Selec TC544C User manual

Auxiliary output

Relay contact (SPST) 5A resistive @ 250V AC / 30V DC

SSR drive (Voltage pulse) 12V DC, 30 mA

Relay contact (SPST) 5A resistive @ 250V AC / 30V DC

Control output (Relay or SSR user selectable)

Output specifications

Features :

! 4+4 digits, 7 segment LED dual display

! TC / RTD input

! PID / ON - OFF control

! Two set points

!o o

C / F selectable

! Auxiliary output : Relay / SSR

! Field selectable control output (Relay or SSR)

! Auto tune / Self tune

TC544C Temperature Controller

Display 4+4 digits, 7 Segment LED dual display

Height of upper display : 15.3mm

Height of lower display : 8mm

Display specifications

LED indication 1. Output 1 ON T : Auto tune

2. Output 2 ON S : Dwell timer

Indication accuracy For J, K & T inputs : 0.25% of F.S. ±1

For R & S inputs : 0.5% of F.S. ±2

(20 min of warm up time for TC inputs)

For RTD inputs : 0.1% of F.S. ±1

(F.S. = Full scale)

Input filter (FTC) 0.2 to 10.0sec

Input specifications

Resolution 0.1 / 1 for TC / RTD inputs

(fixed 1 for R & S type TC input)

Inputs Thermocouple (J, K, T, R, S) / RTD (PT100)

Sampling time 250 ms

o o

Temperature unit C / F selectable

Hysteresis 0.1 to 99.9

Proportional band (P) 1.0 to 400.0

Cycle time-cool 0.1 to 99.9 sec

Dead band Programmable from set point low limit

to set point high limit.

Settings for alarm output

Modes Deviation, Absolute

Cycle time 0.1 to 99.9 sec

Heat-cool

Control action PID

Hysteresis width 0.1 to 99.9

Manual reset value -19.9 to 19.9

Proportional band-cool 0.0 to 400.0

Functional specifications

Derivative time (D) 0 to 9999 sec

Control action 1) PID Control with auto tuning

2) ON-OFF control

Integral time (I) 0 to 9999 sec

Weight 116 gms

Mechanical specifications

Mounting Panel

Supply voltage 90 to 270V AC / DC (50 / 60Hz)

Auxiliary supply specifications

Power consumption 6 VA max @ 230V AC

o o

Temperature Operating : 0 C to 50 C

o o

Storage : -20 C to 75 C

Environmental specifications

Humidity (non - condensing) 95% RH

Dimension (All are in mm)

Front bezel Side view Panel Cutout

Terminal Connection

Voltage dips and

interruptions

Dips : 0% residual voltage /

1 cycle (Criteria B), 40% residual voltage /

10 cycles 50Hz / 12 cycles 60Hz

(Criteria C)70% residual voltage /

25 cycles50Hz / 30 cycles 60Hz

(Criteria C)

Interruptions : 0% residual voltage /

250 cycles 50Hz / 300 cycles 60Hz

(Criteria C)

IEC 61000-4-11

Level III

Conducted emission

Radiated emission

Electrical fast transient

CISPR-11

IEC 61000-4-4

Compliance

Applicable EMI / EMC standards

Product standard : IEC 61326-1

Category Standards compliance

ESD immunity Level III

Surge immunity +/- 2 kV common mode,

+/- 1 kV differential mode

Radiated susceptibility

Level III, 80 to 1000MHz

Level II, 1.4GHz to 2GHz

Level I, 2GHz to 2.7GHz

Conducted susceptibility Level II

IEC 61000-4-2

IEC 61000-4-5

IEC 61000-4-3

IEC 61000-4-6

TC544C Temperature Controller

Supply voltage

Output 2Output 1 Certification

Product code

RELAY

TC544C RELAY SSR 90 to 270V AC / DC

Ordering Information

Accessories (Optional)

Standard SELEC accessories that can be used with this product.

Mounting accessories (Supplied with units)

Input sensor ranges

Download

Device

Independent Downloader module (IDM)

Control Output

(Relay or SSR

user selectable)

OUTPUT SPECIFICATIONS

Relay Contact :

5A resistive@250V AC / 30V DC

SSR Drive Output (Voltage Pulse):

12V DC, 30 mA

Auxiliary Output Relay Contact :

5A resistive@250V AC / 30V DC

Supply Voltage

Temperature

POWER SUPPLY SPECIFICATIONS

85 to 270V AC / DC

(AC : 50 / 60 Hz )

Operating : 0 to 50°C

Storage : -20 to 75°C

Power Consumption 6 VA max@270V AC

Humidity

Weight

95% RH (non-condensing)

116 g

ELECTRICAL PRECAUTIONS DURING USE

Electrical noise generated by switching of inductive

loads can create momentary disruption, erratic display,

latch up, data loss or permanent damage to the

instrument.

To reduce noise :

a) Use of snubber circuits across loads as shown above,

is recommended.

b) Use separate shielded wires for inputs.

C NO

LOAD

R C

Snubber

MOV

Snubber

C NO

R C

Contactor

LOAD

MOV

For bigger loads, use interposing relay / contactor

For load current less than 0.5A

selec TC544C

Operating Instructions

OP723-V03

LOAD CONNECTIONS

1. The service life of the output relays depends on the

switching capacity and switching conditions. Consider

the actual application conditions and use the product

within the rated load and electrical service life.

2. Although the relay output is rated at 5/10 amps it is

always necessary to use an interposing relay or

contactor that will switch the load. This avoids damage to

the controller in the event of a fault short developing on

the power output circuit.

3. Always use a separate fused supply for the “power load

circuit”and do not take this from the live and neutral

terminals supplying power to the controller.

All safety related codifications, symbols and instructions

that appear in this operating manual or on the equipment must

be strictly followed to ensure the safety of the operating

personnel as well as the instrument.

If the equipment is not handled in a manner specified by

the manufacturer it might impair the protection provided by the

equipment.

Read complete instructions prior to installation and

operation of the unit.

WARNING : Risk of electric shock.

WIRING GUIDELINES

1. To prevent the risk of electric shock power supply to the

equipment must be kept OFF while doing the wiring

arrangement. Do not touch the terminals while power is

being supplied.

2. To eliminate electromagnetic interference use short wire

with adequate ratings; twists of the same in equal size shall

be made. For the input and output signal lines, be sure to

use shielded wires and keep them away from each other.

3. Cable used for connection to power source, must have a

cross section of 1mm or greater. These wires shall have

insulation capacity made of at least 1.5kV.

4. When extending the thermocouple lead wires, always use

thermocouple compensation wires for wiring. For the RTD

type, use a wiring material with a small lead resistance (5Ω

max per line) and no resistance differentials among three

wires.

5. A better anti-noise effect can be expected by using

standard power supply cable for the instrument.

MAINTENANCE

1. The equipment should be cleaned regularly to avoid

blockage of ventilating parts.

2. Clean the equipment with a clean soft cloth. Do not use

Isopropyl alcohol or any other cleaning agent.

SAFETY PRECAUTIONS

WARNING :

TERMINAL CONNECTIONS

1. When powering up for the first time, disconnect the

output connections.

2. Fuse Protection : The unit is normally supplied without a

power switch and fuses. Make wiring so that the fuse is

placed between the mains power supply switch and the

controller. (2 pole breaker fuse - rating : 275V AC,1A for

electrical circuitry is highly recommended)

3. Since this is a built-in-type equipment (finds place in main

control panel), its output terminals get connected to host

equipment. Such equipment shall also comply with basic

EMI/EMC and other safety requirements like BSEN61326-1

and BSEN 61010 respectively.

4. Thermal dissipation of equipment is met through

ventilation holes provided on chassis of equipment. Such

ventilation holes shall not be obstructed else it can lead to a

safety hazard.

5. The output terminals shall be strictly loaded to the

manufacturer specified values / range.

1. This equipment, being built-in-type, normally becomes a

part of main control panel and in such case the terminals do

not remain accessible to the end user after installation and

Internal wiring.

2. Do not allow pieces of metal, wire clippings, or fine metallic

fillings from installation to enter the product or else it may

lead to a safety hazard that may in turn endanger life or

cause electrical shock to the operator.

3. Circuit breaker or mains switch must be installed between

power source and supply terminals to facilitate power 'ON'

or ‘OFF’ function. However this switch or breaker must be

installed in a convenient position normally accessible to the

operator.

4. Use and store the temperature controller within the

specified ambient temperature and humidity ranges as

mentioned in this manual.

CAUTION

INSTALLATION GUIDELINES

1. Prepare the panel cutout with proper dimensions as shown

above.

2. Fit the unit into the panel with the help of clamp given.

3. The equipment in its installed state must not come in close

proximity to any heating sources, caustic vapors, oils,

steam or other unwanted process by-products.

4. Use the specified size of crimp terminals (M3.5 screws) to

wire the terminal block. Tighten the screws on the terminal

block using the tightening torque within the range of 1.2

N.m.

5. Do not connect anything to unused terminals.

MECHANICAL INSTALLATION

EMC GUIDELINES

1. Use proper input power cables with shortest

connections and twisted type.

2. Layout of connecting cables shall be away from any

internal EMI source.

Doc. Name : OP INST TC544C OP723-V03(Page 1 of 4)

48 x 48

5.4

SPECIFICATIONS

PARAMETERS

FUNCTIONAL SPECIFICATIONS

Control Method

Proportional Band(P)

1) PID control with Auto or

Self Tuning

2) ON-OFF control

1.0 to 400.0°C, 1.0 to 752.0°F

Integral Time(I)

Derivative Time(D)

Hysteresis Width

Dwell Timer

Manual Reset Value

Control Method

Proportional

Band-Cool

Cycle Time-Cool

Dead Band

HEAT COOL PID SPECIFICATIONS

0 to 9999 sec

0.1 to 99.9 sec

0 to 9999 min

-19.9 to 19.9°C / °F

PID

1.0 to 400.0°C

1.0 to 752.0°F

0.1 to 99.9 sec

SPLL to SPHL(Programmable)

Display

4 digits (White) + 4 digits (Green)

Display Height:-

White Display:- 15.3 mm

Green Display:- 8 mm

7 segment digital display

LED Indications

Input Signal

Sampling time

Keys

1 : Output 1 ON

2 : Output 2 ON

T : Tune

S : Dwell Timer

Thermocouple (J,K,T,R,S) /

RTD (PT100)

250 msec

3 keys for digital setting

INPUT SPECIFICATIONS

Resolution

Input Filter (FTC)

Temperature Unit

Indication Accuracy

0.1 / 1° for TC/RTD input

(Fixed 1° for R & S type TC input)

0.2 to 10.0 sec

oC / °F selectable

For TC inputs :

0.25% of F. S ±1°C

For R & S inputs :

0.5% of F. S ±2°C

( 30 min of warm up time

for TC input )

For RTD inputs :

0.1% of F. S ±1°C

Cycle Time

0.1 to 99.9°C

SSR

TC /RTD1

TC /RTD2

RTD3

NO2

COM1

NO1

COM2

( )

Resolution: 1 Resolution: 0.1

RANGE

INPUT TYPE

UNIT

FUNCTIONS

To view Level 1

To view Level 2

To view Protection Level

KEY PRESS

Press key for 3 sec.

Press + keys for 3 sec.

FRONT KEYS DESCRIPTION

ONLINE

To view online

parameters

PROGRAMMING MODE

To change online

parameter values

Press + / to change

parameter value.

Lower display selectable between

SET1/SET2/TIME using key.

To view parameters on

the same level.

To increase or decrease

the value of a particular

parameter.

or key once to view the next or

previous function in operational menu.

+ to increase and + to

decrease the function value.

Note : Parameter value will not alter

when respective level is locked.

NOTE : The unit will auto exit programming mode after 30 sec.

of inactivity.

By pressing the or or + keys for 3 sec.

NOTE : Elapsed time / Remaining time dependent on the

selection of ONL parameter in level1.

1Process-value (PV) /

Parameter name

display

1) Displays a process value (PV).

2) Displays the parameter symbols

at configuration mode/online menu.

3) Displays PV error conditions.

(refer Table 2)

FRONT PANEL DESCRIPTION

5Tune

6Dwell timer

Auto tune : Blinking (With faster rate)

Self tune : Blinking (With slower rate)

Blinking : Dwell timer is in progress.

Continuous ON : Time over.

3Control output 1

indication

2Parameter setting

display

The LED is glow when the control

output 1 is ON

Displays the parameter settings at

configuration mode/online menu.

4Control output 2

indication

The LED is glow when the control

output 2 is ON

FOR THERMOCOUPLE

J-199 to 750 °C

When an error has occurred, the upper display indicates error

codes as given below.

Error

Sensor break /

Over range condition

Sensor reverse /

Under range condition OFF

OFF

Description Control Output

Status

Table 2 : ERROR DISPLAY

R, S

If upper display is selected as / then,

Pressing key will show on Upper display : /

Lower display: <0>

Press + / keys to increment / decrement

/ value.

If upper display is selected as then,

Pressing key will show on Upper display :

Lower display : <50>

Press + / keys to increment / decrement

value.

Range : SPLL to SPHL

Default : 50

Programming online parameters

Setpoint 1

Range : SPLL to SPHL

Setpoint 2 / Dead band Default : 0

If upper display is selected as / then,

Pressing key will show on Upper display :

Lower display : <OFF>

Press + / keys to increment / decrement

time value.

Range : OFF, 1 to 9999 min

Dwell Timer Default : OFF

Use only the correct thermocouple wire or

compensating cable from the probe to instrument

terminals avoiding joints in the cable if possible.

Failure to use the correct wire type will lead to

inaccurate readings.

Ensure that the input sensor connected at the

terminals and the input type set in the temperature

controller configuration are the same.

USER GUIDEUSER GUIDE

1. Display Bias : This function is used to adjust the PV

value in cases where it is necessary for PV value to agree

with another recorder or indicator, or when the sensor

cannot be mounted in correct location.

2. Filter Time Constant : The input filter is used to filter out

quick changes that occur to the process variable in a

dynamic or quick responding application which causes

erratic control.

The digital filter also aids in controlling processes where

the electrical noise affects the input signal.

Larger the value of FTC entered, greater the filter added

and the slower the controller reacts to the process and

vice versa.

3. Auto tune (AT) : The Auto-tuning function automatically

computes and sets the proportional band (P),

integral time (I), Derivative time (D), ARW% and

cycle time (CY.T) as per process characteristics.

Tune LED blinks at faster rate when auto-tuning is in

progress.

At the completion of Auto-tuning, Tune LED stops

blinking.

If the power goes OFF before auto-tuning is completed,

Auto-tuning will be restarted at next power ON.

Temp.

set point

Proportional band

PID - time proportioning with auto reset & rate

Time

AT off

Self-tuning is initiated under the following conditions :

1) When setpoint is altered.

2) When tune mode is altered. (TUNE=ST)

ST will start only if PV < 50% of setpoint.

ST will work only when ACT=RE.

6. Self Tune (ST) : It is used where modification of PID

parameters is required repeatedly due to frequent

change in process condition eg. Setpoint.

Tune LED blinks at slower rate when Self-tuning is in

progress.

At the completion of self-tuning, Tune LED stop

blinking.

Time

Set point

Temp. Proportional band Reduced overshoot

5. Manual Reset (for PID control & I = 0) : After some

time the process temperature settles at some point

and there is a difference between the set temperature

& the controlled temperature. This difference can be

removed by setting the manual reset value equal &

opposite to the offset.

If auto-tuning is not completed after 3-4 cycles, the auto-

tuning is suspected to fail. In this case, check the wiring

& parameters such as the control action, input type, etc.

Carry out the auto-tuning again, if there is a change in

setpoint or process parameters.

4. ON/OFF control action (For Reverse Mode) :

The relay is ‘ON’ up to the set temperature and cuts

‘OFF' above the set temperature. As the temperature of

the system drops, the relay is switched ‘ON' at a

temperature slightly lower than the set point.

HYSTERESIS :

The difference between the temperature at which

relay switches ‘ON’ and at which the relay switches

‘OFF’ is the hysteresis or dead band.

set point

Temp.

Offset Manual reset

adjusted

Time Proportional With Manual Reset

Time

set point

overshoot

Hysteresis

ON ONOFF

Output

Temp.

Time

Reverse

set point

Hysteresis

OFF ON OFF

Temp.

Time

Output

Forward

Table 1 : INPUT RANGE

Resolution: 1 Resolution: 0.1

-238 to 1562 -199.9 to 999.9

RANGE

PT100

FOR RTD

INPUT TYPE

°F

-150 to 850 -150.0 to 850.0 °C

UNIT

-199 to 1350

-199 to 400

0 to 1750

-199 to 999

-199 to 400

N/A

-328 to 2462

-328 to 750

32 to 3182

-199 to 999

-199 to 750

N/A

°C

°F

-328 to 1382 -199 to 999 °F

-199 to 750

TC544

Doc. Name : OP INST TC544C OP723-V03(Page 2 of 4)

7. Thermocouple Compensation :

COMP = YES

Configure Yes if compensating cable is connected as

thermocouple extension. Yes should also be configured

in the case if the sensor is directly connected to the

terminal without extension.

COMP = NO

Configure No if non-compensating cable is connected

as thermocouple extension.

IDM Level

IndependentDownloader Module

Upload from product to IDM

Download te Parameter

Display Parameter Description

Download from IDM to product

Operation Successful

Operation unsuccessful

Key

+ Key

+ Key /

KeyKey

(Blinking)

Note:

1) IDM Level - IDM should be connected before

powering on the unit to enter in IDM Level.

2) Long Press or key for 3 sec to exit from IDM mode.

Caution: After Downloading, switch of the unit and then remove the IDM

**IDM is applicable only for IDM compatible Product.

Level 1 Level 2

Display DisplayDefault

Value

Default

Value

Range Range

J/K/T/R/S/RTD

1/0.1

1.0 to 400.0°

°C/°F

0 to 9999 sec

Min range of sensor

selected to SPHL

0 to 9999 sec

SPLL to Max range

of sensor selected

AUTO/USR.F

0.2 to10.0 sec 0.1 to 99.9 sec

0.1 to 99.9 sec

RE/FD

RE/FD/TIME

NO/YES

0.1 to 99.9°

PID/ONF

RELAY/SSR

-19.9 to +19.9°

1.0 to 400.0°

NO/YES

OFF, 1 to 9999 min

-19.9 to 19.9°

Display

Condition

Display

Condition

Not prompted

for R & S type

For CNTL=ONF

For HC=NO or

HC=YES &

CNTL=ONF

For CNTL=PID

& I=0

Description

Input type

(Refer Table 1)

Tune

(Refer user guide)

Display Resolution

Proportional band

Temperature unit

Integral time

Set point low limit Derivative time

Set point high limit Cycle time mode

Cycle time

Cycle time-cool

Control action for

relay 1

Control action for

relay 2

Factory default

(Reset all)

Hysteresis 1

Hysteresis 2

Control logic

Control Output selection

Dwell mode enable

Manual reset

Proportional

band-cool

Heat-cool mode

selection

POWER ON

OPERATIONAL MENU

Description

Dwell time

Display bias

Filter time constant

NO/YES

When HC=NO.

TIME prompted

when DWEL

=YES

When DWEL

=YES

When CNTL

=PID

REMN/ELPS

1.0 to 100.0%

Online menu for timer

Anti-reset windup %

DEV/ABS

Relay 2 type When

ACT2=RE/FD

For CNTL=PID

& HC=YES

When DWEL

=YES

CONFIGURATION INSTRUCTIONS

Press once to view online parameters Press for 3 sec to enter Level 2 Press once to view next parameter in configuration menu

Press for 3 sec to view Level 1 Press once to view previous parameter in configuration menu

+ or + Allows the user to increase or decrease associated parameter value or or +To exit configuration menu press any of these keys for 3 sec

+Press for 3 sec to enter protection Level

Not prompted

for HC=YES

Protection Level

Display Default

Value

Range

UNLK/READ

Display

Condition

Lock setpoint 1

Lock level 1

Lock level 2

Lock dwell time

Description

Prompted when

DWEL=YES

Note

UNLK/READ/LOCK

Lock setpoint 2

Press key for 3sec.

Press + keys for 3sec.

1. Locking parameters (LVL1 or LVL2 or SP or DWEL) will not permit

change in the value of respective level parameters.

Time value (online) can be altered only when DWEL is not locked

in protection level.

2. Continuous operation of + / keys for SP or other parameters

makes update speed faster in 3 stages after 3 sec.

For CNTL=PID

& HC=YES

Note : At power ON lower display shows (momentary) input type selected in Level 1.

Press key for 3sec.

KEY FUNCTIONS

OFF / ST / AT

TC544

Doc. Name : OP INST TC544C OP723-V03(Page 3 of 4)

YES/NO

RTD

SENSOR

SELECTION

VERIFICATION

VALUE (°C)

25.0

0.0

475.0

323.5

975.0

800.0

CALIBRATION CERTIFICATE

Model No : TC544C

Claimed Accuracy :

For TC inputs : 0.25% of FS ±1°C

For R & S inputs : 0.5% of F.S ±2°C

(30 min of warm up time for TC input)

For RTD inputs : 0.1% of FS ±1°C

Standard used for Calibration of product is

traceable to NABL

The calibration of this unit has been verified at the

following values :

The thermocouple / RTD curves are linearized in

this microprocessor based product; and hence the

values interpolated across the input range are also

equally accurate ; at every point in the curve.

Unit is accepted as accuracy is within the specified

limit of claimed accuracy and certificate is valid upto

one year from the date of issue.

(Specifications are subject to change, since development is

a continuous process.)

Selec Controls Pvt. Ltd., India

Factory Address :

EL-27/1, Electronic Zone, TTC Industrial Area, MIDC, Mahape,

Navi Mumbai - 400 710, INDIA.

Tel. No. : +91-22-41 418 452/468 | Fax No. : +91-22-28471733

Toll free : 1800 227 353 (BSNL/MTNL Subscribers only)

Website : www.selec.com | Email : sales@selec.com

Doc. Name : OP INST TC544C OP723-V03(Page 4 of 4)

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