TC24 User`s Manual
Contents
1. OFF 1 Figure 3 4 Output 2 Process lime Low Alarm 33 3 4 Alarm Output 2 can be selected as alarm output There are 6 types of alarm functions and one dwell timer can be selected and four kinds of alarm modes ALMD are available for each alarm function A process alarm sets two absolute trigger levels When the process is higher than SP2 a process high alarm occurs and the alarm is off as the process is lower than SP2 O2HY When the process is lower than SP2 a process low alarm PV LO occurs and the alarm is off as the process is higher than SP2402HY A process alarm is independent of set point A deviation alarm alerts the user when the process deviates too far from set point When the process is higher than SV SP2 a deviation high alarm DE HI occurs and the alarm is off as the process is lower than SV4SP2 O2HY When the process is lower than SV4SP2 a deviation low alarm DE LO occurs and the alarm is off as the process is higher than SV4SP2402HY Trigger level of deviation alarm is moving with set point A deviation band alarm presets two trigger levels relative to set point The two trigger levels are SV4SP2 and SV SP2 for alarm When the process is higher than SV4SP2 or lower than SV SP2 a deviation band high alarm DB HI occurs When the process is within the trigger levels a deviation band low alarm DB LO occurs In the above descriptions SV de2. 3 12 Manual Tuning In certain applications very few using auto tuning to tune a process may be inadequate for the control requirements this is when manual tuning should be used If the control performance by using auto tuning is still unsatisfactory the following rules can be applied for further adjustment of PID values 42 ADJUSTMENT SEQUENCE SYMPTOM SOLUTION Slow Response Decrease PB 1 Proportional Band PB Hi igh overshoot or Oscillations Increase PB Slow Response Decrease TI 2 Integral Time TI Instability or noes ii Oscillations Slow Response or MR Decrease TD 3 Derivative Time TD Oscillations High Overshoot Increase TD Table 3 2 PID Adjustment Guide Figure 3 9 shows the effects of PID adjustment on process response 3 13 Manual Control Operation To enable manual control the LOCK parameter should be set with NONE then press several times then Heating output or _ J Cooling output will appear on the display Press lt for5 seconds then the display will begin to flash The controller now enters the manual control mode indicates output control variable for output 1 and indicates control variable for output 2 Now you can use up down key to adjust the percentage values for the heating or cooling output The controller performs open loop control as long as it stays in man
3. gt Time 0 17 30 40 minutes Note When the ramp function is used the display will show the current ramping value However it will revert to show the set point value as soon as the up or down key is touched for adjustment The ramping value is initiated to process value either as power up or RR and or set point are changed Setting RR to Zero means no ramp function at all 36 3 7 Dwell Timer Output 2 can be configured as dwell timer by selecting TIMR for OUT2 Asthe dwell timer is configured the parameter SP2 is used for dwell time adjustment The dwell time is measured in minutes ranging from 0 1 to 4553 6 minutes Once the process reaches the setpoint the dwell timer starts to time down to zero time out The timer relay will remain unchanged until time out The dwell timer operation is shown in the following diagram After time out the dwell timer can be restarted by pressing the RESET key The timer stops timing during the manual control mode failure mode calibration period and auto tuning period PV SP gt Time ALM SP3 power off or touch RESET key Time Timer starts Figure 3 6 Dwell Timer Function If output 2 is configured as dwell timer ALMD will be hidden 37 3 8 PVShift In certain applications it is desirable to shift the controller display value from its actual value This can be easily accomplished by using the PV shift function The SHIF function will
4. TC TC PTA PTB PTB COM 0000 RTD ts 7 4 4 50 C max Air ambient te poe er nos 6 B on T C input Figure 2 3 Rear Terminal Connection 22 2 4 Power Wiring The controller is supplied to operate at 11 26 VAC VDCor 90 250 VAC Check thatthe installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller Near the controller a fuse and a switch rated at 2 250VAC should be equiped as shown in the following diagram LFi Fuse 90 250 or N a 2A959 AG 11 26 VAC VDC Figure 2 4 PowerSupply Connections A This equipment is designed for installation inan enclosure which provides adequate protection against electric shock The enclosure must be connected to earth ground Local requirements regarding electrical installation should be rigidly observed Consideration should be given to prevent from unauthorized access to the power terminals 2 5 Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a control system The probe should be placed sothat it can detect any temperature change with minimal thermal lag In a process that requires fairly constant heat output the probe should be placed close to the heater In a process where the heat demand is variable the probe should be close to the workarea Some experiments with pro
5. Internal Circuit ic CE 7 30mA 5V _5V Pulsed Voltage 33 1 33 am Figure 2 8 Output 1 Pulsed Voltage to Drive SSR 25 5 4 20mA Figure 2 9 Output 1 Li 3 0 20mA 6 4 20ma 4 Maximum Load 500 ohms Load near Current LOAD 4 Figure 2 10 7 120V 240VAC Mains Supply Output 2 Relay to Drive Load 120V 240V 5 Three 6 9 Phase 5 6 Heater 2 No Fi Power lo Fuse Phase Contactor Breaker Heater Load Figure 2 11 Output 2 Relay to Drive Contactor 2 8 Alarm Wiring 3 j Ton 120V 240VAC Figure 2 12 Alarm Output to Drive Load 3 9 120V 240V 4 Mains Supply Phase Heater o Power Three Phase No Fuse Delta Contactor Breaker Heater Load Relay Output to Drive Contactor Figure 2 13 Alarm Output to Drive Contactor 27 Chapter 3 Programming Press for 5 seconds and release to enter setup menu Press to select the desired parameter The display indicates the parameter symbol Press 4 or v to view or adjust the value of the selected parameter 3 1 Lockout There are four security levels can be selected by using LOCK parameter If NONE is selected for LOCK then no parameter is locked If SET is selected for LOCK then all setup data are locked If USER is selected for LOCK then all setup da
6. defend and indemnify Eaton against damages claims and expenses arising out of subsequent sales of Durant products or products containing components manufactured by Eaton and based upon personal injuries deaths property damage lost profits and other matters for 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 PL 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 The warranties and remedies provided for herein are available to Buyer and shall not extend to any other person 53 E TN Eaton Corporation Electrical Group 1000 Cherrington Parkway Moon Township 15108 United States 877 ETN CARE 877 386 2273 web site http www Eaton com
7. Displays 9 Chapter 5 Specifications 46 1 4 Menu Overview 11 1 5 Parameter Descriptions 12 Appendix A 1 Error Codes 52 A 2 Warranty 53 Chapter 2 Installation 2 1 Unpaking 2 2 Mounting 2 3 Wiring precautions 2 4 Power Wiring 2 5 Sensor Installation Guidlines 23 2 6 Sensor Input Wiring 24 2 7 Control Output Wiring 24 2 8 Alarm Wiring 27 Chapter 3 Programming 3 1 Lockout 28 3 2 Signal Input 28 3 3 Control Outputs 29 3 4 Alarm 34 3 5 Configure Display 35 3 6 Ramp 36 3 7 Dwell Timer 37 3 8 PV Shift 38 3 9 Digital Filter 39 3 10 Failure Transfer 40 3 11 Auto tuning 41 3 12 Manual tuning 42 3 13 Manual Control 43 Figures amp Tables Figure 1 1 Fuzzy Control Advantage Figure 1 2 Front Panel Description Figure 1 3 Display of Initial Stage Figure 2 1 Mounting Dimensions Figure 2 2 Lead Termination Figure 2 3 Rear Terminal Connection Figure 2 4 Power Supply Connections Figure 2 5 Sensor Input Wiring Figure 2 6 Output 1 Relay to Drive Load Figure 2 7 Output 1 Relayto Drive Contactor Figure 2 8 Output 1 Pulsed Voltage to Drive SSR Figure 2 9 Ou
8. ade pm 8 and change some of the ADDR Value GS previous setting data M RAMP Make sure that the c system will allow application of these modes d O2TY e c 5 1 The flow chart shows eves complete listing of all d parameters For actual application the number of available parameters appr depends on setup conditions and should be SE less than that shown in the flow chart mc STOP agmo press 9 e 2 again for 2 to 3 seconds then E see H release to enter the 5 SEL3 calibration menu SEL4 5 SELS 5817 9 sas 11 1 6 Parameter Descriptions input Parameter ipti Default Notation Parameter Description Range Value SP1 Set point for output 1 Low High SP1H 25 0 C OW igh 77 09F Set point for output 2 when output 2 performs a Seb 10 0 5 2 alarm function or dwell Low 19999 High 45536 18 0 F timer 0 No parameter is locked 1 Setup data are LOCK Select parameters to be locked 0 locked 2 uSEr Setup data and User data except Set point are locked 3 ALL All data are locked 0 J EC J type thermocouple 1E EL K type thermocouple 2 _ T type thermocouple _ E type thermocouple 4 _ B type thermocouple 5 r EC R type thermocouple 6 5 EC S type
9. modified Proportional band 0 1 900 0 F Integral time 0 1000 seconds Derivative time 0 360 0 seconds Cycle Time 0 1 90 0 seconds Manual Control Heat MV1 and Cool MV2 Auto tuning Cold start and warm start Failure Mode Auto transfer to manual mode while sensor break or A D converter damage Ramping Control 0 900 0 F minute 0 900 0 F hour ramp rate Digital Filter Function First order Time Constant 0 0 2 0 5 1 2 5 10 20 30 60 seconds programmable 50 Environmental amp Physical Operating Temperature 10 to 50 Storage Temperature 40 to 60 Humidity 0 to 90 non condensing Altitude 2000m maximum Pollution Degree 2 Insulation Resistance 20 Mohms min at 500 VDC Dielectric Strength 2000 VAC 50 60 Hz for 1 minute Vibration Resistance 10 55 Hz 10 m s for 2 hours Shock Resistance 200 m s 202 Moldings Flame retardant polycarbonate Dimensions 50mm W X 26 5mm H X 110 5mm D 98 mm depth behind panel Weight 120 grams Approval Standards Safety UL61010C 1 CSA C22 2 No 24 93 EN61010 1 IEC1010 1 Protective Class IP65 front panel 1 20 for terminals and housing with protective cover All indoor use EMC EN61326 51 Table A 1 Error Codes and Corrective Actions Code Symbol Error Description Corrective Action Illegal setup values been used Check and correct setup values
10. of Before COOL is used for OUT2 OUT2 PB TI and OUT1 IF OUT2 DIRT cooling action has already is required for cooling control the been used for OUT1 or PID mode control should use PID mode PB 4 is not used for OUT thatis PB 0 TI 0 and OUTI should 0 and or TI 0 reverse mode heating action otherwise don t use OUT2 for cooling control Communication error bad function Correct the communication 10 E 00 code software to meet the protocol requirements _ Communication error register Don t issue an over range 11 Er i laddress out of range register address to the slave Communication error attempt Don t write a read only data or a 14 4 to write a read only data or a protected data to the slave protected data Communication error write a Don t write an over range data 15 E 15 value which is out of range to a to the slave register register 1 The PID values obtained after auto tuning procedure are out of range Retry auto tuning 2 Don change set point value 26 Fail to perform auto tuning during auto tuning procedure function 3 Use manual tuning instead of auto tuning 4 Dont set a zero value for PB 5 Dont set a zero value for TI 6 Touch RESET key 29 EEPROM write error Return to factory for repair r _ Cold junction compensation for i 30 JE thermocouple malfunction Return to factory for repair Input sensor break or input c cu
11. value for P control Low 0 High 100 0 25 0 14 Parameter Notation Parameter Description Range Default Value RAMP Ramp function selection 0 Ramp Function 1 Use unit minute as Ramp Rate 2 Hr Useunit hour as Ramp Rate ni nr RR Ramp rate LL 500 0 Low 0 High 900 0 F 0 0 OUT2 Output 2 function 0 Output 2 No Function 1 E nr Dwell timer action 2 Deviation High Alarm Deviation Low Alarm 4 Deviation band out of band Alarm 5 n Deviation band in band Alarm 6 Process High Alarm 7 PYL Process Low Alarm 8 Cooling PID Function O2TY Output 2 signal type 0 Relay output 1 557 d Solid state relay drive output 2 Solid state rela 5 5 g output Y 3 q BD 4 20 current 4 e0 module 4 2 0 20 current module 0 1V voltage module Gu 0 5V voltage 7 module 1 5V voltage module 0 10V voltage module O2FT Output 2 failure transfer mode Select BPLS bumpless transfer or 0 0 100 0 to continue output 2 control function as the unit fails or select ON 0 or OFF 1 for alarm and dwell timer function 15 Parameter Description Range Default Output hysteresis value when output 50 0 0 1
12. 50 60 HZ 5 11 26 or VDC Communications 0 None 11 1 Standard Input Thermocouple J KI E B Output 2 S N L RTD PT100 DIN PT100 J IS 1 Form A relay 2A 240 6 4 20 mA Output 1 1 Relay rated 2A 240VAC 2 Pulsed voltage to drive SSR 5 30mA 3 Isolated 4 20mA 0 20mA 1 3 Keys and Displays KEYPAD OPERATION SCROLL KEY This key is used to select a parameter to be viewed or adjusted UP KEY 4 This key is used to increase the value of selected parameter DOWN KEY v This key is used to decrease the value of selected parameter RESET KEY press a This key is used to 1 Revert the display to the process value or set point value if DISP is set with SP1 2 Reset the latching alarm once the alarm condition is removed 3 Stop the manual control mode auto tuning mode and calibration mode 4 Clear the message of auto tuning error 5 Restart the dwell timer when the dwell timer has been time out 6 Enter the manual control menu when failure occurs ENTER KEY Press for a minimum of 5 seconds Press for 5 seconds to 1 Enter setup menu The display shows CSEE 2 Enter manual control mode when manual control mode or is selected 3 Enter auto tuning mode when auto tuning mode A E is selected Output 2 Indicator Output 1 Indicator 3 Silicone Rubber Buttons for ease of control setup
13. 5V 0 9 1V 5 5 25 10 0 10 0v 10 10 5 V 10 KO min Linear Output Resolution 15 bits Output Regulation 0 02 for full load change Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC Temperature Effect 0 01 76 of SPAN Triac SSR Output Rating 1A 240 VAC Inrush Current 20A for 1 cycle Min Load Current 50 mA rms Max Off state Leakage 3 mA rms Max On state Voltage 1 5 V rms Insulation Resistance 1000 Mohms min at 500 VDC Dielectric Strength 2500 VAC for 1 minute 48 DC Voltage Supply Characteristics Installed at Output 2 Tolerance Max Output Current Ripple Voltage Isolation Barrie 20V 1 V 25 0 2 500 VAC 12V 0 6 V 40 mA 0 1 Vp p 500 VAC 5V 0 25 V 80 0 05 500 Output 2 Functions Dwell timer Deviation High Low Alarm Deviation Band High Low Alarm PV High Low Alarm PID cooling control Alarm Mode Normal Latching Hold Latching Hold Dwell Timer 0 1 4553 6 minutes 49 User Interface Single 4 digit LED Display Keypad 3 keys Control Mode Output 1 Reverse heating or direct cooling action Output 2 PID cooling control cooling P band 50 300 of PB dead band 36 0 36 0 of PB ON OFF 0 1 90 0 F hysteresis control P band 0 P or PD 0 100 0 offset adjustment PID Fuzzy logic
14. 7 00 20 seconds time constan 8 30 30 seconds time constan 9 60 seconds time constan 13 Parameter Notation Parameter Description Range Default Value DISP Normal display selection Display process value normally 0 pu 1 SPH Display set point 1 value normally PB Proportional band value 500 0 High 900 0 F Low 0 10 0 C 18 0 F TI Integral time value Low 0 High 1000 sec 100 TD Derivative time value Low 0 High 360 0 sec 25 0 OUT1 Output 1 function U Reverse heatin 0 F control 9 1di rt Direct cooling control action O1TY Output 1 signal type EL Relay output 1 55rd 2 55r 34 00 40 20 qu Solid state relay drive output Solid state relay outpu 4 20 mA current module 0 20 mA current module 5 0 1V voltage module 0 5V voltage 1 59 module T 8g 6 1 5V voltage module 0 10V voltage 0 module O1FT Output 1 failure transfer mode Select BPLS bumpless transfer or 0 0 100 0 to continue output 1 control function as the unit fails or select OFF 0 or ON 1 for ON OFF control O1HY Output 1 ON OFF control hysteresis Low 0 1 High 50 0 C 90 0 F 0 1 0 2 F Output 1 cycle time Low 0 1 High 90 0 sec 18 0 OFST Offset
15. CK parameter should be set at NONE 3 Set the set point to a normal operating value or a lower value if overshooting beyond the normal process value is likely to cause damage 4 Press several times until amp j appears on the display 5 Press co for at least 5 seconds The display will begin to flash and the auto tuning procedure will begin NOTE The ramping function if used will be disabled once auto tuning mode is entered The auto tuning mode is disabled as soon as either failure mode or manual control mode occurs 4l Procedures The auto tuning can be applied either as the process is warming up Cold Start or as the process has been in steady state Warm Start After the auto tuning procedures are completed the display will stop flashing and the unit will revert to PID control using he new PID values The PID values obtained are stored in the nonvolatile memory Auto Tuning Error If auto tuning fails an ATER message will appear on the display in cases of e f PB exceeds 9000 9000 PU 900 0 F or 500 0 C or if Tl exceeds 1000 seconds e or if set point is changed during auto tuning procedure Solutions to HEE 1 Try auto tuning once again 2 Don t change set point value during auto tuning procedure 3 Don t set zero value for PB and TI 4 Use manual tuning instead of auto tuning See section 3 12 5 Touch RESET key to reset H message
16. O2HY fi Low 0 1 High NIS alarm 9 90 0 0 2 F CYC2 Output 2 cycle time Low 0 1 High 90 0 sec 18 0 Cooling proportional i jah nd vallo Low 50 High 300 100 Heating cooling dead DB band negative value Low 36 0 High 36 0 0 overlap 0 nor Normal alarm action T 1 L Ec h Latching alarm action ALMD arm operation mode Hol d Hold alarm action 0 3 L Latching 8 Hold action 0 nonE communication 1 Modbus RTU mode protocol 24 20 4 20mA retransmission 28 output 3 N 0 20mA retransmission Communication 0 20 output COMM function 1 4 D 5 t 0 5V retransmission 7 output 5 J 5Y 1 5V retransmission 7 output 6 0 10V retransmission Address assignment of EM ADDR digital communication Low 1 High 255 0 2 4 Kbits s baud rate 1 48 4 8 Kbits s baud rate 2 GB 9 6 Kbits s baud rate Baud rate of digital 1 BAUD Communication 3 IHH 14 4 Kbits s baud rate 2 4 190 19 2 Kbits s baud rate 5 288 28 8 Kbits s baud rate 6 2384 38 4 Kbits s baud rate 16 Parameter Description Range Default DATA Data bit count of digital 0 7b E 7 data bits communication 1 Bb L 8 data bits 0 EU En Even parity Parity bit of digital gt PARI communication add Odd parity 0 2 none No parity bit stop Stop bit count of digital 0 ib E stop bit 0 commun
17. P to alter the resolution 3 3 Control Outputs There are 4 kinds of control modes can be configured as shown in Table 3 1 Table 3 1 Heat Cool Control Setup Value Control Modes OUT1 OUT2 O1HY Du Heat only REVR x v Cool only DIRT x d Heat PID Cool ON orr REVR DE HI x x Heat PID Cool pip REVR COOL x O X Don t Adjust to met process requirements x Required if ON OFF control is configured 29 Heat Only ON OFF Control Select REVR for OUT1 Set to 0 O1HY is used to adjust dead band for ON OFF control The output 1 hysteresis O1HY is enabled in case of PB 0 The heat only on off control function is shown in the following diagram PV SP11 Dead band O1HY SP1 O1HY OUT1 Action Time ON OFF Time Figure 3 2 Heat Only ON OFF Control The ON OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest ON OFF control is set ie PB 0 TI TD CYC1 OFST CYC2 CPB DB will be hidden and have no function to the system The auto tuning mode and bumpless transfer will be disabled too Heat only P or PD control Select REVR for OUT1 set TI to 0 OFST is used to adjust the control offset manual reset O1HY is hidden if PB is not equal to 0 OFST Function OFST is measured by with range 0 100 0 In the steady state ie process has been stabil
18. User s Manual TC 24 PC 24 Auto Tune Fuzzy PID Process Temperature Controller E T N Warning Symbol N The Symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in personal injury or damage to or destruction of part or all of the product and system Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met Use the Manual e Installers Read Chapter 1 2 e System Designer Read All Chapters e Expert User Read Page 11 NOTE It is stronglyrecommended that aprocess should incorporate a LIMIT CONTROL like L91 which will shut down the equipment ata preset processcondition in orderto preclude possible damageto products orsystem Some programming parametersshown in thismanual may not be available oncurrently offered models Information in this user s manual is subject to change without This manual isapplicable for theproducts with software version 23 andlater version Copyright April 2003 Eaton Corporation all rights reserved No part of this publication may be reproduced transmitted transcribed or stored in a retrieval system or translated into any language in any form by any means without the written permission of Eaton Corporation Contents Chapter 1 Overview Chapter 4 Calibration 45 1 1 General 5 1 2 Ordering Code 8 D 1 3 Keys and
19. alter PV only Here is an example A process is equipped with a heater a sensor and a object to 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 extent in any thermal system for heat to be transferred from one point to another If the difference between the sensor and the subject is 35 and the desired temperature at the subject to be heated is 200 the controlling value or the temperature at the sensor should be 235 You should input 35 as to subtract 35 from the actual process display This in turn will cause the controller to energize the load and bring the process display up to the set point value Object Object Object Heater Heater Heater Heat Transfer 200 Heat Transfer 35 C temperature Adjust SHIF Display is stable difference is observed SHIF 35 C SHIF 35 SHIF 0 Supply more heat PV SV Figure 3 7 PV Shift Application 38 3 9 Digital Filter In certain application the process value is too unstable to be read To improve this a programmable low pass filter incorporated in the controller can be used This is a first order filter with time constant specified by FILT parameter The default value of FILT is 0 5 sec before shipping Adjust FILTto change the time constant fr
20. and set point adjustment Figure 1 3 Front Panel Description Table1 1 Display Form of Characters FilFlulsfofoltlelyl y P U 12 V S Display program code of the product for 2 5 seconds The diagram shows program no 33 with version 24 Figure 1 4 Display of Initial Stage 10 1 5 Menu Overview Calibration Mode AN User menu 1 Setup menu 1 DISP PV i DISP SP1 29 6 2 sec gt or 5 1 SE ey x 5 1 Pv Value Sy om ad Value SP2 Value ad e ad Ano Wale AEN 4 DP eM RTDL Mode INLO e RTDH e 2 5 INHI De ZJ e 5 _ Manu e CHI Value 5sec Maa uning sar C 5 seconds to Ej Value 9 perform calibration gc NT 25 C OUTI aqi da applying these modes will break the control loop C O1HY
21. be location are often required to findthis optimal position In a liquid process addition of a stirrer will help to eliminate thermal lag Since the thermocouple is basically a point measuring device placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes 23 Proper sensor type is also a very important factor to obtain precise measurements The sensor must have the correct temperature range to meet the process requirements In special processesthe sensor might need to have different requirements such as leak proof anti vibration antiseptic etc Standard sensor limits of error are 4 degrees F 2 degrees C or 0 75960f sensed temperature half that for special plus drift caused by improper protection or an over temperature occurrence This error is far greater than controller error and cannot be corrected on the sensor except by proper selection and replacement 2 6 Sensor Input Wiring PTA 8 TC V 9 PTB mA Pg ma 10 TC V mA RTD Figure 2 5 Sensor Input Wiring 2 7 Control Output Wiring 5 L L0AD 2wpawAC IT Mains Supply Figure 2 6 Output 1 Relay to Drive Load 24 5 o 120V 240V 6 8 No Fi Power lo Fuse Phase Contactor Breaker Heater Load Figure 2 7 Output 1 Relay to Drive Contactor 558 5 e o Load o 6 120V 240V
22. cesses The results is to enable a process to reach a predetermined set point in the shortest time with the minimum of overshoot and undershoot during power up or external load disturbance Auto tune The auto tune function allows the user to simplify initial setup for a new system Aclever algorithm is provided to obtain an optimal set of control parameters for the process and it can be applied either as the process is warming up cold start or as the process has been in steady state warm start Lockout Protection According to actual security requirement one of four lockout levels can be selected to prevent the unit from beingchanged abnormally Bumpless Transfer Bumpless transfer allows the controller to continue to control by using its previous value as the sensor breaks Hence the process can be well controlled temporarily as if the sensoris normal Soft start Ramp The ramping function is performed during power up as well as any time the set point is changed It can be ramping up or ramping down The process value will reach the set point with a predetermined constant rate Digital Filter A first order low pass filter with a programmable time constant is used to improve the stability of process value This is particularly useful in certain application where the process value is too unstable to be read 1 2 Ordering Code TC24 1 PC 24 Display Color Power Input 0 Red color 4 90 250 VAC
23. g media adjust at 100 99 For oil used as cooling media adjust CPB at 125 99 For water used as cooling media adjust CPB at 250 99 DB Programming Adjustment of DB is dependent on the system requirements If more positive value of DB greater dead band is used an unwanted cooling action can be avoided but an excessive overshoot over the set point will occur If more negative value of DB greater overlap is used an excessive overshoot over the set point can be minimized but an unwanted cooling action will occur It is adjustable in the range 36 096to 36 0 of PB A negative DB value shows an overlap area over which both outputs are active A positive DB value shows a dead band area over which neither Output 2 ON OFF Control Alarm function Output 2 can also be configured as alarm function There are 4 alarm functions that can be selected for output 2 DE HI deviation high alarm DE LO deviation low alarm PV HI process high alarm and PV LO process low alarm Refer to Figure 3 3 and Figure 3 4 for the description of deviation alarm and process alarm 32 PV OUT2 DE HI A SV SP2 SV SP2 O2HY OUT Action Time A EL cllc le E SL sc ON OFF Figure 3 3 Output 2 Deviation rime High Alarm PV A 1 1 1 1 2 2 1 1 1 1 1 1 SP2 1 1 1 1 1 1 1 1 i OUT2 Action I I Time n 1 1 1 1 1 1 1 1 1
24. ication 1 gp E Two stop bits Retransmission low ih 0 0 C RELO value Low 19999 High 45536 32 0 F Retransmission high lah 100 0 scale value Low 19999 High 45536 0 E No parameter selected 1 L LOCK is put ahead 2 n PLE INPT is put ahead E UNIT is put ahead 4 DP is put ahead 5 SH E SHIF is put ahead 6 PB is put ahead 7 Tlis put ahead Select 1st parameter fo TDi SELT 552 menu metere 8 d is put ahead 2 9 THY O1HY is put ahead of YL CYC1 is put ahead fF SE OFST is put ahead 2 RR is put ahead 39 CHY O2HY is put ahead 4L CYC2 is put ahead 5 Pb CPBis put ahead 6 db DB is put ahead 7 Addr ADDR is put ahead 17 Narameter Parameter Description Range Default mE ix Same SEL 3 seis Select 3rd parameter same as SEL SEL4 59 2 parameter same as SEL SEL5 5 ectSth parameter same as SEL SEL6 ect eth parameter Same as SEL SEL7 n parameter Same as SEL SEL8 Select 8th parameter Same as SEL pe or user menu 18 Chapter 2 Installation AN Dangerous voltages capable of causing death are sometimes present in this instrument Before installation or beginning any cleaning or troubleshooting procedures the power to all equipment must be switched off and isolated Units suspected of being faulty must be d
25. in thecutout 19 Figure 2 1 Mounting Dimensions MOUNTING 12 5mm 98 0mm 10 0mm 20 2 3 Wiring Precautions Before wiring verify the label for correct model number and options Switch off the power while checking Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded It is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools wiring must conform to appropriate standards of good practice and local codes and regulations Wiring must be suitable for voltage current and temperature rating of the system Beware not to over tighten the terminal screws Thetorque should not exceed 1 N m 8 9 Lb in or 10 2 KgF cm Unused control terminals should not be used asjumper points as they may be internally connected causing damage to the unit Verify that the ratings of the output devices and the inputs as specified in Chapter 6 are not exceeded Except the thermocouple wiring all wiring should use stranded copper conductor with maximum gauge 18AWG 21 2 0mm 0 08 max Tm Figure 2 2 T Lead Termination F 4 5 7 0 mm 0 18 0 27 OP2 OP1 L N Lo e 90 250 24 240 24 240 47 63 Hz 10VA V mA
26. isconnected and removed to a properly equipped workshop for testing and repair Component replacement and internal adjustments must be made by a qualified maintenance person only This instrument is protected throughout by Double Insulation E To minimize the possibility of fire or shock do not expose this instrument to rain or excessive moisture A Do not use this instrument in areas under hazardous conditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 6 A Remove stains from this instrument using a soft dry cloth Don t use harsh chemicals volatile solvent such as thinner or strong detergents to clean the instrument in order to avoid deformation or discoloration 2 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If any damage due totransit report and claim with the carrier Write down the model number serial number and date code for future reference when corresponding with our service center The serial number S N and date code D C are labeled on the box and thehousing of control 2 2 Mounting Make panel cutoutto dimension shownin Figure 2 1 Remove both mounting clamps andinsert the controllerinto panel cutout Reinstall the mountingclamps Gently tighten the screws inthe clamp until the controller front panel is fitted snugly
27. ized if the process value is lower than the set point a definite value say 5 while 20 is used for PB that is lower 25 30 then increase OFST 25 and vice versa After adjusting OFST value the process value will be varied and eventually coincide with set point Using the P control TI set to 0 the auto tuning is disabled Refer to section 3 12 manual tuning for the adjustment of PB and TD Manual reset adjust OFST is not practical because the load may change from time to time and often need to adjust OFST repeatedly The PID control can avoid this situation Heat only PID control Selecting REVR for OUT1 PB and TI should not be zero Operate auto tuning for the new process or set PB TI and TD with historical values See section 3 11 for auto tuning operation If the control result is still unsatisfactory then use manual tuning to improve the control See section 3 12 for manual tuning The unit contains a very clever PID and Fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is properly tuned Cool only control ON OFF control P PD control and PID control can be used for cool control Set OUT1 to DIRT direct action The other functions for cool only ON OFF control cool only P PD control and cool only PID control are same as descriptions for heat only control except that the output variable and action for the cool control is inverse to the heat con
28. mer can beconfigured for the second output The units are fully programmable for PT100 and thermocouple types J T E B R 5 Lwith no need to modify the unit The input signal is digitized by using a 18 bit Ato D converter Its fast sampling rate allows the unit to control fast processes By using proprietary Fuzzy modified PID technology the control loop will minimize the overshoot and undershoot in a shortest time The following diagram is a comparison of results with and without Fuzzy technology PID control with properly tuned PID Fuzzy control Temperature Set point Figure 1 1 Fuzzy Control Advantage Warm Up Load Disturbance Time High Accuracy The series are manufactured with custom designed ASIC Application Specific Integrated Circuit technology which contains a 18 bit A to D converter for high resolution measurement true 0 1BF resolution for thermocouple and PT100 and a 15 bit Dto Aconverter for linear current or voltage control output TheASIC technology provides improved operating performance low cost enhanced reliability and higher density Fast Sampling Rate The sampling rate of the input Ato D converter reaches 5 times second The fast sampling rate allows this series to control fast processes Fuzzy Control The function of Fuzzy control is to adjust PID parameters from time to time in order to make manipulation output value more flexible and adaptive to various pro
29. notes the current set point value for control which is different from SP1 as the ramp function is performed There are four types of alarm modes available for each alarm function these are Normal alarm Latching alarm Holding alarm and Latching Holding alarm They are described as follows Normal Alarm ALMD NORM When a normal alarm isselected the alarm output isde energized in the non alarm condition and energized in an alarm condition Latching Alarm ALMD If a latching alarm is selected once the alarm output is energized it will remain unchanged even if the alarm condition is cleared The latching alarm is reset when the RESET key is pressed once the alarm condition is removed 34 Holding Alarm ALMD HOLD A holding alarm prevents an alarm from power up The alarm is enabled only when the process reaches the set point value Afterwards the alarm performs same function as normal alarm Latching Holding Alarm ALMD 0 A latching holding alarm performs both holding and latching function The latching alarm is reset when the RESET key is pressed once the alarm condition is removed Alarm Failure Transfer is activated as the unit enters failure mode Alarm will go on if ON is set for O2FT and go off if OFF is set for O2FT The unit will enter failure mode when sensor break occurs or if the A D converter of the unit fails 3 5 Configure Display The controller can be configured to display the proce
30. om 0 to 60 seconds 0 second represents no filter is applied to the input signal The filter is characterized by the following diagram FILT 0 i sec m FILT 1 FILT 30 1 sec PV Time Figure 3 8 Filter Characteristics Note The Filter is available only for PV and is performed for the displayed value only The controller is designed to use unfiltered signal for control even if Filter is applied A lagged filtered signal if used for control may produce an unstable process 39 3 10 Failure Transfer The controller will enter failure mode as one of the following conditions occurs 1 SBER occurs due to the input sensor break or input current below 1mA if 4 20 mA 15 selected or input voltage below 0 25V if 1 5 V is selected 2 ADER occurs due to the A D converter of the controller fails The output 1 and output 2 will perform the failure transfer function as the controller enters failure mode Output 1 Failure Transfer if activated will perform 1 If output 1 is configured as proportional control PB40 and BPLS is selected for O1FT then output 1 will perform bumpless transfer Thereafter the previous averaging value of MV1 will be used for controlling output 1 If output 1 is configured as proportional control PBZO and a value of 0 to 100 0 is set for O1FT then output 1 will perform failure transfer Thereafter the value of O1FT will be used for controlling output 1 If out
31. put 1 is configured as ON OFF control PB 0 then output 1 will transfer to off state if OFF is set for OTFT and transfer to on state if ON is set for O1FT Output 2 Failure Transfer if activated will perform 1 OUT2 is configured as COOL and BPLS is selected for O2FT then output 2 will perform bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 If OUT2 is configured as COOL and a value of 0 to 100 0 is set for O2FT then output 2 will perform failure transfer Thereafter the value of O2FT will be used for controlling output 2 If OUT2 is configured as alarm function and OFF is set for O2FT then output 2 will transfer to off state otherwise output 2 will transfer to on state if ON is set for O2FT 40 3 11 Auto tuning The auto tuning process is performed at set point The process will oscillate around the set point during tuning process Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage The auto tuning is applied in cases of nitial setup for a new process The set point is changed substantially from the previous auto tuning value The control result is unsatisfactory Operation 1 The system has been installed normally 2 Set the correct values for the setup menu of the unit But don t use a zero value for PB and TI otherwise the auto tuning program will be disabled The LO
32. rrent below 1 mA if 4 20 mA is i 39 5 selected or input voltage below Replace input sensor 0 25V if 1 5V is selected 40 AdE D converterorrelated Return to factory for repair component s malfunction 52 Eaton warrants all products against defects in material and workmanship for a period of one 1 year from the date of shipment to Buyer This is a limited warranty limited to its terms This warranty is void if the product has been altered misused taken apart or otherwise abused ALL OTHER WARRANTIES EXPRESS OR IMPLIED ARE EXCLUDED INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANT ABILITY AND FITNESS FOR PURPOSE BUYERS REMEDIES Eaton s obligations and liabilities under the foregoing warranty are limited to repair or replacement of the product without charge To receive the required Return Goods Authorization number RGA contact your local Eaton distributor or Eaton Care at 877 ETN CARE A charge is made for repairing after the expiration of the warranty IN NO EVENT SHALL EATON BE LIABLE FOR CLAIMS BASED UPON BREACH OF EXPRESS OR IMPLIED WARRANTY OR NEGLIGENCE ORANY OTHER DAMAGES WHETHER DIRECT IMMEDIATE FORESEEABLE CONSEQUENTIAL OR SPECIAL OR FOR ANY EXPENSES INCURRED BY REASON OF THE USE OR MISUSE SALE OR FABRICATION OF PRODUCTS WHICH DO OR DO NOT CONFORM TO THE TERMSAND CONDITIONS OF THIS CONTRACT INDEMNIFICATION Buyer agrees to hold Eaton harmless from
33. ss value by selecting PV for DISP or to display the set point value by selecting SP1 for DISP in the normal condition Examples If LOCK is set with NONE OUT2 is set with DEHI DISP is set with PV set SEL1 SHIF SEL2 ADDR SEL3 PB SEL4 SEL8 NONE then the display scrolling becomes J zp ce pe RE t pr F 2 If LOCK is set with NONE OUT1 is set with REVR nonzero value is set for PB and TI OUT2 is set with COOL DISP is set with SP1 set SELISNPT SEL2 PB SEL3 TI SELA SEL8 NONE then the display scrolling becomes SP1 LES e H t Em Ee Pale 3 6 Ramp The ramping function is performed during power up as well as any time the set point is changed Choose MINR or HRR for RAMP the unit will perform the ramping function The ramp rate is programmed by adjusting RR The ramping function is disabled as soon as the failure mode the manual control mode the auto tuning mode or the calibration mode occurs Example without Dwell Timer Select MINR for RAMP selects for UNIT selects 1 DP for DP Set RR 10 0 SV is set to 200 initially and changed to 100 C 30 minutes after power up The starting temperature is 30 After power up the process follows the curve shown below Figure 3 5 RAMP Function 1 1
34. t below 1 mA for 4 20 mA input below 0 25V for 1 5 V input unavailable for other inputs Sensor Break Responding Time Within 4 seconds for TC RTD and mV inputs 0 1 second for 4 20 mA and 1 5 V inputs 46 Characteristics Accuracy Input Range 25 Impedance 120 C 1000 C N J 18 1832 TC 2 2 200 C 1370 328 2 C 22 250 400 C B T Casp 752 F 53 22M9 100 C 900 C ar 16522 2 C 2 2MQ c 1800c 2 B 200 22 32 F 3272F 800 C 0 1767 8 C Fee 22M 0 1767 8 5 32 F 3214 F 2 2 2 MO 250 C 1300 N N 2372 F 42 22M9 200 C 900 C 328 F 1652 F 2 C 2 2 PT100 210 C 700 C DIN 346 F 1292 F 0 476 1 3 PT100 200 C 600 C JIS 328 _ 1112 794 13 mV 8mV 70mV 0 05 2 2 MQ mA 3mA 27mA 0 05 70 50 1 3 11 5V amp 0 05 X 650KQ 47 Output 1 Output 2 Relay Rating 2A 240 VAC life cycles 200 000 for resistive load Pulsed Voltage Source Voltage 5V current limiting resistance 66 Linear Output Characteristics Type 4 20 3 6 4 20 21 5000 max 0 20 0 mA 20 21 mA 5000 max 0 5 0v 5 5 25V 10 KO min 1
35. ta as well as user data refer to section 1 5 except set point are locked to prevent from being changed If ALL is selected for LOCK then all parameters are locked to prevent from being changed 3 2 Signal Input INPT Selects the sensor type or signal type for signal input Range thermocouple J TC K TC T TC E TC B TC R TC S TC TC L TC RTD PT DN 5 linear 4 20 0 20 0 60 0 1V 0 5V 1 5V 0 10 UNIT Selects the process unit Range C F PU process unit If the unit is neither C nor F then selects PU DP Selects the resolution of process value Range for and RTD NO DP 1 DP for linear NO DP 1 DP 2 DP 3 DP INLO Selects the low scale value for the linear type input INHI Selects the high scale value for the linear type input How to use INLO and INHI If 4 20 mA is selected for INPT let SL specifies the input signal low ie 4 mA SH specifies the input signal high ie 20 mA S specifies the current input signal value the conversion curve of the process value is shown as follows 28 process value Formula PV INLO INHI INLO Figure 3 1 Conversion Curve for Linear Type Process Value input signal S SL SH SL Example A 4 20 mA current loop pressure transducer with range 0 15 kg cfn is connected to input then perform the following setup INPT 4 20 INHI 15 00 INLO 0 00 2 DP Of course you may select other value for D
36. thermocouple 7 _ N type thermocouple 81 C L type thermocouple i INPT Input sensor selection 9 PEdn 100 ohms DIN 0 curve 10 JS 100 ohms JIS curve 11 20 4 20 mA linear current input 12 0 21 0 20 mA linear current input 13 8 68 0 60 mV linear millivolt input 14 G 1 0 1V linear voltage input 15 0 54 0 5V linear voltage input 16 GU 1 5V linear voltage input 17 G 10 0 10V linear voltage 12 Default Rarameter Parameter Description Range 0 Degree C unit UNIT Input unit selection 1 OL Degree F unit ay 2 Pu Process unit 0 No decimal nodP point 1 l 1 decimal digit DP Decimal point selection i dP 1 2 gP 2decimal digits 3 40 3 decimal digits he 17 8 C INLO Input low sale value Low 19999 High 45486 5 T 93 3 INHI Input high scale value Low INLO 50 High 45536 200 0 F Low limit of set point lah 17 8 C SPIL te Low 19999 High 45536 0 F High limit of set point ah 537 8 SP1H value Low SP1L High 45536 1000 200 0 200 0 SHIF PV shift offset value Low 360 0 High 360 0 F 0 0 0 0 second time constant 1 0 2 second time constant 2 05 0 5 second time constan 3 1 1 second time constan 4 2 seconds time Filter damping time constan FILT constant of PV 5 6 5 seconds time 2 constan 6 ID 10 seconds time constan
37. tput 1 Linear Current Figure 2 10 Output 2 Relay to Drive Load Figure 2 11 Output 2 Relayto Drive Contactor Figure 2 12 Alarm Output to Drive Load Figure 2 13 Alarm Output to Drive Contactor Figure 3 1 Conversion Curve for Linear Type Process Value Figure 3 2 Heat Only ON OFF Control 30 Figure 3 3 Output 2 Deviation High Alarm Figure 3 4 Output 2 Process Low Alarm Figure 3 5 RAMP Function Figure 3 6 Dwell Timer Function Figure 3 7 PV Shift Application Figure 3 8 Filter Characteristics Figure 3 9 Effects of PID Adjustment able 1 1 Display Form of Characters able 3 1 Heat Cool Control Setup Value able 3 2 PIDAdjustment Guide able A 1 Error Codes and Corrective Actions Chapter 1 1 1 General The Fuzzy Logic plus PID microprocessor based controller series incorporate a bright easy to read 4 digit LED display indicating process value or set point value The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time with the minimum of overshoot during power up or external load disturbance The TC PC 24 is a 1 32 DIN size panel mount controller These units are powered by 11 26 or 90 250 VDC VAC supply incorporating a 2 amp control relay output as standard The second output can be used as cooling control an alarm or dwell timer There are six types of alarm plus a dwell ti
38. trol NOTE The ON OFF control may result excessive overshoot and undershoot problems in the process The P or PD control will result in a deviation process value from the set point It is recommended to use PID control for the Heat Cool control to produce a stable and zero offset process value Other Setup Required O1TY CYC1 O2TY CYC2 O1FT O2FT O1TY amp O2TY are set in accordance with the types of OUT1 amp OUT2 installed CYC1 amp CYC2 are selected according to the output 1 type O1TY amp output 2 type O2TY Generally selects 0 5 2 sec for CYC1 if SSRD SSR is used for O1TY 10 20 sec if relay is used for O1TY and CYC1 is ignored if linear output is used Similar condition is applied for CYC2 selection 31 You can use the auto tuning program for the new process or directly set the appropriate values for PB TI amp TD according to experience If the control behavior is still inadequate then use manual tuning to improve the control See section 3 12 for manual tuning Programming The cooling proportional band is measured by of PB with range 50 300 Initially set 100 for and examine the cooling effect If cooling action is too slow then decrease CPB if cooling action is too fast then increase CPB The value of CPB is related to PB and its value remains unchanged throughout the auto tuning procedures Adjustment of CPB is related to the cooling media used For air used as coolin
39. ual control mode Exit Manual Control v keys and the controller will revert to its normal display mode 43 PB too low Set point P action PB too high Time TI too high Set point action too low Time PV TD too low Perfect Set point D action TD too high Time Figure 3 9 Effects of PID Adjustment 44 Chapter 4 Calibration CALIBRATION SHOULD BE DONE ONLY BY EXPERIENCED PERSONNEL WITH APPROPRIATE CALIBRATION EQUIPMENT THE USE OF A CERTIFIED CALIBRATION LABORATORY IS HIGHLY RECOMMENDED FOR DETAILED CALIBRATION INSTRUCTIONS OR FOR ADDITIONAL INFORMATION PLEASE CONTACT YOUR LOCAL EATON REPRESENTATIVE OR CALL EATON CARE AT 877 ETN CARE 45 Chapter 5 Specifications Power 90 250 VAC 47 63 Hz 10 5W maximum 11 26 VAC VDC 10VA 5W maximum Input Resolution 18 bits Sampling Rate 5 times second Maximum Rating 2 VDC minimum 12 VDC maximum 1 minute for mA input Temperature Effect 1 5uV BC for all inputs except mA input 3 0uV BC for mA input Sensor Lead Resistance Effect T C 0 2uV ohm 3 wire 2 6 C ohm of resistance difference of two leads 2 wire RTD 2 6 C ohm of resistance sum of two leads Burn out Current 200 nA Common Mode Rejection Ratio CMRR 120dB Normal Mode Rejection Ratio NMRR 55dB Sensor Break Detection Sensor open for TC RTD and mV inputs Sensor short for RTD inpu
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