Tempco TEC-9200 User Manual

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: [phone]

800-323-6859
Fax: [phone]
website: http://www.tempco.com
Copyright © 2003, Tempco Electric Heater Corporation, all rights reserved.

Revision 6/2003

Warning Symbol

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

1. Introduction

2. Numbering System

3. Specifications

4. Installation

5. Operation

6. Recalibration

7. Error Messages and Diagnosis

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 process 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 TEC­9200 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 proven 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.

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 ∆MV is large.
If the temperature difference is large, and the temperature rate is small, then ∆MV is small.

PID+Fuzzy Control has been proven to be an efficient method to improve control stability as shown by the comparison curves below:

3

Figure 1.1
Fuzzy PID System Block

Figure 1.2 Fuzzy PID
Enhances Control
Stability

PID + FUZZY CONTROL

MV PV

+

PROCESS

+

PID

FUZZY

_

+

SV

Figure 1.1
Fuzzy PID System Block

Digital
information

Fuzzy Rule

Language
information

Fuzzy Inference
Engine

DefuzzifierFuzzifier

Digital
information

PID control with properly tuned

PID + Fuzzy control

Temperature

Set point

Warm Up

Load Disturbance

Figure 1.2 Fuzzy PID
Enhances Control
Stability

Time

2. Numbering System

TEC-9200-_ _ _ _ _ _ _ _

1 2 3 4 5 6 7 8

(1) Power Input

4 . . . . . . . . 90–264VAC

5 . . . . . . . . 20–32VAC/VDC

9 . . . . . . . . Other

(2) Signal Input (can be programmed in the field)

5 . . . . . . . . TC-Configurable: J, K, T, E, B, R, S, N

6 . . . . . . . . RTD-Configurable: DIN or JIS

7 . . . . . . . . Linear-mV or mA: 4–20, 0–20mA; 0–1, 0–5, 1–5, 0–10VDC

9 . . . . . . . . Other

(3) Range Code

1 . . . . . . . . Field configurable

9 . . . . . . . . Other

(4) Control Mode

3 . . . . . . . . Field configurable

9 . . . . . . . . Other

(5) Output 1

0 . . . . . . . . None

1 . . . . . . . . Relay-3A/240VAC

2 . . . . . . . . Pulse DC for SSR drive-24VDC (20mA max)

3 . . . . . . . . 4–20mA, linear (max. load 500 ohms)

4 . . . . . . . . 0–20mA, linear (max. load 500 ohms)

5 . . . . . . . . 0–10VDC, linear (min. impedance 500K ohms)

6 . . . . . . . . Triac-SSR output 1A/240VAC

9 . . . . . . . . Other

(6) Output 2

0 . . . . . . . . None

(7) Alarm

0 . . . . . . . . None

2 . . . . . . . . Dual relays-2A/240VAC, field configurable (Alarm 2 can be used for output 2/cooling)

9 . . . . . . . . Other

(8) Data Communications

0 . . . . . . . . None

1 . . . . . . . . RS-485

2 . . . . . . . . 4–20mA retransmission

3 . . . . . . . . 0–20mA retransmission

9 . . . . . . . . Other

4

3. Specifications

Input

*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

Sensor Input Type Range (°F) *Accuracy (°F) Range (°C) *Accuracy (°C)

J Iron/Constantan -58 to 1832°F ±3.6°F -50 to 1000°C ±2°C

K Chromel/Alumel -58 to 2500°F ±3.6°F -50 to 1370°C ±2°C

T Copper/Constantan -454 to 752°F ±3.6°F -270 to 400°C ±2°C

E Chromel/Constantan -58 to 1382°F ±3.6°F -50 to 750°C ±2°C

B Pt30%RH/Pt6%RH 32 to 3272°F ±5.4°F 0 to 1800°C ±3°C

R Pt13%RH/Pt 32 to 3182°F ±3.6°F 0 to 1750°C ±2°C

S Pt10%RH/Pt 32 to 3182°F ±3.6°F 0 to 1750°C ±2°C

N Nicrosil/Nisil -58 to 2372°F ±3.6°F -50 to 1300°C ±2°C

RTD PT 100 ohms (DIN) -328 to 752°F ±0.72°F -200 to 400°C ±0.4°C

RTD PT 100 ohms (JIS) -328 to 752°F ±0.72°F -200 to 400°C ±0.4°C

Linear 4–20mA -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%

Linear 0–20mA -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%

Linear 0–1VDC -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%

Linear 0–5VDC -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%

Linear 1–5VDC -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%

Linear 0–10VDC -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%

5

Operating temperature: 14 to 122°F (-10 to 50°C)
Humidity: 0 to 90% RH (non-condensing)
Insulation: 20M ohms min. (500VDC)
Breakdown: 2000V (AC), 50/60Hz, 1 minute
Vibration: 10–55 Hz, amplitude 1mm
Shock: 200m/s² (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

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.

To minimize the possibility of fire or shock hazards, do not expose this instrument to rain or excessive moisture.

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 the 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.

6

Figure 4.1 Mounting Dimensions

MOUNTING
CLAMP

Figure .1 Mounting Dimensions

1.81"

(46mm)

1.81"

(46mm)

Panel cutout

0.5"

(13.5mm)

0.4"

(11.0mm)

Panel

2.95"

(75.0 mm)

SCREW

4–3 Wiring Precautions

• Before wiring, check the label to verify the correct model number and options. Switch off the power while checking.

• Care must be taken to ensure that the maximum voltage ratings specified in section 3 are not exceeded.

• 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.

• The "stripped" leads as specified in figure 4.2 below are used for power and sensor connections.

• Beware not to over-tighten the terminal screws.

• Unused control terminals should not be used as jumper points as they may be internally connected, causing damage to
the unit.

• Verify that the ratings of the output devices and the inputs are not exceeded.

• 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.

4–4 Connection and Wiring

The following connections for outputs and inputs are found on the back of the controller housing.

7

Figure 4.2 Lead Termination

2.0mm

0.08" max.

Figure .2 Lead Termination

4.5 7.0 mm

~

0.18" 0.27"

~

90-264VAC

50-60Hz

1 2

N L

AO+

AO-

TX1

TX2

109

OUT2
ALM2

- +

ALARM 1

OUT1

34 6578

TC-

TC+

mV-

COM+

14

B

0-20mA
4-20mA

mA- V-

V

-

+
0-10V

PTA

11 12

A

RTD

13

B

mV

- +

- +

T/C

- +

Figure 4.3 Rear T erminal Connections

1615

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.

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 terminals.

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

* 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 TEC­9200, depending on the control 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.

Thermocouple

Type

Cable

Material

American

ANSI

BritishBSGerman

DIN

French

NFE

J Iron/Constantan

+ white

- red
* black

+ yellow

- blue
* black

+ red

- blue
* blue

+ yellow

- black
* black

K Chromel/Alumel

+ yellow

- red
* yellow

+ brown

- black
* red

+ red

- green
* green

+ yellow

- purple
* yellow

T

Copper/
Constantan

+ blue

- red
* blue

+ white

- blue
* blue

+ red

- brown
* brown

+ yellow

- black
* black

R
S

Platinum/Rhodium

+ black

- red
* green

+ white

- blue
* green

+ red

- white
* white

+ yellow

- green
* green

B Platinum/Rhodium

+ grey

- red
* grey

+ red

- grey
* grey

8