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1 OVEN INDUSTRIES, INC. OPERATING MANUAL Model 5C7-252 TEMPERATURE CONTROLLER With PLC Inputs

2 Introduction Thank you for purchasing our controller. The Model 5C7-252 is an exceptionally versatile unit and we want you to understand its total capability. TABLE OF CONTENTS Page Features... 1 Description... 2 Block Diagram... 3 Communications Connections... 3 Hookup... 4 Customer Drawing... 5 Expansion Connector Wiring Diagram C7-252 Expansion Connector Applications... 7 Setup Screen with Factory Default Settings... 8 Set-Up Instructions... 9 Appendix A - Troubleshooting Communications Port Application Note 353 (5 Minutes to PID Tuning) In no event shall Oven Industries, Inc. be liable for any damages whatsoever (including without limitation, damage for loss of business profits, business interruption, loss of business information, or any other pecuniary loss) arising out of the use or inability to use this Oven Industries, Inc. product, even if Oven Industries, Inc. has been advised of the possibility of such damages.

3 FEATURES WIDE CHOICE OF STANDARD OR CUSTOM THERMISTOR HOUSINGS THAT PROVIDE TEMPERATURE RANGES OF -20 C to 110 C WITH OUR TS67 SENSOR, OR 50 C to 225 C WITH OUR TS133 SENSOR. TEMPERATURE RESOLUTION: TO 0.05 C 1500 VAC INPUT ISOLATION 15 AMPERE, 110/220 VAC SOLID STATE RELAY OUTPUT: 50/60Hz HEATING OR COOLING MODE SELECTION CONTROL ALGORITHM: PROPORTIONAL (P), INTEGRAL (I), AND DERIVATIVE (D) THAT CAN BE SELECTED AS P, PI, PD, OR PID; OR ON/OFF WITH AN ADJUSTABLE HYSTERESIS ALARM OUTPUTS: OPTICALLY ISOLATED 0.5 AMPERE, 110/220 VAC SOLID STATE RELAY. ADDITIONALLY, A 5 20 MA DRIVE FOR AN OPTIONAL LED ALARM MONITOR, SOLID STATE RELAY, OR REED RELAY ALARM MODES: HIGH AND/OR LOW TEMPERATURE ALARMS OR TRACKING ALARMS THAT CAN BE SELECTED AS LATCHING OR NON-LATCHING ALARMS. THE ALARMS ARE RESET BY A COMMUNICATIONS INTERFACE OR OPTIONAL LOCAL SWITCH SELECT OUTPUT POWER ON OR OFF FOR ALARM CONDITION PLC INPUTS: FOUR SET TEMPERATURES CAN BE SET REMOTELY STAND-ALONE OPERATION RS-232 COMMUNICATIONS INTERFACE (ISOLATED) USED FOR SELECTING OR ADJUSTING FIELD PARAMETERS, OR FOR DATA ACQUISITION. NO COMPUTER PROGRAMMING EXPERIENCE IS NEEDED TO USE THE INCLUDED COMMUNICATIONS SOFTWARE PROGRAM. COMMAND SET IS PROVIDED WHICH ENABLES USERS TO CREATE THEIR OWN SOFTWARE INTERFACE OR EMBEDDED CONTROLLER APPLICATION. NON-VOLATILE MEMORY RETENTION OF PARAMETERS OPTIONAL LOCAL ANALOG SET POINT: POTENTIOMETER, 4-20 MA, OR 1-5 VDC WITH ADJUSTABLE RANGE CONFIGURED BY USER. 1

4 GENERAL DESCRIPTION Model 5C7-252 is a PC compatible temperature controller that accepts NTC thermistor sensors. It accepts our TS67 sensors, which are C and provide a temperature range of 20 C to 110 C. It will also accept our TS133 sensors which are C and provide a temperature range of 50 C to 225 C. An RS-232 communications link is provided for direct interface to a PC. This allows the controller to be configured for different modes of operation from the PC. The RS-232 communications interface is used to select or adjust field parameters, or for data acquisition. Once the controller is configured, the PC may be disconnected and the controller can be operated as a stand-alone unit. Communications can be re-established at any time to adjust the settings. All parameter settings are retained in non-volatile memory. The controller has PLC inputs for up to four (4) set temperatures. The controller package consists of a printed circuit card mounted to a metal mounting bracket that is DIN compatible and may be mounted either horizontally or vertically. The controller can be operated from either 110 VAC or 220VAC, which is field selectable. Input and power outputs are made via.250 and.110 fast tab connections. The sensor inputs and RS-232 connections are via a Eurostyle screw terminal strip. A Solid State relay output provides current capability up to 15 amperes at either 110 VAC or 220 VAC. In addition, an alarm output solid state relay is provided which is rated for 0.5 ampere at either 110 VAC or 220 VAC plus a 5 volt drive signal rated at 20 ma for an optional LED alarm monitor, solid state relay, or reed relay. The PC permits the monitoring of actual temperature, set temperature, percent of power applied to the load, and alarm status. It allows selection of the set temperature, turning the power on or off, canceling an alarm condition by silencing the PC audio alarm, tuning the controller setting parameters and displaying the current sensor selection. Controller tuning parameters consists of proportional bandwidth (P), integral gain in repeats per minute (I), and the derivative rate in minutes (D) for selecting P, PI, PD, or PID operation. An on/off operating mode with an adjustable hysteresis may also be selected. A controller configuration command allows for additional optional settings. The configuration mode allows the operator to select the applicable type of thermistor; type of optional auxiliary input; set control limits for the application; plus select either heating or cooling mode. The TS67 sensor has an operating range of 20 C to 100 C. The TS133 Sensor has an operating range of +50 C to 255 C Alarm selections consist of no alarm function, a fixed high and/or low temperature alarm or tracking alarms. These alarms can be selected for either a latching or non-latching operation. Reset of the alarms is accomplished via PC communications interface or an optional local switch. 2

5 Model 5C7-252 Block Diagram Input #1 Sensor Type Control Outputs TS67 TS133 Input Selection PID PID w/alarm Deadband Deadband w/alarm JP2 1 to 15 A zero switched optically isolated SSR 0.5 A zero switched optically isolated SSR 5K ohm Potentiometer 0 to 5VDC * 4 to 20ma DC ** PC Setpoint * Controller input impedence 10,000ohms ** Requires addition of external sensor. PLC Temp Selection Revision - 10/30/2003 Remote Indicator Red / Yellow / Green LED's PLC Relay Contacts RS-232 COMMUNICATIONS CONNECTIONS Voltage Input Diagram JP RX TX SHLD TX RX COMMON RS232 COMPUTER PC CONNECTION TABEL PC CONNECTOR PC FUNCTION* CONTROLLER 9 PIN 25 PIN PIN 2 3 RECEIVE (RX) TRANSMIT (TX) PIN 3 2 TRANSMIT (TX) RECEIVE (RX) PIN 5 7 COMMON SHIELD 3

6 4

7 5

8 Expansion Connector Wiring Diagram R1 R2 Set Tem p Open Ope n Temp 1 Closed Ope n Temp 2 Open Close d Temp 3 Closed Close d Temp 4 6

9 CONNECTOR WIRING EXPANSION DIAGRAM 5C7-252 EXPANSION CONNECTOR APPLICATIONS Using the Expansion Connector as a High Alarm, Low Alarm, and No Alarm Indicator (Diagram #1): Using the Window Alarm Menu selection provides LED indicators for High Alarm temp, Low Alarm temp and No Alarm (On Temp). JP2 pin 8 may be selected to show a No Alarm condition. The No Alarm LED is on when neither a High or Low Alarm condition exists. The total current to the Expansion Connector is 25ma. The selection of series resistors should limit the current through each LED to less than 25ma. Diagram #1 limits the current to 10ma through the LED s at 6 volts. The No Alarm becomes a visual indicator that the unit is within the configured alarm limits. Using the Expansion Connector as a High Alarm, Low Alarm, with Solid State Relay (SSR) Output (Diagram #2): Using the SSR Drive Menu selection provides an LED indicator for High Alarm temp, Low Alarm temp and SSR Drive output. JP2 pin 8 may be selected to drive a SSR in synchronization with the load circuit control. The total current to the Expansion Connector is 25ma. If a High and/or Low Alarm LED is used in this form, the current draw must be limited to provide a suitable current for the SSR. The High and Low Alarm LED s should be limited to 6 volts to insure 15ma. drive to the SSR. Series resistors in the LED circuits will insure the desired current sharing. The SSR drive can be used to drive higher wattage loads than available from the provided load output. Using the Expansion Connector as a High Alarm, Low Alarm, and Load On Indicator: Using Diagram #1 and the SSR Drive configuration from the Menu selection, the No Alarm LED becomes an isolated low voltage indicator of the load output. The No Alarm LED is in synchronization with the load circuit control, but is a separate low voltage indicator of the load output. 7

10 Comm 1 Comm 2 Comm 3 Comm 4 8

11 SET-UP INSTRUCTIONS FOR MODEL 5C7-252 PC PROGRAMMABLE TEMPERATURE CONTROLLER 1 Connect the appropriate AC power to the controller in accordance with the customer hook-up drawings in the Operating Manual (See the SYSTEM BLOCK DIAGRAM and the MECHANICAL/SYSTEM WIRING DIAGRAM). Select the correct configuration for either 110 VAC (jumper from WP4 to WP6), or 220 VAC (jumper from WP4 to WP3). Connect the AC power between WP2 and WP8. Note: The AC power supply must also match the voltage ratings of the load (heater or cooler). 2. Connect the RS-232 Communications Port from the controller to the RS-232 input on the PC. 3. Turn power on to the PC and temperature controller. 4. Insert the 5C7-252 software disk into the computer A:\ drive. To launch the software from the floppy disk, select START, RUN from your Windows Desktop and then enter A:\MC252.exe and OK. This will load the PC interface into your computer s RAM. 5. The Window s based GUI of the Setup program will appear on your PC monitor. 6. NOTE: If you receive an error message, please refer to Appendix A of the Operating Manual. 7. All selections are made from this menu screen. In the PC COMMUNICATIONS box, select the COMM PORT (1 through 4) which will be your communications link to the controller. Click on the INITIALIZE button and communications should be established with the controller. You should see configuration values displayed in the Set-up window. 8. In the CONFIGURATION box, the various menu selections are used to establish the custom operating criteria for the controller. 9. First, click on the SENSOR TYPE INPUT 1 menu key. Select the sensor type that is appropriate for your application. 10. Click on TIMEBASE: This is the time the controller completes one full cycle, and is expressin seconds. Acceptable values are 0.1 second to 1.0 second. Enter the timebase that is appropriate for your application. DEFAULT: 1.0. This value only really matters when using PID control. The timebase establishes the longest pulse of power that can be used. If the timebase is 1 second, then at full power the AC power is applied for 1 second, and then another second, and so on. Each pulse of power is adjacent to the previous pulse and so this is really like connecting directly to the AC source. However, say that only 50% power is going to be applied. Each pulse of power is only ½ second, ½ second on and ½ second off fills the timebase of 1 second and then this pattern repeats. To supply the equivalent of 25% power using Pulse Width Modulated (PWM), each pulse of power lasts only ¼ second, ¼ second on and ¾ seconds off fills the timebase of 1 second and then this pattern repeats. If the load responds slowly, a 1 second timebase will probably be appropriate. But if the load responds quickly to these pulses then a 1 second timebase may be too slow. For example, consider a very small relay as the load. With a one second timebase you could see the relay opening and closing every half second. With a 0.1 second timebase it may stay open if insufficient power was supplied, and stay closed if sufficient power was supplied. A smaller timebase is more appropriate for loads with a fast reaction time. 11. Next, click on the SET TEMP TYPE INPUT 2 menu key to reveal the options available. DEFAULT: EXT. COMPUTER EXT. COMPUTER (default) allows you to set the desired control temperature using the SET TEMP or VALUE field of the TUNING box. EXT. POTENTIOMETER, EXT. 0 to 5 vdc, and EXT. 0 to 20 ma, are for external set temperature adjustments. The controller s default setting for these three options is the full range of the thermistor input sensor, however you can adjust this range using the step below. 12. Associated with the external set temperature adjustments are the SET TEMP HIGH RANGE and SET TEMP LOW RANGE selections. If you selected the EXT. POTENTIOMETER, EXT. 0 to 5 vdc, and or the EXT. 0 to 20ma option for the SET TEMP TYPE INPUT 2, then these 2 fields permit the selection of limitations on the temperature range of the external adjustments. Enter the desired values for these settings. These set limit values must be within the full range specified for the sensor. DEFAULTS: 100 for HIGH and 0 (zero) for LOW 9

12 13. Now, click on the CONTROL TYPE menu key and select which type is appropriate for your application. DEFAULT: PID CONTROL. DEADBAND CONTROL is an on/off control. PID CONTROL is a proportional/integral/derivative control. COMPUTER CONTROL acts like an electronic variac in that a fixed percentage of power may be applied to the load using the SET TEMP or VALUE field of the TUNING box. (See the step below that describes the SET TEMP or VALUE field for more information.). 14. Clicking on the CONTROL MODE menu key permits the selection of either COOLING MODE or HEATING MODE. In the cooling mode power increases as the temperature rises above the set point temperature. In the heating mode power increases as the temperature falls below the set point temperature. DEFAULT: HEATING MODE. 15. The ALARM TYPE setting permits the selection of available alarm options with this controller. The drop down menu allows for four selections. NO ALARMS indicates that no alarm parameters are desired. SET TRACKING ALARMS allows an alarm to be set with respect to the set temperature and will move, accordingly, with a change of the temperature setting. This option can be used for a high alarm, low alarm, or both settings. FIXED VALUE ALARMS permits the setting of a fixed, absolute temperature either above or below the set point temperature, or both. COMPUTER CONTROLLED is not an actual alarm, but a user activation of the alarm relay via the PC. DEFAULT: NO ALARMS. 16. Associated with the ALARM TYPE configuration are the HIGH ALARM SETTING, LOW ALARM SETTING, and the ALARM DEADBAND selections. These are set in 1 (one) degree increments. If an alarm type has been selected, enter the desired high and/or low alarm temperature values. The ALARM DEADBAND option is for setting the hysteresis of the alarm values. DEFAULTS: 500 for HIGH, 0 (zero) for LOW, and 0 (zero) for DEADBAND. 17. The POWER SHUT DOWN IF ALARM menu key provides two selections. NO OUTPUT SHUT DOWN, which will let the power output stage of the controller to continue to function, or MAIN OUTPUT SHUTDOWN, which disables the power output stage under an alarm condition. DEFAULT: NO OUTPUT SHUTDOWN. 18. The ALARM LATCH option permits the selection of an ALARM LATCH OFF, where the controller will automatically reset if the alarm condition is self-correcting, or ALARM LATCH ON, which will maintain that an alarm condition existed and must be manually cleared. DEFAULT: ALARM LATCH OFF. 19. The ALARM OUTPUT FUNCTION provides a WINDOW ALARM for an on-temperature indication somewhere between the high and low alarm settings, or may be configured to drive an external solid state relay (SSR DRIVE). Refer to the Operating Manual, Appendix D, 5C7-252 Expansion Connector Application, for the external configuration. DEFAULT: WINDOW ALARM. 20. If you choose to use the PLC temperature selection, click the PLC on box. If you select this function then the controllers set temp is disabled: the PID constants will still be functional. By selecting PLC temperatures you are moving the temperature selection from the main controller section to the PLC section. 21. Select the control temperatures desired and enter these set points into the boxes for temperatures 1 through Select the ramp times for temp1 to temp 2: temp 2 to temp 3: and temp 3 to temp 4, and enter into the appropriate boxes. If you do not desire a specific ramp time then enter a 0 into the ramp time box. The time at a selected temperature (soak time) is controlled externally by operation contacts R1 and R The default setting of the four PLC set temperatures is OFF. If you wish to only use one or two of the temperatures then leave the others at OFF. 24. Refer to expansion connector application for additional PLC temperature selection information. 25. Review all of your controller configuration selections. If all the configuration selections are correct for your application, select the Send Box Values button in the CONFIGURATION box to download these settings to the controller. 26. You are now ready to tune the controller. All selections for this portion will occur in the TUNING box displayed on the monitor. The various constants required by the controller to optimize the system performance are entered in this section. 27. The SET TEMP or VALUE is the set temperature value entered in degrees. This temperature is within the range of the input sensor or the limits of low and high set ranges from the controller s configuration setup. (The low and high set ranges are set by you in the SET TEMP LOW RANGE and SET TEMP HIGH RANGE fields of the CONFIGURATION box as described above.) This field can also be used to set the output power manually. That is, instead of setting the desired temperature here, you can set a fixed value for the output power of the controller. If the CONTROL TYPE in the CONFIGURATION box is set to the COMPUTER CONTROL option, you can use the SET TEMP or VALUE field to provide a fixed percentage of power to the +load. This power resolution with an entry of 0 (zero) is equal to 0% power and 24 equals 100%. 10

13 28. Note: You can set the following to their default values and then return to these fields later to tune the controller. 29. When using PID control, PROPORTIONAL BANDWIDTH is the temperature band in which 0% to 100% power will be applied to the load. The acceptable bandwidth values that may be entered are 1.0 to DEFAULT: When using PID control, INTEGRAL GAIN shifts the proportional bandwidth with respect to the set point to compensate for droop. This value is expressed in repeats per minute and the acceptable values that may be entered are.01 to10 repeats per minute.. DEFAULT: When using PID control, DERIVATIVE GAIN senses the rate of rise or fall of the system temperature and adjusts the cycle time of the controller to minimize overshoot or undershoot. This value is expressed in cycle rates per minute and the acceptable values that may be entered are.01 to 10 cycles per minute.. DEFAULT: When using On/Off control, CONTROL DEADBAND is the temperature band where the controller is turned on and off by either rising or falling temperatures where no heating or cooling takes place. This band is expressed in F. and the acceptable values that may be entered are 0.1 F. to F. DEFAULT: Review the tuning parameters for correctness and then select the Send Box Values button in the TUNING box to download these constants to the controller. 34. You are now ready to calibrate your controller. All of these settings are made in the CALIBRATE box. 35. The CALIBRATE box provides additional variables that can be used to fine tune your system s operation. You may want to try controlling with the initial settings prior to entering values in this section. 36. INPUT 1 OFFSET is a manual method of compensating for the sensor 1 temperature and actual control temperature. DEFAULT: If you have entered values in the CONFIGURATON box and they are the desired settings, select the Send Box Values button in the CONFIGURATION box to download these constants to the controller. 38. Initial set-up of your Model 5C7-252 controller is complete. Appendix A Troubleshooting Communications Por Error Cause Solution Comm Port Timeout No power to 5C7-252 Apply power to 5C7-252, review Customer Drawing for proper hookup. Comm Port Timeout Wrong Comm Port selected Check Computer hardware settings and set to the correct Comm Port Comm Port Timeout Incorrect wiring of the Comm Port Check for the correct wiring from to the computer JP3 to the Computer Comm Port Open Error No Comm Port available at this Check computer hardware setting port setting and set to the correct Comm Port 11

14 APPLICATION NOTE Minutes to PID Tuning of the 5C7-252 Controller Tuning the Model 5C7-252 temperature controller involves three variables. (P)ropotional bandwidth, (I)ntegral action, and (D)erivative rate. The control algorithm sums the three values of these terms to determine the output power. P + I + D = % Power Applied Most applications work satisfactorily with only the P and I values used. Start the tuning process by setting the Integral and Derivative functions to zero. Proportional Bandwidth is defined as the temperature range around the setpoint where the controller modulates (proportions) the output power. In a heating application, if the temperature is above the proportional band, the controller output is OFF. If the temperature is below the proportional band, the controller output is ON. Each thermal system has its own time constants determined by the thermal mass of the components and the placement of the sensor relative to the load. To tune the system the bandwidth must be wide enough that the controller can sense a change and react to it before the temperature drifts outside the bandwidth. If the bandwidth is too small the output will oscillate above and below the setpoint, never settling into control. The bandwidth range of the 5C7-252 is 1 to 100. The units are shipped with a default setting of 20. Assuming the controller is configured for your requirements, start the tuning process by applying power with the default settings and observing the system s response. If the system comes into the proportional band and maintains a steady temperature near setpoint, without overshoot, the bandwidth setting is satisfactory or too large. Reduce the bandwidth setting until the system just begins to oscillate. At this point, the bandwidth is too small. Note the bandwidth setting that just caused the system to oscillate, record the period of oscillation for use in determining the Integral Reset setting. To set the proportional bandwidth, multiply the current bandwidth setting by 1.5 and use it as your new bandwidth setting. The system should come into control and maintain a steady temperature near the setpoint. Integral Reset monitors the difference between the set point and the actual temperature. Its function is to slowly change the output power until the difference between actual temperature and set temperature is zero. The function works by integrating the error signal at fixed intervals. These intervals are expressed in repeats/minute. The acceptable range for the 5C7-252 is 0.01 to 10 repeats / minute. Start with a setting determined by the following formula. Integral Reset = 1/ 2(period) Note: Period is expressed in minutes. Example: The system s period of oscillation with narrow bandwidth was 75 seconds. Therefore the suggested Integral Rate is Integral Reset = 1/ 2(1.25 minutes) Integral Reset = repeats/minute For slower response reduce the number of repeats per minute. NOTE: DERIVATIVE RATE IS DIFFICULT TO APPLY. IF YOU ARE NOT EXPERIENCED IN PROCESS CONTROL, ASK FOR HELP NOW! Derivative Rate senses the rate of change of the temperature and allows the controller to anticipate power needed to compensate for rapid changes in system loading. This term is generally used only on very sluggish systems or where very quick response is necessary. The acceptable range for the 5C7-252 is 0.01 to 10 cycles/minute. To determine an appropriate derivative rate, use the following formula. Derivative Rate = Integral Reset / 10 For the example above the Derivative Rate would be.04 cycles per minute. The Derivative function is difficult to use and often causes more trouble than it is worth! 12

15 Oven Industries, Inc. Mechanicsburg PA Phone: Fax: /2004 Rev: A

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