Tempco TEC-2500 User manual

Instruction Manual

TEC-2500

Self-Tune Fuzzy / PID

Process Temperature Controller

Manual TEC-2500 Revision 9/2013

Agency Approvals

TEMPCO Electric Heater Corporation

607 N. Central Avenue • Wood Dale, IL 60191-1452 USA

Tel: 630-350-2252 • Toll Free: 800-323-6859

Fax: 630-350-0232 • E-mail: [email protected]

Web: www.tempco.com

Serving Industry Since 1972

OTES

CONTENTS

Page No.

Chapter 1 Overview

1-1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2 Ordering Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-3 Programming Port and DIP Switch . . . . . . . . . . . . . 4

1-4 Keys and Displays . . . . . . . . . . . . . . . . . . . . . . . . . 5

1-5 Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1-6 System Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1-7 Parameter Description . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 2 Installation

2-1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2-2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2-3 Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . 18

2-4 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2-5 Sensor Installation Guidelines . . . . . . . . . . . . . . . 19

2-6 Thermocouple Input Wiring . . . . . . . . . . . . . . . . . 19

2-7 RTD Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 20

2-8 Linear DC Input Wiring . . . . . . . . . . . . . . . . . . . . . 20

2-9 CT/Heater Current Input Wiring . . . . . . . . . . . . . . 21

2-10 vent Input wiring . . . . . . . . . . . . . . . . . . . . . . . . 22

2-11 Output 1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2-12 Output 2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2-13 Alarm 1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2-14 Alarm 2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2-15 RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2-16 RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2-17 Analog Retransmission . . . . . . . . . . . . . . . . . . . . 30

2-18 Programming Port . . . . . . . . . . . . . . . . . . . . . . . 31

Chapter 3 Programming Basic Functions

3-1 Input 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3-2 OUT1 and OUT2 Types . . . . . . . . . . . . . . . . . . . . 34

3-3 Configuring User Menu . . . . . . . . . . . . . . . . . . . . . 35

3-4 Display SV Instead of PV . . . . . . . . . . . . . . . . . . . 35

3-5 Heat Only Control . . . . . . . . . . . . . . . . . . . . . . . . . 36

3-6 Cool Only Control . . . . . . . . . . . . . . . . . . . . . . . . . 37

3-7 Heat-Cool Control . . . . . . . . . . . . . . . . . . . . . . . . . 38

3-8 Dwell Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3-9 Process Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3-10 Deviation Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 42

3-11 Deviation Band Alarms . . . . . . . . . . . . . . . . . . . . 43

3-12 Heater Break Alarm . . . . . . . . . . . . . . . . . . . . . . 44

3-13 Loop Break Alarm . . . . . . . . . . . . . . . . . . . . . . . . 45

3-14 Sensor Break Alarm . . . . . . . . . . . . . . . . . . . . . . 46

3-15 SP1 Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3-16 PV1 Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3-17 Failure Transfer . . . . . . . . . . . . . . . . . . . . . . . . . 48

CONTENTS

Page No.

3-18 Bumpless Transfer . . . . . . . . . . . . . . . . . . . . . . . 49

3-19 Self-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3-20 Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3-21 Manual Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . 53

3-22 Signal Conditioner DC Power Supply . . . . . . . . . 55

3-23 Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . 56

3-24 Display Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3-25 Heater Current Monitoring . . . . . . . . . . . . . . . . . 58

3-26 Reload Default Values . . . . . . . . . . . . . . . . . . . . . 58

Chapter 4 Full Function Programming

4-1 vent Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

4-2 Second Set Point . . . . . . . . . . . . . . . . . . . . . . . . . 60

4-3 Second PID Set . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4-4 Ramp and Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . 62

4-5 Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . 63

4-6 Differential Control . . . . . . . . . . . . . . . . . . . . . . . . 64

4-7 Output Power Limits . . . . . . . . . . . . . . . . . . . . . . . 65

4-8 Data Communication . . . . . . . . . . . . . . . . . . . . . . 66

4-9 Analog Retransmission . . . . . . . . . . . . . . . . . . . . . 67

4-10 Digital Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4-11 Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4-12 Pump Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4-13 Remote Lockout . . . . . . . . . . . . . . . . . . . . . . . . . 70

Chapter 5 Applications

5-1 Pump/Pressure Control . . . . . . . . . . . . . . . . . . . . 71

5-2 Variable Period Full Wave SSR (VPFW SSR) . . . 73

5-3 Heat Only Control . . . . . . . . . . . . . . . . . . . . . . . . . 75

5-4 Cool Only Control . . . . . . . . . . . . . . . . . . . . . . . . . 76

5-5 Heat-Cool Control . . . . . . . . . . . . . . . . . . . . . . . . . 77

5-6 Ramp and Dwell . . . . . . . . . . . . . . . . . . . . . . . . . . 78

5-7 Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . 80

5-8 Differential Control . . . . . . . . . . . . . . . . . . . . . . . . 81

5-9 Dual Set Point/PID . . . . . . . . . . . . . . . . . . . . . . . . 82

5-10 RS-485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

5-11 RS-232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5-12 Retransmit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Chapter 6 Calibration . . . . . . . . . . . . . . . . . . . . . . . . 87

Chapter 7 Error Codes and Troubleshooting . . . . 91

Chapter 8 Specifications . . . . . . . . . . . . . . . . . . . . . 95

Appendix

A-1 Menu xistence Conditions . . . . . . . . . . . . . . . . . 97

A-2 Factory Menu Description . . . . . . . . . . . . . . . . . 100

A-5 Memo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

A-6 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Warnin 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

symbol until the indicated conditions are fully understood and met.

Usin the Manual

Installers. . . . . . . . . . . . . . . . . . . . . . . . . . . . Read Chapters 1, 2

Basic Function User. . . . . . . . . . . . . . . . . Read Chapters 1, 3, 5

Enhanced Function User . . . . . . . . . . . Read Chapters 1, 3, 4, 5

System Designer . . . . . . . . . . . . . . . . . . . . . . Read All Chapters

Expert User. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Read Page 10

NOTE:

It is strongly recommended t at a process s ould incorporate

a LIMIT CONTROL like TEC-910 w ic will s ut down t e

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.

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.

OTES

Unique

** High accuracy 18-bit input A–D

** High accuracy 15-bit output D–A

** Fast input sample rate (5 times/second)

** Two function complexity levels

** User menu configurable

** Pump control

Chapter 1 Overview

1–1 Features

* Fuzzy plus PID microprocessor-based control

* Automatic programming

* Differential control

* Auto-tune function

* Self-tune function

* Sleep mode function

* "Soft-start" ramp and dwell timer

* Programmable inputs(thermocouple, RTD, mA, VDC)

* Analog input for remote set point and CT

* vent input for changing function and set point

* Programmable digital filter

* Hardware lockout and remote lockout protection

* Loop break alarm

* Heater break alarm

* Sensor break alarm and bumpless transfer

* RS-485, RS-232 communication

* Analog retransmission

* Signal conditioner DC power supply

* A wide variety of output modules available

* Safety UL/CSA/I C1010–1

* MC/C N61326

* Front panel sealed to N MA 4X and IP65

TEC-2500 Fuzzy ogic plus PID microprocessor-based controller

incorporates a bright, easy to read, 4-digit ED display which

indicates the process value. Fuzzy ogic 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 1/32 DIN case, measuring

24mm x 48mm with 98mm 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 SE 1 to SE 5

found in the setup menu. This is particularly useful to OEM's as it

is easy to configure the menu to suit the specific application.

TEC-2500 is powered by 11–26 or 90–264VDC/AC supply,

incorporating a 2 amp control relay output, 5V logic alarm output

and a 2 amp alarm relay output as standard with a second alarm

that can be configured in the second output for cooling purposes

or as a dwell timer. Alternative output options include SSR drive,

triac, 4–20mA and 0–10 volts. TEC-2500 is fully programmable

for PT100, thermocouple types J, K, T, E, B, R, S, N, , 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-2500 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-2500 to be integrated with supervisory control

systems and software, or alternatively to drive remote displays,

chart recorders, or data loggers.

Two different methods can be used to program the TEC-2500.

1. Use the keys on the front panel to program the unit manually or

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 changes and/or load disturbances, 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 vary from time to time. In order to overcome the

imperfections of PID control, Fuzzy ogic was introduced.

What is Fuzzy Control? It works like a good driver. Under

different speeds and circumstances, he can control a car well

based on previous experience, and does not require knowledge of

the kinetic theory of motion. Fuzzy ogic is a linguistic control

which is different from numerical PID control. It controls the

system by experience and does not need to simulate the system

precisely as a PID controller would.

The function of Fuzzy Logic is to adjust PID parameters

internally in order to make manipulation of output value

MV more flexible and adaptive to various processes.

The Fuzzy Rule may work like this:

If the temperature difference is large, and the temperature

rate is large, then ΔMV is large.

If the temperature difference is large, and the temperature

rate is small, then ΔMV is small.

PID+Fuzzy Control has been proven to be an efficient

method to improve the control stability as shown by the

comparison curves below:

Accessories

TEC-101-101 — Isolated 4–20mA/0–20mA analog output module

TEC-101-114 — Isolated 1–5V/0–5V analog output module

TEC-101-115 — Isolated 0–10V analog output module

TEC-101-109 — Isolated 1A/240VAC triac output module (SSR)

TEC-101-111 — Isolated 20V/25mA DC output power supply

TEC-101-112 — Isolated 12V/40mA DC output power supply

TEC-101-113 — Isolated 5V/80mA DC output power supply

TEC-102-101 — Isolated RS-485 interface module

TEC-102-103 — Isolated RS-232 interface module

TEC-102-104 — Isolated 4–20mA/0–20mA retransmission module

TEC-102-105 — Isolated 1–5V/0–5V retransmission module

TEC-102-106 — Isolated 0–10V retransmission module

TEC99014 — RS-232 interface cable (2M)

TEC99999 — 0–50amp AC current transformer

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