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Instruction Manual

TEC-2500

Self-Tune Fuzzy / PID

Process Temperature Controller

Manual TEC-2500 Revision 9/2013

Agency Approvals

TEMPCO Electric Heater Corporation
607 N. Central Avenue  •  Wood Dale, IL 60191-1452 USA
Tel: 630-350-2252  •  Toll Free: 800-323-6859
Fax: 630-350-0232  •  E-mail: [email protected]
Web: www.tempco.com

Serving Industry Since 1972

Summary of Contents for TEC-2500

Page 1: ...ontroller Manual TEC 2500 Revision 9 2013 Agency Approvals TEMPCO Electric Heater Corporation 607 N Central Avenue Wood Dale IL 60191 1452 USA Tel 630 350 2252 Toll Free 800 323 6859 Fax 630 350 0232...

Page 2: ...NOTES...

Page 3: ...4 8 Data Communication 66 4 9 Analog Retransmission 67 4 10 Digital Filter 68 4 11 Sleep Mode 68 4 12 Pump Control 69 4 13 Remote Lockout 70 Chapter 5 Applications 5 1 Pump Pressure Control 71 5 2 Va...

Page 4: ...NOTES...

Page 5: ...de SSR drive triac 4 20mA and 0 10 volts TEC 2500 is fully programmable for PT100 thermocouple types J K T E B R S N L 0 20mA 4 20mA and voltage signal input with no need to modify the unit The input...

Page 6: ...processes The Fuzzy Rule may work like this If the temperature difference is large and the temperature rate is large then MV is large If the temperature difference is large and the temperature rate is...

Page 7: ...ted RS 485 interface module TEC 102 103 Isolated RS 232 interface module TEC 102 104 Isolated 4 20mA 0 20mA retransmission module TEC 102 105 Isolated 1 5V 0 5V retransmission module TEC 102 106 Isola...

Page 8: ...switch is set so that TC and RTD are selected for input 1 and all parameters are unlocked Lockout function is used to disable the adjustment of parameters as well as operation of calibration mode Howe...

Page 9: ...ons are listed in the following table How to display a 5 digit number For a number with a decimal point the display will be shifted one digit to the right 199 99 will be displayed as 199 9 4553 6 will...

Page 10: ...6...

Page 11: ...7 1 5 Menu Overview...

Page 12: ...mode and auto tuning mode All of these modes perform in an open loop control except auto tuning mode which performs ON OFF plus PID closed loop control The mode transfer is governed by the priority co...

Page 13: ...9 1 7 Parameter Description...

Page 14: ...10...

Page 15: ...ms DIN curve PT 100 ohms JIS curve 4 20 mA linear current input 0 20 mA linear current input 0 1V linear Voltage input 0 5V linear Voltage input 1 5V linear Voltage input 0 10V linear Voltage input Sp...

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Page 20: ...16 NOTES...

Page 21: ...cessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified in chapter 8 2 1 Unpacking Upon receipt of the shipment...

Page 22: ...de a suitably grounded metal enclosure to prevent live parts from being accessible to human hands and metal tools All wiring must conform to the appropriate standards of good practice and local codes...

Page 23: ...ror and cannot be corrected on the sensor except by proper selection and replacement 2 6 Thermocouple Input Wiring The color codes used on the thermocouple extension leads are shown in Table 2 1 1 1 2...

Page 24: ...n provided that the three leads are the same gauge and equal in length For the purpose of accuracy two wire RTD should be avoided if possible A 0 4ohm lead resistance in a two wire RTD will produce 1...

Page 25: ...21 2 9 CT Heater Current Input Wiring...

Page 26: ...ause of the limited number of pins pin 11 is used for both event input and RS 232 If you want to change function of the TEC 2500 from RS 232 to event input you must modify jumpers J51 and J52 on the C...

Page 27: ...23 2 11 Output 1 Wiring Continued...

Page 28: ...ter Power Three Phase Delta Heater Load Three Phase Delta Heater Load Contactor Contactor 1 2 3 4 5 8 9 10 11 6 7 12 13 14 1 2 3 4 5 8 9 10 11 6 7 12 13 14 Relay Output Direct Drive _ _ _ _ SSR SSR 1...

Page 29: ...25...

Page 30: ...use Breaker No Fuse Breaker Three Phase Heater Power Three Phase Heater Power Three Phase Delta Heater Load Three Phase Delta Heater Load Contactor Contactor 1 2 3 4 5 8 9 10 11 6 7 12 13 14 1 2 3 4 5...

Page 31: ...27 2 14 Alarm 2 Wiring...

Page 32: ...28 2 15 RS 485...

Page 33: ...J52 must be modified as following J52 must be shorted and J51 must be cut and left open The location of the jumpers are shown in the following diagram 2 16 RS 232 If you use a conventional 9 pin RS 2...

Page 34: ...30 2 17 Analog Retransmission...

Page 35: ...31 2 18 Programming Port See figure 1 3 in section 1 3 to find the programming port location...

Page 36: ...32 NOTES...

Page 37: ...sfer 12 Bumpless transfer 13 PV1 shift 14 Programmable SP1 range 15 Heat cool control 16 Hardware lockout 17 Self tune 18 Auto tune 19 ON OFF P PD PI PID control 20 User defined menu SEL 21 Manual con...

Page 38: ...be consistent with the output 2 module installed The available output 2 signal types are the same as for O1TY The range for linear current or voltage may not be very accurate For 0 output the value f...

Page 39: ...rs you may not see all of the above parameters The number of visible parameters is dependent on the setup condition The hidden parameters for the specific application are also deleted from the SEL sel...

Page 40: ...TI1 set to 0 the auto tuning and self tuning are disabled Refer to section 3 21 manual tuning for the adjustment of PB1 and TD1 Manual reset adjust OFST is not practical because the load may change f...

Page 41: ...ol only P PD control and cool only PID control are the same as the descriptions in section 3 5 for heat only control except that the output variable and action for the cool control is inverse to the h...

Page 42: ...N OFF control by selecting AL2 OUT2 will act as alarm output and the process alarm as well as deviation alarm see sections 3 9 and 3 10 can be used Adjust A2SP to change the set point if process alarm...

Page 43: ...ge of 1 255 Initially set 100 for CPB and examine the cooling effect If the cooling action should be enhanced then decrease CPB if the cooling action is too strong then increase CPB The value of CPB i...

Page 44: ...erference action of alarm in a noisy environment Normally A1HY can be set with a minimum 0 1 value A1DV and or A2DV are hidden if alarm 1 and or alarm 2 are set for process alarm Normal Alarm A1MD NOR...

Page 45: ...41 Although the above descriptions are based on alarm 1 the same conditions can be applied to alarm 2...

Page 46: ...A1HY and A2HY can be set with a minimum 0 1 value The trigger level of the alarm moves with the set point For alarm 1 trigger level SP1 A1DV A1HY For alarm 2 trigger level SP1 A2DV A2HY A1SP and or A...

Page 47: ...d alarm The trigger level for deviation band alarm moves with the set point For alarm 1 the trigger level SP1 A1DV For alarm 2 the trigger level SP1 A2DV One of four alarm modes can be selected for al...

Page 48: ...ion 3 25 Example A furnace uses two 2KW heaters connected in parallel to warm up the process The line voltage is 220V and the rating current for each heater is 9 09A If we want to detect any one heate...

Page 49: ...for descriptions of these alarm modes Loop break conditions are detected during a time interval of 2TI1 double the integral time but 120 seconds maximum Hence the loop break alarm doesn t respond as...

Page 50: ...alarm and latching holding alarm However the holding alarm and latching holding alarm are not recommended for the sensor break alarm since the sensor break alarm will not perform the holding function...

Page 51: ...o be warmed up Due to the design and position of the components in the system the sensor could not be placed any closer to the part Thermal gradient different temperature is common and necessary to an...

Page 52: ...ven OFF if O1FN selects REVR and be driven ON if O1FN selects DIRT Output 2 failure transfer if activated will perform 1 If COOL is selected for OUT2 and BPLS is selected for O1FT then output 2 will p...

Page 53: ...riable is applied immediately as power is recovered and the disturbance is small During sensor breaks the controller continues to control by using its previous value If the load doesn t change the pro...

Page 54: ...of the following conditions occurs 1 NONE is selected for SELF 2 The controller is used for on off control that is PB 0 3 The controller is used for manual reset that is TI 0 4 The controller is in a...

Page 55: ...in a steady state warm start See figure 3 22 If auto tuning begins apart from the set point cold start the unit enters warm up cycle As the process reaches the set point value the unit enters a waitin...

Page 56: ...PB exceeds 9000 9000 PU 900 0 F or 500 0 C if TI exceeds 1000 seconds if the set point is changed during the auto tuning procedure or if the event input state is changed so that the set point value i...

Page 57: ...ocess and perform the procedures according to the flow chart shown in the following diagram The above procedure may take a long time before reaching a new steady state since the P band was changed Thi...

Page 58: ...When this occurs the process is said to be in a critical steady state figure 3 24 shows an example of a critical steady state If the control performance using above tuning is still unsatisfactory the...

Page 59: ...ansmitter or sensor These are 20V rated at 25mA 12V rated at 40mA and 5V rated at 80mA The DC voltage is delivered to the output 2 terminals Caution To avoid damage don t use a DC power supply beyond...

Page 60: ...play will show and alternately where indicates output 1 or heating on time and indicates output 2 or cooling on time Now you can use the up and down keys to adjust the percentage values for H or C Thi...

Page 61: ...t 2 DV shows the difference value between process and set point i e PV SV This value is used to control output 1 and output 2 PV1 shows the process value of input 1 PV2 shows the process value of inpu...

Page 62: ...y a DC or half wave AC current can t be measured 3 26 Reload Default Values The default values listed in table 1 4 are stored in the memory when the product leaves the factory On certain occasions it...

Page 63: ...ut is activated However if the alarm 1 condition is still existent alarm 1 will be retriggered when the event input is released RS A2 Resets alarm 2 as the event input is activated However if the alar...

Page 64: ...PLC an alarm relay a manual switch or other devices Select SP2 for EIFN which is in the setup menu This is available only when SP1 2 MIN R or HR R is used for SPMD where MIN R and HR R are used for t...

Page 65: ...tored in PB2 TI2 and TD2 as soon as auto tuning is completed Application 1 programmed by the set point Choose SP P2 for EIFN then both set point and PID values will be switched to another set simultan...

Page 66: ...nt Setting RAMP to zero means no ramp function at all Dwell The dwell timer can be used separately or in conjunction with a ramp If A1FN is set for TIMR alarm 1 will act as a dwell timer Similarly ala...

Page 67: ...N2H if available are set according to the process signal SPMD PV1 Note 1 If PV1 is chosen for both SPMD and PVMD an error code will appear If PV2 is chosen for both SPMD and PVMD an error code will ap...

Page 68: ...esponse of PV2 will be parallel to PV1 as shown in the following diagram The PV display will indicate PV1 PV2 value if P1 2 is chosen for PVMD or PV2 PV1 value if P2 1 is chosen for PVMD If you need P...

Page 69: ...is COOL is not selected for OUT2 then PL2 is hidden If the controller is used for ON OFF control then both PL1 and PL2 are hidden Operation Press for 3 seconds then press several times to reach PL1 a...

Page 70: ...ed Select RTU i e Modbus protocol RTU mode for PROT Set individual addresses for any units that are connected to the same port Set the baud rate BAUD data bit DATA parity bit PARI and stop bit STOP so...

Page 71: ...AOS corresponding to an arbitrary value of parameter AOV is determined by the following curve Notes The setup values used for AOHI and AOLO must not be equal otherwise incorrect values will occur How...

Page 72: ...power Replaces power switch Setup menu FUNC FULL SLEP YES 4 10 Digital Filter In certain applications the process value is too unstable to be read A programmable low pass filter incorporated in the T...

Page 73: ...l power To avoid this the TEC 2500 provides a reference constant REFC in the user menu If PUMP is selected for SPMD the controller will periodically test the process by using this reference constant a...

Page 74: ...valves are closed A typical value for REFC is between 3 and 5 5 An ordinary pump may slowly lose pressure even if the valves are completely closed Adjust SP2 according to the rule that a more negative...

Page 75: ...ere is an example The water pressure in this example must be controlled at 10Kg cm To achieve this the following devices are used for this example Inverter To supply a variable frequency AC voltage to...

Page 76: ...NONE OUT1 REVR O1TY 4 20 O1FT 0 OUT2 DCPS A1FN optional EIFN NONE PVMD PV1 FILT 1 SELF NONE SLEP NONE SPMD PUMP SP1L 5 00 SP1H 15 00 SP2F DEVI Adjust the following parameters in the user menu A1SP op...

Page 77: ...rent minimizing the harmonic current and stress on the load This prolongs the load life Since the duty cycle i e output power level of the control input is small the off period will be extended to kee...

Page 78: ...SR are summarized in the following table Output 1 and output 2 of the TEC 2500 can be connected to the VPFW SSR directly provided that a pulsed voltage drive output is ordered Here is an example Three...

Page 79: ...C 2500 equipped with dwell timer is used for this purpose The system diagram is shown as follows To achieve this function set the following parameters in the setup menu FUNC BASC basic function IN1 K_...

Page 80: ...C and SP1H is set at 0 C Because the temperature is lower than the ambient a cooling action is required so select DIRT for OUT1 Since output 1 is used to drive a magnetic contactor select RELY for O1...

Page 81: ...s O1FT 0 0 OUT2 COOL O2TY 4 20 O2FT 0 0 SELF YES Adjust SP1 to 120 0 C CPB to 125 and DB to 4 0 Apply auto tuning at 120 C for a new system to get optimal PID values See section 3 20 Adjustment of CPB...

Page 82: ...nput for switching the set point The products under test are required to stay at 60 C for 1 hour and 10 C for 30 minutes The transition interval between the high and low temperatures is required to be...

Page 83: ...A ramp is incorporated to control the thermal gradient to suit for making the bread A dwell timer is used to shut off the oven power and announce this to the baker The system is configured as shown in...

Page 84: ...nsmission unit for the master controller and retransmit its set point to input 2 on the rest of the slave controllers each zone will be synchronized with the same temperature Here is an example Set th...

Page 85: ...2 Adjust SP1 here it is 1 00 to control the difference between PV1 and PV2 Choose P1 2 for PVMD the PV display will show the difference value PV1 PV2 between PV1 and PV2 and this value will be stabili...

Page 86: ...treating furnace is used over the range of 400 C to 1200 C 1 Set the following parameters in the setup menu FUNC FULL A1FN PV1H A1MD NORM EIFN PID2 PVMD PV1 SPMD MINR 2 Adjust the following parameters...

Page 87: ...Set the following parameters in the setup menu FUNC FULL A1FN TIMR EIFN SP P2 PVMD PV1 SPMD MINR 2 Adjust the following parameters in the user menu TIME 30 0 minutes RAMP 20 0 C minute SP1 1000 C SP2...

Page 88: ...wire max distance 1 Km Setup Enter setup mode to configure each TEC 2500 Choose FULL for FUNC 485 for COMM RTU for PROT and select a different address ADDR for each unit Use the same values of BAUD DA...

Page 89: ...unit application it is adequate to order a TEC 2500 with RS 232 communication and BC Net software Using the BC Net software the temperature data can be viewed and stored in a file The user can program...

Page 90: ...meters are 20 C to 30 C and 40 RH to 60 RH The recorder inputs accept a 0 5V signal To achieve this set the following parameters in the setup menu UNIT 1 UNIT 2 FUNC FULL FUNC FULL COM 0 5V COMM 0 5V...

Page 91: ...ed for input 1 Chapter 6 Calibration Do not proceed through this section unless there is a definite need to recalibrate the controller If you do recalibrate all previous calibration data will be lost...

Page 92: ...199 9 or 199 9 then calibration failed Perform step 7 to calibrate mA function if required for input 1 Step 7 Set the DIP switch for mA input Press the scroll key until the display shows Send a 20mA...

Page 93: ...ue of 0 0 is obtained Press the scroll key for at least 3 seconds The display will blink for a moment until a new value is obtained If the display didn t blink or if the obtained value is equal to 199...

Page 94: ...90 NOTES...

Page 95: ...nals are open missing or loose Thermocouple is open at tip Thermocouple lead is broken Shorted thermocouple leads Short across terminals Open or shorted heater circuit Open coil in external contactor...

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Page 98: ...94 NOTES...

Page 99: ...ristics Input 2 Resolution 18 bits Sampling rate 1 66x second Maximum rating 2VDC minimum 12VDC maximum Temperature effect 1 5uV C Common mode rejection ratio CMRR 120dB Sensor break detection below 0...

Page 100: ...4 20mA 0 5 55V 0 5V 1 5V 0 11 1V 0 10V User Interface Dual 4 digit LED displays Upper 0 4 10mm lower 0 3 8mm Keypad 3 keys Programming port For automatic setup calibration and testing Communication po...

Page 101: ...97 A 1 Menu Existence Conditions...

Page 102: ...98...

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Page 104: ...100 A 2 Factory Menu Description...

Page 105: ...101 A 5 Memo Use the following table as a master copy for your settings page 1 of 2...

Page 106: ...102...

Page 107: ...ance with any applicable specification TEC Temperature Controllers are warranted to be free from defects in material and workmanship for two 2 years after delivery to the first purchaser for use Tempc...

Page 108: ...antages of our Diverse and Innovative Products Copyright 2013 All Rights Reserved 1P100K13 Electric Heating Elements Thermocouples and RTD Assemblies SCR Power Controls Solid State Relays Mechanical R...

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