Red-lion TCU User Manual

THE TEMPERATURECONTROLLER MODEL TCU INSTRUCTION MANUALTCUCOVR.QXD 12/6/01 10:37 AM Page 1

The optional RS485 multi-drop serial communication interface providestwo-way communication between a TCU unit and other compatibleequipment such as a

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LIMITED WARRANTYThe Company warrants the products it manufactures against defects in materials and workmanship for a period limited to two years from

TCU/IM - N 02/13DRAWING NO. LP0235Red Lion ControlsHeadquarters20 Willow Springs CircleYork PA 17406Tel +1 (717) 767-6511Fax +1 (717) 764-0839Red

INSTALLATION & CONNECTIONSInstallation EnvironmentThe unit should be installed in a location that does not exceed the maximumoperating temperature

4Figure 1, Panel Installation & Removal

Unit Removal ProcedureTo remove a NEMA 4X/IP65 or standard unit from the panel, first unscrewand remove the panel latch screws. Insert flat blade scre

Output ModulesThe main control, optional Alarm, optional Cooling output and optionalValve Position control output sockets must be fitted with the appr

Triac:Type: Isolated, Zero Crossing Detection.Rating:Voltage: 120/240 VAC.Max. Load Current: 1 amp @ 35°C0.75 amp @ 50°CMin. Load Current: 10 mAOff St

8EMC INSTALLATION GUIDELINESAlthough this unit is designed with a high degree of immunity toElectroMagnetic Interference (EMI), proper installation an

Signal WiringWhen connecting the thermocouple or RTD leads, be certain that theconnections are clean and tight, refer to Figures 7 and 8 for terminalc

Valve Positioner WiringUnits with Valve Positioner option have three output connections forcontrolling the valve motor and three input connections for

Heater Current Monitor WiringUnits with Heater Current Monitor option have two input terminals toreceive the output directly from a 100 mA current tra

INTRODUCTIONThe Temperature Control Unit (TCU) is a multi-purpose series ofindustrial control products that are field-programmable for solvin

FRONT PANEL DESCRIPTIONThe front panel bezel material isflame and scratch resistant, tintedplastic. An optional NEMA4X/IP65 bezel version is available

OPERATION OVERVIEWController Power-upUpon applying power, the controller delays control action and temperatureindication for five seconds to perform s

Remote And Local Setpoint OperationThe controller setpoint mode can be switched between Local Setpointoperation and Remote Setpoint operation. In the

Configuration Of ParametersAs supplied from the factory, the controller parameters have beenprogrammed to the values listed in the Programming Quick R

Parameter EntryThe PAR button is used to select the desired parameter. To modify theparameter setting use the UP and DOWN buttons. Press PAR to enter

UNPROTECTED PARAMETER MODEThe Unprotected Parameter Mode is accessed by pressing the PAR buttonfrom the normal display mode with program disable inact

Display ParameterRange andUnits (FactorySetting Value)Description/Commentsdt-2 DerivativeTime #2(Secondary)0 to 9999 sec.(0)0 is off. This parameter d

Protected Parameter Mode Reference TableDisplay ParameterRange andunits (FactorySetting Value)Description/CommentsProp ProportionalBand0.0 to 999.9%of

Front Panel Program DisableThere are several ways to limit the programming of parameters from thefront panel buttons. The settings of the parameters i

HIDDEN FUNCTION MODEThe Hidden Function Mode is only accessible from the normal displaymode by pressing and holding the PAR button for three seconds.

Table of ContentsGENERALDESCRIPTION ······················································· 1SAFETYSUMMARY ···········································

CONFIGURATION PARAMETER MODULESAccessible from the unprotected parameter mode, the configurationparameter modules allow the operator access to the con

Input Sensor Correction Constants (SPAN & SHFt)If the controller temperature disagrees with a reference temperatureinstrument or if the temperatur

On models equipped with Second Analog Input, configured as RemoteSetpoint, this parameter may be used to establish a maximum rate of change ofthe Remo

Output Module (2-OP)The controller has parameters that affect how the main control output(OP1) responds to temperature changes and sensor failures.Tim

Output Power Dampening (OPdP)The output power calculated by the PID controller can be dampened(filtered) to reduce the controller output activity. Tho

Linear DC Analog Output (ANAS, ANLO, ANHI, ANdb, ANUt)(Optional)The Linear DC output can be programmed to transmit one of the followingcontroller para

Lockouts Module (3-LC)The controller can be programmed to limit operator access to variousparameters, control modes, and display contents. The configu

Alarm Module (4-AL) (Optional)The controller may be optionally fitted with the dual alarm option (AL1and AL2). Some models are equipped only with a si

The alarm triggers under the two following conditions:1. The valve slidewire feedback position does not match the controller outputpower (within the v

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ConfigurationOfParameters ·················································· 15ParameterEntry·························································

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Alarm Reset (rSt1, rSt2)Each alarm reset action may be independently conf igured.LAtC - LatchingAuto - AutomaticLatched alarms require operator acknow

Alarm Hysteresis (AHYS)The alarm(s) values have a programmable hysteresis b and to prevent alarmoutput chatter near the alarm trigger temperature. The

In practice with the cooling output, observe the controlled temperaturecharacteristics and if the temperature remains above setpoint with a sluggishre

Print Options (PoPt)Selecting YES for the print options allows the operator to scroll throughthe available options using the PAR button. The up and do

Square Root Linearization (root) (Cont’d)As a result of the scaling and square root linearization, the followingrepresents the readings at various inp

Local/Remote Setpoint Transfer Modes (SPtr)When switching from/to Local or Remote Setpoint, the response of thecontroller can be programmed to act in

Valve Position 1 And Valve Position 2 (VPS1, VPS2) (Cont’d)3) Measure the resistance of the open and closed positions and divide by thetotal s lidewir

Reference Table: Configuration Parameter ModuleConfigure Module 1 - Input Parameters (1-IN)Display ParameterRange and Units(Factory SettingValue)Descr

Configure Module 2 - Output Parameters (2-OP)Display ParameterRange and Units(Factory SettingValue)Description/CommentsCYCt Cycle time 0 to 250 second

LowerDisplayLockouts(SP,OP,HCur,IN-2,dEv,UdSP) ·························28Protected Mode Lockouts (Code, PID, PID2, rtbS & AL) ···················

Configure Module 3 - Lockout Parameters (3-LC)Display ParameterRange and Units(Factory SettingValue)Description/CommentsSP Setpoint access LOC - locko

Configure Module 4 - Alarms (4-AL)Unit returns to configuration access point if alarm(s) are not installed.Display ParameterRange and Units(Factory Se

Configure Module 5 - Cooling Parameters (5-O2)Unit returns to configuration access point if cooling option is not installed.Display ParameterRange and

Configure Module 6 - Serial Communications (6-SC)Unit returns to configuration access point if RS485 serial option is not installed.Display ParameterR

Configure Module 7 - Second Analog Input (7-2N)Unit returns to configuration access point if Second Analog Input option isnot installed.Display Parame

Configure Module 9 - Factory Service Operations (9-FS)Display ParameterRange and Units(Factory SettingValue)Description/CommentsCode Enter factory ser

RS485 SERIAL COMMUNICATIONS INTERFACERS485 communications allows for transmitting and receiving of data overa single pair of wires. This optional feat

Sending Commands And Data (Cont’d)VALUEIDENTIFIERDESCRIPTIONSERIALMNEMONICUNITSA Temperature Display Value TMP F/CB Setpoint SET F/CC Output Power PWR

The following procedure should be used when constructing a commandstring.1. The first two to three characters of the command string must consist of th

Receiving DataData is transmitted from the TCU when a “ T” Transmit Value or a “P”Transmit Print Options command is sent to the unit via the serial po

Valve Position Deadband (VPdb) (Position Mode) ································39Valve Fail Time Alarm (VFAL) (Position Mode) ························

A print-out from a TCU unit with an address of 1 and all print optionsselected is shown below:1 TMP 500F1 SET 525F1 PWR 20.0%1 PBD 4.0%1 INT 120S1 DER

Terminal Emulation Program For IBM®PCUtilizing the Serial communications capability of the TCU requires the useof an RS485 serial card in the computer

Terminal Emulation Program For IBM®PC (Cont’d)If an RS485 card cannot be obtained, and only an RS232 port is available,the Red Lion Controls GCM232 &a

55Figure 25, Connecting To An RLC PrinterOne or several TCU units can be connected to an RLC model DMPC printerusing an optional RLC GCM422 converter

Connecting To A Host TerminalSix TCU units are used to control a process in a plant. The TCU units arelocated at the proper location to optimize the p

HEATER CURRENT MONITOR OPTIONThis option allows monitoring of heater element current controlled by theTCU via the main output OP1. The actual heater c

VALVE POSITION OPTIONThe Valve Position option of the TCU directly controls the position o f avalve. The Valve Motor Open and Valve Motor Close output

Velocity Mode Valve ControlThe Velocity mode of the Valve Positioner option is a special valve controlalgorithm that does not use a slidewire feedback

SECOND ANALOG INPUT OPTIONThe Second Analog Input option is an additional analog input used forRemote Setpoint or Internal Cascade operation. The mode

External Cascade ControlExternal Cascade Control involves the use of two controllers, one of whichhas a Remote Setpoint Input.The outer loop controlle

ExternalCascadeControl ·················································· 61InternalCascadeControl ··················································6

Internal Cascade ControlThe Internal Cascade control mode of the TCU embodies the function oftwo Cascade controllers into a single unit. In all other

PID CONTROLProportional BandProportional band is defined as the “band” of temperature the processchanges to cause the percent output power to change f

Derivative TimeDerivative time is defined as the time, in seconds, in which the output dueto proportional action alone equals the output due to deriva

PID Adjustments (Cont’d)65Figure 35, Process Response Extremes

ON/OFF CONTROLThe controller operates in the ON/OFFcontrol mode by setting the proportional band =0.0%. The ON/OFF control hysteresis band(CHYS) param

ON/OFF and PID control can be used for the heat and cool outputs inseveral combinations.The following lists the v alid control modes:OP1 & OP2 VAL

AUTO-TUNEAuto-Tune is a user initiated function in which the controller automaticallydetermines the PID settings based upon the process characteristic

As shown in the Auto-Tune Operation Figure 40, Auto-Tune cycles theprocess at a control point 3/4 o f the distance between the current processtemperat

The following additional parameters are calculated and set as a result ofAuto-Tuning of the secondary:Secondary Proportional Band (Pb-2)Secondary Inte

APPENDIX “A” - Application ExamplesPlastics Extruder ApplicationSeveral TCU controllers are employed to control the temperature of aplastics extruder.

Calibration ································································ 84ConfigureStep9-FactoryServiceOperations(9-Fs) ·························

Temperature Control Programming ExampleA TCU is used to control the temperature of cooking kettles at a foodprocessing f acility. The 4-20 mA linear D

APPENDIX “B” - SPECIFICATIONS AND DIMENSIONS1. DISPLAY:Dual4-digitUpper Temperature Display: 0.4" (10.2 mm) high red LEDLower Auxiliary Display:

3. ANNUNCIATORS:LED Backlight Status Indicators (Model dependent):%PW - Lower auxiliary display shows power output in (%).DEV - Lower auxiliary displa

9. OUTPUT MODULES [Optional] (For All Output Channels):Relay:Type: Form-C (Form-A with some models. See Ordering Information)Rating: 5 Amps @ 120/240

Valve fail time: Off to 9999 secondsAlarm mode: Dual acting; loss of slidewire feedback signal and valvefail detection15. SECOND ANALOG INPUT:Range: 0

21. CERTIFICATIONS AND COMPLIANCES:SAFETYUL Listed, File #E137808, UL508, CSA C22.2 No. 14-M95LISTED by Und. Lab. Inc. to U.S. and Canadian safety sta

APPENDIX “C” - TROUBLESHOOTING78The majority of problems can be traced to improper connections or incorrect set-up parameters.Be sure all connections

79Problems Possible Cause Remedies“OLOL” IN DISPLAY 1. Temperature exceeds range of input probe.2. Excessive positive probe temperature.3. Loss of set

Output Leakage CurrentThe AL1 and AL2/OP2 outputs of the TCU have an RC Network (Snubber)on the Normally Open contacts. High energy noise spikes are g

APPENDIX “D” - MANUAL TUNINGOpen Loop Step Response MethodThe Open Loop Step Response Method is a tuning procedure that does notinduce process oscilla

GENERAL DESCRIPTIONThe TCU Controller accepts signals from a variety of temperature sensors(thermocouple or RTD elements), precisely displays the proc

Closed Loop Cycling MethodAn alternative to auto-tuning is manual tuning. This tuning methodinduces oscillations into the process in the same way as t

APPENDIX “E” - CALIBRATIONCalibration CheckThe instrument has been fully calibrated at the factory for all thermocoupleand RTD types. If the unit appe

Second Input CheckThe Second Input Check applies to those models that have the SecondAnalog Input (Remote Setpoint), Heater Current Monitor and ValveP

Millivolt Calibration (Cal)Connect precision millivolt s ource with an accuracy of 0.01% to terminals(+) #9 and (-) #10. Place the input sensor select

Analog Output Calibration (ANCL) (Cont’d)0to10VDCPress PAR until ANCL appears in the display. Connect a p recisionvoltmeter (0.1% accuracy) to rear te

APPENDIX “F”- USER PARAMETER VALUE CHARTUNIT NUMBERMNEMONIC PARAMETERUSER SETTINGSP Temperature SetpointOPOF Output Power OffsetOP Output PowerProP Pr

CONFIGURE LOCKOUTSMNEMONIC PARAMETERUSER SETTINGSP Access SetpointOP Access Output PowerdEv Access Deviation DisplayHCur Access Heater Current Display

CONFIGURE SECOND ANALOG INPUTMNEMONIC PARAMETER USER SETTINGOPEr Second Input Operating Moderoot Second Input Square RootLinearizationdPt2 Second Inpu

APPENDIX “G” ORDERING INFORMATION90MODELS WITHOUT SECOND INPUT OPTIONS (STANDARD)NEMA4X/IP65BEZEL4to20mAANALOGOUTPUT0to10VDCANALOGOUTPUTALARMOUTPUTSCO

91DESCRIPTION PART NUMBERRelay Module OMD00000Triac Module OMD00001Logic/SSR Drive Module OMD0000345 A Single Phase Panel Mount Solid State Relay RLY5