Red Lion TSC PID Controller Product Manual

Red Lion TSC PID Controller Product Manual
Bulletin No. TSC-C
Drawing No. LP0326
Released 08/13
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
www.redlion.net
MODEL TSC - TEMPERATURE SETPOINT CONTROLLER




UL
R
US LISTED



PROGRAMMABLE USER INPUT FOR CONTROLLER AND
SETPOINT PROGRAM CONTROL
100 MSEC SAMPLING PERIOD WITH 0.15% ACCURACY
ON DEMAND AUTO-TUNING OF PID CONTROL SETTINGS


SETPOINT PROGRAM CONTROLLER FOR TIME VS.
TEMPERATURE (RAMP/SOAK) AND SPECIAL BATCH/RECIPE
APPLICATIONS
FOUR SETPOINT & PID PARAMETER SETS FOR QUICK RECALL
OF SETPOINTS AND/OR GAIN VALUES DURING BATCH OR
PROCESS CHANGEOVER

IND. CONT. EQ.
51EB
DUAL EVENT OUTPUTS FOR TIMED ACTIVATION OF PROCESS
EQUIPMENT SUCH AS STIRRERS, FANS, HEATERS, ETC. (Uses
Alarm Output Channels)


C
AUTOMATIC PROGRAM DELAY FOR PROFILE CONFORMITY,
PLUS PROGRAM LINKING, REPEATING AND AUTO POWER-ON
FUNCTIONS FOR ENHANCED CAPABILITY
DUAL LED DISPLAYS FOR SIMULTANEOUS INDICATION OF
TEMPERATURE AND SETPOINT OR TEMPERATURE AND
PROFILE STATUS
ACCEPTS ANY ONE OF 10 DIFFERENT TYPES OF SENSOR
INPUTS (Thermocouple or RTD)
FIELD REPLACEABLE AND INTERCHANGEABLE OUTPUT
MODULES (Relay, Logic/SSR drive, and Triac)

OPTIONAL DUAL ALARM OUTPUTS (Uses Output Modules)
ADVANCED PROGRAM PROFILING IN A 1/8 DIN PACKAGE

OPTIONAL COOLING OUTPUT (Uses Output Module)
ON-LINE MONITORING AND CONTROL OF PROGRAM STATUS,
TIME, AND SETPOINT VALUE (Program Run, Pause, Stop,
Advance, Modify Time, & Setpoint Value)

DESCRIPTION
OPTIONAL LINEAR 4 to 20 mA or 0 to 10 VDC OUTPUT FOR
CONTROL OR TEMPERATURE RE-TRANSMISSION

OPTIONAL RS485 SERIAL COMMUNICATIONS INTERFACE

OPTIONAL TYPE 4X/IP65 SEALED FRONT BEZEL
The controller can operate in the standard PID control mode for both heating
or cooling with on-demand auto-tune which establishes the PID gain set. The
PID gain set can be fine tuned by the operator at any time or may be locked from
further modification. The unit can be transferred to the manual control mode
providing the operator with direct control of the output.
The TSC features four programs or profile recipes, each with up to eight
ramp/soak segments, which can be easily stored and executed at any time.
Longer profiles can be achieved by linking one or more profiles together,
creating a single profile of up to 32 ramp/soak segments. Temperature profile
conformity is assured during either soak (hold) phases or both ramp and hold
phases by an adjustable error band parameter. The program repeat function
cycles the profile either continuously or a set number of times. Power-on options
automatically re-start, stop, or resume a running profile. The profile can be
controlled via the front panel buttons, the user input, or the optional serial
communications port.
Four control points, each having a setpoint and PID parameter set, are
available for instant front panel implementation during batch changeover, or
The TSC is a setpoint controller suitable for time vs. temperature, process
control applications. The TSC accepts signals from a variety of temperature
sensors (thermocouple and 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 satisfy various applications. The user
input can be programmed to perform a variety of controller functions.
Dual 4-digit displays allow viewing of the measured temperature value and
setpoint or temperature and profile status simultaneously. Front panel indicators
inform the operator of controller status and output states. Replaceable output
modules (Relay, logic/SSR drive or Triac) can be fitted to the main control output,
alarm output(s) or timed event output(s), and cooling output.
The TSC has been designed to simplify the set-up and operation of a controlled
setpoint profile program. The setpoint program is easily entered and controlled
through the front panel. Full display capabilities keep the operator informed of the
process temperature, profile status, output states, and setpoint value.
DIMENSIONS In inches (mm)
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
1.77 +.02
-.00
(45 +.6
-.0)
%PW MAN AL1
PGM OP1 AL2
3.80
(96.5)
3.60
(91.4)
3.62 +.03
-.00
(92 +.8
-.0 )
DSP
PAR
1.95
(49.5)
.40
(10.2)
5.29
(134.4)
1.75
(44.4)
1
DESCRIPTION (Cont’d)
Program Auto Cycle: 1 to 249, or continuous.
Event Outputs: 2, time activated with profile [uses Alarm output(s)].
Control: Front panel buttons, user input, or RS485 communications.
6. CONTROL POINTS:
Setpoints: 4
PID gain sets: 4
Control: Front panel buttons or user input.
7. 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 50/60 Hz.
Protection: Input overload voltage; 240 VAC @ 30 sec max.
8. THERMOCOUPLE:
Types: T, E, J, K, R, S, B, N or Linear mV.
Input Impedance: 20 MΩ, all types.
Lead Resistance Effect: 20 µV/350 Ω.
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.
9. 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 max.
10. RANGE AND ACCURACY:
Errors include NIST conformity and A/D conversion errors at 23°C after 20
minutes warm-up. Thermocouple errors include cold junction effect. Errors
are expressed as ±(% of reading) and ±3/4 LSD unless otherwise noted.
other process conditions. A control point may have its PID gain set values
disabled when implementing the control point.
The optional RS485 multidrop serial communications interface provides the
capability of two-way communication between a TSC 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.
Optional alarm output(s) may be configured to operate as a timed event
output or as a standard alarm output. As an alarm output it may be configured to
activate according to a variety of actions (Absolute HI or LO, Deviation HI or
LO, or Band IN or OUT) with adjustable hysteresis. Also, a standby feature
suppresses the output(s) on power-up until the temperature stabilizes outside the
alarm region. Timed event output(s) allow the controller to activate other
equipment while a programmed profile is running. Each profile can define up to
16 event states (phases), for each output(s).
An optional secondary output is available for processes that require cooling
which provides increased control accuracy and response.
The optional linear 4 to 20 mA or 0 to 10 VDC output signal is available to
interface with final actuators, chart recorders, indicators, or other controllers. The
output signal can be digitally scaled and selected to transmit one of the following:
% Output Power
Measurement Value
Measurement Value Deviation
Setpoint Value
An optional Type 4X/IP65 rated bezel is available for washdown 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 TSC 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.
TC TYPE
T
E
J
K
R
SPECIFICATIONS
1. DISPLAY: Dual 4-digit
Upper Temperature Display: 0.4" (10.2 mm) Red LED
Lower Auxiliary Display: 0.3" (7.6 mm) Green LED
Display Messages:
“OLOL”
“ULUL”
“OPEN”
“SHrt”
“....”
“-...”
-
Appears
Appears
Appears
Appears
Appears
Appears
when
when
when
when
when
when
S
B
measurement exceeds + sensor range.
measurement exceeds - sensor range.
open sensor is detected.
shorted sensor is detected (RTD only).
display value exceeds + display range.
display value exceeds - display range.
N
mV
RTD
(385)
RTD
(392)
OHMS
2. POWER: Switch selectable for 115/230 VAC (+10%, -15%) no observable
line variation effect, 48-62 Hz, 10 VA.
3. ANNUNCIATORS:
6 LED Backlight Status Indicators:
%PW
PGM
MAN
OP1
AL1
AL2
OP2
-
RANGE
ACCURACY
-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 +3300°F
-200 to +1300°C
-328 to +2372°F
-5.00 to 56.00
-200 to +600°C
-328 to +1100°F
-200 to +600°C
-328 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
WIRE COLOR
(ANSI)
blue
violet
white
yellow
black
black
grey
orange
__
__
__
__
11. OUTPUT MODULES [Optional] (For All Output Channels):
Relay:
Type: Form-C (Form-A with RS485 option)
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. 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.
Ratings:
Voltage: 120/240 VAC
Max Load Current: 1 AMP @ 35°C
0.75 AMP @ 50°C
Min Load Current: 10 mA
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 500 Hz
Protection: Internal Transient Snubber, Fused.
Lower auxiliary display shows power output in (%).
Lower auxiliary display shows profile status or profile
time remaining.
Controller is in manual mode.
Main control output is active.
Alarm #1 is active.
Alarm #2 is active (for Dual Alarm Option)
Cooling output is active (for Cooling Option).
4. CONTROLS: Four front panel push buttons for setup and modification of
controller functions and one external input.
5. SETPOINT PROFILE:
Profiles: 4
Segments Per Profile: 8 ramp/hold segments (linkable to 32 segments).
Ramp Rate: 0.1 to 999.9 degrees/minute or no ramp.
Hold Time: Off or from 0.1 to 999.9 minutes, can be extended to 500 hours
by linking.
Error Band Conformity: Off or from 1 to 9999 degrees deviation, + value
for hold phases, - value for both ramp and hold phases.
Power-On Modes: Stop, auto-start, or profile resume.
Start Mode: Ramps from process temperature.
2
SPECIFICATIONS (Cont’d)
19. 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 TSC0
Type 4X/IP65 Enclosure rating (Face only) for TSC1
Refer to EMC Installation Guidelines section of the manual for additional
information.
20. CONNECTION: Jaw-type terminal block.
21. 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 2 captive mounting screws
(panel gasket included).This unit is rated for Type 4X/IP65 indoor use.
Installation Category II, Pollution Degree 2.
22. WEIGHT: 1.3 lbs. (0.6 kgs)
12. 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 performed, sets proportional band, integral time, and
derivative time values.
Probe Break Action: Programmable.
13. 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: Programmable.
14. LINEAR DC DRIVE (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 Ω max. loop impedance).
0 to 10 VDC:
Resolution: 1 part in 3500 typ.
Accuracy: ±(0.1% of reading + 35 mV).
Min. Load Resistance: 10 KΩ (1 mA max.)
Source: % output power, setpoint, deviation, or temperature.
(Available for heat or cool, but not both.)
15. ALARMS (Optional):
Hardware: Plug-in, replaceable output module.
Modes: Absolute high acting
Absolute low acting
Deviation high acting
Deviation low acting
Inside band acting
Outside band acting
Timed event output(s)
Reset Action: Programmable; automatic or latched.
Delay: Programmable; enable or disable.
Hysteresis: Programmable.
Probe Break Action: Upscale.
Annunciator: LED backlight for “AL1”, “AL2”, (Alarm #2 not available
with cooling output).
16. SERIAL COMMUNICATIONS (Optional):
Type: RS485 Multi-point, Balanced Interface.
Communication Format:
Baud Rate: Programmable from 300-9600.
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 0-99, 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: VIN max = 5.25 VDC, VIL = 0.85 VMAX; VIH = 2.0 VMIN,
Response time 100 msec max.
Functions:
Program Lock
Integral Action Lock
Auto/Manual Transfer
Setpoint Ramp Select
Reset Alarms
BASIC OPERATION
The TSC controls the temperature profile of a system by measuring the
temperature via an input probe, compares the actual temperature to the setpoint
profile in progress, and calculates the new output power value by use of a
modified PID control algorithm. The unit controls the system with the new
output power value so the process temperature conforms to the programmed
profile. The PID control algorithm incorporates features which provide
minimum overshoot and excellent temperature control accuracy for a process.
FRONT PANEL FEATURES
In the normal display mode, the unit will display the process temperature in
the upper display. One of five other parameters may be selected for viewing in
the lower display:
Target Setpoint Profile Phase Time Remaining
% Output Power Temperature Symbol (F/C)
Profile Status
The program profile status display indicates the active profile number with
the current ramp or hold phase of the profile. The profile can be started, stopped,
advanced, etc. from the front panel when the profile status display is viewed, if
not locked from access.
The phase time remaining display, shows the time remaining in a ramp or
hold phase and, if not locked from access, may be changed on-line to effect
temporary changes to the program. Additionally, the target setpoint and %
output power (manual mode only) may also be changed on-line or locked from
operator access.
From 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 from any parameter module. The controller configuration and
parameter settings are stored in an internal E2PROM device.
Print Request
Load Control Point
Run/Hold Profile 1
Run/Stop Profile 1
18. ENVIRONMENTAL CONDITIONS:
Operating Temperature: 0 to 50°C
Storage Temperature: -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
Operating and Storage Humidity: 85% max. (non-condensing) from 0°C
to 50°C.
Span Drift: ≤ 100 ppm/°C
Zero Drift: ≤ 1 µ V/°C
Altitude: Up to 2000 meters
3
CONFIGURATION MODE
Configuration 5,.Cooling *
The configuration modules serve to provide the basic set-ups required by
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, which
allows the user to return to the normal display mode, or advance to a later
configuration stage.
Configuration 1, Inputs
“tYPE”
“SCAL”
“dCPt”
“FLtr”
“SPAN”
“SHFt”
“SPLO”
“SPHI”
“SPrP”
“InPt”
Configuration 2, Outputs
“CYCt”
“OPAC”
“OPLO”
“OPHI”
“OPFL”
“CHYS”
“tcod”
“ANAS”
“ANLO”
“ANHI”
-
Select input probe type
Select temperature scale
Select temperature resolution
Select degree of input filtering
Enter input correction span (slope)
Enter input correction shift (offset)
Enter setpoint lower limit
Enter setpoint higher limit
Enter setpoint ramp rate
Select user input function
-
Enter time proportioning cycle time
Select control action
Enter output power low limit
Enter output power high limit
Enter probe fail power preset
Enter ON/OF control hysteresis
Select auto-tuning damping
Select linear DC output assignment *
Enter linear DC low scaling value *
Enter linear DC high scaling value *
Configuration 4, Alarms *
“Act 1”
“rSt1”
“Stb1”
“AL-1”
“Act2”
“rSt2”
“Stb2”
“AL-2”
“AHYS”
“bAUd”
“PArb”
“Addr”
“Abrv”
“PrAt”
“PoPt”
-
Select baud rate
Select parity bit
Enter unit address number
Select abbreviated or full mnemonic
transmissions
- Enter automatic print rate
- Select parameters to be included
in print-out
Configuration 7, Control Points
“CSEt”
“SP-x”
“PId”
“PB-x”
“It-x”
“dt-x”
Configuration 8, Profiles
“PSEt”
“PnCC”
“PnLn”
“PnEb”
“PnPC”
“Pnr1”
“PnL1”
“PnH1”
.
.
.
.
“Pnr8”
“PnL8”
“PnH8”
“Pn 1”
.
.
.
.
“Pn16”
- Select degree of setpoint access
- Select degree of power access
- Select degree of profile status
access
- Select degree of phase time remaining
access
- Enable temperature units display
- Enter parameter access code
- Select degree of PID access
- Select degree of alarm access *
- Enable manual reset of alarms *
- Enable control point access
- Enable ramp/hold program access
- Enable automatic/manual transfer
- Enable auto-tune invocation
-
- Enter cooling time proportioning cycle time
- Enter cooling relative gain
- Enter heat/cool deadband or overlap
Configuration 6, Serial Communications *
Configuration 3, Parameter lock-outs
“SP”
“OP”
“P-CS”
“P-tr”
“UdSP”
“CodE”
“PId”
“AL”
“ALrS”
“CPAC”
“PrAC”
“trnF”
“tUNE”
“CYC2”
“GAN2”
“db-2”
Select operation mode of alarm #1
Select reset mode of alarm #1
Enable activation delay of alarm #1
Enter value for alarm #1
Select operation mode of alarm #2
Select reset mode of alarm #2
Enable activation delay of alarm #2
Enter value for alarm #2
Enter hysteresis value for both alarms
- Select control point number for set-up 1, 2,
3, & 4
- Enter setpoint value for selected control
point
- Select if PID gain set to be loaded with
setpoint
- Enter proportional band for selected
control point *
- Enter integral time for selected control
point *
- Enter derivative time for selected control
point *
- Select profile or event output for set-up 1,
2, 3, or 4
- Enter program-repeat cycle count for
selected profile
- Select link option for selected profile
- Enter error band for temperature
conformity for selected profile
- Enter power-down resume status for
selected profile
- Enter ramp rate 1 for selected profile *
- Enter setpoint level 1 for selected profile *
- Enter hold time 1 for selected profile *
-
Enter ramp rate 8 for selected profile *
Enter setpoint level 8 for selected profile
Enter hold time 8 for selected profile *
Select event outputs at phase 1 for
selected profile *
*
- Select event outputs at phase 16 for
selected profile *
Configuration 9, Factory Service Operations
(Detailed in the operator’s manual)
* These parameters may not appear due to option configuration or other
programming
HARDWARE FEATURES
SETPOINT FEATURES
Type 4X/IP65 BEZEL
The fast 100 msec input sampling rate
provides quick controller response to a process
disturbance for excellent temperature control.
Measurement accuracy of 0.15% provides
closer process control conforming to the
desired control setpoint value.
The unit accepts a variety of both
thermocouple or RTD temperature probes.
The A.C. input power is switch selectable,
allowing the unit to operate from either 115
%PW MAN AL1
PGM OP1 AL2
VAC or 230 VAC. Since the controller is
serviceable from the front of the panel, the
output modules may be easily changed or
DSP
replaced without disturbing the wiring behind
the panel and NO re-programming is required.
The standard model simply requires pressing a
PAR
latch to remove the unit. The Type 4X/IP65
rated model utilizes two panel securing screws
and a neoprene gasket to guarantee a water
tight seal, when properly installed.
Low-drift, highly stable circuit design
ensures years of reliable and accurate temperature control. The recommended
two year re-calibration interval is easily accomplished via the programming
menu.
The controller’s setpoint can be protected from out of range values, by
programming the setpoint range limit values. Additionally, safeguards from
inadvertent data entry can also 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, independent of a
programmed profile. This feature reduces thermal shock to the process and
also helps to minimize temperature overshoot.
The active setpoint, which can be a running profile, may also be transmitted
by the linear DC output for slave control loops.
Four control points are available which can be implemented at any time.
Each control point is programmed independently, with each having a setpoint
and a PID gain set value. With gain value changes, the output power control
signal will not “bump” resulting in a smooth control transition.
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 TSC units indicate the same
nominal temperature.
A programmable User Input is available to control a variety of controller
functions, such as profile control, auto/manual transfer, serial communication
print requests, etc.
4
OUTPUT FEATURES
HIDDEN FUNCTIONS MODE *
Programmable output power limits provide protection for processes where
too much 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 D.C. Linear output, the controller can satisfy a
wide variety of output requirements.
During execution of a profile, two independent, timed event outputs are
available to control or signal other equipment. The event outputs use the alarm
channels.
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.
The hidden mode is accessible from the normal operating mode by holding
the PAR button for 3 seconds. The five functions in this mode may be locked-out
individually in configuration 3 parameter lock-outs section.
“ CP”
“Prun”
“trnF”
“tUNE”
“ALrS”
OUTPUT VARIATIONS WITHOUT RS485 OPTION
The Dual Alarm or the Cooling with Alarm output, without the RS485 option,
has independent outputs. Therefore, the cooling output and/or alarm output(s)
can be installed with any combination of output modules.
AUTO-TUNE
The model TSC 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 at start-up, while ramping, or at setpoint,
depending on the process requirements. A programmable auto-tune damping
factor produces various levels of process control and response characteristics.
ALARM 2 OR
OUTPUT 2
COOLING
OPTION
ALARM 1
OPTION
CONTROLLER PROGRAMMING
ALARM 1 AND ALARM 2
OR
ALARM 1 WITH
COOLING
OPTION
Enter setpoint *
Enter %output power offset *
Enter output power *
Enter proportional band
Enter integral time *
Enter derivative time *
Enter value for alarm #1 *
Enter value for alarm #2 *
Select basic configuration module
Return to normal display mode
RS-485
OPTION
LOGIC/SSR DRIVE
+12VDC
+
DO NOT CONNECT
NOT
ISOLATED
TRIAC
1A @ 240VAC
(ISOLATED)
B
DO NOT CONNECT
C
OUTPUT MODULES
AL/OP2 COMM.-A
AL2/OP2-B
AL1-B
TX/RX(+)
TX/RX(-)
TX EN.
RS-485 COMM.
A
RELAY
B
1
2
3
13
14
15
16
A
B
A
B
5A @ 240VAC
(RESISTIVE LOAD)
+
LOGIC/SSR DRIVE
+12VDC
NOT
ISOLATED
TRIAC
1A @ 240VAC
(ISOLATED)
* These parameters may not appear due to option configuration or other
PROTECTED PARAMETER MODE *
programming
The protected mode is accessible when program disable is active, also 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-outs section can be accessed.
-
-
A
13
14
15
16
DUAL ALARM OR
COOLING W/ALARM OPTION
WITH RS-485 OPTION
The unprotected mode is accessible when program disable is inactive or when
the proper access code number from the protected mode is entered. Only from
this mode can the configuration modes be accessed.
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“CodE”
“End”
A
B
The Dual Alarm or the Cooling with Alarm output, with RS485 option, does
not have independent outputs. In this case, the cooling output and/or alarm
output(s) must have the same type of output modules installed since they share
the common terminal.
UNPROTECTED PARAMETER MODE
N/C
AL1-A
AL1-B
AL1-C
5A @ 240VAC
(RESISTIVE LOAD)
C
1
2
3
AL2/OP2-A
AL2/OP2-B
AL2/OP2-C
RELAY
B
OUTPUT VARIATIONS WITH RS485 OPTION
The model TSC 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:
Hidden Mode
Protected Mode
Unprotected Mode
Configuration Mode
These four programming modes allow the controller to adapt to any required
user-interface level.
-
A
C
Profiles are programmed independently of each other and are separate from
the configuration of other controller parameters. Each profile has parameters for
error band (profile conformity), linking, auto-start and program repeat cycles.
Profiles may be altered during execution, so changes take effect as the
programmed profile advances.
“SP”
“OPOF”
“OP”
“ProP”
“Intt”
“dErt”
“AL-1”
“AL-2”
“CNFP”
“End”
OUTPUT MODULES
DUAL ALARM OR
COOLING W/ALARM OPTION
WITHOUT RS-485 OPTION
PROFILE PROGRAMMING
- Load control point x
- Control ramp/hold profile state
- Transfer between automatic (PID) control
and Manual control
- Invoke/Cancel PID auto-tune
- Reset latched alarms
Enter proportional band
Enter integral time
Enter derivative time
Enter value for alarm #1
Enter value for alarm #2
Enter access value to unprotected mode
Return to normal display mode
5
OUTPUT MODULES
LOGIC/SSR DRIVE
MODULE
+12VDC
UNREG.
Units equipped with RS485 option must have the Dual Alarm or Cooling w/
alarm options fitted with the same type of output modules. The controller’s
main output (OP1) can be fitted with any output module. Output modules are
shipped separately and must be installed by the user.
POWER
B
C
C
POWER
LOAD
Logic/SSR Drive: can drive multiple SSR Power Units.
Type: Non-isolated switched DC, 12 VDC typical.
Drive: 45 mA max.
A
5 AMPS
AT
240VAC
+
DO NOT CONNECT
RELAY
MODULE
SSR 1
POWER
3 UNIT 2
4
B
NOT
ISOLATED
TYPICAL CONNECTIONS
A
120VAC
TRIAC MODULE
A
ISOLATED
1 AMP
AT
120/240VAC
LOAD
Relay:
Type: Form -C (Form-A with RS485 option only)
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.
(Decreasing load and/or increasing cycle time, increases life expectancy).
RELAY OR
TRIAC
DEVICE
B
C
DO NOT CONNECT
POWER
LOAD
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
Off State Leakage Current: 7 mA max. @ 60 Hz
Operating Frequency: 20 to 500 Hz.
Protection: Internal Transient Snubber, Fused.
115 VAC
APPLICATION
(MAIN POWER)
TSC GLASS TEMPERING APPLICATION
A manufacturer of glass items needs to
anneal (temper) their products to reduce the
brittleness of the glass structure. The tempering
process requires the glass to be heated and
subsequently cooled at a controlled rate to
change the structure of the glass. Different
tempering profiles are required for different
types of glass products.
A TSC is employed to control the
temperature profile of the annealing oven.
Four different temperature profiles are stored in
the controller. The 4 to 20 mA analog output
option is utilized to cool the annealing oven
during the cool down ramp phases. An event
output is used to quickly cool the oven at the
end of the batch run (alarm 1). Alarm 2 is used
to signal the operator whenever the temperature
is outside the prescribed program profile.
Note: Units equipped with the RS485 option
have different terminal designators. See
“Output Variations with or without the
RS485 Option”.
115 VAC
TEMPERATURE DEVIATION
ALARM
ANNEALING
OVEN
220 VAC
HORN
SSR
POWER
UNIT
-
-
+
+
HEATER
PROGRAM
DISABLE
I/P CONVERTER
AL2/OP2-A
AL2/OP2-B
3
AL2/OP2-C
4
OP1-A
5
OP1-B
6
OP1-C
7
USER INPUT
8
+
TYPE-J
1
2
ALARM 2 OPTION
(RELAY MODULE INSTALLED)
MAIN CONTROL OUTPUT
(LOGIC/SSR DRIVE MODULE INSTALLED)
+
9
THERMOCOUPLE INPUT
+
10
COMM.
11
OUT+
-
4-20mA ANALOG OUTPUT OPTION
12
OUT-
(RETRANSMIT % OUTPUT POWER)
13
N/C
14
AL1-A
15
AL1-B
16
AL1-C
COOLING
AUXILIARY
EXHAUST
FAN
-
ALARM 1 OPTION
(RELAY MODULE INSTALLED)
POWER
TEMPERATURE
300°
The programming for this profile is as follows:
Parameter Value
“P1r1”
5.0
“P1L1”
300
“P1H1”
40.0
“P1r2”
3.0
“P1L2”
150
“P1H2”
0.0
“P1r3”
-0.1
“P1 1”
1F2F
“P1 2”
1F2F
“P1 3”
1F2F
“P1 4”
1N2F
Description
Ramp from ambient temp. during heat phase at
5.0°/min.
Target setpoint level 300°
Heat at 300° for 40.0 minutes
Ramp down 3.0°/min. during cooling phase
Target Setpoint is 150°
Do not hold at 150° (used as “phantom” hold time
for triggering event output for auxiliary cooling)
End Program
Turn off output 1 (output 2 is alarm)
Keep off output 1
Keep off output 1
Turn on output 1 for Auxiliary Exhaust Fan
RE-START
150°
START
AMBIENT 80°
R1=5°Min
0
PROFILE
PHASE
H1=40Min
40
R2=3°Min
80
STOP
TIME
(Minutes)
120
P1r1
P1H1
P1r2
P1 1
P1 2
P1 3
ON
EVENT
STATE
(Aux. Fan)
6
P1 4
OFF
ORDERING INFORMATION
MODEL NO
TSC
PMK5
RLY
DESCRIPTION
Temperature
Setpoint
Controller
Type 4X/IP65
BEZEL
4 to 20 mA
ANALOG OUTPUT
0 to 10 VDC
ANALOG OUTPUT
ALARM
OUTPUTS
COOLING
OUTPUT
RS485 COM
PART NUMBER
NO
YES
NO
2
NO
NO
TSC01001
YES
YES
NO
2
NO
NO
TSC11001
YES
YES
NO
1
YES
NO
TSC11002
YES
YES
NO
2
NO
YES
TSC11004
YES
YES
NO
1
YES
YES
TSC11005
YES
NO
YES
2
NO
YES
TSC12004
YES
NO
YES
1
YES
YES
TSC12005
Relay Module
OMD00000
Triac Module
OMD00001
Logic/SSR Drive Module
OMD00003
Panel Mount Adapter Kit (1/4 DIN to 1/8 DIN)
PMK50000
45 A Single Phase Panel Mount SSR
RLY50000
25 A Single Phase DIN Rail Mount SSR
RLY60000
40 A Single Phase DIN Rail Mount SSR
RLY6A000
25 A Three Phase DIN Rail Mount SSR
RLY70000
These models have dual alarm outputs, or single alarm with secondary 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
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) and cooling output.
The controller can be fitted with any combination of output modules that do not have the RS485 option.
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 a line voltage.
All modules are shipped separately and must be installed by the user.
7
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.
Red Lion Controls
Headquarters
20 Willow Springs Circle
York PA 17406
Tel +1 (717) 767-6511
Fax +1 (717) 764-0839
Red Lion Controls
Europe
Softwareweg 9
NL - 3821 BN Amersfoort
Tel +31 (0) 334 723 225
Fax +31 (0) 334 893 793
Red Lion Controls
India
201-B, 2nd Floor, Park Centra
Opp 32 Mile Stone, Sector-30
Gurgaon-122002 Haryana, India
Tel +91 984 487 0503
Red Lion Controls
China
Unit 302, XinAn Plaza
Building 13, No.99 Tianzhou Road
ShangHai, P.R. China 200223
Tel +86 21 6113 3688
Fax +86 21 6113 3683
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