TEC 9200 Manual - Tempco Electric Heater Corporation
Contents
1. Change the security level of the selected parameter gt Enters the selection Exits Tool Programs 12 5 5 Setting Up Procedures When power is applied the model number and software version number of the controller will be displayed for 3 2 seconds then all of the display segments and LED indicators will light up for 3 2 seconds After this initial cycle the controller will enter normal display mode showing the process value in the upper display and the set point value in the lower display The upper display will flash continuously in the following cases 1 while executing autotune program while executing manual mode program 3 to warn that the next parameter is a higher level parameter as the scroll key is pressed The warning will remain for 3 2 seconds If the scroll key is released after this duration elapses the upper display will show the code of the next parameter and the lower display will show its value Otherwise it will return to normal display mode The upper display will blink for a moment when a new value of a parameter is being written into the non volatile memory The upper display is also used to display error messages if an abnormal condition occurs Parameter Definitions SV Set Point Value This parameter is the desired target of the process It can be adjusted within the range defined by the low scale value Lo SC and high scale value hi SC The default value is 2122. eee 2 A M Peak Process Value rE o Stored minimum and maximum values PEAY Calibrate A D converter Fail Safe Defines the status of FAL the outputs if the SAFE sensor fails Lock Parameters ior Parameter levels can LoLE be locked out to PI r prevent tampering Configure Security Levels Parameters can be r moved from one L security level to L another LESI 0 Puts parameter in Level 0 1 Puts parameter in Level 1 2 Puts parameter in Level 2 I mwa E E Used if sensor fails Cont The Tool Programs menu can be entered at any time by pressing 4 Indicates percentage power Long Adjust the percentage of on time for output 1 ol of output 1 heating using the up and down keys Range 0 100 Indicates percentage power Long tL of output 2 cooling Not functional with TEC 9200 _ Long Arey Indicates maximum peak process value Resets the maximum process value 0 i Long Lo PY Indicates minimum peak process value Resets the minimum process value Q A or Adjusts Cold Junction compensation Long Calibrate the A D converter and enter gt r R code range
3. 23 7 Error Messages and Diagnosis A This procedure requires access to the circuitry of a unit connected to live power Dangerous accidental contact with line voltage is possible Only qualified personnel are to perform these procedures Potentially lethal voltages are present Experience has proven that many control problems are not caused by a defective instrument See the chart below and table 7 1 for some of the other common causes of failures e Line wires are improperly connected e No voltage between line terminals e Incorrect voltage between line terminals e Connections to terminals are open loose or missing Thermocouple is open at tip Thermocouple lead is broken e Shorted thermocouple leads e Short across terminals e Open or shorted heater circuit e Open coil in external contactor e Burned out line fuses e Burned out relay inside control e Defective solid state relays e Defective line switches e Burned out contactor e Defective circuit breakers If the points listed on the chart have been checked and the controller still does not function it is suggested that the instrument be returned for inspection Do not attempt to make repairs Be sure to use adequate packing materials to prevent damage during shipment Press both sides of the latch located on rear terminal block Hold tightly and remove the terminal block from the housing Expand the rear edge of the housing by using a tool Pull out the
4. Unlocks keypad operation and resets the front panel display to normal display mode exits tool program or stops the autotuning function Press Autotune Key Starts the autotune program for at least 3 2 seconds It takes 12 seconds with power on to memorize the new value of a parameter once it has been changed Reset Exit Key 9 5 3 Menu Overview and Descriptions of Parameters PROCESS VALUE SET POINT VALUE a on a ma 1 Ni i pae M 1 a a J q 4 L a p a a La rm Short scroll l returns to PV SV H Short scroll Exits parameters returns to PV SV n rr a D ore J en lt Liz a ps liz Cr vr s Lo wn LE me a returns to PV SV and NOTE The display will return to PV SV in 25 seconds if no entry is made Short scroll returns to PV SV Short scroll advances forward through parameters step by step Security Level 0 Hold until display stops flashing 3 2 seconds Short scroll advances forward through parameters step by step Security Level 1 Scrolls through parameters step by step in reverse order tA Hold until display stops flashing 3 2 seconds Short scroll advances forward through parameters step by step T rm Pay it Wry irs 0 0 Peps e
5. TI TD ASP2 15 5 6 Auto Tune A The auto tuning process is performed at the set point The process will oscillate around the set point during the auto tuning process Set the set point to a lower value if overshooting beyond the normal process value would be likely to cause damage The auto tune program should be applied e During initial set up e When the set point is changed substantially from the previous auto tune e When the control results are unsatisfactory When preparing to run the auto tune program e Make sure that all parameters are configured correctly e Make sure that PB is not set to zero because the auto tune program cannot be run in on off control mode e Set the set point at the normal operating process value or at a lower value if overshoot is likely to cause damage and use normal load conditions e Press and hold the up and down keys for 3 2 seconds then release together The upper display will flash while the auto tune program is running Auto tune teaches the controller the main characteristics of the process It learns by cycling the output on and off The results are measured and used to calculate the optimum PID values for the process which are then automatically entered into the nonvolatile memory During the second period of the auto tune program the controller performs PID control to verify the results and an OFST value is obtained and entered in the memory To stop the au
6. Range CF Accuracy CPI Range tC Accuracy CO E Chromel Constantan 58 to 1382 F 50 to 750 C 2 C Pt30 RH Pt6 RH 32 to 3272 F 0 to 1800 C 3 C OR Pt13 RH Pt 32 to 3182 F 0 to 1750 C a Pt10 RH Pt 32 to 3182 F 0 to 1750 C ke PT To0 ohms TS ie O 08 20 08 O 08 O 08 20 08 0 10VDC 1999 to 9999 0 05 1999 to 9999 0 05 Accuracy Linearity Error Cold Junction Compensating Error Lead Compensating Error Offset Drift Error Linear voltage input impedance 100K ohms Cold junction compensation 0 1 F F ambient typical Sensor break protection Configurable by operator External resistance 100 ohms max Normal mode rejection 60dB Common mode rejection 120dB Sample rate 5x second Control Proportion band 0 360 F 0 200 C Reset Integral 0 3600 seconds Rate Derivative 0 1000 seconds Ramp rate 0 99 99 F 0 55 55 C minute Dwell 0 9999 minutes On off Adjustable hysteresis 0 1 19 9 F 0 11 0 C Cycle time 0 99 seconds Control action Direct for cooling and reverse for heating Power Rating 90 264VAC 50 60Hz Consumption Less than 5VA Environmental and Physical Safety UL 873 CSA 22 2 142 87 IEC 1010 1 Protection NEMA 4x IP65 EMC emission EN50081 1 EN55011 EMC immunity IEC801 2 IEC801 3 IEC801 4 Operating temperature 14 to 122 F 10 to 50 C Humidity 0 to 90 RH non condensing Insulation 20M ohms min 500VDC Breakdown 200
7. parameter is set to zero the ramp function is disabled In the example below RAMP is set at 5 00 F minute the ambient temperature is 50 F and power is applied at zero time The process value climbs to the initial set point of 150 F over a period of 20 minutes The process temperature is held until the set point value is changed to 175 F at 40 minutes The process value then climbs to the new set point over a period of 5 minutes and the new set point is held At 70 minutes the set point value is decreased to 100 F and the process value falls to the new set point over a period of 15 minutes 0 20 40 45 70 85 Time minutes 20 Ramp and Soak Function The soak function is enabled by configuring alarm 1 to act as a dwell timer If A1SF is set for TOON time out on the alarm 1 relay will act as a timer contact with the contact being open at power up and closing after the time set in ASP1 has elapsed If A1SF is set for TOOF time out off the alarm 1 relay will perform the reverse action If the heater or contactor coil is wired in series through the alarm 1 relay and the out 1 relay the controller will act as a guaranteed soak controller In the example below RAMP is set for 5 00 F minute A1SF TOOF and ASP1 40 minutes Power is applied at zero time and the process climbs from the ambient temperature of 50 F to the set point of 200 F over 30 minutes The dwell timer is activated upon reaching the set point and after the so
8. the process value will read 0 LOSC and for a 20mA input the process value will read 100 0 HISC For a 10mA input the process value will read 37 5 If the input signal is outside of the range defined by LOSC and HISC an error message LLEr or HLEr will be shown in the upper display 21 PV 100 0 HISC 0 LOSC input signal mA 5 15 Read Peak Process Values The maximum and minimum values of the process value are continuously updated and stored in the memory after power up Press both and to access the READ PEAK tool program Press the scroll key to select fh Por in the lower display The upper display will now show the high peak value or low peak value of the process respectively To reset the peak values press and hold the scroll key for 3 2 seconds then release Both the low and high peak values will now be revised by the current process value 5 16 Lock Unlock Parameters e Lock all of the parameters Press and hold both and for 3 2 seconds then release Keypad operation is now disabled to protect the parameters from tampering To unlock the keypad press and release the up and down keys e Lock all parameters in a given security level Refer to LOCK Parameter in section 5 5 6 Recalibration A Do not proceed through this section unless there is a definite need to recalibrate the controller All previous calibration data will be lost Do not attempt recalibration unless you have the appropr
9. 19 9 42 7 the Cold Junction compensation code y Ae A Long Calibrate the 0 20mA and enter it Ao 4 Adjusts Drift compensation code Long ee range 6 6 6 6 Enter the Drift compensation code or Long wel Select the status for Output 1 ON or OFF Enters the selection Long Select the status for Alarm 1 ON or OFF gt Enters the selection Long Select the status for Alarm 2 ON or OFF gt Enters the selection ong Select the status for Output 2 ON or OFF Enters the selection or Long LEY Select LOCK or FREE for all Level 0 parameters gt Enters the selection al or Long LEY l Select LOCK or FREE for all Level 1 parameters gt Enters the selection oj Ae Long LEY or Select LOCK or FREE for all Level 2 parameters gt Enters the selection co i Long gt Change the security level of the selected parameter gt Enters the selection ASI Q i Displays the rest of the parameters according to the standard sequence A or eS b Long
10. as described above Hysteresis AHY1 adjustment Example no special function used with deviation high alarm SV 100 C ASP1 10 C AHY1 4 C ly vv Process proceeds x a X 112 112 ON 112 112 112 108 108 108 108 OFF gt 108 100 100 100 100 100 Below 108C Below 1089C Above 112 C Above 108 C Below 108 C alarm off alarm off alarm on alarm stays on alarm off 19 5 11 Viewing the Output Percentage Power Scroll through the tool programs until you come to HAND CONTROL ont then press the scroll key The upper display will now show the process value and the lower display will show the percentage power of output 1 for example To view the cooling output press scroll again If alarm 2 is configured as a cooling output A2SF COOL the lower display will now show the percentage power of alarm 2 for example If alarm 2 is configured as an alarm this percentage power reading is invalid and should be ignored The range of percentage power is from 0 100 If the unit is configured for on off control only O or 100 will be displayed For a proportional control the output percentage power represents the percentage of the duty cycle the output spends in the ON state e g if cycle time CYC 10 seconds and the output spends 4 seconds on and 6 seconds off during each duty cycle the lower display would read H_ 4 4 5 12 Manual Control Follow the procedures from section 5 11 then press and hold the scroll key for 3 2 seconds and
11. or EEPROM non volatile memory Check and replace incorrect defective Key switch defective Read the operation procedure carefully Operation of control incorrect 19 Display blinks entered values Electromagnetic interference EMI or Radio Suppress arcing contacts in system to change by themselves Frequency interface RFI eliminate high voltage spike sources EEPROM defective Separate sensor and controller wiring from dirty power lines Ground heaters Replace EEPROM 25 TEMPCO Electric Heater Corporation 607 N Central Avenue Wood Dale IL 60191 1452 USA Tel 630 350 2252 i 800 323 6859 a MW F Fax 630 350 0232 aih r g website http www tempco com Copyright 2003 Tempco Electric Heater Corporation all rights reserved 26
12. order to maximize the life of the relay The following table provides cycle time recommendations for avoiding premature relay failure Output Device Cycle Time Load resistive OUT1 or Cooling Output CYC or CCYC 20 sec or more 2A 250VAC recommended or contactor 10 sec minimum TAZ5OVAC Sold State Relay Dive Linear Current Voltage Phase control module Note In an on off control when PB is set to zero the cycle time parameter may be ignored FAIL SAFE Configuration FAIL SAFE is a tool program used to define as on or off the status of output 1 OUT1 output 2 OUT2 alarm 1 output ALM1 and alarm 2 output ALM2 in the event of a failure Press and release and repeatedly until FAIL SAFE appears in the display windows Press the scroll key until the desired output is shown in the upper display Now press and hold the up or down key to change the status as shown in the lower display Note that if the desired setting is different from the original one a long scroll pressing the scroll key for 3 2 seconds will be required to enter the new value before proceeding to the next tool parameter If the FAIL SAFE status is not critical for a process if the controller should fail then this section can be ignored LOCK Parameter The flow chart in section 5 4 shows how to reach LOCK PARA and from there reach LEVEL LEV 0 LEV 2 which is shown in the upper display and the lock status of that level LOCK or FREE which is shown i
13. time will be decreased If the control has linear current or linear voltage outputs the actual output levels will be decreased These are only used for processes where heating or cooling at full speed would be dangerous or would produce unsatisfactory results For normal applications these parameters are set at 100 INPT Input Type This is used to program the control for the type of input sensor used UNIT Process Units This parameter is used to select the units displayed For linear process input Pu process unit can be selected in addition to F or C RESO Resolution Set Decimal Point Placement This parameter defines the position of the decimal point in the process and set point values no dP no decimal point 1 dP one decimal point 2 dP two decimal points Note that 2 dP can only be used for linear process input when Pu is selected for UNIT CON A Control Action of Output 1 This selects reverse heating action or direct cooling action for output 1 A1 MD A2 MD Alarm Mode Selection for Alarm 1 and Alarm 2 This sets the type of alarm required deviation alarm band alarm or process alarm See section 5 10 for more details A1 SF Alarm 1 Special Function Use this parameter to select any special functions required for use with alarm 1 Latching or holding alarms can be selected see section 5 10 or to on or to of can be selected if dwell timer function is required see section 5 13 A2 SF Alarm 2 Specia
14. 0V AC 50 60Hz 1 minute Vibration 10 55 Hz amplitude 1mm Shock 200m s 20g Moldings Flame retardant polycarbonate Dimensions H 1 875 48mm x W 1 875 48mm x D 3 375 86mm Depth behind panel 2 875 73mm Weight 4 oz 110g 4 Installation A Dangerous voltage capable of causing death can be present in this instrument Before installation or beginning any troubleshooting procedures the power to all equipment must be switched off and isolated Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair Component replacement and internal adjustments must be made by a qualified maintenance person only A To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture A Do not use this instrument in areas under hazardous conditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified 4 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If there is any damage due to transit report the damage and file a claim with the carrier Write down the model number serial number and date code for future reference when corresponding with our service center The serial number S N and date code D C are labeled on the box and the housing of th
15. E J I rc 5 2 JIS Qo Pehle Security Level 2 pm Lt mt mx T lt lt ea el lt lt q lt lt l Iul EL c x a I nn nm om a m a Ir N nee 2s ra sts my e j 0 lt T rq a a es a 10 Parameter descriptions Display aoe Default Set point value of control Low scale to high scale value 212 F Alarm 1 set point value or Dwell Trip point within high low scale or 18 F 10 C time 0 9999 minutes for dwell time 0 99 99 F minute 0 55 55 C minute C Offset value for manual reset 0 100 Only functional if integral TI is set to 0 00 Alarm 2 set point value Trip point within high low scale 18 F 10 C C SHIF Display shift 199 199 F 111 111 C een at BB Proportional band of Output 1 0 360 F 0 200 C 0 for ON OFF control 18 F 10 C Integral reset time of Output 1 0 3600 seconds SP1 HIF TD hY1 hy2 D Derivative rate time of Output 1 0 1000 seconds Hysteresis of Alarm 1 0 19 F 0 11 C S i A DET A Hysteresis of Alarm 2 0 19 F 0 11 C fe AOR iy Hysteresis of ON OFF control 0 19 F 0 11 C EES C a es ee l 0 F C Al LDW eae al eahige Minimum value for the selected input to high scale Adjust for your process hI S High Seale OL range Low scale to maximum val
16. F 100 C ASP1 Alarm 1 Set Point Value or Dwell Time This sets the levels at which alarm 1 will function if A1 SF alarm 1 special function is set for an alarm function If A1 SF is selected for dwell timer to on or to of then ASP1 is the timer setting in minutes The dwell timer starts counting when the process value reaches the set point value See sections 5 10 and 5 13 for more details RAMP Ramp Rate This controls the heating or cooling rate of the process The setting is in degrees per minute Set this parameter to zero if no ramp is needed OFST Offset Value for Manual Reset This parameter will only function if the integral time Tl is set to zero OFST is then used to compensate for any deviation between the process temperature and the set point temperature If the process temperature stabilizes below the set point set a positive value for OFST if the process temperature stabilizes above the set point set a negative value for OFST Wait for the system to stabilize then make additional adjustments as needed ASP2 Alarm 2 Set Point Value This sets the levels at which alarm 2 will function if A2 SF is set for an alarm function If A2 SF is set for cooling alarm 2 will preform as a cooling output which is governed by CCyC C pb and d b ASP2 will then have no effect SHIF Shift Process Value This value will be added to or subtracted from the process value This can be used to compensate if the sensor reads a diffe
17. L j z CPB DB CCYC SV 18 Functions of CPB and DB the cooling P band CPB and the deadband DB are measured in degrees i DB Negative DB Positive Cooling Output 100 l i O l 0 PV F or C SV DB 5 10 Alarm There are at most two independent alarms that can be made available by adjusting the alarm special function parameters A1SF and A2SF While the descriptions in this section are based on alarm 1 they can also be applied to alarm 2 e No special function A1SF Alarm on A1iMD A1iMD A1MD A1MD A1MD A1MD Deviation Deviation Deviation band Deviation band Full scale Full scale high alarm low alarm high alarm low alarm high alarm low alarm ON SV ASP1 ON I SV ASP1 ON SV ASP1 SV sv sv ON gt F ASP1 ON gt F ASP1 sv oN gt SV ASP1 ON gt LS V ASP1 ON gt F SV ASP1 ASP1 negative Latch Alarm A1SF LTCH When selected the alarm output and indicator latch as the alarm occurs The alarm output and indicator will be energized even if the alarm condition has been cleared unless the power is shut off Hold Alarm A1SF HOLD When selected in any alarm mode prevents an alarm on power up The alarm is enabled when the process value reaches the set point value Latch and Hold Alarm A1SF LT HO When selected in any alarm mode prevents an alarm on power up The alarm is enabled when the process value reaches the set point value Thereafter the alarm acts as a latch alarm
18. PCB from the housing Dismantling the Controller 24 Table 7 1 Troubleshooting ss Symptoms Probable Probable Cause s 1 ee doesn t function Bad connection between PCB and Pee eee a contact area on PCB Replace keypads 2 LEDs will not light No power to instrument Check power line connections Power supply defective Replace power supply board 3 Some segments of the display or LED display or LED lamp defective Replace LED display or LED lamp LED lamps not lit or lit erroneously Related LED driver defective Replace the related transistor or IC chip 4 Process display shows SBER Sensor break error Replace RTD or sensor Use manual mode operation 5 Process display shows LLER Input signal beyond the low range sensor fails Replace sensor Incorrect input type selected Check sensor or thermocouple type correct input selection 6 Process display shows HLER Input signal beyond the high range sensor fails Replace sensor Incorrect input type selected Check sensor or thermocouple type correct input selection 7 Process display shows ADER A to D module damage Replace module Check for outside source of damage such as transient voltage spikes 8 Process display shows OPER Incorrect operation of autotune Set P band greater than 0 repeat procedure Set point for autotune too low Increase set point Manual mode does not allow on off control Increase proportional band 9 Process display shows C
19. SER Check sum error values in memory may have Check and reconfigure the control changed accidentally parameters 10 Process display shows NTER Data failed to be entered into EEPROM Replace EEPROM 11 Process display shows OVER Overflow error data out of range during Check for electrical noise execution of software program 12 Process display shows LOCK Attempt to change a locked parameter Unlock parameter see section 5 16 13 Display unstable Analog portion or A D converter defective Replace related components or board Thermocouple RTD or sensor defective Check thermocouple RTD or sensor Intermittent connection of sensor wiring Check sensor wiring connections 14 Considerable error in temperature Wrong sensor or thermocouple type wrong Check sensor or thermocouple type and if indication input mode selected proper input mode was selected Analog portion or A D converter defective Replace related components or board 15 Display goes in reverse direction Reversed input wiring of sensor Check and correct counts down scale as process warms 16 No heat or output No heater power output incorrect output Check output wiring and output device device used Replace output device Output device defective Replace output fuse Open fuse outside of the instrument 17 Heat or output stays on but Output device or power source shorted Check and replace indicator reads normal 18 Control abnormal or operation CPU
20. User s Manual TEC 9200 Self Tune Fuzzy PID Process Temperature Controller TEMPCO Electric Heater Corporation 607 N Central Avenue Wood Dale IL 60191 1452 USA Tel 630 350 2252 800 323 6859 hf Fax 630 350 0232 QoS ECT GSS website http www tempco com Copyright 2003 Tempco Electric Heater Corporation all rights reserved Ss Revision 6 2003 Warning Symbol AN This symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in personal injury or damage to or destruction of part or all of the product and system Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met CONTENTS Introduction Numbering System Specifications Installation Operation Recalibration Error Messages and Diagnosis NO oR OND Information in this user s manual is subject to change without notice Copyright 2003 Tempco Electric Heater Corporation all rights reserved No part of this publication may be reproduced transmitted transcribed or stored in a retrieval system or translated into any language in any form by any means without the written permission of Tempco Electric Heater Corporation 1 Introduction TEC 9200 Fuzzy Logic plus PID microprocessor based controller incorporates a bright easy to read 4 digit LED display which indicates the process value Fuzzy Logic technology enables a pro
21. ak time of 40 minutes the alarm 1 relay will open switching off the output The process temperature will then fall at an undetermined rate 40 minutes a 200 i Process value Alarm 1 output OFF ra 30 70 Time minutes 50 Dwell Function The dwell function is enabled by configuring alarm 1 to act as a dwell timer If A1SF is set to TOON time out on the alarm 1 relay will operate as a timer contact with the contact being open on initial start up The timer begins to count down once the set point temperature has been reached After the amount of time set in ASP1 has elapsed the alarm 1 relay will close This function can be used to operate an external device such as a siren or a light for example to alert the operator when a minimum desired soak time has been reached In the example below the ramp rate has been set to zero AISF TOON and ASP1 40 minutes Initial start up is at zero time and the process climbs to the 200 F set point at the maximum rate Once the set point is reached the dwell timer begins to count After 40 minutes the alarm 1 relay closes The controller will continue to act as a fixed set point controller Alarm 1 OFF Time minutes lt 49 minutes 5 14 Re ranging Linear Process Inputs Select an appropriate input type INPT Define the range by adjusting LOSC and HISC In the example below INPT 4 20 mA LOSC 0 HISC 100 0 and RESO 1DP For a 4mA input
22. ature difference is large and the temperature rate is small then AMV is small PID Fuzzy Control has been proven to be an efficient method to improve control stability as shown by the comparison curves below PID control with properly tuned PID Fuzzy control Temperature Set point Figure 1 2 Fuzzy PID Enhances Control Load Disturbance Stability Time 2 Numbering System TEC 9200 12345678 1 Power Input Aia bai 90 264VAC Dink aed alan 20 32VAC VDC Perana Other 2 Signal Input can be programmed in the field DRS TC Configurable J K T E B R S N aPN RTD Configurable DIN or JIS Teaia pea Linear mV or mA 4 20 0 20mA 0 1 0 5 1 5 O 10VDC Fror paeis Other 3 Range Code Terien Field configurable EET Other 4 Control Mode TEETE Field configurable See Other 5 Output 1 Qicarwimaed a None Tidee Relay 3A 240VAC Deanne ape Y Pulse DC for SSR drive 24VDC 20mA max S POEN es 4 20mA linear max load 500 ohms TE 0 20mA linear max load 500 ohms Duasi 0 10VDC linear min impedance 500K ohms Oinas a Triac SSR output 1A 240VAC POETES Other 6 Output 2 REENU None 7 Alarm Outed betes None Qi BAR Mes Dual relays 2A 240VAC field configurable Alarm 2 can be used for output 2 cooling Qik aed Other 8 Data Communications Orns betes None Taa aa a RS 485 E E 4 20mA retransmission Seat bates 0 20mA retransmission Deis taints Other 3 Specifications Input Sensor Input Type
23. cess to reach a predetermined set point in the shortest time with the minimum of overshoot during power up or external load disturbance The units are housed in a 1 16 DIN case measuring 48mm x 48mm with 75mm behind panel depth The units feature three touch keys to select the various control and input parameters Using a unique function you can determine which parameters are accessible by the user You can also put up to five parameters at the front of the user menu by using SEL1 to SEL5 found in the setup menu These are particularly useful to OEM s as it is easy to limit access and configure the menu to suit the specific application TEC 9200 is powered by 20 32 or 90 264VAC supply incorporating a 3 amp control relay output and dual 3 amp alarm relay outputs as standard with a second alarm that can be configured in the second output for cooling purposes or as a dwell timer Alternative output options include SSR drive triac 4 20mA and 0 10 volts TEC 9200 is fully programmable for PT100 thermocouple types J K T E B R S N 0 20mA 4 20mA and voltage signal input with no need to modify the unit Digital communications format RS 485 or 4 20mA retransmission are available as an additional option These options allow the TEC 9200 to be integrated with supervisory control systems and software or alternatively to drive remote displays chart recorders or data loggers For nearly a hundred years PID control has been used and has prov
24. e controller 4 2 Mounting Make the panel cutout to fit the dimensions shown in figure 4 1 Remove both mounting clamps and insert the controller into the panel cutout Reinstall the mounting clamps Gently tighten the screws in the clamp until the controller front panel fits snugly in the cutout MOUNTING 4 mm Panel cu 1 81 46mm tout Figure 4 1 Mounting Dimensions 0 5 13 5mm o4 __ 11 0mm 4 3 Wiring Precautions e Before wiring check the label to verify the correct model number and options Switch off the power while checking e Care must be taken to ensure that the maximum voltage ratings specified in section 3 are not exceeded e It is recommended that the power source for these units be protected by fuses or circuit breakers rated at the minimum value possible All units should be installed inside a suitably grounded metal enclosure to prevent live parts from being accessible to human hands and metal tools All wiring must conform to the appropriate standards of good practice and local codes and regulations Wiring must be suitable for the voltage current and temperature ratings of the system e The stripped leads as specified in figure 4 2 below are used for power and sensor connections e Beware not to over tighten the terminal screws e Unused control terminals should not be used as jumper points as they may be internally connected causing damage to the unit e Veri
25. en to be an efficient controlling method by many industries yet PID has difficulty dealing with some sophisticated systems such as second and higher order systems long time lag systems during set point changes and or load disturbances etc The PID principle is based on a mathematical model which is obtained by tuning the process Unfortunately many systems are too complex to describe precisely in numerical terms In addition these systems may vary from time to time In order to overcome the imperfections of PID control Fuzzy Technology was introduced What is Fuzzy Control It works like a good driver Under different speeds and circumstances he can control a car well based on previous experience and does not require knowledge of the kinetic theory of motion Fuzzy Logic is a linguistic control which is different from numerical PID control It controls the system by experience and does not need to simulate the system precisely as a PID controller would PID FUZZY CONTROL Figure 1 1 Fuzzy PID System Block Language information Digital _ Fuzzifier uezy_ inference gt Defuzzifier Digital information Engine information The function of Fuzzy Logic is to adjust PID parameters internally in order to make manipulation of output value MV more flexible and adaptive to various processes The Fuzzy Rule may work like this If the temperature difference is large and the temperature rate is large then AMV is large If the temper
26. fy that the ratings of the output devices and the inputs are not exceeded e Electrical power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes This electrical noise can adversely affect the operation of microprocessor based controls For this reason we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the controller This wire is a twisted pair construction with foil wrap and drain wire The drain wire is to be attached to ground at one end only 2 0mm 0 08 max om O Figure 4 2 Lead Termination 0 18 0 27 4 4 Connection and Wiring The following connections for outputs and inputs are found on the back of the controller housing 90 264VAC OUT2 50 60Hz ALM2 ALARM 1 OUTI Figure 4 3 Rear Terminal Connections AO AO TC TC TX1 TX2 PTA mV COM mA V Power Wiring The controller is supplied to operate on 24V 20 32VAC VDC or 90 264VAC Verify that the voltage of the power supply corresponds to that indicated on the product label before connecting power to the controller A This equipment is designed for installation in an enclosure which provides adequate protection against electrical shock The enclosure must be connected to earth ground Local requirements regarding electrical installation should be rigidly observed Consideration should be given to prevent unauthorized personnel from gaining access to the power ter
27. iate calibration equipment available If the calibration data is lost you will need to return the controller to your supplier who may charge you a service fee to recalibrate the controller Equipment needed Standard millivolt source with a range of 0 100mV with accuracy of 0 01 Standard voltage source with a range of 0 10V with accuracy of 0 01 Standard current source with a range of 0 20mA with accuracy of 0 01 Standard ohm source with a range of 0 300 ohms with accuracy of 0 01 Standard thermometer with a range of 32 122 F 0 50 C with accuracy of 0 36 F 0 2 C A cooling fan or ideally a calibration fixture equipped with a fan and a push button switch Thermocouple simulator NOaRWN gt e Calibration setup Select T C input UNIT F RESO 1DP Switch the power off Disconnect the sensor wiring Connect the input terminals of the controller to the signal sources according to the following diagram Install a fan to blow on the cold junction compensator located at the rear edge of the lower PCB to prevent it from warming up akwON gt 22 PTA TC COM mA V Fe F 200 ohm e Calibration procedures 1 Press both scroll and down keys then release to access the tool programs Repeat until A dlappears on the displays Press and release the scroll key The lower display will show a number with the prefix t Use the up and down keys to change the value of the lower display unti
28. l Function Select hold function or latch function for alarm 2 or select COOL to reconfigure alarm 2 as a cooling output CYC CCYC Proportional Cycle Time of Output 1 and Cooling Output Select a proper value for the process in accordance with the output devices used Note that CCYC is only used if A2 SF has been set for cooling See the following section on initial setup for further discussion C PB D B Cooling Proportional Band Cooling Deadband Only used if A2 SF has been set for cooling Otherwise they may be ignored See section 5 9 for more details Initial Setup Use the keypad to view the value of each parameter Use the up and down keys to set the correct value for each parameter Note that the new value of each parameter is automatically entered into nonvolatile memory The adjustment of proportional cycle time CYC and CCYC is related to the speed of the process response and the output device fitted For a faster process it is recommended to use SSR select SSR drive output or SCR select linear current or voltage output to drive the load The relay output is used to drive a magnetic contactor in a slow process If a 14 long cycle time is selected for a fast process the process may become unstable as a result Theoretically the smaller the cycle time selected the better the control that can be achieved However for a relay output the cycle time should be as large as possible while maintaining satisfactory control in
29. l application Make sure the output device you selected is appropriate for your application requirements The external connections will depend on the type of output installed If pulsed voltage is selected note that pulsed voltage output is non isolated Sensor Placement Proper sensor installation can eliminate many problems in a control system The probe should be placed so that it can detect any temperature change with minimal thermal lag In a process that requires fairly constant heat output the probe should be placed close to the heater In a process where the heat demand is variable the probe should be close to the work area Some experiments with probe location are often required to find the optimum position In a liquid process the addition of a stirrer will help eliminate thermal lag Since a thermocouple is basically a point measuring device placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes The proper sensor type is also a very important factor in obtaining precise measurements The sensor must have the correct temperature range to meet the process requirements In special processes the sensor might have additional requirements such as leak proof anti vibration antiseptic etc Standard sensor limits of error are 4 F 42 C or 0 75 of sensed temperature half that for special plus drift caused by improper protection or an over tempe
30. l it matches the ambient temperature in F as measured by the standard thermometer Press the scroll key for at least 3 2 seconds then release The upper display will blink for a moment and then show the ambient temperature in F Press and release the scroll key The lower display will show a number with the prefix A and the upper display will show 0 00 Press and hold down push button switch SW1 from the diagram above While holding down SW1 Press and hold the scroll key for at least 3 2 seconds then release The upper display will now show 20 00 Release SW1 Press and release the scroll key The lower display will show a number with the prefix d If the number is not 0 0 use the up and down keys to set it to 0 0 then press the scroll key for at least 3 2 seconds then release e Verify calibration accuracy 1 2 Repeat step 1 from the calibration procedures as described above Press and release the scroll key until an A code is shown in the display The display will indicate process value with respect to the 0O 20mA input Feed a standard signal to the correct mA input terminals and examine the accuracy of the display Press and release the scroll key again until a d code is shown in the display Now the display will indicate process value with respect to the INPT type selected Feed a standard signal to the appropriate input terminals and examine the accuracy of the display Press the scroll and u
31. minals Input Wiring Connect the appropriate sensor to terminals 12 13 14 15 or 16 as indicated in figure 4 3 Make sure that the correct sensor type is selected on the controller and that the correct polarity is observed at both ends of the cable For thermocouple wiring the correct type of extension wire must be used for the entire distance between the controller and the thermocouple The extension wires must be the same alloy and polarity as the thermocouple and joints in the cable should be avoided if possible The color codes used on the thermocouple extension wires are shown in table 4 1 For wiring three wire RTD the two common wires should be connected to terminals 13 and 14 compensating lead connected to terminal 13 When using a two wire RTD install a jumper between terminals 13 and 14 A three wire RTD offers the capability of lead resistance compensation provided that all three leads are the same gauge and material and of equal length Table 4 1 International Thermocouple Cable Color Codes Thermocouple Cable American British Type Material ANSI BS lron Constantan Chromel Alumel Copper blue white red yellow AUR red blue brown black blue blue brown black black i Platinum Rhodium Platinum Rhodium Color of overall sheath Output Wiring There are several types of output modules see section 2 that can be selected for output 1 when ordering the TEC 9200 depending on the contro
32. n the lower display For example if you select LOCK for LEV 2 and press the scroll key for 3 2 seconds to enter the selection the all parameters in level 2 can no longer be changed ALOCK message will appear in the upper display if someone attempts to change a locked parameter Configuring Security Levels of Parameters One of the features of this controller is the ability to assign the security level for each parameter individually One of four levels level 0 level 1 level 2 or level 3 can be assigned to any parameter The parameters with lower security levels will be displayed before parameters with higher security levels as one cycles through the parameters using the scroll key Furthermore level 3 parameters are not displayed on the front panel so any unused parameters can be assigned security level 3 and removed from the viewing rotation completely As shown in section 5 4 to configure a new level for a parameter press and to reach CONF LEVL then press to display the desired parameter The lower display will indicate the level of the selected parameter You can now change the level for that parameter using the up and down keys Finally press and hold for 3 2 seconds or longer to enter the new value For example if ASP1 and RAMP are set as level 0 PB TI and TD are set as level 1 ASP2 is set at level 2 and all other parameters are set as level 3 the scrolling sequence of parameters will be as follows _ ASP1 RAMP gt PB
33. p keys then release quickly The display will indicate process value with respect to the PT100 DIN input Feed a standard signal to the PT100 input terminals and examine the accuracy of the display Press the scroll and up keys then release quickly The display will indicate process value with respect to the 0 10V input Feed a standard signal to the voltage input terminals and examine the accuracy of the display Warm up drift correction for thermocouple input After completing the calibration procedures above connect a thermocouple to terminals 13 and 14 observing polarity and select the correct INPT for the thermocouple Switch the power on and leave it on for at least 30 minutes If the controller does not measure the correct temperature for the thermocouple the following procedures may be used to correct the error 1 2 3 4 Perform steps 1 and 2 from the calibration procedures Press and release the scroll key Press and release the scroll key again Now the d code with zero value will show on the display Use the up and down keys to change the d code value until the upper display shows the correct temperature The d code is always shown in C regardless of the setting of the UNIT parameter Press the scroll key for at least 3 2 seconds then release The upper display will blink for a moment then show an accurate temperature If the accuracy of the controller is still unsatisfactory replace the controller
34. ponse or oscillations TD High overshoot Effects of PID adjustments on process response P action PV PB too low Perfect Set point PB too high Time Laction TI too high PV Set point f Perfect TI too low Time D action pv TD too low Perfect Set point TD too high Time 17 5 8 On Off Control If the alarm output is configured as an alarm function it basically performs as an on off control If you adjust the P band to PB 0 you can get an additional channel of on off control with variable hysteresis Hysteresis also called differential or deadband is measured in degrees See the figure below for a description of on off control P action PV SP HYST 2 SP SP HYST 2 OUTPUT l l E Reverse 100 Action CONA REVR 0 Direct 100 Action CONA DIRT 0 B Time On off control may create excessive process variation from the set point even if the hysteresis is set at the minimum possible value When using on off control the parameters TI TD and CYC will have no effect on the system and both manual mode and the auto tune program will be disabled 5 9 Cooling Control Cooling control options Output 4 3 Configurations Heating Output Cooling Output Adjusted Parameters m Off Cooling no heating eo Cooling CONA DIRT CONA REVR Heating A2SF NONE On Off Cooling OuUT1 ALM2 A2MD DVHI or FSHI AHY2 SV or ASP2 Heating CONA REVR Pro ee Coolin OUT1 ALM2 A2SF COO
35. rature occurrence This error is far greater than controller error and cannot be corrected on the sensor except by proper selection and replacement 5 Operation 5 1 Front Panel Description Alarm Outputs Process Value Set Point Value Control Output 3 Silicone Rubber Buttons for ease of control setup and set point adjustment 5 2 Keypad Operation TOUCHKEYS FUNCTION DESCRIPTION Press and release quickly to select which digit of a numerical parameter to change Up Key Press and hold to increase the value of the selected digit or to change the selection for an index parameter Press and release quickly to select which digit of a numerical parameter to change Down Key Press and hold to decrease the value of the selected digit or to change the selection for an index parameter Direct Scroll Key oo in a direct sequence Also used to select the tool program Press Long Scroll Enter Key Selects the parameters in higher security level and actuates the selected tool for at least 3 2 seconds program whenever the display is showing a tool program Reverse Scroll Callibration Selects the parameters in a reverse direction during parameter scrolling or verifies a Press Verification Key the display accuracy for various input types during callibration Press Lock Key Disables keypad operation to protect all the parameters from being tampered with for at least 3 2 seconds Press Tool Program Key Selects the tool programs in sequence
36. release The controller will now enter manual control mode The upper display will begin to flash and the output percentage can now be adjusted using the up and down keys Note that manual control mode is not available if the control is configured for on off control PB 0 If it is attempted an error message OPER will appear in the upper display Manual control mode should be used e When teaching the process If the controller fails A Manual control mode is an open loop control The process may rise to a dangerous temperature Special attention must be paid to the process in order to prevent damage to the system 5 13 Ramp and Dwell The controller can be configured to act either as a fixed set point controller or as a single ramp controller on power up This function enables the user to set a predetermined ramp rate RAMP to allow the process to reach the set point temperature gradually producing a soft start effect A dwell timer is incorporated in the controller Alarm 1 can be configured to provide either a dwell function or a soak function when used in conjunction with the ramp function Ramp Function If the ramp function is selected the process will increase or decrease at a predetermined rate during initial power up or with set point changes or process variations The ramp rate is determined by the RAMP parameter which can be adjusted through a range from 0 99 99 F minute 0 55 55 C minute If the RAMP
37. rent temperature than the item being sensed PB TI and TD PID Values Proportional band Integral reset and Derivative rate time constants These must be set as close as possible to the process application requirements See section 5 7 for more details AHY1 AHY2 Hysteresis Values of Alarm 1 and Alarm 2 These values define the deadbands for the alarms The alarms will not change state until the temperature is outside the deadband HYST Hysteresis Value of On Off Control This parameter defines the deadband when on off control is being used and PID control has been disabled 13 ADDR Interface Address This parameter provides an identity code for the RS 485 interface Note that no two controllers communicating with the same computer can have the same identity code Ignore this parameter if the controller does not use the RS 485 interface LO SC HI SC Low High Scale Range If thermocouple or PT100 is selected as the input type INPT these parameters are used to define the range of the set point adjustment If linear process input is selected these parameters are used to define the range of the process value and set point adjustment See section 5 14 for more details PL 1 PL 2 Power Limit for Heating and Cooling Outputs These parameters limit the maximum output percentage of power for heating or cooling during warm up and in proportional band If the control has relay or pulsed voltage outputs the percentage of on
38. to tune program press the up and down keys and release them together The upper display will stop flashing indicating that the auto tune program has been aborted Once the controller has entered the verifying period auto tuning cannot be stopped 5 7 Tuning the Controller Manually e Make sure that all parameters are configured correctly e Set PB to zero Set HYST to minimum 0 1 F or 0 C e Set the set point at the normal operating process value or at a lower value if overshoot is likely to cause damage and use normal load conditions e Switch on the power supply to the heater Under these conditions the process value will oscillate about the set point and the following parameters should be noted 1 The peak to peak variation P of the first cycle in F or C i e the difference between the highest value of the first overshoot and the lowest value of the first undershoot 2 The cycle time T of the oscillation in seconds see figure below The control setting should then be adjusted as follows PV PB P F or C TI T seconds TD T 4 seconds Time 16 The PID parameters determined by the above procedures are rough values If the control results using the above values are unsatisfactory the following rules may be used to further adjust the PID parameters Adjustment Sequence Symptom Solution High overshoot or oscillations PB egal Tine T Tl Instability or oscillations Derivative Time D Slow res
39. ue for the selected input 999 F Adjust for your process Power limit of Output 1 0 100 100 Power limit of Output 2 0 100 100 Input type selection J K T E B R S or N TC 4d K T E B R S or N type INPT T C J TC PT100 DIN P TDN PT100 JIS PTIS 4 20mA 0 20mA Display units oc C OF F PU process units Engineering Resolution NODP No decimal point 1DP 1 decimal place RESO 2DP 2 decimal places only when UNIT P U NODE CON A Control action of Output 1 DIRT Direct cool action REVR Reverse heat action REVR DvhI Deviation high DVLO Deviation low Alarm 1 mode DBhI Deviation band high DBLO Deviation low DVhI FShI Full scale high F SLO Full scale low NON E No special function LTCh Latching alarm A1 SF Alarm 1 special function hOLD Holding alarm LThoO Latching holding alarm NONE TO O N Timer on as time out TO O F Timer off as time out A2 MD Alarm 2 mode Same as Alarm 1 mode DVhI Alarm 2 special function NONEE No special function LThO Latch hold alarm A2 SF hOLD Hold alarm LTch Latch alarm co0 L Out 2 NONE Cyc Rroporionalcyeleune OLARU 0 99 seconds 0 for linear current voltage output 20 for 1 relay output 20 for relay output Cooling P band 0 360 F 0 200 C 18 F 10 C Deadband for PB and CPB 199 199 F 111 111 C a ev Cooling cycle time 0 99 seconds 0 for linear current voltage output 11 5 4 Flow Chart of Tool Programs
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