TCM120. Operation Manual

Transcription

1 TCM120 Operation Manual This manual covers operation of the tcm120, tcm121, tcm122, tcm123, tcm125, and the European version tcm121e. The term tcm120 is used throughout this manual as the generic name for this family of temperature controllers. Likewise, the term itc2200 is the generic name for a family of heating system cabinets that includes the itc2208, itc2216 and the itc2224. VTI, Incorporated 24 McMillan Way Newark, DE Phone (302) FAX (302) Revision Level 3.00 March, 2000 Manual No

2 Table of Contents Introduction 1 Module 1: Understanding the Function of the tcm120 2 Module 2: Managing the tcm120: Powering Up, Shutting Down, and Moving 8 Module 3: Reading the LEDs and the Display Screen 13 Module 4: Using the tcm120 Keys 18 Module 5: Accessing Parent Menus and Their Submenus 26 Module 6: Responding to tcm120 Alarms 41 Module 7: Commencing System Startup 52 Appendix A: Changing the JP1 Jumper Configuration 60 Appendix B: Guide to tcm120 Input and Output Options 61 Appendix C: Guide to Maximum Heater Resistance 62 Appendix D: Guide to Self Limiting Heating Cable Constants 65 Appendix E: Default tcm120 Configuration Parameters 67 Appendix F: Revisions 70

3 Introduction to the Manual This manual is divided into seven modules. Each module includes a list of learning objectives, and some modules include exercises that provide an opportunity for you to practice the operations covered in the module. This manual assumes that you have a basic understanding of heating systems and heat monitoring terminology, and that you are familiar with the process that the tcm120 monitors and controls. To use this manual, you need a tcm120 in front of you so that you can do the exercises in the modules. This tcm120 should be electrically powered, but it should not be attached to a heating zone. If you do not have a spare tcm120, disconnect the load from one tcm120 within your heating system so that you can complete the exercises in this tutorial. Note: The JP1 jumper configuration within the tcm120 hardware is factory set at VTI and determines what functions you can perform on a particular tcm120. If an action is not permitted, the tcm120 s display screen shows the code ENBL. If the tcm120 you are using does not allow you to do an exercise in this tutorial, the JP1 jumper may need to be changed. For instructions on changing the JP1 jumper configuration, See Appendix A. Before proceeding with this manual, meet with the process engineer overseeing your operations to discuss what variables you will be monitoring and what functions you will be performing. After completing this manual, you will be able to > explain the information communicated on the front panel > use the keys to access data and set parameters > respond to alarms, and > commence system startup tcm120 Operation Manual/Rev Introduction

4 Module 1 Understanding the Function of the tcm120 In this module, you learn the function of the tcm120 temperature controller and your role as an operator. Learning Objectives After completing this module, you will be able to > discuss the function of the tcm120 temperature controller > describe the itc2200 cabinet > describe the font panel of the tcm120 tcm120 Operation Manual/Rev Module 1

5 Introduction to the tcm120 The tcm120 temperature controller is used to monitor and regulate individual heating circuits or zones within a heating system. The tcm120 helps prevent expensive damage to heating systems (such as heater damage due to groundfault currents) and freezing of process materials in pipes. The tcm120 alarms alert you when the heating zone is not operating within the desired parameters. For example, a tcm120 may be connected to a heating cable on a long pipeline that is at risk of freezing in winter. The tcm120 monitors and controls the temperature of the pipe. If the pipe s temperature falls a pre set amount below the set point (desired temperature), the tcm120 sets off a low temperature alarm to alert you. You can adjust the heating zone parameters to meet your particular application requirements. To make these adjustments, you use keys on the tcm120 s front panel to access one of the menus you will learn about in Modules 5 and 6. Through the menus, you can change the operating parameters of the heating zone and the tcm120, and enable and disable the alarms. As an operator, your primary task is to monitor the tcm120 and to respond to alarms. To respond to an alarm, you need to understand how to read the front panel of the tcm120 and how to use the keys to access menus in the controller. tcm120 Operation Manual/Rev Module 1

6 The tcm120: A Communication Center and Controller The tcm120 is a small computer that acts as a control and communication center between you and a heating zone. Figure 1 shows the communication flow between you and the heating zone through the tcm120. Heating Zone Data/Info Instructions Instructions tcm120 Data/Info You Figure 1. You can give instructions to the tcm120 to obtain information about the heating zone or to change the operating conditions of the heating zone. tcm120 Operation Manual/Rev Module 1

7 The itc2200 Cabinet As shown in Figure 2, a tcm120 is positioned in an itc2200 cabinet with up to 23 other tcm120s. Depending on what model cabinet you are using, you may have one, two, or three racks. Each position in the racks is assigned an address (R1 1 through R3 8) that corresponds to the individual circuit breaker (CB1 1 through CB3 8) that controls power to the zone. Each itc2200 cabinet also has a main circuit breaker. Figure 2. tcm120 Operation Manual/Rev Module 1

8 The tcm120 s Front Panel You can perform all functions from the front panel of the tcm120. As shown in Figure 3, the front panel contains a four digit alphanumeric display screen, 10 circular Light Emitting Diodes (LEDs), and six keys. Figure 3. The tcm120 s screen reveals information that the tcm120 has learned about the heating zone and displays new instructions as you enter them into the controller. Module 3 explains the LEDs and their use. Module 4 explains the keys and their use. tcm120 Operation Manual/Rev Module 1

9 tcm120 Operation Manual/Rev Module 1

10 Module 2 Managing the tcm120: Powering Up, Shutting Down and Moving In this module, you learn how to power up, shut down, and move a tcm120. Learning Objectives After completing this module, you will be able to > start up and shut down a tcm120 > define three precautions necessary in handling a tcm120, and > move a tcm120 tcm120 Operation Manual/Rev Module 2

11 Powering Up the tcm120 Because it is designed to run continuously, the tcm120 is powered up only at first use or if you need to turn it back on after power or equipment failure. Figure 4 shows the location of the main circuit breaker, which supplies power to the entire itc2200 cabinet, and the individual circuit breakers that are connected to individual tcm120s. Figure 4. Although you will learn in this module how to power up the tcm120, you should not actually start up your heating system until you have completed Modules 1 7. You will then be ready to operate a tcm120 that is connected to an actual heating zone. Module 7 will walk you through starting up your system and answer common questions. tcm120 Operation Manual/Rev Module 2

12 To power up the tcm120: 1. Flip on the main circuit breaker, located at the bottom of the distribution section of the itc2200 cabinet. 2. Flip on the individual circuit breakers, located in the distribution section of the itc2200 cabinet, for each tcm120 zone. The four digit alphanumeric display lights up on each tcm102 after a few seconds, indicating that the tcm120 is powered up. (Note: Powering up may falsely trip the watch dog timer alarm or other alarms due to turn on transients. Module 6 discusses how to respond to alarms.) Shutting Down the tcm120 Because the tcm120 runs continuously, you will need to shut it down only for repair work. If repair work is taking place in a particular zone, always turn off the individual breaker for that zone. To shut down a single tcm120, flip off the individual circuit breaker, located in the distribution section of the itc2200 cabinet, for the zone you want to shut down. To shut down all tcm120s in the itc2200 cabinet: 1. Flip off the individual circuit breakers, located in the distribution section of the itc2200 cabinet, for each tcm120 zone (24 breakers). 2. Flip off the main circuit breaker, located at the bottom of the distribution section of the itc2200 cabinet. tcm120 Operation Manual/Rev Module 2

13 Moving the tcm120 Moving a tcm120 may become necessary > if a tcm120 malfunctions, or > if repair work is being done in the corresponding zone Handling electrical equipment is hazardous, so it is important to follow safety instructions carefully. Always turn the individual breaker off before removing, replacing, or inserting a tcm120. The tcm120 is sensitive to static when not enclosed in the itc2200 cabinet. To protect the tcm120 from static discharge, keep it wrapped in static free bubble packaging when it is not in the itc2200 cabinet. To avoid static shock, handle the tcm120 by picking it up with two hands, touching only the front panel and rear connector. Do not touch the components on the circuit board. Removing a tcm120 To remove a tcm120: 1. If the master circuit breaker is off, proceed to Step If the master circuit breaker is on, you must turn off the individual circuit breaker corresponding to the particular tcm Remove the screws from the four corners of the front panel 4. Remove the tcm120 from the rack by pulling on the handle located at the bottom of the front panel. tcm120 Operation Manual/Rev Module 2

14 Inserting a tcm120 To insert a new tcm120 or a tcm120 you have taken from another zone: 1. If the master circuit breaker is off, proceed to Step If the master circuit breaker is on, you must turn off the individual circuit breaker corresponding to the particular tcm Insert the tcm120 into the rack. 4. Position the four screws on the corners of the front panel, and tighten them. Resetting Parameters Each of the tcm120 s operating parameters is preprogrammed by VTI prior to shipment for the particular specifications of the heating zone that the tcm120 is intended to control. The tcm120 has a small memory capacity that can remember these operating parameters even when it is unpowered. When a tcm120 is moved to a new zone, however, you consult with the process engineer to set up new parameters for that zone. Module 5 explains how to change operating parameters. tcm120 Operation Manual/Rev Module 2

15 Module 3 Reading the LEDs and the Display Screen In this module, you learn what information is communicated by the two rows of circular Light Emitting Diodes (LEDs) on the tcm120 s front panel. You also learn about seven process variables that you can access from the front panel to monitor the heating zone. Learning Objectives After completing this module, you will be able to > name the LEDs in the top row and describe the function of each > name the LEDs in the bottom row and describe the function of each, and > explain the seven process variables that you can access from the front panel to monitor the heating zone tcm120 Operation Manual/Rev Module 3

16 Reading the LEDs in the Top Row The five LEDs in the top row of the front panel correspond to important information about the heating zone, such as the present temperature, temperature deviation from the set point, and the voltage applied to the heating element. Figure 5 shows the position of the five LEDs in the top row. Figure 5. The display screen between the two rows of LEDs communicates values for the following five process variables of the heating zone when the corresponding LED is lit: Temp T Dev Present temperature of the heating zone in degrees Fahrenheit or degrees Celsius. Difference between the temperature of the zone and the desired temperature, called the set point (T Dev= Temp Set Pt). A negative T Dev indicates that the zone s temperature is less than the set point; a positive T Dev indicates that the zone s temperature is greater than the set point. tcm120 Operation Manual/Rev Module 3

17 Volt Cur Set Pt Voltage applied to the heating element. Current flowing in the heating element. Desired temperature or set point You will learn in Module 4 how to use the [INDEX] key to access the five LEDs in the top row to determine the corresponding value of the process variable for the zone you are monitoring. Two additional process variables, resistance and ground current, are also accessible from the front panel, even though there are no corresponding LEDs. The value shown on the screen when you access these process variables indicate the resistance or the ground current of the heating element, depending on which process variable you have selected. Module 4 explains how to use the [INDEX] key to access the resistance and ground current of the heater. tcm120 Operation Manual/Rev Module 3

18 Reading the LEDs in the Bottom Row The LEDs in the bottom row also provide important information. Figure 6 shows the position of these LEDs. Figure 6. Man The amber LED in the center, Man, indicates whether the tcm120 is in manual or automatic mode. When the LED is lit, the controller is in manual. When the LED is not lit, the controller is in automatic mode. The controller usually remains in automatic mode, but you can use the manual mode to override the existing controller output voltage. tcm120 Operation Manual/Rev Module 3

19 F and C The green LEDs on either side of the Man LED indicate whether the displayed temperature is in Fahrenheit or in Celsius. Either the F LED or the C LED is always lit when the tcm120 is powered up. Alarm L Alarm H The red LED at the left end of the row lights if the heating zone falls below a specified parameter. The red LED at the right end of the row lights if the heating zone exceeds a specified parameter. tcm120 Operation Manual/Rev Module 3

20 Module 4 Using the tcm120 Keys In this module, you learn the functions of the six tcm120 keys, how to obtain information from the heating zone, and how to enter instructions into the tcm120. Learning Objectives After completing this module, you will be able to > define the purpose of each key > use the keys to monitor the temperature, temperature deviation, voltage, current, set point, resistance, and ground current, and > use the keys to change the voltage and set point tcm120 Operation Manual/Rev Module 4

21 Using the Keys The six black keys positioned on the lower portion of the front panel allow you to monitor the heating zone and communicate instructions to it. Figure 7 shows the position of the six keys. Figure 7. tcm120 Operation Manual/Rev Module 4

22 The keys are used for the following purposes: [INDEX] [q] and [p] [ENTER] [RESET] [AUTO/MAN] The [INDEX] key is used to move sequentially through the seven process variables you learned about in Module 3 and through the four parent menus (groups of submenus) that will be explained in Module 5. The [q] and [p] keys have a variety of functions. They can decrease and or increase the value of the number showing on the display screen, or provide access to submenus from the parent menus. Module 5 explains submenus and parent menus. The [ENTER] key tells the tcm120 that you have finished creating a new instruction. Pressing the [ENTER] key prompts the tcm120 to record the new data. The [RESET] key has a dual function: it acknowledges alarms and also resets enabled alarms that require a manual reset. Module 6 explains how to respond to alarms. The [AUTO/MAN] key allows you to toggle between auto and manual operation. Recall that the manual (or automatic) mode is indicated by the amber colored LED on the bottom row. In the automatic mode, the tcm120 controls the heater voltage to produce the exact amount of heat necessary to hold the zone temperature equal to the set point temperature. The manual mode allows you to change the heater voltage to whatever value you choose. tcm120 Operation Manual/Rev Module 4

23 Exercise: In this exercise you will use the [INDEX] key to access the seven variables you learned about in Module 3. Press the [INDEX] key successively until the Temp LED lights up, as shown in Figure 8. You are now at the beginning of the process variable sequence. If your tcm120 is connected to a heating zone, the actual temperature of the heating zone is indicated on the display. Figure 8. Press the [INDEX] key again, and the T Dev LED lights up. Notice the temperature deviation indicted on the screen. The temperature deviation is the difference between the actual temperature of the heating zone (shown when the Temp LED is lit) and the set point (shown when the Set Pt LED is lit). tcm120 Operation Manual/Rev Module 4

24 If your tcm120 is connected to a heating zone, the actual temperature deviation is indicated on the display. Press the [INDEX] key again, and the Volt LED lights up. Notice the voltage indicated on the screen in volts. The numbers on the screen may be changing constantly if the voltage being applied to the heating element is changing. Press the [INDEX] key again, and the Cur LED lights up. Notice the actual heating element current indicated in amps on the screen. Press the [INDEX] key again, and the Set Pt LED lights up. Notice the set point temperature indicated on the screen. Press the [INDEX] key again and notice that no LED lights up, as shown in Figure 9. Notice the resistance indicated in ohms on the screen: three numbers followed by an R. Figure 9. tcm120 Operation Manual/Rev Module 4

25 Press the [INDEX] key again and notice that no LED lights up, as shown in Figure 10. Notice the ground current display in milliamps on the screen: three numbers followed by a G. Figure 10. Press the [INDEX] key four times until you see the Temp LED light up again. The three selections that follow the ground current process variable do not have LEDs. These selections are parent menus that you will learn about in Module 5. tcm120 Operation Manual/Rev Module 4

26 Changing Voltage and Set Point All the process variables read information from the electrical heating zone and communicate it to you. You can also enter information into the electrical heating zone through the third and fifth process variables, Volt and Set Pt by using the keys on the front panel. To change the voltage, use the [INDEX] key to select the Volt process variable; then, press the [AUTO/MAN] key to access the manual mode. To decrease or increase the voltage, use the [q] and [p] keys. The voltage changes as the display changes; you do not need to press the [ENTER] key. [AUTO/MAN] key. To restore the automatic mode, press the To change the set point, use the [INDEX] key to select the Set Pt process variable. To decrease or increase the set point, use the [q] and [p] keys to change the displayed value. Then press the [ENTER] key to record the data. The tcm120 blinks to indicate it has accepted the data as the new set point. Exercise: In this exercise you will increase the heater voltage to full scale for maximum heat. Use the [INDEX] key to select Volt. Press the [AUTO/MAN] key to access the manual mode. Press the [p] key and hold it depressed until the voltage reaches full scale. When maximum heat is no longer needed, press the [AUTO/MAN] key to restore automatic mode. The tcm120 will resume controlling according to the set point temperature. tcm120 Operation Manual/Rev Module 4

27 Exercise: In this exercise you will increase the set point by five degrees.. Use the [INDEX] key to select Set Pt. Press the [p] key to increase the displayed value by five degrees. After obtaining the desired temperature in the display, press the [ENTER] key to enter the data. The tcm120 indicates it has accepted the data as the new set point by blinking. tcm120 Operation Manual/Rev Module 4

28 Module 5 Accessing Parent Menus and Their Submenus In this module, you learn the functions of the parent menus and how to access their submenus. You also learn the difference between numeric and discrete menus, and how to change operating parameters. Learning Objectives After completing this module, you will be able to > explain the functions of the three parent menus accessible to the operator > access these parent menus and their submenus, > define the difference between numeric and discrete menus, and > change operating parameters tcm120 Operation Manual/Rev Module 5

29 Accessing the Parent Menus Three parent menus follow the ground current process variable. The parent menus do not have corresponding LEDs. (Note: a fourth parent menu, CALB, is not visible or accessible to the operator from the front panel. Access to the CALB parent menu, which allows calibration of internal tcm120 operating constants, is blocked by the JP1 jumper configuration. The tcm120 is factory calibrated prior to shipment and does not normally require field calibration of operating constants in this parent menu. Only factory representatives or other qualified persons should alter the calibration settings in the CALB parent menu.) The parent menus can be accessed in sequence by pressing the [INDEX] key. When you access a parent menu, a four letter abbreviation appears on the display screen. CNFG CONT ALRM allows you to configure operating parameters allows you to adjust control loop parameters allows you to select alarm actions and enter the alarm set points Each parent menus has a number of submenus. This module covers the submenus for the configuration (CNFG) and control (CONT) parent menus, with which you should be familiar. However, you will rarely use these menus, except as directed by the process engineer. The alarm (ALRM) parent menu and its submenus will be covered in Module 6. tcm120 Operation Manual/Rev Module 5

30 Submenus: Discrete versus Numeric Submenus either discrete or numeric define a particular parameter or command that you can change. A discrete submenu requires you to choose from a limited number of possible selections. A numeric submenu allows you to choose a value by decreasing or increasing the number on the display screen. In discrete submenus, press the [q] or [p] key to select the desired option. In numeric submenus, press the [q] or [p] key to decrease or increase the value. For both kinds of submenus, press [ENTER] to record the data. The tcm120 signals it has recorded the data by blinking. Accessing the Submenus The [INDEX] key allows you to move through the seven process variables and three parent menus to survey the information available to you about the heating zone or to access a parameter you want to change. To access the submenu list within a parent menu, press the [q] key. The first submenu will be displayed. To go to the next submenu, press the [INDEX] key. To enter any submenu, press the [q] key. Within a submenu, the [q] and [p] keys allow you to select either discrete or numeric options as previously discussed. To return to the parent menu after accessing the submenu options, press the [INDEX] key to return to the submenu loop; then press [p] to return to the parent menu. The charts on the following three pages show the location of the submenus within the CNFG, CONT, and ALRM parent menus. The exercises in Modules 5 and 6 offer an opportunity to practice using the [q] and [p] keys and the [INDEX] key to access the submenus. tcm120 Operation Manual/Rev Module 5

31 MENU CHART 1 CNFG tcm120 Operation Manual/Rev Module 5

32 MENU CHART 2 CONT tcm120 Operation Manual/Rev Module 5

33 MENU CHART 3 ALRM tcm120 Operation Manual/Rev Module 5

34 The CNFG Menu The configuration parent menu allows you or the process engineer to manipulate operating parameters. The menu contains 17 submenus. The following chart lists the submenus in the order they appear on the display screen when you access them. The second column explains the function of each submenu. The third column lists the options for discrete submenus and ranges for numeric submenus and ranges for numeric submenus. Submenu Function CNFG Parent Menu Discrete Submenu Options Or Numeric Submenu Ranges TEMP Sets temperature unit display. F Fahrenheit C Celsius TFB Sets source for temperature measurement. RTD Resistance Temperature Device T/C Thermocouple RES Resistance Inference XMIT Remote 4 20 ma Transmitter (see X4 and X20 submenus for range selection) T/C Sets thermocouple type. J Type J Thermocouple K Type K Thermocouple X4 Sets temperature in degrees corresponding to the 4 ma signal from an external transmitter (cannot exceed limits set by RMIN and RMAX values.) X4< X20. Range : 0( C to 1300( C X20 Sets temperature in degrees corresponding to the 20 ma signal from an external transmitter (cannot exceed limits set by RMIN and RMAX values.) X20 > X4. Range : 0( C to 1300( C Submenu Function CNFG Parent Menu Discrete Submenu Options Or Numeric Submenu Ranges tcm120 Operation Manual/Rev Module 5

35 RMIN Sets minimum temperature to be Range : 0( C to 1300( C measured by the controller in degrees. It is used internally to scale all temperature values. RMIN < RMAX RMAX Sets maximum temperature to be measured by the controller in degrees. It is used internally to scale all temperature values. RMAX > RMIN. Range : 0( C to 1300( C OUT Sets output selection. PHAS Phase Controlled Output PRO Time Proportioned Output REMI Isolated 4 20 ma Output (Requires 4 20 ma output option to be installed. See X4 and X20 submenus for range selection.) SP Sets source for process set point. LOC Local Source, i.e., Front Panel COMP Remote Source via Serial Interface; LOC locked out REMI Remote 4 20 ma Transmitter (See X4 and X20 submenus for range selection.) BAUD Sets baud rate for serial interface. 150 baud 300 baud 600 baud 1200 baud 1800 baud 2400 baud 4800 baud 9600 baud tcm120 Operation Manual/Rev Module 5

36 CNFG Parent Menu Submenu Function Sets output current limit in amps ILIM (only effective if phase fired SCRs are used as output mode.) Discrete Submenu Options Or Numeric Submenu Ranges Range: 0 to 20 amps for tcm120 series 0 to 5 amps for tcm125, and 0 to 25 amps for tcm121e. RNOM * Sets default heater resistance in Normally set at 10 or at the ohms. Used by tcm120 in resistance approximate nominal resistance of inference mode whenever controller the heater when the heater is 50( output is <15 watts. F. Range: 1 to 2000 ohms DEF Sets default display (activated when front panel operations not conducted for 15 minutes). T Temperature D Deviation V Voltage I Current SP Set Point REV Shows current software revision (cannot be changed from front panel). * When operating in resistance inference mode, the tcm120 requires a minimum load of 15 watts in order to measure resistance and infer temperature accurately. If the controller load is less than 15 watts, the Temp display shows P.LOW, indicating that accurate readings cannot be achieved. tcm120 Operation Manual/Rev Module 5

37 CNFG Parent Menu Submenu Function W0 Modeling constant for particular self regulating heating cable being used (used in resistance inference mode only). W1 Modeling constant for particular self regulating heating cable being used (used in resistance inference mode only). VMAX** Input power voltage to controller, usually 120, 208 or 240 volts Discrete Submenu Options Or Numeric Submenu Ranges As required. See Appendix D for details. As required. See Appendix D for details. Range 0 to 250 volts ** The tcm120 cannot achieve full output because there will always be some voltage loss due to the tcm120 s solid state power switching device, the circuit breakers in the itc2200 cabinet, and the typical voltage loss through wiring that always occurs in an electrical system. Consequently, the maximum output voltage is volts on a 120 volt system, on a 208 volt system and volts on a 240 volt system. tcm120 Operation Manual/Rev Module 5

38 Exercise: In this exercise you will change the temperature scale from Fahrenheit to Celsius or vice versa. Access the CNFG parent menu. Press the [q] key to move to the submenu, TEMP. Press the [q] key again to enter the submenu, TEMP. You will see either F or C on your screen. The letter indicates the temperature scale that is presently used (Fahrenheit or Celsius, respectively). You can change F to C or C to F by pressing the [q] or [p] key. When you have selected the desired temperature scale, press [ENTER] to register it as the new temperature scale. The tcm120 indicates it has accepted the data by blinking. Note that the corresponding F or C LED on the front panel is now lit to indicate the new temperature scale. Press the [INDEX] key to exit the Temp submenu and go to the next submenu, TFB, within the CNFG parent menu.. Press the [p] key to return to the CNFG parent menu. tcm120 Operation Manual/Rev Module 5

39 Exercise: In this exercise, you will set the baud rate to Access the CNFG parent menu Press the [q] key to access the first submenu in the CNFG parent menu; then press the [INDEX] key to move to the submenu, BAUD. Press the [q] key to enter the BAUD submenu. Press the [q] or [p] key to move to Press [ENTER] to register 1200 as the new value. The tcm120 indicates it has accepted the data by blinking. Press the [INDEX] key to exit the BAUD submenu and to go the next submenu, ILIM, within the CNFG parent menu. Press the [p] key to return to the CNFG parent menu. The CONT Menu The control parent menu permits you or the process engineer to change control loop parameters. The tcm120 uses PID control when utilizing thermocouple, RTD, or remote transmitter temperature sensing. A proprietary algorithm is used for control when resistance inference temperature sensing is operating. There are actually two CONT parent menus within the tcm120 controller, one menu for the PID control algorithm and one menu for the proprietary algorithm. The menu is selected automatically by the tcm120. The selection is based on whether the controller is operating in resistance inference mode. Each tcm120 Operation Manual/Rev Module 5

40 CONT parent menu contains six submenus. When resistance inference mode is operating, the submenus consist of a resistance calibration mode and five parameters. When resistance inference mode is not operating, the submenus consist of five parameters and an auto tuning option. The parameters have numeric submenus. By pressing the [q] or [p] key, you can decrease or increase the value of the selected parameter. Pressing [ENTER] records the new value. Without direct instructions from the process engineer, the resistance calibration mode and the auto tuning option are probably the only submenus you will use. However, you will use them infrequently, if at all. The following charts show the two CONT parent menus and their submenus in the order they appear on the display screen when you access them. The second column explains the function of each submenu. The third column lists the units in which the value is measured. The fourth column lists the options for discrete submenus and ranges for numeric submenus. Submenu CNFG Parent Menu #1 Resistance Inference Mode Function Measured In RCAL Activates resistance calibration cycle Discrete Submenu Options Or Numeric Submenu Ranges YES * NO MOFF Adds manual offset to the set point Degrees Normally set to 0. Range: 199 to +199 R0 Wire model constant. Should be set to 0.0 for current software revision. Used only in resistance inference mode. R1 Sets controller dead band. (Used in software revisions 0.20 and higher.) Used only in resistance inference mode. R2 Not used with software revision 0.03 and subsequent revisions. (C Normally set at 10. Range: 3 to 50 SLEW Sets output slew rate. Percent Per Normally set at 2. Second Range: 0 to 100 * Used only to reactivate the resistance calibration mode for self limiting cable if changes to heating circuit have been made since last calibration. tcm120 Operation Manual/Rev Module 5

41 CNFG Parent Menu #2 Not Resistance Inference Mode Discrete Submenu Options Or Numeric Submenu Function Measured In Submenu Ranges RATE Sets PID RATE (derivative) action. Seconds Normally set at 0. Range: 0 to 9999 RST Sets PID reset (integral) action. Seconds Normally set at 600. Range: 0 to 9999 PRO Sets PID gain (proportional) action. Degrees Normally set at 40. Range: 0 to 9999 MOFF Adds manual offset to the set point Degrees Normally set at 0. Range: 199 to +199 SLEW Sets output slew rate. Percent Per Normally set at 2. Second Range: 0 to 100 TUNE Activates auto tuning feature. YES NO PID loop parameters are sometimes sensitive to specific thermal characteristics of your heating zone. Auto turning a tcm120 in the field may polish its performance. To check whether the control loop parameters can be better tuned, use the auto tuning feature. (The auto tuning feature is not available when using resistance inference mode.) The auto tuning feature is a discrete submenu with two options: YES and NO. auto tune the tcm120, press the [q] or [p] key to select YES. Press [ENTER] to record the information. Once set to YES the tcm120 switches immediately to the manual mode (the yellow Man LED lights up) and waits. You initiate an auto tune cycle by pushing the [AUTO/MAN] button; the tcm120 enters an auto tune sequence to adjust the RATE, RST, and PRO parameters for best possible control loop dynamics. The yellow Man LED on the front panel of the tcm120 blinks while the auto tune cycle is in progress. The cycle can take several hours, depending on the thermal dynamics of your heating zone. When the cycle is complete, the controller switches to automatic mode. To tcm120 Operation Manual/Rev Module 5

42 Exercise: In this exercise, you will activate the auto tuning mode to refine the parameters. (Remember: The auto tune option is available only in the second CONT menu. You will not be able to access it when the tcm120 is operating in resistance inference mode.) Access the CONT parent menu. Press the [q] key to access the first submenu in the CONT parent menu; then press the [INDEX] key to move to the submenu, TUNE. Press the [q] key to enter the TUNE submenu.. Press the [q] or [p] key to select YES. Press [ENTER] to record the information. Once set to YES, the controller switches automatically to the manual mode (the yellow Man LED lights up). Start the auto tuning sequence by pushing the [AUTO/MAN] button; the tcm120 initiates an auto tune cycle to adjust the RATE, RST, and PRO parameters. The yellow Man LED on the front panel of the tcm120 blinks while the auto tune cycle is in progress. Press the [INDEX] key to exit the TUNE submenu and go to the next submenu. (Because TUNE is the last submenu in the list, you return to the first submenu, RATE.) Press the [p] key to return to the CONT parent menu. The ALRM Menu The alarm parent menu allows you to select alarm actions and enter the alarm set points. Module 6 discusses the alarm parent menu in detail. tcm120 Operation Manual/Rev Module 5

43 Module 6 Responding to tcm120 Alarms In this module, you learn how to recognize and identify an alarm, and how to use your knowledge of the menus and keys to respond to an alarm. Learning Objectives After completing this module, you will be able to > respond to alarms > access the alarm menu and submenus > set parameters for alarms, and > enable and disable alarms tcm120 Operation Manual/Rev Module 6

44 Responding to Alarms How often do alarms go off? If all equipment operates properly, the alarms should never go off. When alarms do go off, however, it is important to respond quickly. More than one alarm can go off at once. It does not matter to the tcm120 in what order you respond to alarms. However, some alarms could indicate more harm to your heating zone than other alarms; therefore, the more urgent fault conditions should be addressed first. When a tcm120 enters an alarm condition, the front panel LEDs for the high and/or low alarms light up and flash. To identify which of the 16 possible alarms are activated, select the Temp process variable on the front panel. The names of the activated alarms flash on the display screen, identifying the alarms so that you can take appropriate action. Whenever the Temp process variable is displayed, the alarm names will continue to flash until you clear the fault condition in the field and reset the alarms. To respond to an alarm, press the [RESET] key once to acknowledge the alarm. The alarm LED stops flashing, but remains lit until you correct the fault condition. If you do not correct the fault condition within four hours, the alarm reactivates and the alarm LED starts flashing again. If a new alarm occurs after you have acknowledged an activated alarm, the LED starts flashing again. If the alarm is configured for automatic reset, the alarm clears automatically and the LED turns off after you correct the fault condition. If the alarm is configured for manual reset, you must press the [RESET] key again to clear the alarm and return the LED to normal. In review, if an alarm goes off, follow these steps: 1. Press the [RESET] key to acknowledge the alarm. 2. Clear the fault condition. 3. Press the [RESET] key to clear the alarm if it is configured for manual reset. Example: The T Dev LED of a tcm120 is lit, and the display screen shows a temperature deviation of Suddenly, because the ground current exceeds its alarm set point, the Alarm H LED starts flashing. tcm120 Operation Manual/Rev Module 6

45 Respond to the alarm as follows: Use the [INDEX] key to step to the Temp process variable display. (On the display, the alarm GFI alternates with the temperature.) Press the [RESET] key to acknowedge the alarm (the Alarm H LED will stop flashing). Correct the fault condition that created the alarm. When the condition has been corrected, the alarm will clear automatically if it is configured for automatic reset. If the alarm is configured for manual reset, you must press the [RESET] key again to clear the alarm. It is possible to completely disable alarms, but, in general, you should only disable alarms under unusual or extenuating circumstances. After all, the purpose of an alarm is to notify you of a condition that requires correction. System Alarms Each tcm120 has two separate alarm relays. In the itc2200 cabinet, each alarm relay output is wired in parallel with the corresponding relay outputs from all other tcm120s. These outputs activate two system alarm relays to generate two overall heating system alarms. A third system alarm relay detects loss of power to the cabinet to ensure fail safe system alarm operation. The outputs of these system alarm relays are available to you to activate an annunciator or to serve as an input to a DCS computer. Accessing the ALRM Submenus The alarm parent menu allows you to enable individual alarms (or, when appropriate, disable alarms), to select manual or automatic reset of specific alarms, to enter alarm set points, and to select the operation for the two alarm relays (see submenus K1 or K2 in the chart on the following pages). The alarm parent menu contains 27 submenus. Submenus for specifying alarm set points are numeric. Use the [q] and [p] keys to decrease or increase the set point; then press the [ENTER] key. The tcm120 signals it has recorded the data by blinking. Submenus for disabling or enabling alarms are discrete. Use the [q] and [p] keys to select the desired alarm mode; then press the [ENTER] key. The tcm120 signals it has recorded the data by blinking. The following chart lists the submenus, their functions, and the options for discrete submenus. tcm120 Operation Manual/Rev Module 6

46 ALRM Parent Menu Submenu Function Comments AH Sets the alarm point in degrees for high temperature Set as an absolute temperature that is independent of set point temperature. AHD Sets the alarm point in degrees for high temperature deviation. AL Sets the alarm point in degrees for low temperature. ALD Sets the alarm point in degrees for low temperature deviation. RHI Sets the alarm point in ohms for high heater resistance; detects an open heater or a high resistance connection in the heater circuit. Set as a positive delta above the set point temperature: Dev = Temp Set Pt Set as an absolute temperature independent of set point temperature. Set as a negative delta above the set point temperature: Dev = Temp Set Pt Alarm also activated when heater resistance changes more than +20% in 2.5 seconds. RLOW Sets the alarm point in ohms for low activated when heater resistance changes heater resistance; detects a shorted more than +20% in 2.5 seconds. heater or low selflimiting heater resistance. GFIS Sets the alarm point for ground fault Adjustable from 10ma to 100ma. Normally current, measured in milliamps. set at 30ma. TAMB Sets the alarm point in degrees for high ambient temperature (if air around tcm120 >85(C, damage to circuitry could result. OCS Sets alarm point in amps for the output overcurrent (amount of current flowing into zone.) Factory set at 85(C. Tcm120 series: Adjustable from 0 to 25 amps. Normally set at 22 amps. Tcm125: Adjustable from 0.5 to 6 amps. Normally set at 6 amps. Tcm121E: Adjustable from 0 to 28 amps. Normally set at 27.5 amps. tcm120 Operation Manual/Rev Module 6

47 ALRM Parent Menu Submenu Function Discrete Submenu Options K1 Selects alarms assigned to the K1 alarm relay. ALL Activated by all enabled alarm conditions. HI Activated by high temp alarms and ground fault alarm (HT, HTD, GFI). HI+ Activated by high temp alarms, ground fault alarm, and any nontemperature related alarm. K2 Selects alarms assigned to the K2 alarm relay. ALL Activated by all enabled alarm conditions. LOW Activated by low temp alarms (LT, LTD). LOW+ Activated by low temp alarms, and any non temperature related alarm. FUSE Disables or enables alarm for blown DIS Disables alarm. fuse. A/DF SCRs* will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required HAMB Disables or enables alarm for high ambient temperature DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required * Silicon Controlled Rectifier tcm120 Operation Manual/Rev Module 6

48 ALRM Parent Menu Submenu Function HT Disables or enables alarm for high process temperature. HTD Disables or enables alarm for high process temperature deviation. LT Disables or enables alarm for low process temperature. LTD Disables or enables alarm for low process temperature deviation Discrete Submenu Options DIS Disables alarm. A/DF SCRs* will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required * Silicon Controlled Rectifier ALRM Parent Menu Submenu Function Discrete Submenu Options tcm120 Operation Manual/Rev Module 6

49 RESH Disables or enables alarm for high heater resistance. RESL Disables or enables alarm for low heater resistance. GFI Disables or enables alarm for ground fault OC Disables or enables alarm for overcurrent condition DIS Disables alarm. A/DF SCRs* will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required * Silicon Controlled Rectifier tcm120 Operation Manual/Rev Module 6

50 ALRM Parent Menu Submenu Function OT/C Disables or enables alarm for open thermocouple. Discrete Submenu Options DIS Disables alarm. A/DF SCRs* will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required SRTD Disables or enables alarm for shorted RTD.** DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required ORTD Disables or enables alarm for open RTD. DATA Disables or enables alarm for data loss. (Data loss occurs when data DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required DIS Disables alarm. A/DF SCRs will be disabled if alarm stored in the configuration parameter occurs; automatic reset EEPROM is corrupted.) A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required * Silicon Controlled Rectifier ** Resistance Thermonic Device ALRM Parent Menu tcm120 Operation Manual/Rev Module 6 Function

51 Submenu Discrete Submenu Options MAN Disables or enables alarm for manual mode. WDT Disables or enables the watch dog timer. (If program execution is interrupted for any reason, a watch dog timer will reboot the system.) DIS Disables alarm. A/DF SCRs* will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required DIS Disables alarm. A/DF SCRs will be disabled if alarm occurs; automatic reset A/EF SCRs will not be disabled if alarm occurs; automatic reset M/DF SCRs will be disabled if alarm occurs; manual reset required M/EF SCRs will not be disabled if alarm occurs; manual reset required * Silicon Controlled Rectifier Exercise: tcm120 Operation Manual/Rev Module 6

52 In this exercise, you will increase the low temperature set point by five degrees. Select ALRM. Press the [q] key to access the first submenu in the ALRM parent menu; then press the [INDEX] key to move to the submenu, AL. Press the [q] key to enter the AL submenu. Use the [p] key to raise the set point by five degrees. Press the [ENTER] key to enter the data. The tcm120 indicates it has accepted the data by blinking. Press the [INDEX] key to exit the AL submenu and go to the next submenu, ALD. Press the [p] key to return the ALRM parent menu. Exercise: tcm120 Operation Manual/Rev Module 6

53 In this exercise, you will disable the GFI alarm. Select ALRM. Press the [q] key to access the first submenu in the ALRM parent menu; then press the [INDEX] key to move to the submenu, GFI. Press the [q] key to enter the GFI submenu. Press the [q] or [p] key to select DIS. Press the [ENTER] key to enter the data. The tcm120 indicates it has accepted the data by blinking. Press the [INDEX] key to exit the GFI submenu and move to the next submenu, OC. Press the [p] key to return the ALRM parent menu. tcm120 Operation Manual/Rev Module 6

54 Module 7 Commencing System Startup In the previous six modules, you have learned how to operate a tcm120. You are now ready to work with the process engineer to commence system startup. Module 7 takes you through actual system startup, step by step. Learning Objectives After completing this module, you will be able to > start up the system > check the thermal system > check the field wiring > energize the transformer, and > energize the heating zones tcm120 Operation Manual/Rev Module 7

55 Starting Up the System The startup procedure for the itc2200 heating system involves the following important steps: > checking the thermal system > checking and verifying field wiring > energizing the transformer > energizing each heating zone Checking the Thermal System The thermal characteristics of your heating system are just as important as the electrical controls in achieving overall system performance objectives. After installing the heating elements but before connecting them to an itc2200 system and before applying thermal insulation, complete the following steps: > Carefully inspect each heating element to make sure no physical damage has occurred during installation > Verify that good thermal contact has been achieved between each heating element and pipe or vessel. > Megger test each lead of every heating element to exceed 20 Mohms to ground. > Energize each heating element to full rated voltage and measure the current. > Check the measured current against calculated design specifications. After thermal insulation is installed and carefully inspected for weatherproofing, each heating element should be energized again to full rated voltage. The measured current should be rechecked to design specification. Each lead of every heating element should also be megger tested again to exceed 20 Mohms to ground. tcm120 Operation Manual/Rev Module 7