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Tempco TEC-4230 User Manual

Self-tune fuzzy/pid process/temperature controller
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TEC-4230
Self-Tune Fuzzy/PID
Process/Temperature Controller
TEMPCO Electric Heater Corporation
607 N. Central Avenue
Wood Dale, IL 60191-1452 USA
Tel:
630-350-2252
800-323-6859
Fax:
630-350-0232
website: http://www.tempco.com
Copyright © 2003, Tempco Electric Heater Corporation, all rights reserved.
User's Manual
Revision 6/2003

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  • Page 1 User's Manual TEC-4230 Self-Tune Fuzzy/PID Process/Temperature Controller TEMPCO Electric Heater Corporation 607 N. Central Avenue Wood Dale, IL 60191-1452 USA Tel: 630-350-2252 800-323-6859 Fax: 630-350-0232 website: http://www.tempco.com Copyright © 2003, Tempco Electric Heater Corporation, all rights reserved. Revision 6/2003...

  • Page 2: Table Of Contents

    Information in this user's manual is subject to change without notice. Copyright © 2003, Tempco Electric Heater 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...

  • Page 3: Introduction

    Alternative output options include SSR drive, triac, 4–20mA and 0–10 volts. TEC-4230 is fully programmable for PT100, thermocouple types J, K, T, E, B, R, S, N, 0–20mA, 4–20mA, and voltage signal input, with no need to modify the unit.

  • Page 4: Numbering System

    2. Numbering System TEC-4230-_ _ _ _ _ _ _ _ 1 2 3 4 5 6 7 8 (1) Power Input 4 ..90–264VAC 5 ..20–32VAC/VDC 9 .

  • Page 5: Specifications

    3. Specifications Input Sensor Input Type Range (°F) *Accuracy (°F) Range (°C) *Accuracy (°C) Iron/Constantan -58 to 1832°F ±3.6°F -50 to 1000°C ±2°C Chromel/Alumel -58 to 2500°F ±3.6°F -50 to 1370°C ±2°C Copper/Constantan -454 to 752°F ±3.6°F -270 to 400°C ±2°C Chromel/Constantan -58 to 1382°F...

  • Page 6: Installation

    Operating temperature: 14 to 122°F (-10 to 50°C) Humidity: 0 to 90% RH (non-condensing) Insulation: 20M ohms min. (500VDC) Breakdown: 2000V (AC), 50/60Hz, 1 minute Vibration: 10–55 Hz, amplitude 1mm Shock: 200m/s² (20g) Moldings: Flame retardant polycarbonate Dimensions: H: 3.75” (96mm) x W: 3.75” (96mm) Depth behind panel: 2.07”...
  • Page 7 4–3 Wiring Precautions • Before wiring, check the label to verify the correct model number and options. Switch off the power while checking. • Care must be taken to ensure that the maximum voltage ratings specified in section 3 are not exceeded. •...
  • Page 8 Power Wiring The controller is supplied to operate on 24V (20–32VAC/VDC) or 90–264VAC. Verify that the voltage of the power supply corresponds to that indicated on the product label before connecting power to the controller. This equipment is designed for installation in an enclosure which provides adequate protection against electrical shock.

  • Page 9: Operation

    The proper sensor type is also a very important factor in obtaining precise measurements. The sensor must have the correct temperature range to meet the process requirements. In special processes, the sensor might have additional requirements such as leak-proof, anti-vibration, antiseptic, etc. Standard sensor limits of error are ±4°F (±2°C) or 0.75% of sensed temperature (half that for special) plus drift caused by improper protection or an over-temperature occurrence.
  • Page 10 5–3 Menu Overview and Descriptions of Parameters PROCESS VALUE SET POINT VALUE Short scroll advances forward Security ASP1 through parameters step by step Level 0 RAMP OFST ASP2 Hold until display stops Short scroll flashing (3.2 seconds) returns to PV/SV Short scroll advances forward SHIF through parameters step by step...
  • Page 11 Parameter descriptions: Default Display Default Security Description Adjustment Range Code Setting Level Set point value of control Low scale to high scale value 212°F Alarm 1 set point value or Dwell Trip point within high/low scale or 18°F (10°C) ASP1 time 0–9999 minutes (for dwell time) Ramp rate...
  • Page 12 5–4 Flow Chart of Tool Programs The Tool Programs menu can be entered at any time by pressing HAND Manual Mode (hand control) CONT Used if sensor fails. h___ Indicates percentage power Long Adjust the percentage of on-time for output 1 of output 1 (heating) using the up and down keys.
  • Page 13 5–5 Setting-Up Procedures When power is applied, the model number and software version number of the controller will be displayed for 3.2 seconds, then all of the display segments and LED indicators will light up for 3.2 seconds. After this initial cycle, the controller will enter normal display mode, showing the process value in the upper display, and the set point value in the lower display.
  • Page 14 ADDR—Interface Address This parameter provides an identity code for the RS-485 interface. Note that no two controllers communicating with the same computer can have the same identity code. Ignore this parameter if the controller does not use the RS-485 interface. LO.SC, HI.SC—Low/High Scale Range If thermocouple or PT100 is selected as the input type (INPT), these parameters are used to define the range of the set point adjustment.
  • Page 15 long cycle time is selected for a fast process, the process may become unstable as a result. Theoretically, the smaller the cycle time selected, the better the control that can be achieved. However, for a relay output, the cycle time should be as large as possible (while maintaining satisfactory control) in order to maximize the life of the relay.
  • Page 16 5–6 Auto-Tune The auto-tuning process is performed at the set point. The process will oscillate around the set point during the auto-tuning process. Set the set point to a lower value if overshooting beyond the normal process value would be likely to cause damage.
  • Page 17 The PID parameters determined by the above procedures are rough values. If the control results using the above values are unsatisfactory, the following rules may be used to further adjust the PID parameters: Adjustment Sequence Symptom Solution Slow response Decrease PB Proportional Band (P) High overshoot or oscillations Increase PB...

  • Page 18: Control

    5–8 On-Off Control If the alarm output is configured as an alarm function, it basically performs as an on-off control. If you adjust the P band to PB=0, you can get an additional channel of on-off control with variable hysteresis. Hysteresis, also called differential or deadband, is measured in degrees.

  • Page 19: Alarm

    Functions of CPB and DB: the cooling P band CPB and the deadband DB are measured in degrees. Cooling Output DB Negative 100% DB Positive PV (∞F or ∞C) SV+DB 5–10 Alarm There are at most two independent alarms that can be made available by adjusting the alarm special function parameters A1SF and A2SF.
  • Page 20 5–11 Viewing the Output Percentage Power Scroll through the tool programs until you come to HAND CONTROL , then press the scroll key. The upper display will now show the process value and the lower display will show the percentage power of output 1 (for example, ).
  • Page 21 Ramp and Soak Function The soak function is enabled by configuring alarm 1 to act as a dwell timer. If A1SF is set for TOON (time out on), the alarm 1 relay will act as a timer contact, with the contact being open at power up and closing after the time set in ASP1 has elapsed.

  • Page 22: Recalibration

    100.0 (HISC) HLEr LLEr (LOSC) Input signal (mA) 5–15 Read Peak Process Values The maximum and minimum values of the process value are continuously updated and stored in the memory after power up. Press both to access the “READ PEAK” tool program. Press the scroll key to select in the lower display.

  • Page 23: Pta

    COM+ 40mV 200 ohm 20mA • Calibration procedures 1. Press both scroll and down keys, then release to access the tool programs. Repeat until appears on the displays. 2. Press and release the scroll key. The lower display will show a number with the prefix “t”. 3.

  • Page 24: Error Messages And Diagnosis

    7. Error Messages and Diagnosis This procedure requires access to the circuitry of a unit connected to live power. Dangerous accidental contact with line voltage is possible. Only qualified personnel are to perform these procedures. Potentially lethal voltages are present. Experience has proven that many control problems are not caused by a defective instrument.
  • Page 25 Table 7.1 Troubleshooting Symptom Probable Cause(s) Solution(s) 1. Keypad doesn’t function -Bad connection between PCB and keypads -Clean contact area on PCB -Replace keypads 2. LEDs will not light -No power to instrument -Check power line connections -Power supply defective -Replace power supply board 3.
  • Page 26 TEMPCO Electric Heater Corporation 607 N. Central Avenue Wood Dale, IL 60191-1452 USA Tel: 630-350-2252 800-323-6859 Fax: 630-350-0232 website: http://www.tempco.com Copyright © 2003, Tempco Electric Heater Corporation, all rights reserved.

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