Tempco TEC-9100 User manual

1
Instructions for TPC Power Through Control Console
SPECIFICATIONS
Temperature Controller: Model TEC-9100, 1/16 DIN Dual Display with PID Auto-tuning
Sensor Input: Type “J” or type “K” thermocouple dependent on model ordered
(Alternative inputs available for special order)
Power Cord/voltage Input: 120VAC or 240VAC (dependent on model ordered)
Heater Output: 12A max for 1-zone consoles
6A max per zone for 2-zone consoles
4A max per zone for 3-zone consoles
3A max per zone for 4-zone consoles
Output Device: Solid State Relay
Main Power Switch: Located on front panel
Fuse Main Power: See replacement parts list (located on back panel)
Fuse Control Power: See replacement parts list (located on back panel)
WARNINGS
1. Air vents located on top and bottom of console must not be blocked! To prevent an
overheating condition the internal components must remain as close to room
temperature (75ºF / 24ºC) as possible.
2. Dangerous voltage capable of causing injury or death is present within this console.
Power to all equipment must be disconnected before installation or beginning any
troubleshooting procedures. Heater output wiring and component replacement must
be made by qualified personnel only.
3. To minimize the possibility of fire or shock, do not expose this console to rain or
excessive moisture.
4. Do not use this console in areas where hazardous conditions exist such as excessive
shock, vibration, dirt, corrosive gases, oil or where explosive gases or vapors are
present.
WIRING (For safety, disconnect all power sources prior to wiring)
1. Attach the leads from your type thermocouple to the mini-plug provided. Take care to
note the correct polarity. The red lead is (-) negative.
2. The heater output current is sourced directly through the line cord. The rear console
output receptacle and mating Hubbell plug provides live controlled power for direct
connection to your heater(s). Connect one lead from your heater to one prong of the
Hubbell plug (not ground). Connect the other lead from your heater to the other prong.
Connect heater ground (if applicable) to the ground connection (G) on the plug.
© Copyright 2020. All Rights Reserved. Rev. 3/20 D1304.01

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OPERATION
1. Verify the power switch is in the off position. Plug your heater & thermocouple into the rear
connectors. Plug the provided line cord from the console into a standard outlet. Switch on
the console.
2. Set your desired temperature setpoint by using the up and down arrow buttons on the
TEC-9100 temperature controller.
3. Refer to the following pages for complete operation and auto-tuning of the TEC-9100
temperature controller.
SPARE/REPLACEMENT PARTS
Tempco Description
Part Number
EHD-124-148 Fuse, rated 15 Amps/ 250V, ¼" x 1¼", fast acting, BUSS ABC-15-R.
Used for main and heater power.
EHD-124-276 (for 1, 2, and 3-zone units) Fuse (1), rated 1 Amp/ 250V, ¼" x 1¼", fast acting,
BUSS ABC-1-R. Used for TEC-9100 Controller.
EHD-124-290 (for 4-zone units) Fuse (1), rated 1.5 Amp/ 250V, ¼" x 1¼", slow acting,
BUSS ABC-1.5-R. Used for TEC-9100 Controller.).
EHD-124-300 (for 2-zone units) Fuses (2), rated 8 amps, 250V, ¼" x 1¼", fast acting, BUSS ABC-8-R.
EHD-124-279 (for 3-zone units) Fuses (3), rated 5A, 250V, ¼"x 1¼", fast acting, BUSS ABC-5-R.
EHD-124-282 (for 4-zone units) Fuses (4), rated 4 amps, 250V, ¼" x 1¼", fast acting, BUSS ABC-4-R.
EHD-102-113 (for 120V units) Power output plug (1 per zone), Hubbell HBL4720C, 15A 125V Twist-Lock.
EHD-102-121 (for 240V units) Power output plug (1 per zone), Hubbell HBL4570C, 15A 250V Twist-Lock.
(Type of plug dependent on console model ordered)
TCA-101-104 Type “K” thermocouple mini plug (1 per zone), yellow
TCA-101-105 Type “J” thermocouple mini plug (1 per zone), black
TCA-101-136 Type “CU” mini-plug, white (for 2-wire RTD)
NOTE: For all fuses, use listed BUSS part numbers or equivaliant.

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1–1 General
Tempco’s TEC-x100 Series Fuzzy Logic plus PID
microprocessor-based controllers incorporate two bright easy to
read 4-digit LED displays, indicating process value and set point
value. The process value (PV) display is always the top digital
display. The setpoint (SV) display is always the bottom display.
Fuzzy Logic technology enables a process to reach a
predetermined set point in the shortest time with a minimum of
overshoot during power-up or external load disturbance.
TEC-9100 is a 1/16 DIN size panel mount controller. TEC-7100
is a 72×72 DIN size panel mount controller. TEC-8100 is a 1/8
DIN size panel mount controller and TEC-4100 is a 1/4 DIN size
panel mount controller. These units are powered by 11–26 or 90–
250 VDC/VAC 50/60 Hz supply, incorporating a 2 amp control
relay output as standard. The second output can be used as a
cooling control or an alarm. Both outputs can select triac, 5V
logic output, linear current, or linear voltage to drive an external
device. There are six types of alarm plus a dwell timer that can
be configured for the third output. The units are fully
programmable for PT100 RTD and thermocouple types J, K, T,
E, B, R, S, N, and L with no need to modify the unit. The input
signal is digitized by using an 18-bit A to D converter. Its fast
sampling rate allows the unit to control fast processes.
Digital communications RS-485 or RS-232 (excluding TEC-
7100) are available as an additional option. These options allow
the units to be integrated with supervisory control systems and
software.
A programming port is available for automatic configuration,
calibration, and testing without the need to access the keys on the
front panel.
By using proprietary Fuzzy modified PID technology, the control
loop will minimize overshoot and undershoot in a short time. The
following diagram is a comparison of results with and without
Fuzzy technology.
High accuracy
This series is manufactured with custom
designed ASIC (Application Specific
Integrated Circuit) technology which
contains an 18-bit A to D converter for
high resolution measurement (true 0.1°F
resolution for thermocouple and PT100)
and a 15-bit D to A converter for linear
current or voltage control output. The
ASIC technology provides improved
operating performance, low cost,
enhanced reliability and higher density.
Fast sampling rate
The sampling rate of the input A to D
converter is 5 times/second. The fast
sampling rate allows this series to control
fast processes.
Fuzzy control
The function of Fuzzy control is to adjust
PID parameters from time to time in order
to make manipulation of the output value
more flexible and adaptive to various
processes. The result is to enable a process
to reach a predetermined set point in the
shortest time, with the minimum of
overshoot and undershoot during power-
up or external load disturbance.
Digital communication
The units are equipped with an optional
RS-485 or RS-232 interface cards to
provide digital communication. By using
twisted pair wires, up to 247 units can be
connected together via RS-485 interface
to a host computer.
Programming port
A programming port can be used to
connect the unit to a PC for quick
configuration. It also can be connected to
an ATE system for automatic testing and
calibration.
Auto-tune
The auto-tune function allows the user to
simplify initial setup for a new system. An
advanced algorithm is used to obtain an
optimal set of control parameters for the
process, and it can be applied either as the
process is warming up (cold start) or
when the process is in a steady state
(warm start).
Lockout protection
Depending on security requirements, one
of four lockout levels can be selected to
prevent the unit from being changed
without permission.
Bumpless transfer
Bumpless transfer allows the controller to
continue to control if the sensor breaks by
using its previous value. Hence, the
process can be controlled temporarily as
if the sensor is normal.
Soft-start ramp
The ramping function is performed during
power up as well as any time the set point
is changed. It can be ramping up or
ramping down. The process value will
reach the set point at a predetermined
constant rate.
Digital filter
A first order low pass filter with a
programmable time constant is used to
improve the stability of the process value.
This is particularly useful in certain
applications where the process value is
too unstable to be read.
SEL function
The units have the flexibility to allow the
user to select those parameters which are
most significant to him and put these
parameters in the front of the display
sequence. Up to eight parameters can be
selected to allow the user to build his own
display sequence.
Figure 1.1 Fuzzy Control Advantage
Chapter 1 Overview

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1–4 Keys and Displays
KEYPAD OPERATION
SCROLL KEY:
This key is used to select a parameter to be viewed or adjusted.
UP KEY:
This key is used to increase the value of the selected parameter.
DOWN KEY:
This key is used to decrease the value of the selected parameter.
RESET KEY:
This key is used to:
1. Revert the display to show the process value.
2. Reset the latching alarm, once the alarm condition is removed.
3. Stop the manual control mode, auto-tuning mode, and
calibration mode.
4. Clear the message of communication error and auto-tuning
error.
5. Restart the dwell timer when the dwell timer has timed out.
6. Enter the manual control menu when in failure mode.
ENTER KEY: Press for 5 seconds or longer.
Press for 5 seconds to:
1. Enter setup menu. The display shows .
2. Enter manual control mode—when manual control mode
is selected.
3. Enter auto-tuning mode—when auto-tuning mode is
selected.
4. Perform calibration to a selected parameter during the
calibration procedure.
Press for 6.2 seconds to select manual control mode.
Press for 7.4 seconds to select auto-tuning mode.
Press for 8.6 seconds to select calibration mode.
R
TEMPCO
Table 1.1 Display Form of Characters
Display program code of the product for
2.5 seconds.
The left diagram shows program number
6 for TEC-9100 with version 12.
The program no. for TEC-7100 is 13, for
TEC-8100 is 11 and for TEC-4100 is 12.

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1–5 Menu Overview

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Parameter Descriptions (TEC-9100 Temperature Controller)
Controller Parameter Descriptions that are not applicable are not shown in the above table.
NOTE:
It is strongly recommended that a process should
incorporate a LIMIT CONTROL such as the
TEC-910 which will shut down the equipment at
a preset process condition in order to preclude
possible damage to products or system.
Information in this user's manual is subject to change
without notice.

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Chapter 3 Programming
Press for 5 seconds and release to enter the setup menu. Press
to select the desired parameter. The upper display indicates
the parameter symbol, and the lower display indicates the selected
value of the parameter.
3–1 Lockout
There are four security levels that can be selected using the
LOCK parameter.
If NONE is selected for LOCK, then no parameter is locked.
If SET is selected for LOCK, then all setup data are locked.
If USER is selected for LOCK, then all setup data as well as
user data (refer to section 1-5) except the set point are
locked to prevent them from being changed.
If ALL is selected for LOCK, then all parameters are locked to
prevent them from being changed.
3–2 Signal Input
INPT: Selects the sensor type or signal type for signal input.
Range: (thermocouple) J-TC, K-TC, T-TC, E-TC, B-TC,
R-TC, S-TC, N-TC, L-TC
(RTD) PT.DN, PT.JS
(Linear) 4–20mA, 0–20mA, 0–60mV, 0–1VDC,
0–5VDC, 1–5VDC, 0–10VDC
UNIT: Selects the process unit
Range: °C, °F, PU (process unit). If the unit is set for
neither °C nor °F, then it defaults to PU.
DP: Selects the resolution of process value.
Range: (For T/C and RTD) NO.DP, 1-DP
SL = Setpoint Low Stop SH = Setpoint High Stop

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PV Shift
In certain applications it is desirable to shift the controller
display value (PV) from its actual value. This can easily
be accomplished by using the PV shift function.
The SHIF function will alter PV only.
Example: A process is equipped with a heater, a sensor,
and a subject to be warmed up. Due to the design and
position of the components in the system, the sensor
could not be placed any closer to the part. Thermal
gradient (differing temperatures) is common and
necessary to an extent in any thermal system for heat to
be transferred from one point to another. If the difference
between the sensor and the subject is 35°C, and the
desired temperature at the subject to be heated is 200°C,
the temperature at the sensor should be 235°C. You
should enter -35°C to subtract 35°C from the actual
process display. This in turn will cause the controller to
energize the load and bring the process display up to the
set point value.
Figure 3.7 PV Shift Application
3–9 Digital Filter
In certain applications, the process value is too unstable
to be read due possibly to electrical noise. A
programmable low-pass filter incorporated in the
controller is used to improve this. It is a first-order filter
with the time constant specified by the FILT parameter.
The default value of FILT is set at 0.5 seconds before
shipping. Adjust FILT to change the time constant from
0 to 60 seconds. 0 seconds means no filter is applied to
the input signal. The filter is characterized by the
following diagram:
Note
The filter is available only for PV, and is performed for
the displayed value only. The controller is designed to
use unfiltered signal for control even if the filter is
applied. A lagged (filtered) signal, if used for control,
may produce an unstable process.
The controller will enter failure mode if one
of the following conditions occurs:
1. SBER occurs due to input sensor break
or input current below 1mA if 4–20 mA
is selected or input voltage below 0.25V
if 1–5V is selected.
2. ADER occurs due to the A-D converter
of the controller failing.
Output 1 and output 2 will perform the
failure transfer function as the controller
enters failure mode.
Output 1 failure transfer, if activated, will
perform:
1. If output 1 is configured as proportional
control (PB≠ 0), and BPLS is selected
for O1FT, then output 1 will perform
bumpless transfer. Thereafter, the
previous averaging value of MV1 will
be used for controlling output 1.
2. If output 1 is configured as proportional
control (PB≠ 0), and a value of 0 to
100.0% is set for O1FT, then output 1
will perform failure transfer. Thereafter,
the value of O1FT will be used for
controlling output 1.
3. If output 1 is configured as ON-OFF
control (PB=0), then output 1 will be
driven OFF if OFF is set for O1FT and
will be driven ON if ON is set for O1FT.
Output 2 failure transfer, if activated, will
perform:
1. If OUT2 is configured as COOL, and
BPLS is selected for O1FT, then output
2 will perform bumpless transfer.
Thereafter, the previous averaging value
of MV2 will be used for controlling
output 2.
2. If OUT2 is configured as COOL, and a
value of 0 to 100.0% is set for O2FT,
then output 2 will perform failure
transfer. Thereafter, the value of O1FT
will be used for controlling output 2.
3. If OUT2 is configured as alarm
function, and O2FT is set to OFF, then
output 2 will go off. Otherwise, output
2 will go on if O2FT is set to ON.
Alarm failure transfer is activated as the
controller enters failure mode. Thereafter,
the alarm will transfer to the ON or OFF
state preset by ALFT.
3–10 Failure Transfer
Figure 3.8 Filter Characteristics

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Auto-tuning
The auto-tuning process is performed near the set point. The process
will oscillate around the set point during the tuning process. Set the
set point at a lower value if overshooting beyond the normal process
value is likely to cause damage.
Auto-tuning is applied in cases of:
• Initial setup for a new process
• The set point is changed substantially from the previous
auto-tuning value
• The control result is unsatisfactory
Operation:
1. The system has been installed normally.
2. Set the correct values for the setup menu of the unit, but don’t
set a zero value for PB and TI, or the auto-tuning program will
be disabled. The LOCK parameter should be set at NONE.
3. Set the set point to a normal operating value, or a lower value if
overshooting beyond the normal process value is likely to cause
damage.
4. Press and hold until appears on the display.
5. Then press again for at least 5 seconds. The AT indicator will
begin to flash and the auto-tuning procedure begins.
NOTE: The ramping function, if used, will be disabled when
auto-tuning is taking place.
Auto-tuning mode is disabled as soon as either failure mode or
manual control mode is entered.
Procedures:
Auto-tuning can be applied either as the process is warming up
(cold start), or when the process has been in a steady state (warm
start). After the auto-tuning procedures are completed, the AT
indicator will cease to flash and the unit will revert to PID control
using its new PID values. The PID values obtained are stored in
the nonvolatile memory.
Auto-Tuning Error
If auto-tuning fails an ATER message will appear on the upper
display in the following cases:
• If PB exceeds 9000 (9000 PU, 900.0°F or 500.0°C),
• if TI exceeds 1000 seconds,
• if the set point is changed during the auto-tuning procedure.
Solutions to
1. Try auto-tuning once again.
2. Don’t change the set point value during the auto-tuning procedure.
3. Don’t set a zero value for PB and TI.
4. Use manual tuning instead of auto-tuning (see section 3-12).
5. Touch RESET key to reset message.
Manual Tuning
In certain applications auto-tuning may be inadequate for the
control requirements. You can try manual tuning for these
applications.
If the control performance using auto-tuning is still unsatisfactory,
the following rules can be applied for further adjustment of PID
values:
Figure 3.9 shows the effects of PID
adjustment on process response.
Figure 3.9 Effects of PID Adjustment
Table 3.2 PID Adjustment Guide

10
Table A.1 Error Codes and Corrective Actions

11
WARRANTY
Tempco Electric Heater Corporation is pleased to offer
suggestions on the use of its products. However, Tempco makes
no warranties or representations of any sort regarding the fitness
for use, or the application of its products by the Purchaser. The
selection, application, or use of Tempco products is the
Purchaser's responsibility. No claims will be allowed for any
damages or losses, whether direct, indirect, incidental, special, or
consequential. Specifications are subject to change without
notice. In addition, Tempco reserves the right to make changes–
without notification to the Purchaser–to materials or processing
that do not affect compliance with any applicable specification.
TEC Temperature Controllers are warranted to be free from
defects in material and workmanship for two (2) years after
delivery to the first purchaser for use. Tempco's sole
responsibility under this warranty, at Tempco's option, is limited
to replacement or repair, free of charge, or refund of purchase
price within the warranty period specified. This warranty does
not apply to damage resulting from transportation, alteration,
misuse, or abuse.
RETURNS
No product returns can be accepted without a completed Return
Material Authorization (RMA) form.
TECHNICAL SUPPORT
Technical questions and troubleshooting help is available from
Tempco. When calling or writing please give as much
background information on the application or process as possible.
E-mail: [email protected]
Phone: [phone]
800-323-6859

607 N. Central Avenue Wood Dale, IL 60191-1452 USA
P: 630-350-2252 Toll Free: 800-323-6859
F: 630-350-0232 E: [email protected]
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