Tempco TPC20052 User manual

TPC20052 - Power Control Console (2 zones)
with TEC-9400 (PID + Fuzzy Logic Process Controller)
D1306.TE-401-402-404-405 Revision 2/22/2019
USER MANUAL
Manual TPC20052
Revision 4/21 • D1352.02

SPECIFICATIONS
Temperature Controllers: Model TEC-9400, 1/16 DIN Dual Display with PID Auto-tuning
Sensor Inputs: Type “K” thermocouples
Connector Bodys: Yellow
Power Cord/voltage Input: 120VAC, 50/60 HZ, 15A
Heater Outputs: 6A Max, 720 watts max per zone.
Output Devices: Solid State Relays
Main Power Switch: Located on front panel
Fuse Main Power: See replacement parts list on next page (located on back panel)
Fuse Control Power: See replacement parts list on next page (located on back panel)
WARNINGS
1. Air vents located on top and bottom of console must not be blocked! To prevent an overheating condition
the internal components must remain as close to room temperature (75ºF / 24ºC) as possible.
2. Dangerous voltage capable of causing injury or death is present within this console. Power to all
equipment must be disconnected before installation or beginning any troubleshooting procedures. Heater
output wiring and component replacement must be made by qualified personnel only.
3. To minimize the possibility of fire or shock, do not expose this console to rain or excessive moisture.
4. Do not use this console in areas where hazardous conditions exist such as excessive shock, vibration,
dirt, corrosive gases, oil or where explosive gases or vapors are present.
5. It is strongly recommended that a process should incorporate a Limit Control like a Tempco TEC-910
which will shut down the equipment at a preset process condition in order to avoid possible damage to
products or systems.
WIRING (For safety, disconnect all power sources prior to wiring)
1. Attach the leads from your type thermocouples to the mini-plugs provided. Take care to note the correct
polarity. The red lead is (-) negative.
2. The heater output current is sourced directly through the line cord. The rear console output receptacles
and mating Hubbell plugs provide live controlled power for direct connection to your heater(s). Connect one
lead from your heater to one prong of the Hubbell plug (not ground). Connect the other lead from your heater
to the other prong. Connect heater ground (if applicable) to the ground connection (G) on the plug.
1

OPERATION
1. Verify the power switch is in the off position. Plug your heaters & thermocouples into the rear connectors. Plug the provided
line cord from the console into a standard 120V, 15A outlet. Switch on the console.
2. Set your desired temperature setpoint by using the up and down arrow buttons on the TEC-9400 temperature controllers.
3. Refer to the following pages for complete operation and page 4 for auto-tuning of the TEC-9400 temperature controllers.
SPARE/REPLACEMENT PARTS
Tempco Description
Part Number
EHD-124-148 Fuse, rated 15 Amp/250V, ¼x 1 ¼”, fast acting BUSS ABC-15-R.
Used for main control console power.
EHD-124-276 Fuse, rated 1 Amp/ 250V, ¼" x 1¼", fast acting,
BUSS ABC-1-R. Used for TEC-9400 Controllers.
EHD-124-300 Fuses (2), rated 8 Amp/ 250V, ¼" x 1¼", fast acting,
BUSS ABC-8-R. Used for individual heater outputs.
EHD-102-113 Power output plugs (1 per zone), Hubbell HBL4720C, 15A 125V Twist-Lock.
TCA-101-105 Type “K” thermocouple mini plug (1 per zone), Yellow
NOTE: For all fuses, use listed BUSS part numbers or equivaliant.
2

TEC-9400 Front Panel Keys and Display
KEYPAD OPERATION
SCROLL KEY:
This key is used to scroll through a menu to select a parameter to be viewed or adjusted.
UP KEY:
This key is used to increase the value of the selected parameter.
DOWN KEY:
This key is used to decrease the value of the selected parameter.
RESET KEY:
This key is used to:
1. Revert the display to the home screen.
2. Reset a latching alarm once the alarm condition is removed.
3. Stop manual control mode, Auto-Tuning mode or calibration mode.
4. Clear an Auto-Tuning or communication error message.
5. Restart the dwell timer when the dwell timer has timed out.
6. Enter the manual control menu if failure mode occurs.
ENTER KEY: Press and hold for 5 seconds or longer to:
.
for 6.2 seconds, then let go, to select manual control
for 7.4 seconds, then let go to select Auto-Tuning
1. Enter the setup menu. The display will show
2. Enter manual control mode. Press and hold
mode. The display will show .
3. Enter Auto-Tuning mode. Press and hold
mode. The display will show .
4. Perform calibration of a selected parameter during the calibration procedure. Press and hold for
8.6 seconds, then let go to select calibration mode.
During power-up, the upper display will show PROG and the lower display will show
the Firmware version for 6 seconds. 3

1.1 Menu Flowchart
The Menu has been divided in to 5 groups. They are as follows:
1. User Menu - Below
2. Setup Menu - Page 5
3. Manual Mode Menu - Page 7
4. Auto-Tuning Mode Menu - Page 7
5. Calibration Mode Menu (not recommended, calibration section has been removed)
User Menu Setup
Menu
Manual Mode Auto-Tuning Mode Calibration Mode
5 Sec 6.2 Sec 7.4 Sec 8.6 Sec 9.8 Sec
5 Sec 5 Sec
To access
parameter
In the User Menu,
Refer to
Section 1.1.1
To access
parameter in
the Setup Menu,
Refer to
Section 1.1.2
Page 5
To start
Manual Control
Mode, Refer to
Section 1.1.3
Page 7
To start
Auto-Tuning
Mode, Refer to
Section 1.1.4
Page 7
Press for the next parameter
Press and key to return to the previous parameter.
1.1.1 User Menu
The below user menu parameters are available depending on user selection.
PV,SV
SP1
SP2
SP3
SP4
SP5
SP6
SP7
SFtR
CT1R
CT2R
DTMR
PASS
RUN
CYCR
ST EP
T IMR
SEL1
SEL2
SEL3
SEL4
SEL5
SEL6
SEL7
SEL8
Below
4

1.1.2 Setup Menu
The setup menu has been categorized in to eight categories. They are listed below.
*5. User Select Menu1. Basic Menu - Below
2. Output Menu) - Page 6 *6. Communication Menu
*7. Current Transformer Menu
*3. Alarm Menu
*4. Event Input Menu *8. Profile Menu (Ramp and Soak)
1.1.2.1 Basic Menu (bASE)
In thesetup menu, when theupper display says “SET”, Use the or keys to get “bASE” in thelower display.
Then, use the key to cycle through the “bASE” menu parameters (Note Chart on pg. 8).
or
SET bASE
OFS1
OFS2
OFS3
INPT
UNIT
DP
INLO
INHI
SP1L
SP1H
FILT
DISP
PB
TI
TD
RAMP
RR
RETY
RELO
REHI
RMSP
RINL
RINH
CODE
OFSTL
OFSTH
CALO
CAHI
SFT
SFL1
SFL2
SFtH
*Does not apply to the controller used in this console.
5

1.1.2.2 Output Menu (oUT)
In the setup menu, when the upper display says “SET”, use the or key to get “oUT” in the lower
display. Then, use the key to cycle through the “oUT” menu parameters (Note Chart on pg. 9).
or
SET OUT
OUT1
O1TY
O1FT
O1HY
CYC1
OFST
OUT2
O2TY
O2FT
CYC2
CPB
DB
PL1L
PL1H
PL2L
PL2H
6

1.1.3 Manual Mode Menu – (Use for Temporary Operation if Sensor Fails) (Also refer to pg. 18)
Press and hold the “ ” key for approx. 6sec until the “HAND” parameter is shown in the upper display.
Then, press and hold the “ ” key for an additional 5 sec. until an “MANU” led starts to flash in the lower left
of the display. Then, use the “ ” key to cycle through the available options.
User is able to manually set the out output to be energized from 0-100% of the cycle time.
“Hx.xx” is used to adjust output 1.
“Cx.xx” is used to adjust output 2.
You are able to exit manual mode by pressing and holding the key.
1.1.4 Auto-Tuning Mode – (Tunes PID Parameters to Your Application) (Also refer to pg. 15)
Press and hold the “ ” key for approx. 7sec until the “A-T” parameter is shown in the upper display.
Press and hold the “ ” key for 5 seconds to activate Auto-Tuning Mode. Continue to hold the “ ” key for
an additional 3 seconds, else the display will revert to a “User Menu” parameter.
Auto-tuning allows the controller to find its own optimal control parameters (PID) by measuring the speed of
your thermal process.
HANd
5 Sec
MV1
MV2
FILE
Press key 5 Sec To execute the selected default program
7

1.2 Parameter Description
(*Parameters that are not applicable are not shown)
Register
Address
Parameter
Notation Parameter Description Range Default Value
0 SP1 Set Point 1
(Used for Output 1)
Low: SP1L
High: SP1H 77.0° F
8 INPT
(See Pg. 11) Input sensor selection
0J_tC: Jtype Thermocouple
1K_tC: Ktype Thermocouple
2T_tC: Ttype Thermocouple
3E_tC: Etype Thermocouple
4B_tC: Btype Thermocouple
5R_tC: Rtype Thermocouple
6S_tC: Stype Thermocouple
7N_tC: Ntype Thermocouple
8L_tC: Ltype Thermocouple
9U_tC: Utype Thermocouple
10 P_tC: Ptype Thermocouple
11 C_tC: Ctype Thermocouple
12 D_tC: Dtype Thermocouple
13 Pt.dN: PT100 DIN curve
14 Pt.JS: PT100 JIS curve
15 4-20: 4-20mA linear current input
16 0-20: 0-20mA linear current input
17 0-5V: 0-5VDC linear voltage input
18 1-5V: 1-5VDC linear voltage input
19 0-10: 0-10VDC linear voltage input
1
9 UNIT Input unit selection
0oC:°C unit
1oF:°F unit
2
Pu:Process unit
1
10 DP Decimal point selection
0No.dP: No decimal point
11-dP: 1 decimal digit
22-dP: 2 decimal digit
3
3-dP: 3 decimal digit
0
13 SP1L Low limit of set point 1
(Span Value)
Low: -19999
High :SP1H
0.0° F
(-18.0° C)
14 SP1H High limit of set point 1
(Span Value)
Low: SP1L
High: 45536
1000.0° F
(538° C)
15 FILT
Filter damping time constant of
PV Sensor
(See Pg. 14)
0
0: 0 second time constant
10.2: 0.2 second time constant
20.5: 0.5 second time constant
31: 1 second time constant
42: 2 second time constant
55: 5 second time constant
610: 10 second time constant
720: 20 second time constant
830: 30 second time constant
960: 60 second time constant
2
Basic
Menu
8