Introduction to CCC TIOC-555HD
Product Description
The CCC TIOC-555HD is a high-density thermocouple input/output controller designed for industrial process monitoring and control systems. It specializes in acquiring, processing, and converting thermocouple signals from high-temperature environments, making it ideal for applications such as furnace control, heat treatment processes, and chemical reactor monitoring in metallurgy, automotive, and petrochemical industries.
This controller features a ruggedized design with advanced signal conditioning technology, enabling it to handle the unique challenges of thermocouple measurements—including cold junction compensation, noise immunity, and wide temperature range compatibility. Its high-density configuration allows simultaneous monitoring of multiple thermal zones, while built-in control logic supports closed-loop regulation of heating elements. With industrial-grade reliability and flexible communication options, the TIOC-555HD serves as a critical bridge between temperature sensors and supervisory control systems.
Technical Parameters
- Input Channels: 16 thermocouple inputs (compatible with K, J, T, E, R, S, B types)
- Input Range:
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- K-type: -200°C to 1372°C
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- J-type: -210°C to 1200°C
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- R/S-type: 0°C to 1767°C
- Measurement Accuracy: ±0.1% of reading + 0.5°C (including cold junction compensation)
- Cold Junction Compensation: Internal, ±0.3°C accuracy (0°C to 60°C)
- Output Channels: 8 relay outputs (5A/250V AC) + 4 analog outputs (4-20mA, 16-bit)
- Sampling Rate: 10 samples/second per channel
- Communication Interfaces: RS485 (Modbus RTU), Ethernet (Modbus TCP/IP), USB (configuration)
- Power Supply: 24V DC (18-36V DC), power consumption ≤ 25W
- Operating Environment: Temperature -40°C to +70°C; humidity 5-95% RH (non-condensing)
- Isolation: 2500V AC channel-to-channel and channel-to-bus isolation
- Dimensions: 177mm × 125mm × 75mm (W × H × D)
- Mounting: 35mm DIN rail
- Certifications: CE, UL 508, ATEX II 3D (for hazardous locations)
Usage Methods
- Installation:
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- Mount the controller on a 35mm DIN rail in a control cabinet, ensuring at least 20mm clearance from adjacent devices for 散热.
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- Avoid mounting near strong electromagnetic interference sources (e.g., variable frequency drives) or direct heat sources.
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- Secure the rail to prevent vibration, which may affect measurement stability.
- Wiring:
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- Connect thermocouple wires to the input terminals using twisted-pair, shielded cable. Connect shields to the dedicated ground terminal (one-point grounding).
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- Wire relay outputs to heating elements or alarms, ensuring load currents do not exceed 5A per channel.
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- Connect analog outputs to variable speed drives or valves for proportional control.
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- Establish communication links via RS485 or Ethernet, using shielded cables with proper termination resistors (120Ω for RS485).
- Configuration:
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- Connect a PC to the USB port and use CCC ConfigTool software to configure thermocouple types for each channel.
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- Set temperature ranges, filtering parameters, and cold junction compensation options.
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- Program control logic (e.g., PID loops) for each output channel, defining setpoints and hysteresis values.
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- Configure communication parameters (baud rate, IP address) and data logging intervals.
- Operation and Maintenance:
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- Power on the controller and verify all input channels display stable readings (check against reference thermometers).
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- Monitor output status via front-panel LEDs or software interface to ensure proper actuation.
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- Perform quarterly calibration using a thermocouple calibrator, adjusting offset values via software if needed.
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- Inspect wiring connections annually for corrosion or loosening, especially in high-humidity environments.
System Introduction
The CCC TIOC-555HD functions as a central thermal control node in industrial systems, integrating with three key layers:
- Sensor Layer: Interfaces with thermocouples embedded in process equipment to capture real-time temperature data, with specialized conditioning to minimize noise and drift.
- Processing Layer: Converts millivolt signals from thermocouples to temperature values using precision ADCs, applying cold junction compensation and linearization algorithms.
- Control Layer: Executes PID or on/off control logic based on measured temperatures, activating outputs to maintain setpoints. Supports cascaded control loops for complex processes.
- Communication Layer: Transmits temperature data and status information to SCADA/DCS systems, enabling remote monitoring and parameter adjustment.
In a typical heat treatment furnace application, the TIOC-555HD monitors 12 zone temperatures via K-type thermocouples. When a zone exceeds its setpoint (e.g., 900°C), the controller reduces power to the corresponding heating element via a relay output. Analog outputs modulate gas flow valves for fine temperature tuning, while Ethernet communication provides real-time data to plant historians.
Related Models in the Series
- TIOC-555MD: Medium-density version with 8 thermocouple inputs and 4 outputs, suitable for smaller thermal systems.
- TIOC-555XD: Extreme-temperature model supporting B-type thermocouples (-50°C to 1820°C) for high-temperature furnaces.
- TIOC-555RTD: RTD-specialized variant with 16 Pt100 inputs, offering ±0.05% accuracy for precision applications.
- TIOC-555EX: Explosion-proof controller (ATEX II 2G) with intrinsic safety barriers, designed for hazardous areas.
- TIOC-555WL: Wireless version with 4G/LoRa connectivity, eliminating wiring constraints in remote installations.
- TIOC-CTRL-8: Expansion module adding 8 relay outputs, compatible with TIOC-555HD for extended control capability.
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