Honeywell TC4S User manual

Honeywell Process Solutions
Isolated Thermocouple Input Module
TC4S
User's Guide
ML200-ITIM
R200
September 2010
Release 200
Honeywell

ii Isolated Thermocouple Input Module TC4S User's Guide R200
Honeywell September 2010
Notices and Trademarks
Copyright 2010 by Honeywell International Sárl.
Release 200 September 2010
While this information is presented in good faith and believed to be accurate, Honeywell disclaims
the implied warranties of merchantability and fitness for a particular purpose and makes no
express warranties except as may be stated in its written agreement with and for its customers.
In no event is Honeywell liable to anyone for any indirect, special or consequential damages. The
information and specifications in this document are subject to change without notice.
Honeywell, PlantScape, Experion PKS, and TotalPlant are registered trademarks of Honeywell
International Inc.
Other brand or product names are trademarks of their respective owners.
Honeywell Process Solutions
1860 W. Rose Garden Lane
Phoenix, AZ 85027 USA
1-800 822-7673

R200 Isolated Thermocouple Input Module TC4S User's Guide iii
September 2010 Honeywell
About This Document
This document describes how to install and configure the Experion Station-TPS (ES-T) and
Experion Server TPS (ESVT) nodes. The nodes become full members in Experion PKS as well as
connect directly to the TPN (TotalPlant Network).
Release Information
Document Name Document
ID
Release
Number
Publication
Date
TC4S User's Guide ML200-
ITIM
200 September
2010
References
The following list identifies all documents that may be source of reference for material discussed
in this publication.
Document Title

Support and Other Contacts
iv Isolated Thermocouple Input Module TC4S User's Guide R200
Honeywell September 2010
Support and Other Contacts
United States and Canada
Contact:
Phone:
Fascimile:
Mail:
Honeywell Solution Support Center
1-800-822-7673
Calls are answered by dispatcher between 6:00 am and 4:00 pm
Mountain Standard Time. Emergency calls outside normal working hours
are received by an answering service and returned within one hour.
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Honeywell TAC, MS L17
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Europe, Middle East, and Africa (EMEA)
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[phone]
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Pacific
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Fascimile:
Mail:
Email:
Honeywell Global TAC – Pacific
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[phone] (outside Australia)
[phone]
Honeywell Limited Australia
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Burswood 6100, Western Australia
[email protected]
India
Contact:
Phone:
Fascimile:
Mail:
Email:
Honeywell Global TAC – India
[phone]
[phone]
Honeywell Automation India Ltd
56 and 57, Hadapsar Industrial Estate
Hadapsar, Pune –411 013, India
[e-mail]

Support and Other Contacts
R200 Isolated Thermocouple Input Module TC4S User's Guide v
September 2010 Honeywell
Korea
Contact:
Phone:
Fascimile:
Mail:
Email:
Honeywell Global TAC – Korea
[phone]
[phone]
Honeywell Co., Ltd
4F, Sangam IT Tower
1590, DMC Sangam-dong, Mapo-gu
Seoul, 121-836, Korea
[e-mail]
People’s Republic of China
Contact:
Phone:
Mail:
Email:
Honeywell Global TAC – China
[phone]
800-820-0237
400-820-0386
Honeywell (China) Co., Ltd
33/F, Tower A, City Center, 100 Zunyi Rd.
Shanghai 200051, People’s Republic of China
[e-mail]
Singapore
Contact:
Phone:
Fascimile:
Mail:
Email:
Honeywell Global TAC – South East Asia
[phone]
[phone]
[phone]
Honeywell Private Limited
Honeywell Building
17, Changi Business Park Central 1
Singapore 486073
[e-mail]
Taiwan
Contact:
Phone:
Fascimile:
Mail:
Email:
Honeywell Global TAC – Taiwan
[phone]
[phone]
Honeywell Taiwan Ltd.
17F-1, No. 260, Jhongshan 2nd Road.
Cianjhen District
Kaohsiung, Taiwan, ROC
[e-mail]

Support and Other Contacts
vi Isolated Thermocouple Input Module TC4S User's Guide R200
Honeywell September 2010
Japan
Contact:
Phone:
Fascimile:
Mail:
Email:
Honeywell Global TAC – Japan
[phone]
[phone]
Honeywell Japan Inc.
New Pier Takeshiba, South Tower Building,
20th Floor, 1-16-1 Kaigan, Minato-ku,
Tokyo 105-0022, Japan
[e-mail]
Elsewhere
Call your nearest Honeywell office.
World Wide Web
Honeywell Solution Support Online:
http://www.honeywell.com/ps
Training Classes
Honeywell Automation College:
http://www.automationcollege.com

Symbol Definitions
R200 Isolated Thermocouple Input Module TC4S User's Guide vii
September 2010 Honeywell
Symbol Definitions
The following table lists the symbols used in this document to denote certain conditions.
Symbol Definition
ATTENTION: Identifies information that requires special
consideration.
TIP: Identifies advice or hints for the user, often in terms of
performing a task.
REFERENCE -EXTERNAL: Identifies an additional source of
information outside of the bookset.
REFERENCE - INTERNAL: Identifies an additional source of
information within the bookset.
CAUTION
Indicates a situation which, if not avoided, may result in equipment
or work (data) on the system being damaged or lost, or may result in
the inability to properly operate the process.
CAUTION: Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used
to alert against unsafe practices.
CAUTION symbol on the equipment refers the user to the product
manual for additional information. The symbol appears next to
required information in the manual.
WARNING: Indicates a potentially hazardous situation, which, if not
avoided, could result in serious injury or death.
WARNING symbol on the equipment refers the user to the product
manual for additional information. The symbol appears next to
required information in the manual.
WARNING, Risk of electrical shock: Potential shock hazard where
HAZARDOUS LIVE voltages greater than 30 Vrms, 42.4 Vpeak, or
60 VDC may be accessible.

Symbol Definitions
viii Isolated Thermocouple Input Module TC4S User's Guide R200
Honeywell September 2010
Symbol Definition
ESD HAZARD: Danger of an electro-static discharge to which
equipment may be sensitive. Observe precautions for handling
electrostatically sensitive devices.
Protective Earth (PE) terminal: Provided for connection of the
protective earth (green or green/yellow) supply system conductor.
Functional earth terminal: Used for non-safety purposes such as
noise immunity improvement.
NOTE: This connection shall be bonded to Protective Earth at the
source of supply in accordance with national local electrical code
requirements.
Earth Ground:Functional earth connection.
NOTE: This connection shall be bonded to Protective Earth at the
source of supply in accordance with national and local electrical
code requirements.
Chassis Ground: Identifies a connection to the chassis or frame of
the equipment shall be bonded to Protective Earth at the source of
supply in accordance with national and local electrical code
requirements.

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Contents
1. INTRODUCTION ..........................................................................13
1.1 Overview of 2MLF-TC4S ............................................................................... 13
Background ..........................................................................................................................13
Features ...............................................................................................................................13
1.2 Terms and definitions................................................................................... 14
Analog quality – A ................................................................................................................14
Digital quality – D .................................................................................................................14
Thermocouple sensor ..........................................................................................................15
Disconnection detection .......................................................................................................15
Compensating cable ............................................................................................................15
Thermo electromotive force..................................................................................................15
Reference junction compensation (RJC)..............................................................................15
2. SPECIFICATIONS........................................................................17
2.1 Performance specifications ......................................................................... 17
2.2 Part names and functions ............................................................................ 19
2.3 Characteristics of thermocouple temperature sensor input module ...... 21
Temperature conversion characteristics ..............................................................................27
Conversion speed ................................................................................................................27
Preciseness..........................................................................................................................28
Temperature display ............................................................................................................29
Scaling function....................................................................................................................29
Disconnection detection function..........................................................................................30
Sensor connection ...............................................................................................................30
2.4 Input module function of thermocouple temperature sensor .................. 31
Average function ..................................................................................................................31
Filter function........................................................................................................................33
Alarm function ......................................................................................................................34
Maximum /Minimum display .................................................................................................36
3. INSTALLATION AND WIRING ....................................................37
3.1 Installation ..................................................................................................... 37
Installation environment .......................................................................................................37
3.2 Wiring ............................................................................................................. 37
Wiring precautions ...............................................................................................................37

Contents
Symbol Definitions
x Isolated Thermocouple Input Module TC4S User's Guide R200
Honeywell September 2010
Wiring example.................................................................................................................... 38
4. OPERATIONS AND MONITORING ............................................ 39
4.1 Operating the thermocouple module...........................................................39
Operations........................................................................................................................... 39
4.2 Parameter Setting ..........................................................................................40
Special module parameter setting of I/O parameter ............................................................ 40
Setting by program (instruction) .......................................................................................... 43
4.3 Module information monitoring ...................................................................46
4.4 Module data monitoring................................................................................48
Data monitoring through Special Module Monitoring........................................................... 48
Data monitoring by program ................................................................................................ 51
4.5 Other settings ................................................................................................52
Special Module Monitoring .................................................................................................. 52
Registering special module variables .................................................................................. 54
5. INTERNAL MEMORY.................................................................. 57
5.1 Configuration of internal memory................................................................57
Overview of internal memory configuration ......................................................................... 57
I/O data of thermocouple I/O module .................................................................................. 57
Operation parameter setting area (use of PUT/PUTP)........................................................ 62
Other data monitoring area (use of GET/GETP) ................................................................. 65
5.2 I/O area of TC module conversion data.......................................................66
Module status flag (%UXa.b, a: base number, b: slot number) ........................................... 66
Channel status flag (%UX.a.b.16~27, a: base number, b: slot number).............................. 67
Process alarm output flag (%UXa.b.32~47, A: base number, A: slot number) .................... 67
Rate-change-alarm flag....................................................................................................... 68
Channel temperature conversion value............................................................................... 69
Channel scale operation value ............................................................................................ 70
Minimum/maximum channel temperature conversion value................................................ 71
Data upload time ................................................................................................................. 72
Command junction .............................................................................................................. 73
5.3 Operation parameter setting area ................................................................74
Assigning channel (address 0); channel status ................................................................... 74
Sensor type setting area (address 1~4); sensor status ....................................................... 75
Temperature metric system indication area (address 5); temp.unit..................................... 76
Filter value setting area (address 6~9); filter constant......................................................... 77
Averaging method setting area (address 10~13); average processing ............................... 78
Average setting area (address 14~17); average value........................................................ 79
Scale type setting area (address 18); scaling data type ...................................................... 80

Contents
Symbol Definitions
R200 Isolated Thermocouple Input Module TC4S User's Guide xi
September 2010 Honeywell
Minimum/maximum scale range setting area (address 19~26); scaling minimum
value/maximum value ..........................................................................................................81
Process alarm boundary value setting area (address 27~42); Process alarm H.H. limit,
Process alarm H. limit, Process alarm L. limit, Process alarm L.L. limit ...............................83
Process alarm hysteresis setting area (address 43~46); Process alarm HYS .....................84
Alarm type setting area of Rate Change alarm (address 47); RCA type ..............................85
Rate change alarm H./L. boundary value setting area (address 48~55); RCA high limit, RCA
low limit ................................................................................................................................87
Rate change alarm detection period setting area (address 56~59)......................................88
5.4 Other data monitoring setting area ............................................................. 90
Setting error information output area (Address 60~63) ........................................................90
Rate Change alarm output area (Address 64~67) ...............................................................91
Sensor disconnection information output area (address 68~71) ..........................................92
Cold junction compensation temperature output area (Address 72~75) ..............................93
6. PROGRAMMING..........................................................................95
6.1 Read/write operation parameter setting area............................................. 95
Read operation parameter setting area (GET, GETP Instruction)........................................95
Write operation parameter area (PUT, PUTP instruction) ....................................................96
6.2 Basic program ............................................................................................... 98
Example using I/O parameter setting ...................................................................................98
6.3 Application program ................................................................................... 100
System configuration..........................................................................................................100
Initial settings .....................................................................................................................100
Program description ...........................................................................................................101
Program .............................................................................................................................101
CH data monitor program (I/O slot fixation point assignment: 64points) ............................102
Other data monitoring programs ........................................................................................104
7. TROUBLESHOOTING ...............................................................107
7.1 Introduction ................................................................................................. 107
7.2 LED indication by errors ............................................................................ 107
7.3 Diagnostics and measures......................................................................... 108
Run LED quickly flickers.....................................................................................................108
Run LED slowly flickers......................................................................................................108
Run LED turns off...............................................................................................................109
ALM LED flickers................................................................................................................110
CPU module cannot read temperature conversion value ...................................................110
7.4 Error code .................................................................................................... 111
Error codes of abnormal sensor connection (in case of sensor disconnection)..................111

Contents
Symbol Definitions
xii Isolated Thermocouple Input Module TC4S User's Guide R200
Honeywell September 2010
Error codes of abnormal module H/W (contact the close agency or the company) ........... 112
8. APPENDIX................................................................................. 115
8.1 Terminology .................................................................................................115
8.2 Thermo electromotive force and compensating cable ............................117
Table of thermo electromotive force .................................................................................. 117
Thermocouple ................................................................................................................... 120
Compensating cable.......................................................................................................... 123
8.3 Dimension ....................................................................................................125
2MLF-TC4S....................................................................................................................... 125

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September 2010 Honeywell
1. Introduction
1.1 Overview of 2MLF-TC4S
Background
2MLF-TC4S is an Isolated Thermocouple Input module, used to convert temperature
data to digital values. The module converts data detected by nine different types of
thermocouple sensors (K/J/E/T/B/R/S/N/C) into 16 bit binary data.
Features
1. Modules depending on application
2MLF-TC4S: 4 Ch. Input (inter-channel isolation type)
2. Nine sensors available
K / J / E / T / B / R / S / N / C
3. Detection of disconnection
The module detects and displays the disconnection between the thermocouple
temperature sensor, compensating cable, and modules.
4. Temperature displays in Fahrenheit or Celsius
5. Temperature conversion is scaled into the pre-set 16 bit binary data (it may be used
for additional data and temperature).
Scale operation output of temperature conversion is available within -
32768~32767/0~65535.
6. Additional functions: Filtering, average function (time/frequency/movement), alarm
(process/input change), maximum/minimum detection function.
7. Graphical user interface (GUI) operation parameter setting/monitoring by means of
SoftMaster.
SoftMaster enables I/O parameter setting reducing the sequence program. In
addition, special module monitoring enables monitoring of temperature conversion.

1. Introduction
1.2. Terms and definitions
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1.2 Terms and definitions
Analog quality – A
Analog quality refers to the constantly changing voltage, current, temperature, speed,
pressure, and flow.
For instance, temperature is constantly changing over time as seen in the following
figure. The changing temperature can be treated as a digital value in the PLC by using
resistance temperature detector (RTD) input module.
Digital quality – D
Digital quality refers to discrete changes in voltage, current, temperature, velocity,
pressure, and flow over a period of time as illustrated in the following figure. For
instance, ON/OFF signal is represented as digital quality of 0 and 1.

1. Introduction
1.2. Terms and definitions
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September 2010 Honeywell
The CPU module does not directly accept analog values. Therefore, analog value is
converted into a digital value before feeding to the CPU. In addition, the digital values
from the CPU must be converted back into analog values to provide an analog output.
Thermocouple sensor
A thermocouple is a sensor for measuring temperature. It consists of two dissimilar
metals, joined together at one end. When the junction of the two metals is heated or
cooled a voltage is produced that can be correlated back to the temperature. The
thermocouple alloys are commonly available as wire.
Disconnection detection
When a part of a compensating cable or thermocouple is disconnected, the Isolated
Thermocouple Input module detects the disconnection.
Compensating cable
Cable to compensate the tolerance due to the distance between input thermocouple
terminal and thermocouple input module (temperature change) and in which both
terminals have similar thermo electromotive force between 90 and 150°C.
Thermo electromotive force
Thermo electromotive force for thermocouple temperature has non-linear characteristics.
Therefore, it processes the non-linear characteristics to linear in the module.
Reference junction compensation (RJC)
In a thermocouple sensor, the thermo electromotive force varies, depending on the
temperature of a part measuring electromotive force. Since, the thermo electromotive
force table of standards is based on 0°C, it compensates the gap between the current
temperature and the actual reference temperature (0°C).

1. Introduction
1.2. Terms and definitions
16 Isolated Thermocouple Input Module TC4S User's Guide R200
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2. Specifications
2.1 Performance specifications
Performance specifications are specified in table below.
Item Specifications
Number of input CH 4 CH
Type of input
sensor K,J,E,T,B,R,S,N,C JIS C1602-1995 , ITS-90
Range of input
temperature
K -250 ~ 1350°
J -200 ~ 1200°
E -250 ~ 1000°
T -250 ~ 400°
B 400 ~ 1800°
R -50 ~ 1750°
S -50 ~ 1750°
N -270 ~ 1300°
C 0 ~ 2300°
Digital value
Temp. display (unit of
0.1)
Displaying down to one decimal place
(0.1°)
Scaling display
(user-defined scaling)
0 ~ 65535
-32768 ~ 32767
Preciseness
Ambient temperature
(25°C)
±0.1%
(allowable for some section up to 1% of
measurable temperature range by
sensors)
Temperature
coefficient (range of
operating temp)
±100 ppm/°
Conversion speed 40ms / channel

2. Specifications
2.1. Performance specifications
18 Isolated Thermocouple Input Module TC4S User's Guide R200
Honeywell September 2010
Item Specifications
Isolation method
Inter-channel Isolation
Terminal – PLC power Isolation (Photo-Coupler)
Cold junction
compensation
Automatic compensation by RJC sensing (PT100)
Compensation degree ±1.0°
Function
Averaging function
Time average (320~64000ms)
Frequency average (2~64000 times)
Moving average (2~100)
Alarm function
Process alarm
Rate change alarm
Disconnection detection
Filter function Digital filter (160~64000ms)
Max./Min. display Display Max./Min.
Terminal block 18-point terminal
Current
consumption 5V: 610mA
Weight 150g

2. Specifications
2.2. Part names and functions
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2.2 Part names and functions
No. Description
1
RUN LED
Displays the operation status of 2MLF-TC4S module H/W (displays
error).
On: normal module H/W
Blink: erroneous module H/W
Off: DC5V disconnection or abnormal module H/W

2. Specifications
2.2. Part names and functions
20 Isolated Thermocouple Input Module TC4S User's Guide R200
Honeywell September 2010
No. Description
2
ALM LED
Displays the input/channel operating status of 2MLF-TC4S module
(displays warning).
Blink: input disconnection
Off: normal input status
3
Terminal block
It is designed to connect thermocouple temperature sensor to 2MLF-
TC4S module.
PT100 for compensating nine types of thermocouple sensors and cold
junction (module supplied).