RED LION CONTROLS MODEL TCU - TEMPERATURE CONTROL UNIT

Transcription

1 RED LION CONTROLS INTERNATIONAL HEADQUARTERS EUROPEAN HEADQUARTERS 0 Wiow Springs Circe, York, Pa. 740, (77) FAX: (77) Pymouth Road, Sough, Berkshire SL 4LP Web site- E-mai- saes@redion-contros.com ENGLAND FAX: MODEL TCU - TEMPERATURE CONTROL UNIT BULLETIN. TCU-F DRAWING. LP034 REVISED /98 00 msec SAMPLING PERIOD WITH 0.5% ACCURACY ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF TEMPERATURE AND SETPOINT, SECOND INPUT OR HEATER CURRENT ACCEPTS 0 DIFFERENT TYPES OF SENSOR INPUTS (Thermocoupe or RTD) SELF-DIAGSTICS FULL PID CONTROL WITH REDUCED OVERSHOOT OPTIONAL RS-485 SERIAL COMMUNICATIONS INTERFACE R OPTIONAL DUAL ALARM S (USES MODULES) OPTIONAL COOLING (USES MODULE) OPTIONAL LINEAR 4 to 0 ma or 0 to 0 VDC FOR CONTROL OR TEMPERATURE RE-TRANSMISSION OPTIONAL HEATER CURRENT MONITOR AND BREAK ALARM OPTIONAL MOTORIZED VALVE POSITION CONTROL AND VALVE FAIL ALARM OPTIONAL SECOND INPUT FOR REMOTE SETPOINT AND CASCADE CONTROL OPTIONAL NEMA 4X/IP65 SEALED FRONT BEZEL STATUS INDICATORS FOR S AND CONTROL MODES PROGRAMMABLE USER INPUT (DIGITAL) FOR ADDED FLEXIBILITY SENSOR ERROR COMPENSATION (Sope and Offset) AND BREAK DETECTION MANUAL/AUTOMATIC AND LOCAL/REMOTE SETPOINT CONTROL MODES SETPOINT RAMPING FOR PROCESS STARTUP PARAMETER SECURITY VIA PROGRAMMABLE LOCKOUTS FIELD REPLACEABLE AND INTERCHANGEABLE MODULES (Reay, Logic/SSR Drive and Triac) and C R UL Recognized Component, Fie #E56876 DESCRIPTION The TCU Controer accepts signas from a variety of temperature sensors (thermocoupe or RTD eements), precisey dispays the process temperature, and provides an accurate output contro signa (time proportiona or inear) to maintain a process at the desired contro point. A comprehensive set of easy to use steps aows the controer to sove various appication requirements. The controer can operate in the PID contro mode for both heating and cooing, with on-demand auto-tune, which wi estabish the tuning constants. The PID tuning constants may be fine-tuned by the operator at any time and then ocked out from further modification. The controer empoys a unique overshoot suppression feature, which aows the quickest response without excessive overshoot. The unit can be transferred to operate in the manua mode, providing the operator with direct contro of the output. The controer may aso be programmed to operate in the ON/OFF contro mode with adjustabe hysteresis. Dua 4-digit dispays aow viewing of the process temperature and setpoint simutaneousy. Front pane indicators inform the operator of the controer and output status. Repaceabe and interchangeabe output modues (reay, SSR drive, or triac) can be instaed for the main contro output, aarm output(s) and cooing output. Optiona dua aarms can be configured to activate according to a variety of actions (Absoute HI or LO, Deviation HI or LO, Band IN or OUT, Heater Break and Vave Fai Detect) with adjustabe hysteresis. A standby feature suppresses the output during power-up unti the temperature stabiizes outside the aarm region. An optiona secondary output is avaiabe (for processes that require cooing) which provides increased contro accuracy and response. DIMENSIONS In inches (mm) Note: Recommended minimum cearance (behind the pane) for mounting cip instaation is 5.5 (40) H x. (53.4) W. PANEL CUT-OUT

2 DESCRIPTION (Cont d) OPTIONS A inear 4 to 0 ma or 0 to 0 VDC output signa is avaiabe to interface with actuators, chart recorders, indicators, or other controers. The output signa can be digitay scaed and seected to transmit one of the foowing: % output power, process temperature vaue, process temperature vaue deviation or setpoint vaue. For Linear DC contro appications, the adjustabe output demand dampening, output deadband and output update time parameters expand the versatiity of the TCU with fina contro devices. The optiona Heater Current Monitor serves as a digita ammeter for heater current monitoring. Current transformer accessory (CT00500), is required. An aarm event output can be programmed to signa when the heater or heater contro devices have faied, before damage to process materia occurs. The Heater Break aarm triggers under two conditions: ) The main output (OP) is on and the heater current is beow the heater current aarm vaue, indicating an aged or faied heater. ) Output (OP) is off and the heater current is more than 0% of the aarm vaue, indicating a shorted heater contro device or other probem. The optiona Motorized Vave Positioner directy contros the position of a vave by the use of twin outputs (open and cose) to contro the direction of motor rotation. The motor position defines the opening position of the vave. Two contro modes are possibe: position contro, which makes use of the sidewire feedback signa suppied with the positioner and veocity contro, in which no sidewire feedback signa is used. Parameters are provided to adjust the operation of the vave. These incude: Vave activity hysteresis Vave update time Variabe contro dampening Sidewire signa fai action Adjustabe vave position imits. The vave positioner TCU achieves tight process contro, yet minimizes unnecessary vave activity. An aarm event output or dispay aarm can be programmed under oss of sidewire feedback or under vave fai detection. The optiona Second Anaog Input (0-0 ma DC) can be configured as a remote setpoint signa or as a secondary process signa. Configuration of the second anaog input as a remote setpoint signa aows ratio contro, master setpoint/mutipe save operation, and the abiity to cascade the TCU with another controer (externa cascade). Configuration of the second input as a secondary process signa aows operation as a two-process cascade controer within a singe unit (interna cascade). In either contro mode, parameters are provided to scae, configure, communicate and monitor the activity of both anaog inputs. A square aw inearizer function can be used to inearize signas derived from fow transmitters. The optiona RS-485 mutidrop seria communication interface provides twoway communication between a TCU unit and other compatibe equipment such as a printer, a programmabe controer, or a host computer. In mutipoint appications the address number of each unit on the ine can be programmed from Up to thirty-two units can be instaed on a singe pair of wires. The Setpoint vaue, % Output Power, Setpoint Ramp Rate, etc. can be interrogated or changed by sending the proper command code via seria communications. Aarm output(s) may aso be reset via the seria communications interface option. An optiona NEMA 4X/IP65 rated beze is avaiabe for wash down and/or dirty environments, when propery instaed. Modern surface-mount technoogy, extensive testing, pus high immunity to noise interference makes the controer extremey reiabe in industria environments. SAFETY SUMMARY A safety reated reguations, oca codes and instructions that appear in the manua or on equipment must be observed to ensure persona safety and to prevent damage to either the instrument or equipment connected to it. If equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. Do not use the TCU to directy command motors, vaves, or other actuators not equipped with safeguards. To do so, can be potentiay harmfu to persons or equipment in the event of a faut to the unit. An independent and redundant temperature imit indicator with aarm outputs is strongy recommended. Red Lion Contros mode IMT (thermocoupe) or mode IMR (RTD) units may be used for this purpose. The indicators shoud have input sensors and AC power feeds independent from other equipment. SPECIFICATIONS. DISPLAY: Dua 4-digit Upper Temperature Dispay: 0.4 (0.mm) high red LED Lower Auxiiary Dispay: 0.3 (7.6mm) high green LED Dispay Messages (Mode dependent): OLOL - Appears when measurement exceeds + sensor range. ULUL - Appears when measurement exceeds - sensor range. OPEN - Appears when open sensor is detected. SHrt - Appears when shorted sensor is detected (RTD ony)... - Appears when dispay vaues exceed + dispay range Appears when dispay vaues exceed - dispay range. SLid - Appears when oss of sidewire signa is detected. VALV - Appears when vave actuator error is detected.. POWER: 5/30 VAC (+0%, -5%) no observabe ine variation effect, 48 to 6 Hz, 0 VA, switch seectabe 3. ANNUNCIATORS: LED Backight Status Indicators (Mode dependent): %PW - Lower auxiiary dispay shows power output in (%). DEV - Lower auxiiary dispay shows deviation (error) from temperature setpoint. OP - Main contro output is active. AL - Aarm # is active. AL - Aarm # is active (for Dua Aarm Option). OP - Cooing output is active (for Cooing Option). OPN - Vave positioner OPEN output is active (for Vave Positioner option). CLS - Vave positioner CLOSE output is active (for Vave Positioner option). CUR - Lower auxiiary dispay shows heater current (for Heater Current Monitor option). SEC - Lower auxiiary dispay shows second anaog input (For Second Anaog Input option). MAN - Fashing: Controer is in manua mode. REM - ON: controer is in remote setpoint mode (Second Anaog Input option). - OFF: controer is in oca setpoint mode (Second Anaog Input option). - Fashing: controer is in Manua contro mode (Second Anaog Input optiona). 4. CONTROLS: Four front pane push buttons for modifying and setup of controer functions and one externa input for parameter ockout or other functions. 5. MAIN SENSOR INPUT: Sampe Period: 00 msec Response Time: 300 msec (to within 99% of fina vaue w/step input; typicay, response is imited to response time of probe) Faied Sensor Response: Main Contro Output(s): Programmabe preset output Dispay: OPEN Aarms: Upscae drive DC Linear: Programmabe preset output Norma Mode Rejection: 40 50/60 Hz (improves with increased digita fitering. Common Mode Rejection: 00 db, DC to 60 Hz Protection: Input overoad 0 VAC for 30 seconds. 6. THERMOCOUPLE: Types: T, E, J, K, R, S, B, N, Linear mv Input Impedance: 0 M W a types Lead resistance effect: 0 µv/350 W Cod junction compensation: Less than ± o C error over 0-50 o C ambient temperature range. Disabed for Linear mv type. Resoution: o C/F a types, or 0. o C/F for T, E, J, K, and N ony. 7. RTD:, 3 or 4 wire, 00 W patinum, apha = (DIN 43760), apha = Excitation: 0.75 ma Resoution: or 0. degree Lead Resistance: 7 W maximum 8. RANGE AND ACCURACY: Errors incude NIST conformity and A/D conversion errors at 3 o C after 0 min. warm-up. Thermocoupe errors incude cod junction effect. Errors are expressed as ±percent of reading and ± 3 /4 LSD uness otherwise noted. WIRE TC RANGE ACCURACY COLOR TYPE (ANSI) T -00 to +400 o C 0.0% +.5 o C bue -38 to +75 o F 0.0% +.7 o F E -00 to 750 o C 0.0% +.5 o C vioet -38 to +38 o F 0.0% +.7 o F J -00 to +760 o C 0.5% +.5 o C white -38 to +400 o F 0.5% +.7 o F K -00 to +50 o C 0.0% +.5 o C yeow -38 to +8 o F 0.0% +.7 o F R 0 to +768 o C 0.5% +.5 o C back +3 to +34 o F 0.5% o F S 0 to +768 o C 0.5% +.5 o C back +3 to +34 o F 0.5% o F B +00 to +80 o C 0.5% +.5 o C grey +300 to o F 0.5% o F N -00 to +300 o C 0.0% +.5 o C orange -38 to +37 o F 0.0% +.5 o F mv to % + sd RTD -00 to +600 o C 0.0% o C (385) -38 to +00 o F 0.0% o F RTD -00 to +600 o C 0.0% o C (39) -38 to +00 o F 0.0% o F OHMS.0 to % + sd

3 9. MODULES [Optiona] (For A Output Channes): Reay: Type: Form-C (Form-A with some modes. See Ordering Information.) Rating: 5 0/40 VAC or 8 VDC (resistive oad), /8 0 VAC (inductive oad) Life Expectancy: 00,000 cyces at max. oad rating. (Decreasing oad and/or increasing cyce time, increases ife expectancy). Logic/SSR Drive: Can drive mutipe SSR Power Units. Type: Non-isoated switched DC, VDC typica Drive: 45 ma max. Triac: Type: Isoated, Zero Crossing Detection Rating: Votage: 0/40 VAC Max. Load Current: 35 o C o C Min. Load Current: 0 ma max. Offstate Leakage Current: 7mA 60 Hz Operating Frequency: 0 to 500 Hz Protection: Interna Transient Snubber, Fused 0. MAIN CONTROL (Heating or Cooing): Contro: PID or ON/OFF Output: Time proportioning or inear DC Hardware: Pug-in, repaceabe output modues Cyce time: Programmabe Auto-tune: When seected, sets proportiona band, integra time, and derivative time vaues. Probe Break Action: Programmabe. COOLING (Optiona): Contro: PID or ON/OFF Output: Time proportioning or inear DC Hardware: Pug-in, repaceabe output modues Cyce time: Programmabe Proportiona Gain Adjust: Programmabe Heat/Coo Deadband Overap: Programmabe. LINEAR DC (Optiona): With digita scae and offset, programmabe deadband and update time. 4 to 0 ma: Resoution: part in 3500 typ. Accuracy: ±(0.% of reading + 5 µa) Compiance: 0 V (500 W max. oop impedance) 0 to 0 VDC: Resoution: part in 3500 typ. Accuracy: ±(0.% of reading + 35 mv) Min. Load Resistance: 0 KW ( ma max.) Source: % output power, setpoint, deviation, or temperature (Avaiabe for heat or coo, but not both.) 3. HEATER CURRENT MONITOR (Optiona): Type: Singe phase, fu wave monitoring of oad currents controed by main output (OP) Input: 00 ma AC output from current transformer RLC part number CT00500 or any current transformer with 00 ma AC output Dispay Scae Range:.0 to amperes or 00.0% Input resistance: 5 W Accuracy: % of fu scae ± LSD (0 to 00% of range) Frequency: 50 to 400 Hz Aarm mode: Dua acting; heater eement fai detect and contro device fai detect Overoad: 00 ma (steady state) Min. output on time for Heater break aarm detect: 400 msec 4. MOTORIZED VALVE POSITIONER (Optiona): Two Outputs: Vave open and vave cose or Linear DC (optiona) Hardware: Pug-in, repaceabe output modues Three Inputs: Sidewire feedback, signa fai detect (Isoated from main input) Sidewire Resistance: 00 to 00 KW Sidewire Exciting Votage: 0.9 VDC Sidewire Fai Action: programmabe Contro Mode: Position mode (with sidewire) and veocity mode (w/o sidewire). Contro Deadband: % to 5.0% (position mode) 0. to 5.0 seconds (veocity mode) Update Time: to 50 seconds Motor Time (open, cose): to 9999 seconds Position Limits: Adjustabe 0.0 to 00.0% of vave stroke Vave Fai Time: Off to 9999 seconds Aarm mode: Dua acting; oss of sidewire feedback signa and vave fai detection 5. SECOND INPUT: Range: 0 to 0 ma (Isoated from main input) Overoad: 00 ma (steady state) Input Resistance: 0 W Votage Drop (@ 0 ma): 0. V Accuracy: 0.5% of reading ±0 µa ± LSD Scae Range: -999 to SERIAL COMMUNICATION: Type: RS-485 Muti-point, Baanced Interface Communication Format: Baud Rate: Programmabe from 300 to 9600 Parity: Programmabe for odd, even, or no parity Frame: start bit, 7 data bits, or no parity bit, stop bit Unit Address: Programmabe from 0 to 99, max. of 3 units per ine Transmit Deay: 00 msec min., 00 msec max. RS-485 Common: Isoated from signa input common Auto Print Time: Off to 9999 seconds between print-outs 7. USER INPUT (Optiona): Internay pued up to +5 VDC. V IN MAX = 5.5 VDC, V IL = 0.85 V MAX ; V IH = 3.0 V MIN, Avaiabe on a second input (HCM, MVP & ANA) modes, and on modes with RS485. Response Time: 00 msec max. Functions: Program Lock Integra Action Lock Auto/Manua Mode Seect Setpoint Ramp Seect Reset Aarms Print Request Loca/Remote Setpoint Seect 8. ALARMS (Optiona): Hardware: Pug-in, repaceabe output modue Modes: Absoute high acting Absoute ow acting Deviation high acting Deviation ow acting Inside band acting Heater break Vave fai Second Anaog Input monitoring Reset Action: Programmabe; automatic or atched Standby Mode: Programmabe; enabe or disabe Hysteresis: Programmabe Probe Break Action: Upscae Annunciator: LED backight for AL, AL, (Aarm # not avaiabe with cooing output or motorized vave position option.) 9. ENVIRONMENTAL CONDITIONS: Operating Temperature Range: 0 to 50 o C Storage Temperature Range: -40 to 80 o C Span Drift (maximum): 00 ppm/ o C, main input; 50 ppm/ o C, second input Operating and Storage Humidity: 85% max. (non-condensing) from 0 to 50 o C Zero Drift (maximum): µv/ o C, main input; µa/ o C, second input Atitude: Up to 000 meters 0. ISOLATION BREAKDOWN RATINGS: A inputs and outputs with respect to AC ine: 500V Anaog Outputs, Second Anaog Input, Heater Current Input or Sidewire Input with respect to main input: 500 V. CERTIFICATIONS AND COMPLIANCES: UL Recognized Component, Fie #E56876 Recognized to U.S. and Canadian requirements under the Component Recognition Program of Underwriters Laboratories, Inc. EMC EMISSIONS: Meets EN 5008-: Industria Environment. CISPR Radiated and conducted emissions EMC IMMUNITY: Meets EN 5008-: Industria Environment. ENV Radio-frequency radiated eectromagnetic fied ENV Radio-frequency conducted eectromagnetic fied EN Eectrostatic discharge (ESD) EN Eectrica fast transient/burst (EFT) Notes:. No oss of performance during EMI disturbance at 7 V/m. Permissibe oss of performance during EMI disturbance at 0 V/m: Process signa deviation ess than % of fu scae Anaog output deviation ess than 3 % of fu scae For operation without oss of performance: Insta power ine fiter, RLC #LFIL0000 or equivaent. OR Insta ferrite core turn, RLC #FCOR0000 or equivaent, to power ines at unit.. Permissibe oss of performance during EMI disturbance at 0 Vrms: Process signa deviation ess than 0.5 % of fu scae Anaog output deviation ess than 3 % of fu scae 3

4 For operation without oss of performance: a. Insta power ine fiter, RLC #LFIL0000 or equivaent. OR Insta ferrite core turn, RLC #FCOR0000 or equivaent, to power ines at unit. b. Insta ferrite core, RLC #FCOR0000 or equivaent, to anaog out cabe at unit. Refer to the EMC Instaation Guideines section of the manua for additiona information.. CONNECTION: Jaw-type termina bock 3. CONSTRUCTION: NEMA For Standard Modes. Front Pane: Fame and scratch resistant tinted pastic Case: High impact back pastic. (Mounting coar incuded) NEMA 4X/IP65 mode ony: Seaed beze utiizing two captive mounting screws (pane gasket incuded). This unit is rated for NEMA 4X/IP65 indoor use. Instaation Category II, Poution Degree 4. WEIGHT:.3 bs (0.6 kgs) ACCESSORIES: Externa SSR Power Unit: Switched Votage Range: 50 to 80 VAC (Nomina: 40 VAC) Load Current: 45 5 o C ambient temperature o C ambient temperature On State Input: 3 to W impedance. (isoated) (Use Logic/SSR drive output modue.) Off State Input: 0.0 to.0 VDC Size: 5.5 (4 cm) L x 4.75 ( cm) W x.6 (6.6 cm) H Current Transformer: Current Ratio: 50:0. (Amperes) Accuracy: ±5.0% Operating Frequency: 50 to 400 Hz Insuation Cass: 0.6 Kv BIL 0 Kv fu wave Terminas: Brass studs No. 8-36, (fat washer, washer, nut) Weight: 8.0 oz (6 g) Approvas: UL recognized component BASIC OPERATION The TCU contros a process temperature by measuring the temperature via an input probe, then cacuating a contro output power vaue by use of a modified PID contro agorithm. The unit contros the system with the new output power vaue to keep the process temperature at setpoint. The PID contro agorithm incorporates features which provide for high contro accuracy and ow temperature overshoot from process disturbances. FRONT PANEL FEATURES In the norma operating mode, the unit wi dispay the process temperature in the upper dispay. One of six other parameters can be viewed in the ower dispay: - Setpoint - % Power Output - Temperature Deviation - Heater Current - Second Input Process Vaue - Temperature Symbo (F or C) The six parameters can be scroed through by pressing the DSP button. If enabed, the contro setpoint or power output (manua mode ony) can be directy modified in this mode. In the norma operating mode, parameters are seected by use of the PAR button and modified by use of the UP and DOWN buttons. Parameters are then entered by the PAR button, which advances the user to the next parameter. Pressing the DSP button immediatey returns the controer to the norma operating mode when making a parameter change. The controer s configuration and parameter settings are stored in an interna E PROM device. HARDWARE FEATURES The fast 00 msec input samping rate provides quick controer response to a process disturbance, thus providing exceent temperature contro. Measurement accuracy of 0.5% or better, provides coser process contro conforming to the desired contro setpoint vaue. One mode accepts a variety of both thermocoupe or RTD temperature probes. The AC input power is switch seectabe, aowing the unit to operate from either 5 VAC or 30 VAC. Since the controer is serviceabe from the front of the pane, the output modues may be easiy changed or repaced without disturbing the wiring behind the pane. No re-programming is required when changing or repacing modues. The optiona NEMA 4X/IP65 rated mode utiizes two beze securing screws and a neoprene gasket to guarantee a water tight sea, when propery instaed. The standard mode simpy requires pressing a atch to remove the unit. Low-drift, highy stabe circuitry ensures years of reiabe and accurate temperature contro. The recommended two-year re-caibration interva is easiy accompished via the programming menu. SETPOINT FEATURES The controer setpoint can be protected from out of range vaues by programming the setpoint range imit vaues. Additionay, safeguards from inadvertent data entry can be programmed. The setpoint ramp feature ramps the setpoint vaue at start-up or any time a setpoint change is made, at a user programmabe rate. This feature reduces therma shock to the process and heps to minimize temperature overshoot.the setpoint may aso be transmitted by the optiona inear DC output for save contro oops. The second anaog input may be configured as a remote setpoint. As such, the controer is easiy switched from oca/remote setpoint operation via the front pane or user input. Ratio and bias parameters provide on-ine scaing of the remote setpoint. Absoute imit vaues and maximum rate of change of the remote setpoint further enhance controer fexibiity. INPUT FEATURES A programmabe input fiter can be used to stabiize readings from a process with varying or osciating temperature characteristics, heping to provide better temperature contro. A programmabe temperature shift and sope function can be used to compensate for probe errors or to have mutipe TCU units indicate the same nomina temperature. The programmabe User Input can be used to contro a variety of functions, such as auto/manua transfer of the controer, reset aarm output(s), etc. The second anaog input has independent scaing parameters to match the units of other processes or transmitters, or to match the controer s range. FEATURES Programmabe output power imits provide protection for processes where excessive power can cause damage. Automatic sensor probe break detection, for fai-safe operation, causes the controer to defaut to a programmed output power (upscae or downscae burnout). With adjustabe time proportioningcyce time, and programmabe DC inear output, the controer can satisfy a wide variety of output requirements. Programmabe dampening output hysteresis and output update time parameters can dramaticay reduce actuator activity without degrading contro accuracy. The RS-485 Communication option aows the user to access various controer parameters such as the setpoint, % output power, % proportiona band, etc. The controer may be setup to transmit various parameters at a programmabe automatic print rate. AUTO-TUNE The TCU has an auto-tune feature which, on demand, automaticay determines the PID contro parameters for a particuar therma process. After competion of auto-tune, the PID parameters are automaticay optimized for that process and oaded into nonvoatie memory. The operator may view and modify the parameters as desired. Auto-tune may be invoked either at start-up or at setpoint, depending on the process requirements. An auto-tune programmabe dampening factor produces various eves of process contro and response characteristics. OPTIONS HEATING AND COOLING CONTROL The TCU has dua outputs for providing heating and cooing to those processes that require them. Many extruder appications require both heating and cooing to maintain accurate extruder barre and die temperatures. The TCU is easiy configured for these appications. Cooing Configuration Parameters CYC - Enter cooing time proportioning cyce time GAN - Enter cooing reative gain db- - Enter heat/coo deadband or overap 4

5 HEATER CURRENT MONITOR The Heater Current Monitor serves as a heater eement fai sentry, so operators can take corrective action before significant process errors occur in the event of a faiure. The actua heater current can be viewed in the secondary dispay and/or a heater break aarm output can be programmed. Heater Current Monitor Configuration Parameters HCUR - Enter fu scae current of current transformer ACt, ACt - Program aarm(s) as heater break aarm MOTORIZED VALVE POSITIONER Cascade contro aows the process to be divided into two contro oops: the primary contro oop and the secondary contro oop. The secondary oop receives it s setpoint from the primary oop to contro an intermediate variabe (steam pressure). The contro eve of the intermediate variabe is the input to the primary process. The primary oop (temperature) controer maintains oop reguation by manipuating the setpoint of the secondary controer. The setpoint of the secondary controer, in turn, changes the intermediate variabe. The secondary oop can react faster to disturbances of the intermediate variabe, thereby minimizing the effects to the primary contro oop. Contro oops cascaded in such a manner provide greater contro quaity than woud be possibe with singe oop contro. A singe TCU can accompish two-process cascade contro. Interna Cascade Configuration Parameters OPer - Seect cascade mode root - Seect second input square root inearization dpt - Seect second input decima point dsp - Enter scaing units of second input InP - Enter scaing units of second input dsp - Enter scaing units of second input InP - Enter scaing units of second input Opd - Output dampening of secondary Interna Cascade Operationa Parameters SP- - View secondary setpoint vaue Pb- - Enter secondary proportiona band It- - Enter secondary integra time dt- - Enter secondary derivative time EXTERNAL CASCADE The motorized vave positioner contros the position of a vave directy, by use of open and cose contro outputs. The sidewire feedback signas of the vave may optionay be connected to the controer. Aternativey, the controer may be configured for inear input vave contro using the 4 to 0 ma DC output. Motorized Vave Positioner Configuration Parameters Position mode: VPS - Enter or measure vave cosed position VPS - Enter or measure vave open position Vudt - Enter Vave update time VPdb - Enter vave contro deadband VFAL - Enter vave fai detect time Act - Program aarm as vave fai output Veocity mode: Vudt - Enter Vave update time VOPt - Enter vave open time VCLt Vont INTERNAL CASCADE - Enter vave cose time - Enter vave contro deadband (minimum on time) Simiar to interna cascade contro, externa cascade contro differs by the empoyment of two controers, one of which is equipped with a second anaog input configured as a remote setpoint. A PCU contros the secondary oop, whie a TCU contros the primary oop. Externa Cascade Configuration Parameters OPer - Seect ratio mode root - Seect second input square root inearization dpt - Seect second input decima point dsp - Enter scaing units of second input InP - Enter scaing units of second input dsp - Enter scaing units of second input InP - Enter scaing units of second input SPtr - Loca/Remote seect options Externa Cascade Operationa Parameters rtio - Remote setpoint ratio bias - Remote setpoint bias 5

6 SETPOINT MASTER CONTROL Setpoint Master Contro aows automatic setpoint changes to save controer units (up to 50 units tota) from a master TCU controer. The inear DC output of the master is ooped with the second anaog input of the save TCU controers. Each save unit can have unique remote setpoint ratio and bias vaues. Setpoint Save Configuration Parameters OPer - Seect remote setpoint mode root - Seect second input square root Linearization dpt - Seect second input decima point dsp - Enter scaing units of second input InP - Enter scaing units of second input dsp - Enter scaing units of second input InP - Enter scaing units of second input SPLO - Limit range of remote setpoint SPHI SPrP - Limit rate of change of remote setpoint Setpoint Save Operationa Parameters rtio - Second input ratio bias - Second input bias CONTROLLER PROGRAMMING The TCU has been designed to reduce the operator interaction with the controer whie sti maintaining a high degree of contro accuracy and user fexibiity. Front Pane Program Disabe aows a of the controer s set-ups to be ocked-out from further operator intervention after the initia parameter setup. The programming of the controer is divided into four sections: Unprotected Parameter Mode Configuration Parameter Mode Protected Parameter Mode Hidden Function Mode These four programming modes aow the controer to adapt to any required user-interface eve. UNPROTECTED PARAMETER MODE * The unprotected parameter mode is accessibe when program disabe is inactive or when the proper access code number from the protected mode is entered.the configuration parameter modes can be accessed ony from this mode. SP - Enter Setpoint OP - Enter output power ProP - Enter proportina band Intt - Enter integra time dert - Enter derivative time rtio - Enter Remote Setpoint ratio vaue bias - Enter Remote Setpoint bias vaue SP- - View interna cascade secondary setpoint demand Pb- - Enter interna cascade, secondary proportiona band It- - Enter interna cascade, secondary integra * dt- time - Enter interna cascade, secondary derivative time AL- - Enter vaue for aarm # AL- - Enter vaue for aarm # CNFP - Seect basic configuration mode End - Return to norma dispay mode These parameters may not appear due to option configuration or other programming. CONFIGURATION PARAMETER MODE The configuration parameter mode aows the operator to set-up the basic requirements of the controer. It is divided into sections which group together reated programming steps, such as inputs, outputs, aarms, etc. Upon competion of each section, the program returns to the configuration seection stage aowing the user to return to the norma dispay mode. Configuration, Inputs TYPE - Seect input probe type SCAL - Seect temperature scae dcpt - Seect temperature resoution FLtr - Seect eve of input fitering SPAN - Enter input correction span (sope) SHFt - Enter input correction shift (offset) SPLO - Enter setpoint ower imit SPHI - Enter setpoint higher imit SPrP - Enter setpoint ramp rate InPt - Seect user input function * HCUr - Enter fu scae heater current * Configuration, Outputs CYCt - Enter time proportioning cyce time OPAC - Seect contro action OPLO - Enter output power ow imit OPHI - Enter output power high imit OPFL - Enter probe fai power preset OPdP - Enter output contro dampening CHYS - Enter ON/OFF contro hysteresis tcod - Seect auto-tuning dampening ANAS - Seect inear DC output assignment * ANLO - Enter inear DC output ow scaing vaue * ANHI - Enter inear DC output high scaing vaue * ANdb - Enter inear DC output contro deadband * ANUt - Enter inear DC output update time * Configuration 3, Parameter ock-outs SP - Seect degree of setpoint access OP - Seect degree of power access dev - Enabe deviation dispay * IN- - Enabe second input dispay * HCur - Enabe heater current dispay UdSP - Enabe temperature scae dispay CodE - Enter parameter access code PId - Seect degree of PID access PID - Seect degree of secondary PID access * rtbs - Seect degree of ratio/bias access * AL - Seect degree of aarm access * ALrS - Enabe aarm reset access * SPSL - Enabe oca/remote setpoint seection * trnf - Enabe auto/manua mode seection tune - Enabe auto-tune invocation Configuration 4, Aarms * Act - Seect operation mode of aarm # rst - Seect reset mode of aarm # Stb - Enabe activation deay of aarm # AL- - Enter vaue for aarm # Act - Seect operation mode of aarm # rst - Seect reset mode of aarm # Stb - Enabe activation deay of aarm # AL- - Enter vaue for aarm # AHYS - Enter hysteresis vaue for both aarms 6

7 Configuration 5, Cooing * CYC - Enter cooing time proportioning cyce time GAN - Enter cooing reative gain db- - Enter heat/coo deadband or overap Configuration 6, Seria Communications * baud - Seect baud rate PArb - Seect parity bit Addr - Enter unit address number Abrv - Seect abbreviated or fu mnemonic transmissions PrAt - Enter automatic print rate PoPt - Seect parameters to be incuded in print-out Configuration 7, Second Input * OPer - Seect remote setpoint or interna cascade mode root - Seect second input square root inearization dpt - Seect second input decima point dsp - Enter scaing parameters of second input InP - Enter scaing parameters of second input dsp - Enter scaing parameters of second input InP - Enter scaing parameters of second input SPtr - Enter oca/remote seect options OPd - Enter Secondary output contro dampening Configuration 8, Motorized Vave Positioner * Position mode: VPSI - Enter or measure vave cosed position VPS - Enter or measure vave open position VUDt - Enter vave update time VPdb - Enter vave contro deadband VFAL - Enter vave fai detect time Veocity mode: VUDt - Enter vave update time VOPt - Enter vave open time VCLt Vont - Enter vave cose time - Enter vave contro deadband (minimum on time) ACCESSORY - EXTERNAL SSR POWER UNIT The externa SSR Power Unit is used with the Logic/SSR Drive Modue (OMD00003) to switch oads up to amps, 5 o C ambient. The unit is operated by appying a ow eve DC contro signa to the isoated input. The unit features zero cross detection circuits which reduces radiated RFI when switching oad currents. With no contacts to wear out, the SSR Power Unit provides virtuay imitess operationa ife. The unit is suppied with an integra heat sink for immediate instaation. HIDDEN FUNCTION MODE * The hidden function mode is accessibe from the norma operating mode. The four functions in this mode may be ocked-out individuay in configuration 3 parameter ock-out section. SPSL - Seect Loca/Remote Setpoint trnf - Transfer between automatic (PID) contro and manua contro tune - Invoke/cance PID Auto-tune ALrS - Reset atched aarms PROTECTED PARAMETERS MODE * The protected parameters mode is enabed when program disabe is active. This mode prevents access to the configuration modes without the proper access code number. Ony the parameters that are seected in the configuration 3 parameter ock-out section can be accessed. ProP - Enter Proportiona band Intt - Enter integra time dert - Enter derivative time rtio - Enter remote setpoint ratio vaue bias - Enter remote setpoint bias vaue SP- - Enter interna cascade, secondary setpoint Pb- - Enter interna cascade, secondary proportiona band It- - Enter interna cascade, secondary integra time dt- - Enter interna cascade, secondary derivative time * AL- - Enter vaue for aarm # AL- - Enter vaue for aarm # Code - Enter access vaue to unprotected parameters & configuration parameters These parameters may not appear due to option configuration or other programming. 7

8 ACCESSORY - CURRENT TRANSFORMER The externa Current Transformer is used when specifying TCU s equipped with the Heater Current Monitor. The primary current rating is 50 amperes. MODULES TYPICAL CONNECTIONS Reay: Type: Form-C (Form-A with some modes. See ordering information.) Rating: 5 0/40 VAC or 8 VDC (resistive oad), /8 0 VAC (inductive). Life Expectancy: 00,000 cyces at maximum oad rating. (Decreasing oad and/or increasing cyce time, increases ife expectancy). Logic/SSR Drive: Can drive mutipe SSR Power Units. Type: Non-isoated switched DC, VDC typica Drive: 45 ma maximum. Triac: Type: Isoated, Zero Crossing Detection Rating: Votage: 0/40 VAC Max. Load Current: 35 o C o C Min. Load Current: 0 ma Off State Leakage Current: 7 ma 60 Hz Operating Frequency: 0 to 500 Hz Protection: Interna Transient Snubber, Fused APPLICATION Severa TCU controers are empoyed to contro the temperature of a pastics extruder. Each TCU contros a heating eement and a cooing water soenoid to maintain each extruder zone at a desired temperature. The heater current monitor of the TCU is used for eary detection of heater eement faiure. The inear DC output is used to retransmit the process temperature to a contro computer for data ogging purposes. 8

9 ORDERING INFORMATION A prices are subject to change without notice. MODELS WITHOUT SECOND INPUT OPTIONS NEMA 4X/P65 BEZEL 4 to 0 ma 0 to 0 VDC ALARM S COOLING RS485 COM PART NUMBER 5/30 VAC TCU00000 TCU0000 TCU0000 TCU00004 TCU00005 TCU0000 TCU000 TCU000 TCU0004 TCU0005 TCU0000 TCU000 TCU000 TCU0004 TCU0005 TCU0000 TCU000 TCU000 TCU0004 TCU0005 TCU000 TCU00 TCU00 TCU004 TCU005 TCU000 TCU00 TCU00 TCU004 TCU005 These modes have dua aarm outputs, or singe aarm with cooing outputs, with shared common terminas (Form A Type). As a resut, these outputs shoud be fitted with the same type of output modue. The main output (OP) may be fitted with any type of output modue. HEATER CURRENT MONITOR MODELS (HCM) NEMA 4X/IP65 BEZEL 4 to 0 ma 0 to 0 VDC ALARM S COOLING RS485 COM PART NUMBER TCU0004 TCU0005 TCU008 TCU009 TCU008 TCU009 TCU004 TCU005 TCU08 TCU09 TCU08 TCU09 These modes have dua aarm outputs, or singe aarm with cooing outputs, with shared common terminas (Form A Type). As a resut, these outputs shoud be fitted with the same type of output modue. The main output (OP) may be fitted with any type of output modue. 9

10 ORDERING INFORMATION (Cont d) A prices are subject to change without notice. SECOND INPUT MODELS (ANA) NEMA 4X/IP65 BEZEL 4 to 0 ma 0 to 0 VDC ALARM COOLING RS485 COM PART NUMBER TCU0004 TCU008 TCU008 TCU004 TCU08 TCU08 These modes have dua aarm outputs, or singe aarm with cooing outputs, with shared common terminas (Form A Type). As a resut, these outputs shoud be fitted with the same type of output modue. The main output (OP) may be fitted with any type of output modue. MOTORIZED VALVE POSITIONER MODELS (MVP) 4 to 0 ma NEMA 4X/IP65 BEZEL 04 to to 0 0 VDC ma 0 ALARM to 0 VDC COOLING ALARM S COOLING RS485 COM PART NUMBER TCU00307 TCU0306 TCU0306 TCU0307 TCU306 TCU306 DESCRIPTION Reay Modue Triac Modue Logic/SSR Drive Modue SSR Power Unit 50:0. Ampere Current Transformer 40:0. Ampere Current Transformer PART NUMBER OMD00000 OMD0000 OMD00003 RLY50000 CT00500 CT00400 Note: Output Modues are T suppied with the controer. When specifying the controer, be sure to purchase the appropriate output modue for the Main Contro Output and if necessary, the aarm output(s), the cooing output, and vave positioner outputs. The controer can be fitted with any combination of output modues. The Logic/SSR Drive Modue is a switched DC source, intended to drive the DC input of an SSR power unit. It shoud never be connected to ine votage. A modues are packaged separatey and must be instaed by the user 0