communication
The units are equipped with an optional
RS-485 or RS-232 interface cards to pro-
vide digital communication. By using the
twisted pair wires up to 247 units can be
connected together via RS-485 interface
to a host computer.
Programming port
A programming port can be used to con-
nect the unit to a PC for quick configura-
tion.
Auto-tune
The auto-tune function allows the user to
simplify initial setup for a new system.
An advanced algorithm is used to obtain
an optimal set of control parameters for
the process, and it can be applied either as
the process is warming up (cold start) or
when the process is in a steady state
(warm start).
Lockout protection
Depending on security requirements, one
of four lockout levels can be selected to
prevent the unit from being changed
without permission.
Bumpless transfer
Bumpless transfer allows the controller to
continue to control if the sensor breaks by
using its previous value. Hence, the
process can be controlled temporarily as
if the sensor reading is normal and con-
stant.
Soft-start ramp
The ramping function is performed dur-
ing power up as well as any time the set
point is changed. It can be ramping up or
ramping down. The process value will
reach the set point at a predetermined
constant rate.
Digital filter
A first order low pass filter with a pro-
grammable time constant is used to
improve the stability of the process value.
This is particularly useful in certain
applications where the process value is
too unstable to be read.
2
1–2 rdering Code
1–3 Programming Port
A special connector can be used to
connect the programming port to a PC
for automatic configuration.
The programming port is used for off-
line automatic setup and testing proce-
dures only. Don't attempt to make any
connection to these pins when the unit
is under power.
Figure 1.2
Programming Port Overview
3
1–4 Keys and Displays
KEYPAD OPERATIO
SCROLL KEY:
This key is used to select a parameter to be
viewed or adjusted.
UP KEY:
This key is used to increase the value of the
selected parameter.
DOW KEY:
This key is used to decrease the value of the
selected parameter.
RESET KEY: for TEC-920,
for TEC-220
This key is used to:
1. Revert the display to show the process value.
2. Reset the latching alarm, once the alarm condi-
tion is removed.
3. Stop the manual control mode, auto-tuning
mode, and calibration mode.
4. Clear the message of communication error and
auto-tuning error.
5. Restart the dwell timer when the dwell timer has
timed out.
6. Enter the manual control menu when in failure
mode.
E TER KEY: Press for 5 seconds or longer.
Press for 5 seconds to:
1. Enter setup menu. The display shows .
2. Enter manual control mode — when manual
control mode or is selected.
3. Enter auto-tuning mode — when auto-tuning
mode (for 220) or AT (for 920) is selected.
4. Perform calibration to a selected parameter dur-
ing the calibration procedure.
Press for 6.2 seconds to select calibration mode.
R
Displays program code of the
instrument for 2.5 seconds.
The diagram at left shows
program no. 34, version 16
for the TEC-920.
The program no. is 33 for the
TEC-220.
Figure 1.3
Front Panel Description
Figure 1.4
Display in Initial Stage
Table 1.1 Display Form of Characters
4
1–5 Menu verview
5
1–6 Parameter Descriptions
6
1–6 Parameter Descriptions, continued…
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