red lion TCU Product manual

Add to my manuals
10 Pages

advertisement

red lion TCU Product manual | Manualzz

Bulletin No. TCU-H

Drawing No. LP0314

Released 08/13

MODEL TCU - TEMPERATURE CONTROL UNIT

C

R

UL

US LISTED

IND. CONT. EQ.

51EB

100 msec SAMPLING PERIOD WITH 0.15% ACCURACY

ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS

DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF

TEMPERATURE AND SETPOINT, SECOND ANALOG INPUT OR

HEATER CURRENT

ACCEPTS 10 DIFFERENT TYPES OF SENSOR INPUTS

(Thermocouple or RTD)

SELF-DIAGNOSTICS

FULL PID CONTROL WITH REDUCED OVERSHOOT

OPTIONAL RS485 SERIAL COMMUNICATIONS INTERFACE

OPTIONAL DUAL ALARM OUTPUTS (USES OUTPUT MODULES)

OPTIONAL COOLING OUTPUT (USES OUTPUT MODULE)

OPTIONAL LINEAR 4 to 20 mA or 0 to 10 VDC OUTPUT FOR

CONTROL OR TEMPERATURE RE-TRANSMISSION

OPTIONAL HEATER CURRENT MONITOR AND BREAK ALARM

OPTIONAL MOTORIZED VALVE POSITION CONTROL AND

VALVE FAIL ALARM

OPTIONAL SECOND ANALOG INPUT FOR REMOTE SETPOINT

AND CASCADE CONTROL

OPTIONAL TYPE 4X/IP65 SEALED FRONT BEZEL

STATUS INDICATORS FOR OUTPUTS AND CONTROL MODES

PROGRAMMABLE USER INPUT (DIGITAL) FOR ADDED

FLEXIBILITY

SENSOR ERROR COMPENSATION (Slope 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 OUTPUT

MODULES (Relay, Logic/SSR Drive and Triac)

DESCRIPTION

The TCU Controller accepts signals from a variety of temperature sensors

(thermocouple or RTD elements), precisely displays the process temperature,

and provides an accurate output control signal (time proportional or linear) to maintain a process at the desired control point. A comprehensive set of easy to use steps allows the controller to solve various application requirements.

The controller can operate in the PID control mode for both heating and cooling, with on-demand auto-tune, which will establish the tuning constants.

The PID tuning constants may be fine-tuned by the operator at any time and then locked out from further modification. The controller employs a unique overshoot suppression feature, which allows the quickest response without excessive overshoot. The unit can be transferred to operate in the manual mode, providing the operator with direct control of the output. The controller may also be programmed to operate in the ON/OFF control mode with adjustable hysteresis.

DIMENSIONS In inches (mm)

Dual 4-digit displays allow viewing of the process temperature and setpoint simultaneously. Front panel indicators inform the operator of the controller and output status. Replaceable and interchangeable output modules (relay, SSR

drive, or triac) can be installed for the main control output, alarm output(s) and

cooling output.

Optional dual alarms can be configured to activate according to a variety of actions (Absolute HI or LO, Deviation HI or LO, Band IN or OUT, Heater

Break and Valve Fail Detect) with adjustable hysteresis. A standby feature suppresses the output during power-up until the temperature stabilizes outside the alarm region. An optional secondary output is available (for processes that

require cooling) which provides increased control accuracy and response.

Note: Recommended minimum clearance (behind the panel) for mounting clip installation is 5.5" (140) H x 2.1" (53.4) W.

5.41

(137.4)

PANEL CUT-OUT

%PW

DEV

MAN

OP1

AL1

AL2

DSP

PAR

3.80

(96.5)

3.60

(91.4)

1.77

+.02

-.00

(45.0 )

3.62

+.03

-.00

(92.0 )

1.95

(49.5)

.40

(10.2)

5.29

(134.4)

1.75

(44.4)

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

DESCRIPTION (Cont’d)

OPTIONS

A linear 4 to 20 mA or 0 to 10 VDC output signal is available to interface with actuators, chart recorders, indicators, or other controllers. The output signal can be digitally scaled and selected to transmit one of the following: % output power, process temperature value, process temperature value deviation or setpoint value. For Linear DC control applications, the adjustable output demand dampening, output deadband and output update time parameters expand the versatility of the TCU with final control devices.

The optional Heater Current Monitor serves as a digital ammeter for heater current monitoring. Current transformer accessory (CT005001), is required. 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 main output (OP1) is “on” and the heater current is below the heater current alarm value, indicating an aged or failed heater.

2) Output (OP1) is “off” and the heater current is more than 10% of the alarm value, indicating a shorted heater control device or other problem.

The optional Motorized Valve Positioner directly controls the position of a valve by the use of twin outputs (open and close) to control the direction of motor rotation. The motor position defines the opening position of the valve.

Two control modes are possible: position control, which makes use of the slidewire feedback signal supplied with the positioner and velocity control, in which no slidewire feedback signal is used. Parameters are provided to adjust the operation of the valve. These include:

Valve activity hysteresis

Valve update time

Variable control dampening

Slidewire signal fail action

Adjustable valve position limits.

The valve positioner TCU achieves tight process control, yet minimizes unnecessary valve activity. An alarm event output or display alarm can be programmed under loss of slidewire feedback or under valve fail detection.

The optional Second Analog Input (0-20 mA DC) can be configured as a remote setpoint signal or as a secondary process signal. Configuration of the second analog input as a remote setpoint signal allows ratio control, master setpoint/multiple slave operation, and the ability to cascade the TCU with another controller (external cascade). Configuration of the second input as a secondary process signal allows operation as a two-process cascade controller within a single unit (internal cascade). In either control mode, parameters are provided to scale, configure, communicate and monitor the activity of both analog inputs. A square law linearizer function can be used to linearize signals derived from flow transmitters.

The optional RS485 multidrop serial communication interface provides twoway communication between a TCU unit and other compatible equipment such as a printer, a programmable controller, or a host computer. In multipoint applications the address number of each unit on the line can be programmed from

0-99. Up to thirty-two units can be installed on a single pair of wires. The

Setpoint value, % Output Power, Setpoint Ramp Rate, etc. can be interrogated or changed by sending the proper command code via serial communications. Alarm output(s) may also be reset via the serial communications interface option.

An optional Type 4X/IP65 rated bezel is available for wash down and/or dirty environments, when properly installed. Modern surface-mount technology, extensive testing, plus high immunity to noise interference makes the controller extremely reliable in industrial environments.

SAFETY SUMMARY

All safety related regulations, local codes and instructions that appear in the manual or on equipment must be observed to ensure personal 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 directly command motors, valves, or other actuators not equipped with safeguards. To do so, can be potentially harmful to persons or equipment in the event of a fault to the unit. An independent and redundant temperature limit indicator with alarm outputs is strongly recommended. The indicators should have input sensors and AC power feeds independent from other equipment.

SPECIFICATIONS

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” - 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 only)

“....”

“-...”

- Appears when display values exceed + display range.

- Appears when display values exceed - display range.

“SLid” - Appears when loss of slidewire signal is detected.

“VALV” - Appears when valve actuator error is detected.

2. POWER: Switch selectable for 115/230 VAC (+10%, -15%) no observable line variation effect, 48 to 62 Hz, 10 VA

3. ANNUNCIATORS:

LED Backlight Status Indicators (Model dependent):

%PW

DEV

OP1

AL1

AL2

OP2

OPN

CLS

CUR

SEC

MAN

REM

- Lower auxiliary display shows power output in (%).

- Lower auxiliary display shows deviation (error)

from temperature setpoint.

- Main control output is active.

- Alarm #1 is active.

- Alarm #2 is active (for Dual Alarm Option).

- Cooling output is active (for Cooling Option).

- Valve positioner OPEN output is active

(for Valve Positioner option).

- Valve positioner CLOSE output is active

(for Valve Positioner option).

- Lower auxiliary display shows heater current

(for Heater Current Monitor option).

- Lower auxiliary display shows second analog input

(For Second Analog Input option).

- Flashing: Controller is in manual mode.

- ON: controller is in remote setpoint mode

(Second Analog Input option).

- OFF: controller is in local setpoint mode

(Second Analog Input option).

- Flashing: controller is in Manual control mode

(Second Analog Input optional).

4. CONTROLS: Four front panel push buttons for modifying and setup of controller functions and one external input for parameter lockout or other functions.

5. MAIN SENSOR INPUT:

Sample Period: 100 msec

Response Time: 300 msec (to within 99% of final value w/step input;

typically, response is limited to response time of probe)

Failed Sensor Response:

Main Control Output(s): Programmable preset output

Display: “OPEN”

Alarms: Upscale drive

DC Linear: Programmable preset output

Normal Mode Rejection: 40 dB @ 50/60 Hz (improves with increased

digital filtering.

Common Mode Rejection: 100 dB, DC to 60 Hz

Protection: Input overload 120 VAC for 30 seconds.

6. THERMOCOUPLE:

Types: T, E, J, K, R, S, B, N, Linear mV

Input Impedance: 20 M

Ω all types

Lead resistance effect: 20 µV/350

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, 100

Ω platinum, alpha = 0.00385 (DIN 43760), alpha = 0.003916

Excitation: 0.175 mA

Resolution: 1 or 0.1 degree

Lead Resistance: 7

Ω maximum

8. RANGE AND ACCURACY:

Errors include NIST conformity and A/D conversion errors at 23°C after 20 min. warm-up. Thermocouple errors include cold junction effect. Errors are expressed as ±percent of reading and ± 3

/

4

LSD unless otherwise noted.

TC TYPE RANGE ACCURACY

WIRE COLOR

(ANSI)

T

E

J

K

R

S

B

N mV

RTD

(385)

RTD

(392)

OHMS

-200 to +400°C

-328 to +752°F

-200 to 750°C

-328 to +1382°F

-200 to +760°C

-328 to +1400°F

-200 to +1250°C

-328 to +2282°F

0 to +1768°C

+32 to +3214°F

0 to +1768°C

+32 to +3214°F

+200 to +1820°C

+300 to +3308°F

-200 to +1300°C

-328 to +2372°F

-5.00 to 56.00

-200 to +600°C

-328 to +1100°F

-160 to +600°C

-256 to +1100°F

1.0 to 320.0

0.20% + 1.5°C

0.20% + 2.7°F

0.20% + 1.5°C

0.20% + 2.7°F

0.15% + 1.5°C

0.15% + 2.7°F

0.20% + 1.5°C

0.20% + 2.7°F

0.15% + 2.5°C

0.15% + 4.5°F

0.15% + 2.5°C

0.15% + 4.5°F

0.15% + 2.5°C

0.15% + 4.5°F

0.20% + 1.5°C

0.20% + 2.5°F

0.15% + 1 LSD

0.10% + 0.5°C

0.10% + 0.9°F

0.10% + 0.5°C

0.10% + 0.9°F

0.15% + 1 LSD blue violet white yellow black black grey orange

__

__

__

__

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

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 max. load rating. (Decreasing load

and/or increasing cycle time, increases life expectancy).

Logic/SSR Drive: Can drive multiple SSR Power Units.

Type: Non-isolated switched DC, 12 VDC typical

Drive: 45 mA max.

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 max.

Offstate Leakage Current: 7mA max. @ 60 Hz

Operating Frequency: 20 to 400 Hz

Protection: Internal Transient Snubber, Fused

10. MAIN CONTROL OUTPUT (Heating or Cooling):

Control: PID or ON/OFF

Output: Time proportioning or linear DC

Hardware: Plug-in, replaceable output modules

Cycle time: Programmable

Auto-tune: When selected, sets proportional band, integral time, and derivative time values.

Probe Break Action: Programmable

11 . COOLING OUTPUT (Optional):

Control: PID or ON/OFF

Output: Time proportioning or linear DC

Hardware: Plug-in, replaceable output modules

Cycle time: Programmable

Proportional Gain Adjust: Programmable

Heat/Cool Deadband Overlap: Programmable

12. LINEAR DC OUTPUT (Optional): With digital scale and offset, programmable deadband and update time.

4 to 20 mA:

Resolution: 1 part in 3500 typ.

Accuracy: ±(0.1% of reading + 25 µA)

Compliance: 10 V (500

max. loop impedance)

0 to 10 VDC:

Resolution: 1 part in 3500 typ.

Accuracy: ±(0.1% of reading + 35 mV)

Min. Load Resistance: 10 K

(1 mA max.)

Source: % output power, setpoint, deviation, or temperature

(Available for heat or cool, but not both.)

13. HEATER CURRENT MONITOR (Optional):

Type: Single phase, full wave monitoring of load currents controlled by main output (OP1)

Input: 100 mA AC output from current transformer RLC part number

CT005001 or any current transformer with 100 mA AC output

Display Scale Range: 1.0 to 999.9 amperes or 100.0%

Input resistance: 5

Accuracy: 1% of full scale ±1 LSD (10 to 100% of range)

Frequency: 50 to 400 Hz

Alarm mode: Dual acting; heater element fail detect and control device fail detect

Overload: 200 mA (steady state)

Min. output “on” time for Heater break alarm detect: 400 msec

14. MOTORIZED VALVE POSITIONER (Optional):

Two Outputs: Valve open and valve close or Linear DC (optional)

Hardware: Plug-in, replaceable output modules

Three Inputs: Slidewire feedback, signal fail detect (Isolated from main

input)

Slidewire Resistance: 100 to 100 K

Slidewire Exciting Voltage: 0.9 VDC

Slidewire Fail Action: programmable

Control Mode: Position mode (with slidewire) and velocity mode (w/o

slidewire).

Control Deadband: 1% to 25.0% (position mode)

0.1 to 25.0 seconds (velocity mode)

Update Time: 1 to 250 seconds

Motor Time (open, close): 1 to 9999 seconds

Position Limits: Adjustable 0.0 to 100.0% of valve stroke

Valve Fail Time: Off to 9999 seconds

Alarm mode: Dual acting; loss of slidewire feedback signal and valve fail detection

15. SECOND ANALOG INPUT:

Range: 0 to 20 mA (Isolated from main input)

Overload: 100 mA (steady state)

Input Resistance: 10

Voltage Drop (@ 20 mA): 0.2 V

Accuracy: 0.15% of reading ±10 µA ±1 LSD

Scale Range: -999 to 9999

16. SERIAL COMMUNICATION:

Type: RS485 Multi-point, Balanced Interface

Communication Format:

Baud Rate: Programmable from 300 to 9600

Parity: Programmable for odd, even, or no parity

Frame: 1 start bit, 7 data bits, 1 or no parity bit, 1 stop bit

Unit Address: Programmable from 0 to 99, max. of 32 units per line

Transmit Delay: 100 msec min., 200 msec max.

RS485 Common: Isolated from signal input common

Auto Print Time: Off to 9999 seconds between print-outs

17. USER INPUT (Optional): Internally pulled up to +5 VDC.

V

IN MAX

= 5.25 VDC, V

IL

= 0.85 V

MAX

; V

IH

= 3.0 V

MIN

,

Available on all second input (HCM, MVP & ANA) models, and on models with RS485.

Response Time: 100 msec max.

Functions: Program Lock

Integral Action Lock

Auto/Manual Mode Select

Setpoint Ramp Select

Reset Alarms

Print Request

Local/Remote Setpoint Select

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. ENVIRONMENTAL CONDITIONS:

Operating Temperature Range: 0 to 50°C

Storage Temperature Range: -40 to 80°C

Vibration to IEC 68-2-6: Operational 5-150 Hz, 1 g

Shock to IEC 68-2-27: Operational 5 g

Span Drift (maximum): 100 ppm/°C, main input; 150 ppm/°C, second input

Operating and Storage Humidity:

85% max. (non-condensing) from 0 to 50°C

Zero Drift (maximum): 1 µV/°C, main input;2 µA/°C, second input

Altitude: Up to 2000 meters

20. ISOLATION BREAKDOWN RATINGS:

All inputs and outputs with respect to AC line: 2300 V

Analog Outputs, Second Analog Input, Heater Current Input or

Slidewire Input with respect to main input: 500 V

21. CERTIFICATIONS AND COMPLIANCES:

CE Approved

EN 61326-1 Immunity to Industrial Locations

Emission CISPR 11 Class A

EN 61010-1

RoHS Compliant

UL Recognized Component: File #E156876

UL Listed: File #E137808

Type 2 Enclosure rating (Face only) for TCU0

Type 4X/IP65 Enclosure rating (Face only) for TCU1

Refer to EMC Installation Guidelines section of the manual for additional information.

22. CONNECTION: Jaw-type terminal block

Wire Range: 12-30 AWG copper wire

Torque: 5-7 inch-lbs (56-79 N-cm)

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

23. CONSTRUCTION:

Front Panel: Flame and scratch resistant tinted plastic

Case: High impact black plastic. (Mounting collar included)

Type 4X/IP65 model only: Sealed bezel utilizing two captive mounting screws (panel gasket included). This unit is rated for Type 4X/IP65 indoor use. Installation Category II, Pollution Degree 2

24. WEIGHT: 1.3 lbs (0.6 kgs)

ACCESSORIES:

External SSR Power Unit:

Switched Voltage Range: 50 to 280 VAC (Nominal: 240 VAC)

Load Current: 45 Amps @ 25°C ambient temperature

35 Amps @ 50°C ambient temperature

On State Input: 3 to 32 VDC @ 1500

Ω impedance. (isolated)

(Use Logic/SSR drive output module.)

Off State Input: 0.0 to 1.0 VDC

Size: 5.5" (14 cm) L x 4.75" (12 cm) W x 2.62" (6.6 cm) H

Current Transformer:

Current Ratio: 50:0.1 (Amperes)

Accuracy: ±5.0%

Operating Frequency: 50 to 400 Hz

Insulation Class: 0.6 Kv BIL 10 Kv full wave

Terminals: Brass studs No. 8-36, (flat washer, washer, nut)

Weight: 8.0 oz (226 g)

Approvals: UL recognized component

SETPOINT FEATURES

The controller setpoint can be protected from out of range values by programming the setpoint range limit values. Additionally, safeguards from inadvertent data entry can be programmed.

The setpoint ramp feature ramps the setpoint value at start-up or any time a setpoint change is made, at a user programmable rate. This feature reduces thermal shock to the process and helps to minimize temperature overshoot.The setpoint may also be transmitted by the optional linear DC output for slave control loops.

The second analog input may be configured as a remote setpoint. As such, the controller is easily switched from local/remote setpoint operation via the front panel or user input. Ratio and bias parameters provide on-line scaling of the remote setpoint. Absolute limit values and maximum rate of change of the remote setpoint further enhance controller flexibility.

INPUT FEATURES

A programmable input filter can be used to stabilize readings from a process with varying or oscillating temperature characteristics, helping to provide better temperature control. A programmable temperature shift and slope function can be used to compensate for probe errors or to have multiple TCU units indicate the same nominal temperature.

The programmable User Input can be used to control a variety of functions, such as auto/manual transfer of the controller, reset alarm output(s), etc.

The second analog input has independent scaling parameters to match the units of other processes or transmitters, or to match the controller’s range.

BASIC OPERATION

The TCU controls a process temperature by measuring the temperature via an input probe, then calculating a control output power value by use of a modified

PID control algorithm. The unit controls the system with the new output power value to keep the process temperature at setpoint. The PID control algorithm incorporates features which provide for high control accuracy and low temperature overshoot from process disturbances.

FRONT PANEL FEATURES

In the normal operating mode, the unit will display the process temperature in the upper display. One of six other parameters can be viewed in the lower display:

- Setpoint

- % Power Output

- Temperature Deviation

- Heater Current

- Second Input Process Value

- Temperature Symbol (F or C)

The six parameters can be scrolled through by pressing the DSP button. If enabled, the control setpoint or power output (manual mode only) can be directly modified in this mode.

In the normal operating mode, parameters are selected 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 immediately returns the controller to the normal operating mode when making a parameter change. The controller’s configuration and parameter settings are stored in an internal E

2

PROM device.

OUTPUT FEATURES

Programmable output power limits provide protection for processes where excessive power can cause damage. Automatic sensor probe break detection, for fail-safe operation, causes the controller to default to a programmed output power (upscale or downscale burnout). With adjustable time proportioningcycle time, and programmable DC linear output, the controller can satisfy a wide variety of output requirements.

Programmable dampening output hysteresis and output update time parameters can dramatically reduce actuator activity without degrading control accuracy.

The RS485 Communication option allows the user to access various controller parameters such as the setpoint, % output power, % proportional band, etc. The controller may be setup to transmit various parameters at a programmable automatic print rate.

AUTO-TUNE

The TCU has an auto-tune feature which, on demand, automatically determines the PID control parameters for a particular thermal process. After completion of auto-tune, the PID parameters are automatically optimized for that process and loaded into nonvolatile 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 programmable dampening factor produces various levels of process control and response characteristics.

HARDWARE FEATURES

The fast 100 msec input sampling rate provides quick controller response to a process disturbance, thus providing excellent temperature control. Measurement accuracy of 0.15% or better, provides closer process control conforming to the desired control setpoint value. One model accepts a variety of both thermocouple or RTD temperature probes. The AC input power is switch selectable, allowing the unit to operate from either 115 VAC or 230 VAC. Since the controller is serviceable from the front of the panel, the output modules may be easily changed or replaced without disturbing the wiring behind the panel. No re-programming is required when changing or replacing modules.

The optional Type 4X/IP65 rated model utilizes two bezel securing screws and a neoprene gasket to guarantee a water tight seal, when properly installed.

The standard model simply requires pressing a latch to remove the unit.

Low-drift, highly stable circuitry ensures years of reliable and accurate temperature control. The recommended two-year re-calibration interval is easily accomplished via the programming menu.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

OPTIONS

HEATING AND COOLING CONTROL

MAIN OUTPUT

(OP1)

HEATING

CONTROL

PROCESS

INTERNAL CASCADE

STEAM

FLOW

%PW

DEV

MAN

OP1

AL1

OP2

DSP

PAR

SECOND OUTPUT

(OP2)

COOLING

CONTROL

MAIN INPUT

TEMPERATURE

%PW

SEC

REM

OP1

AL1

AL2

DSP

PAR

LINEAR DC OUTPUT

SECOND INPUT

STEAM PRESSURE

(SECONDARY VARIABLE)

MAIN INPUT

TEMPERATURE

(PRIMARY VARIABLE)

PROCESS

The TCU has dual outputs for providing heating and cooling to those processes that require them. Many extruder applications require both heating and cooling to maintain accurate extruder barrel and die temperatures. The TCU is easily configured for these applications.

Cooling Configuration Parameters

“CYC2” - Enter cooling time proportioning cycle time

“GAN2” - Enter cooling relative gain

“db-2” - Enter heat/cool deadband or overlap

HEATER CURRENT MONITOR

%PW

CUR

MAN

OP1

AL1

AL2

DSP

AL1 OUTPUT

MAIN

OUTPUT

(OP1)

HEATER

CURRENT

HEATER BREAK

ALARM

POWER

CONTROL

DEVICE

CURRENT TRANSFORMER

HEATING

ELEMENT

PROCESS

PAR

MAIN INPUT

TEMPERATURE

The Heater Current Monitor serves as a heater element fail sentry, so operators can take corrective action before significant process errors occur in the event of a failure. The actual heater current can be viewed in the secondary display and/or a heater break alarm output can be programmed.

Heater Current Monitor Configuration Parameters

“HCur” - Enter full scale current of current transformer

ACt1”, “ACt2” - Program alarm(s) as heater break alarm

MOTORIZED VALVE POSITIONER

AL1 OUTPUT

VALVE FAIL

ALARM

STEAM FLOW

%PW

DEV

MAN

AL1

OPN

CLS

DSP

PAR

VALVE OPEN OUTPUT

VALVE CLOSE OUTPUT

SECOND INPUT

VALVE POSITION

MAIN INPUT

PROCESS

The motorized valve positioner controls the position of a valve directly, by use of “open” and “close” control outputs. The slidewire feedback signals of the valve may optionally be connected to the controller. Alternatively, the controller may be configured for linear input valve control using the 4 to 20 mA DC output.

Motorized Valve Positioner Configuration Parameters

Position mode: “VPS1” - Enter or measure valve closed position

“VPS2” - Enter or measure valve open position

“VUdt”

“VPdb”

- Enter Valve update time

- Enter valve control deadband

“VFAL”

“Act1”

- Enter valve fail detect time

- Program alarm as valve fail output

Velocity mode: “VUdt”

“VOPt”

“VCLt”

“VONt”

- Enter Valve update time

- Enter valve open time

- Enter valve close time

- Enter valve control deadband

(minimum on time)

Cascade control allows the process to be divided into two control loops: the primary control loop and the secondary control loop. The secondary loop receives it’s setpoint from the primary loop to control an intermediate variable

(steam pressure). The control level of the intermediate variable is the input to the primary process. The primary loop (temperature) controller maintains loop regulation by manipulating the setpoint of the secondary controller. The setpoint of the secondary controller, in turn, changes the intermediate variable.

The secondary loop can react faster to disturbances of the intermediate variable, thereby minimizing the effects to the primary control loop. Control loops cascaded in such a manner provide greater control quality than would be possible with single loop control. A single TCU can accomplish two-process cascade control.

Internal Cascade Configuration Parameters

“OPer”

“root”

“dPt2”

“dSP1”

- Select cascade mode

- Select second input square root linearization

- Select second input decimal point

- Enter scaling units of second input

“INP1”

“dSP2”

- Enter scaling units of second input

- Enter scaling units of second input

“INP2” - Enter scaling units of second input

“OPd2” - Output dampening of secondary

Internal Cascade Operational Parameters

“SP-2” - View secondary setpoint value

“Pb-2”

“It-2”

“dt-2”

- Enter secondary proportional band

- Enter secondary integral time

- Enter secondary derivative time

EXTERNAL CASCADE

PRIMARY

CONTROLLER

SECONDARY

CONTROLLER

LINEAR DC

(PRIMARY OUTPUT)

STEAM

SECOND INPUT

REMOTE SETPOINT

%PW

DEV

MAN

OP1

AL1

AL2

DSP

PAR

LINEAR DC

OUTPUT

%PW

SEC

REM

OP1

AL1

AL2

DSP

PAR

MAIN INPUT

STEAM PRESSURE

(SECONDARY VARIABLE)

TCU PCU

PROCESS

MAIN INPUT

PROCESS TEMPERATURE

(PRIMARY VARIABLE)

Similar to internal cascade control, external cascade control differs by the employment of two controllers, one of which is equipped with a second analog input configured as a remote setpoint. A PCU controls the secondary loop, while a TCU controls the primary loop.

External Cascade Configuration Parameters

“OPEr” - Select ratio mode

“root”

“dPt2”

“dSP1”

“INP1”

“dSP2”

“INP2”

“SPtr”

- Select second input square root linearization

- Select second input decimal point

- Enter scaling units of second input

- Enter scaling units of second input

- Enter scaling units of second input

- Enter scaling units of second input

- Local/Remote select options

External Cascade Operational Parameters

“rtio”

“bIAS”

- Remote setpoint ratio

- Remote setpoint bias

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

SETPOINT MASTER CONTROL

Setpoint Master Control allows automatic setpoint changes to slave controller units (up to 50 units total) from a master TCU controller.

The linear DC output of the master is looped with the second analog input of the slave TCU controllers. Each slave unit can have unique remote setpoint ratio and bias values.

Setpoint Slave Configuration Parameters

“OPEr” - Select remote setpoint mode

“root” - Select second input square root

Linearization

“dPt2” - Select second input decimal point

“dSP1” - Enter scaling units of second input

“INP1” - Enter scaling units of second input

“dSP2” - Enter scaling units of second input

“INP2” - Enter scaling units of second input

“SPLO”

“SPHI”

- Limit range of remote setpoint

“SPrP” - Limit rate of change of remote

setpoint

Setpoint Slave Operational Parameters

“rtio” - Second input ratio

“bIAS” - Second input bias

MASTER

UNIT

LINEAR DC OUTPUT SETPOINT RE-TRANSMISSION

SECOND INPUT

REMOTE SETPOINT

SLAVE

UNIT #1

%PW

DEV

MAN AL1

OP1 AL2

DSP

PAR

MAIN

INPUT

PROCESS #1

%PW

SEC

REM

OP1

AL1

AL2

DSP

PAR

MAIN

INPUT

PROCESS #2

CONTROLLER PROGRAMMING

The TCU has been designed to reduce the operator interaction with the controller while still maintaining a high degree of control accuracy and user flexibility. Front Panel Program Disable allows all of the controller’s set-ups to be locked-out from further operator intervention after the initial parameter set-up.

The programming of the controller is divided into four sections:

Unprotected Parameter Mode

Configuration Parameter Mode

Protected Parameter Mode

Hidden Function Mode

These four programming modes allow the controller to adapt to any required user-interface level.

UNPROTECTED PARAMETER MODE

*

The unprotected parameter mode is accessible when program disable is inactive or when the proper access code number from the protected mode is entered.The configuration parameter modes can be accessed only from this mode.

“SP” - Enter Setpoint

“OP” - Enter output power

“ProP” - Enter proportional band

“Intt” - Enter integral time

“dErt” - Enter derivative time

“rtio” - Enter Remote Setpoint ratio value

“bIAS” - Enter Remote Setpoint bias value

“SP-2” - View internal cascade secondary setpoint

demand

“Pb-2” - Enter internal cascade, secondary

proportional band

“It-2” - Enter internal cascade, secondary integral

time

“dt-2” - Enter internal cascade, secondary

derivative time

“AL-1” - Enter value for alarm #1

“AL-2” - Enter value for alarm #2

“CNFP” - Select basic configuration mode

“End” - Return to normal display mode

*

These parameters may not appear due to option configuration or other programming.

CONFIGURATION PARAMETER MODE

The configuration parameter mode allows the operator to set-up the basic requirements of the controller. It is divided into sections which group together related programming steps, such as inputs, outputs, alarms, etc. Upon completion of each section, the program returns to the configuration selection stage allowing the user to return to the normal display mode.

SECOND INPUT

REMOTE SETPOINT

SLAVE

UNIT `N'

(UP TO 50)

%PW REM AL1

SEC OP1 AL2

DSP

PAR

MAIN

INPUT

PROCESS "N"

Configuration 1, Inputs

“tYPE” - Select input probe type

“SCAL” - Select temperature scale

“dCPt” - Select temperature resolution

“FLtr” - Select level of input filtering

“SPAN” - Enter input correction span (slope)

“SHFt” - Enter input correction shift (offset)

“SPLO” - Enter setpoint lower limit

“SPHI” - Enter setpoint higher limit

“SPrP” - Enter setpoint ramp rate

“InPt” - Select user input function *

“HCur” - Enter full scale heater current *

Configuration 2, Outputs

“CYCt” - Enter time proportioning cycle time

“OPAC” - Select control action

“OPLO” - Enter output power low limit

“OPHI” - Enter output power high limit

“OPFL” - Enter probe fail power preset

“OPdP” - Enter output control dampening

“CHYS” - Enter ON/OFF control hysteresis

“tcod” - Select auto-tuning dampening

“ANAS” - Select linear DC output assignment

“ANHI” - Enter linear DC output high scaling value

“ANdb” - Enter linear DC output control deadband

*

*

*

“ANUt” - Enter linear DC output update time *

*

“ANLO” - Enter linear DC output low scaling value

Configuration 3, Parameter lock-outs

“SP” - Select degree of setpoint access

“OP” - Select degree of power access

“dEv” - Enable deviation display *

“IN-2” - Enable second input display *

“HCur” - Enable heater current display

“UdSP” - Enable temperature scale display

“CodE” - Enter parameter access code

“PId” - Select degree of PID access

“PId2” - Select degree of secondary PID access *

“rtbS” - Select degree of ratio/bias access *

“AL” - Select degree of alarm access *

“ALrS” - Enable alarm reset access *

“SPSL” - Enable local/remote setpoint selection *

“trnF” - Enable auto/manual mode selection

“tUNE” - Enable auto-tune invocation

Configuration 4, Alarms

*

“Act1” - Select operation mode of alarm #1

“rSt1” - Select reset mode of alarm #1

“Stb1” - Enable activation delay of alarm #1

“AL-1” - Enter value for alarm #1

“Act2” - Select operation mode of alarm #2

“rSt2” - Select reset mode of alarm #2

“Stb2” - Enable activation delay of alarm #2

“AL-2” - Enter value for alarm #2

“AHYS” - Enter hysteresis value for both alarms

Configuration 5, Cooling

*

“CYC2” - Enter cooling time proportioning cycle time

“GAN2” - Enter cooling relative gain

“db-2” - Enter heat/cool deadband or overlap

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

Configuration 6, Serial Communications

*

“bAUd” - Select baud rate

“PArb” - Select parity bit

“Addr” - Enter unit address number

“Abrv” - Select abbreviated or full mnemonic

transmissions

“PrAt” - Enter automatic print rate

“PoPt” - Select parameters to be included in print-out

Configuration 7, Second Input

*

“OPEr” - Select remote setpoint or internal

cascade mode

“root” - Select second input square root linearization

“dPt2” - Select second input decimal point

“dSP1” - Enter scaling parameters of second input

“INP1” - Enter scaling parameters of second input

“dSP2” - Enter scaling parameters of second input

“INP2” - Enter scaling parameters of second input

“SPtr” - Enter local/remote select options

“OPd2” - Enter Secondary output control dampening

Configuration 8, Motorized Valve Positioner

*

Position mode: “VPS1” - Enter or measure valve closed position

“VPS2” - Enter or measure valve open position

“VUdt” - Enter valve update time

“VPdb” - Enter valve control deadband

“VFAL” - Enter valve fail detect time

Velocity mode: “VUdt” - Enter valve update time

“VOPt” - Enter valve open time

“VCLt” - Enter valve close time

“VONt” - Enter valve control deadband

(minimum on time)

ACCESSORY - EXTERNAL RLY50000 SSR

POWER UNIT SHOWN

(External DIN Rail mount SSR power units available)

The external SSR Power Unit is used with the Logic/SSR Drive Module

(OMD00003) to switch loads up to 240 VAC @ 45 amps, 25°C ambient.

The unit is operated by applying a low level DC control signal to the isolated input. The unit features zero cross detection circuits which reduces radiated RFI when switching load currents. With no contacts to wear out, the SSR Power Unit provides virtually limitless operational life. The unit is supplied with an integral heat sink for immediate installation.

HIDDEN FUNCTION MODE *

The hidden function mode is accessible from the normal operating mode. The four functions in this mode may be locked-out individually in configuration 3 parameter lock-out section.

“SPSL” - Select Local/Remote Setpoint

“trnF” - Transfer between automatic (PID) control

and manual control

“tUNE” - Invoke/cancel PID Auto-tune

“ALrS” - Reset latched alarms

PROTECTED PARAMETERS MODE *

The protected parameters mode is enabled when program disable is active.

This mode prevents access to the configuration modes without the proper access code number. Only the parameters that are selected in the configuration 3 parameter lock-out section can be accessed.

“ProP” - Enter Proportional band

“Intt” - Enter integral time

“dErt” - Enter derivative time

“rtio” - Enter remote setpoint ratio value

“bIAS” - Enter remote setpoint bias value

“SP-2” - Enter internal cascade, secondary setpoint

“Pb-2” - Enter internal cascade, secondary

proportional band

“It-2” - Enter internal cascade, secondary

integral time

“dt-2” - Enter internal cascade, secondary

derivative time

“AL-1” - Enter value for alarm #1

“AL-2” - Enter value for alarm #2

“CodE” - Enter access value to unprotected

parameters & configuration parameters

*

These parameters may not appear due to option configuration or other programming.

ACCESSORY - CT005001 CURRENT

TRANSFORMER SHOWN

(Lower current CT available)

The external Current Transformer is used when specifying TCUs equipped with the Heater Current Monitor. The primary current rating is 50 amperes.

1.60

(40.6)

.96

(24.4)

2.00

(50.8)

2.62

(66.5)

4.75 (121)

4.56 (116)

CENTERS FOR #8 SCREWS

0.22 (TYP.)

(5.5)

1.75

(44.5)

1.10

(27.9)

4X .27

(6.9)

4X .31

(7.9)

2X #8-32UNC TERMINAL

.44

(11.2)

X1

4.50

(114)

5.50

(140)

H1

1.13

(28.7)

1.25

(31.8)

2.68

(67.8)

0.20 (TYP.)

(5.1)

2.40

(61.0)

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

OUTPUT MODULES

TYPICAL CONNECTIONS

RELAY

MODULE

A

B

POWER

5 AMPS

AT

240

VAC

C

LOAD

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).

Life Expectancy: 100,000 cycles at maximum load rating.

LOGIC/SSR DRIVE

MODULE

+12VDC

UNREG.

NOT

ISOLATED

DO NOT CONNECT

-

+

A

B

C

4

3

SSR

POWER

UNIT

1

2

LOAD

POWER

(Decreasing load and/or increasing cycle time, increases life expectancy).

Logic/SSR Drive: Can drive multiple SSR Power Units.

Type: Non-isolated switched DC, 12 VDC typical

TRIAC MODULE

ISOLATED

1 AMP

AT

120/240VAC

DO NOT CONNECT

A

B

C

120VAC

RELAY OR

TRIAC

DEVICE

Drive: 45 mA maximum.

Triac:

Type: Isolated, Zero Crossing Detection

Rating:

Voltage: 120/240 VAC

Max. Load Current: 1 ampere @ 35°C

0.75 ampere @ 50°C

Min. Load Current: 10 mA

Off State Leakage Current: 7 mA max. @ 60 Hz

Operating Frequency: 20 to 400 Hz

Protection: Internal Transient Snubber, Fused

LOAD

POWER

EXTRUDER COOLING

WATER

ALARM/COOLING

SUPPLY

240V HEATER

SUPPLY

HB

ALARM

CURRENT

TRANSFORMER

SSR

POWER

UNIT

DATA

LOGGER

120 VAC

AC POWER

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

AL1/OP2 COMM

OP2-A

AL1-A

OP1-A

OP1-B

OP1-C

USER INPUT

TC +

COMM

OUT +

OUT -

N/C

N/C

CT

CT

COOLING/ALARM COMMON

COOLING OUTPUT

HEATER CURRENT FAIL OUTPUT

MAIN CONTROL OUTPUT

THERMOCOUPLE INPUT

4 -20 mA LINEAR DC OUTPUT

TEMPERATURE RETRANSMISSION

SECOND INPUT

(CURRENT TRANSFORMER)

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 a 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.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

ORDERING INFORMATION

MODELS WITHOUT SECOND INPUT OPTIONS

Type 4X/IP65

BEZEL

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

4 to 20 mA

ANALOG

OUTPUT

NO

NO

NO

YES

YES

YES

NO

NO

NO

YES

YES

YES

0 to 10 VDC

ANALOG

OUTPUT

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

ALARM

OUTPUTS

NO

2

1

2

2

1

NO

2

1

2

1

2

COOLING

OUTPUT

NO

NO

YES

NO

NO

YES

NO

NO

YES

NO

YES

NO

RS485 COM

NO

NO

NO

NO

YES

YES

NO

NO

NO

NO

NO

YES

PART NUMBER

115/230 VAC

TCU00000

TCU00001

TCU00002

TCU01001

TCU01004

TCU01005

TCU10000

TCU10001

TCU10002

TCU11001

TCU11002

TCU11004

YES

YES

YES

YES

NO

NO

NO

YES

YES

1

2

2

YES

NO

NO

YES

NO

YES

TCU11005

TCU12001

TCU12004

YES NO YES 1 YES YES TCU12005

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.

HEATER CURRENT MONITOR MODELS (HCM)

Type 4X/IP65

BEZEL

4 to 20 mA

ANALOG

OUTPUT

0 to 10 VDC

ANALOG

OUTPUT

ALARM

OUTPUTS

COOLING

OUTPUT

RS485 COM PART NUMBER

YES

YES

NO

YES

NO

NO

2

2

NO

NO

YES

NO

TCU10204

TCU11208

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.

SECOND ANALOG INPUT MODELS (ANA)

Type 4X/IP65

BEZEL

YES

YES

YES

4 to 20 mA

ANALOG

OUTPUT

NO

YES

NO

0 to 10 VDC

ANALOG

OUTPUT

NO

NO

YES

ALARM

OUTPUTS

2

2

2

COOLING

OUTPUT

NO

NO

NO

RS485 COM PART NUMBER

YES

NO

NO

TCU10104

TCU11108

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.

MOTORIZED VALVE POSITIONER MODELS (MVP)

Type 4X/IP65

BEZEL

YES

YES

YES

4 to 20 mA

ANALOG

OUTPUT

NO

YES

NO

0 to 10 VDC

ANALOG

OUTPUT

NO

NO

YES

ALARM

OUTPUTS

1

1

1

COOLING

OUTPUT

NO

NO

NO

RS485 COM PART NUMBER

YES

NO

NO

TCU10307

TCU11306

TCU12306

ACCESSORIES

DESCRIPTION PART NUMBER

Relay Module

Triac Module

Logic/SSR Drive Module

45 A Single Phase Panel Mount SSR

25 A Single Phase DIN Rail Mount SSR

40 A Single Phase DIN Rail Mount SSR

25 A Three Phase DIN Rail Mount SSR

50:0.1 Ampere Current Transformer

40:0.1 Ampere Current Transformer

OMD00000

OMD00001

OMD00003

RLY50000

RLY60000

RLY6A000

RLY70000

CT005001

CT004001

Note: Output Modules are NOT supplied with the controller. When specifying the controller, be sure to purchase the appropriate output module for the Main Control Output and if necessary, the alarm output(s), the cooling output, and valve positioner outputs. The controller can be fitted with any combination of output modules.

The Logic/SSR Drive Module is a switched DC source, intended to drive the DC input of an

SSR power unit. It should never be connected to line voltage.

All output modules are packaged separately and must be installed by the user.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

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. The Company disclaims all liability for any affirmation, promise or representation with respect to the products.

The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against damages, claims, and expenses arising out of subsequent sales of RLC products or products containing components manufactured by RLC and based upon personal injuries, deaths, property damage, lost profits, and other matters which Buyer, its employees, or sub-contractors are or may be to any extent liable, including without limitation penalties imposed by the Consumer Product Safety Act (P.L. 92-573) and liability imposed upon any person pursuant to the Magnuson-Moss Warranty Act (P.L. 93-637), as now in effect or as amended hereafter.

No warranties expressed or implied are created with respect to The Company’s products except those expressly contained herein. The Customer acknowledges the disclaimers and limitations contained herein and relies on no other warranties or affirmations.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.the-red-lion.net - Email: [email protected]

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals

Download PDF

advertisement