Tempco TEC-4100 User manual

Instruction Manual
TEC-4100 / 7100 / 8100 / 9100
Auto-Tune Fuzzy / PID Process
Temperature Controller
Manual TEC-100 evision 9/2013
Agency Approvals
TEMPCO Electric Heater Corporation
607 N. Central Avenue • Wood Dale, IL 60191-1452 USA
Tel: [phone] • Toll Free: 800-323-6859
Fax: [phone] • E-mail: [email protected]
Web: www.tempco.com
Serving Industry Since 1972

NOTES

Using the Manual
Installers . . . . . . . . . . . . . . . . . . . . . . . . . . . Read Chapter 1, 2
System Designer . . . . . . . . . . . . . . . . . . . . . Read All Chapters
xpert User . . . . . . . . . . . . . . . . . . . . . . . . . Read Page 11
OTE:
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.
Copyright © 2012, Tempco lectric Heater Corporation, all
rights reserved. No part of this publication may be reproduced,
transmitted, transcribed or stored in a retrieval system, or trans-
lated into any language in any form by any means without the
written permission of Tempco lectric Heater Corporation.
CO TE TS
age No
Chapter 1 Overview
1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2 Ordering Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-3 Programming Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4 Keys and Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5 Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6 Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 2 Installation
2-1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3 Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-4 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-5 Sensor Installation Guidelines . . . . . . . . . . . . . . . . . . . 9
2-6 Sensor Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-7 Control Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . 9
2-8 Alarm Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-9 Data Communication . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Chapter 3 Programming
3-1 Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-2 Signal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-3 Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-4 Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-5 Configuring User Menu . . . . . . . . . . . . . . . . . . . . . . . 15
3-6 Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-7 Dwell Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3-8 PV Shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-9 Digital Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-10 Failure Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3-11 Auto-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-12 Manual Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3-13 Manual Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-14 Data Communication . . . . . . . . . . . . . . . . . . . . . . . . . 18
3-15 Process Variable (PV) Retransmission. . . . . . . . . . . . 18
Chapter 4 Applications
4-1 Heat Only Control With Dwell Timer . . . . . . . . . . . . . 19
4-2 Cool Only Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-3 Heat-Cool Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 5 Calibration . . . . . . . . . . . . . . . 21
Chapter 6 Specifications . . . . . . . . . . . 23
Chapter 7 Modbus Comm. . . . . . . . . . . 25
7-1 Functions Supported . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-2 xception Responses . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-3 Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-4 Data Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7-5 Communication xample . . . . . . . . . . . . . . . . . . . . . . . 29
Appendix
A-1 rror Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
A-2 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
FIGURES & TABLES
age No
Figure 1.1 Fuzzy Control Advantage. . . . . . . . . . . . . . . . . . 1
Figure 1.2 Programming Port Overview . . . . . . . . . . . . . . . 3
Figure 1.3 Front Panel Description . . . . . . . . . . . . . . . . . . 3
Figure 1.4 Display during Power UP . . . . . . . . . . . . . . . . . 3
Figure 2.1 Mounting Dimensions . . . . . . . . . . . . . . . . . . . . 7
Figure 2.2 Lead Termination for T C-4100,
T C-8100 and T C-7100 . . . . . . . . . . . . . . . . . 8
Figure 2.3 Lead Termination for T C-9100 . . . . . . . . . . . . 8
Figure 2.4 Rear Terminal Connection for
T C-4100 and T C-8100 . . . . . . . . . . . . . . . . . 8
Figure 2.5 Rear Terminal Connection for T C-7100 . . . . . 8
Figure 2.6 Rear Terminal Connection for T C-9100 . . . . . 8
Figure 2.7 Power Supply Connections . . . . . . . . . . . . . . . . 9
Figure 2.8 Sensor Input Wiring . . . . . . . . . . . . . . . . . . . . . 9
Figure 2.9 Output 1 Relay or Triac (SSR) to
Drive Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 2.10 Output 1 Relay or Triac (SSR) to
Drive Contactor . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 2.11 Output 1 Pulsed Voltage to Drive SSR . . . . . 10
Figure 2.12 Output 1 Linear Current . . . . . . . . . . . . . . . . . 10
Figure 2.13 Output 1 Linear Voltage . . . . . . . . . . . . . . . . . 10
Figure 2.14 Output 2 Relay or Triac (SSR) to
Drive Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 2.15 Output 2 Relay or Triac (SSR) to
Drive Contactor . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 2.16 Output 2 Pulsed Voltage to Drive SSR . . . . . . 10
Figure 2.17 Output 2 Linear Current . . . . . . . . . . . . . . . . . 10
Figure 2.18 Output 2 Linear Voltage . . . . . . . . . . . . . . . . . 10
Figure 2.19 Alarm Output to Drive Load . . . . . . . . . . . . . 11
Figure 2.20 Alarm Output to Drive Contactor . . . . . . . . . . 11
Figure 2.20.1 Dwell Timer Function . . . . . . . . . . . . . . . . . 11
Figure 2.21 RS-485 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 2.22 RS-232 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 2.23 Configuration of RS-232 Cable . . . . . . . . . . . 11
Figure 3.1 Conversion Curve for Linear Type
Process Value . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 3.2 Heat Only ON-OFF Control . . . . . . . . . . . . . . . 13
Figure 3.3 Output 2 Deviation High Alarm . . . . . . . . . . . . 14
Figure 3.4 Output 2 Process Low Alarm . . . . . . . . . . . . . . 14
Figure 3.5 RAMP Function . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 3.6 Dwell Timer Function . . . . . . . . . . . . . . . . . . . . 15
Figure 3.7 PV Shift Application . . . . . . . . . . . . . . . . . . . . . 16
Figure 3.8 Filter Characteristics . . . . . . . . . . . . . . . . . . . . . 16
Figure 3.9 ffects of PID Adjustment . . . . . . . . . . . . . . . . 17
Figure 4.1 Heating Control xample . . . . . . . . . . . . . . . . . 19
Figure 4.2 Cooling Control xample . . . . . . . . . . . . . . . . . 19
Figure 4.3 Heat-Cool Control xample . . . . . . . . . . . . . . . 20
Figure 5.1 RTD Calibration . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 5.2 Cold Junction Calibration Setup . . . . . . . . . . . . 22
Table 1.1 Display Form of Characters . . . . . . . . . . . . . . . . 3
Table 3.1 Heat-Cool Control Setup Value . . . . . . . . . . . . . 12
Table 3.2 PID Adjustment Guide . . . . . . . . . . . . . . . . . . . . 17
Table A.1 rror Codes and Corrective Actions . . . . . . . . . 30

NOTES

1
1–1 General
Tempco’s T C-x100 Series Fuzzy Logic plus PID microproces-
sor-based controllers incorporate two bright easy to read 4-digit
LD 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.
T C-9100 is a 1/16 DIN size panel mount controller. T C-7100
is a 72×72 DIN size panel mount controller. T C-8100 is a 1/8
DIN size panel mount controller and T C-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 con-
trol 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 program-
mable for PT100 RTD and thermocouple types J, K, T, , 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 T C-
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 con-
trol loop will minimize overshoot and undershoot in a short time.
The following diagram is a comparison of results with and with-
out 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 vari-
ous 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 pro-
vide 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 con-
nect the unit to a PC for quick configura-
tion. It also can be connected to an AT
system for automatic testing and calibra-
tion.
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 dur-
ing 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 pro-
grammable 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.
Chapter 1 Overview
Figure 1.1 Fuzzy Control Advantage

2
1–2 Ordering Code
Data Communication Accessories:
TEC99001 Smart Network Adapter for third party SCADA software
which converts 255 channels of RS-485 or RS-422 to RS-
232 Network.
TEC99003 Smart Network Adapter for connecting the programming
port to the RS-232 PC serial port. Allows downloading and
reading of configuration information directly from a person-
al computer. Can be used with T C-4100, T C-7100, T C-
8100 and T C-9100.
TEC99030 "Tempco Config Set" PC software for use with T C99003
Smart Network Adapter. (can be downloaded at no charge
from www.tempco.com)
Minimum System Requirements:
Microsoft Windows 2000, 98, 95, NT4.0
Pentium 200 MHz or faster
32 MB RAM (64 MB recommended)
Hard disk space: 2 MB
TEC99011 Programming port cable for T C-4100, T C-7100, T C-
8100 and T C-9100. Connects the controller to the
T C99003 Smart Network Adapter.
Power Input
4 = 90-250 VAC
5 = 11-26 VAC/VDC
9 = Other
Signal Input
Universal, can be
programmed in the field
for item 5 or 6
5 = TC: *J,K,T, ,B,R,S,N,L
0-60 mV
6 = RTD: *PT100 DIN,
PT100 JIS
7 = 0-1 VDC
8 = *0-5, 1-5 VDC
A = 0-10 VDC
B = *4-20, 0-20 mA
9 = Other
*indicates default value
Output 1
1 = Relay: 2A/240 VAC
2 = Pulse dc for SSR drive:
5 Vdc (30 mA max)
3 = Isolated, 4-20 mA (default)
0-20 mA
4 = Isolated, VDC, 1-5 (default)
0-5, 0-1
5 = Isolated, VDC, 0-10
6 = Triac-SSR output
1A/240 VAC
C = Pulse dc for SSR drive:
14 Vdc (40 mA max)
9 = Other
Output 2
0 = None
1 = Relay: 2A / 240 VAC
2 = Pulse dc for SSR drive: 5 Vdc (30 mA max)
3 = Isolated, 4-20 mA (default), 0-20 mA
4 = Isolated VDC, 1-5 (default), 0-5, 0-1
5 = Isolated VDC, 0-10
6 = Triac-SSR output 1A / 240 VAC
7 = Isolated 20V @ 25 mA DC, Output Power Supply
8 = Isolated 12V @ 40 mA DC, Output Power Supply
9 = Isolated 5V @ 80 mA DC, Output Power Supply
C = Pulse dc for SSR drive: 14 VDC (40 mA max)
A = Other
Power Input
4 = 90-250 VAC
5 = 11-26 VAC/VDC
9 = Other
Signal Input
Universal, can be programmed in the field
for item 5 or 6
5 = TC: *J,K,T, ,B,R,S,N,L 0-60mV
6 = RTD: *PT100 DIN, PT100 JIS
7 = 0-1 Vdc
8 = *0-5, 1-5 VDC
A = 0-10 VDC
B = *4-20, 0-20 mA
9 = Other
*indicates default value
Output 1
1 = Relay: 2A / 240 VAC
2 = Pulse dc for SSR drive: 5 VDC (30 mA max)
3 = Isolated, 4-20 mA (default), 0-20 mA
4 = Isolated, VDC, 1-5 (default), 0-5, 0-1
5 = Isolated, VDC, 0-10
6 = Triac-SSR output 1A/240 VAC
C = Pulse dc for SSR drive:14 VDC (40 mA max)
9 = Other
Output 2
0 = None
1 = Relay: 2A/240 VAC
2 = Pulse dc for SSR drive: 5 VDC (30 mA max)
3 = Isolated, 4-20 mA (default), 0-20 mA
4 = Isolated VDC, 1-5 (default), 0-5, 0-1
5 = Isolated VDC, 0-10
6 = Triac-SSR output 1A/240 Vac
7 = Isolated 20V @ 25 mA DC, Output Power Supply
8 = Isolated 12V @ 40 mA DC, Output Power Supply
9 = Isolated 5V @ 80 mA DC, Output Power Supply
C = Pulse dc for SSR drive: 14 VDC (40 mA max)
A = Other
Alarm
0 = None
1 = Relay: 2A / 240 VAC, SPDT
9 = Other
Communication
0 = None
1 = RS-485 Interface
2 = RS-232 Interface
3 = Retransmission 4-20 mA (default), 0-20 mA
4 = Retransmission 1-5 VDC (default), 0-5 VDC
5 = Retransmission 0-10 VDC
9 = Other
Case Options
0 = Panel mount standard
1 = Panel mount with N MA 4X/IP65 front panel
2 = DIN rail mount
Alarm
0 = None
1 = Relay: 2A/240 VAC,
SPDT
9 = Other
Communication
0 = None
1 = RS-485 Interface
2 = RS-232 Interface
(not available for T C-7100)
3 = Retransmission 4-20 mA
(default), 0-20 mA
4 = Retransmission 1-5 Vdc
(default), 0-5 VDC
5 = Retransmission 0-10 VDC
9 = Other
NEMA 4X / IP65
0 = No
1 = Yes
TEC-4100-
TEC-7100-
TEC-8100-
TEC-9100-

3
1–4 Keys and Displays
EYPAD OPERATION
SCROLL EY:
This key is used to select a parameter to be viewed or adjusted.
UP EY:
This key is used to increase the value of the selected parameter.
DOWN EY:
This key is used to decrease the value of the selected parameter.
RESET EY:
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 calibra-
tion 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. nter the manual control menu when in failure mode.
ENTER EY: Press for 5 seconds or longer.
Press for 5 seconds to:
1. nter setup menu. The display shows .
2. nter manual control mode—when manual control mode
is selected.
3. nter auto-tuning mode—when auto-tuning mode is
selected.
4. Perform calibration to a selected parameter during the calibra-
tion 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
The T C99011 cable and T C99003
network adapter can be used to con-
nect the programming port to a PC
for automatic configuration.
The programming port is used for
off-line automatic setup and testing
procedures only. Don't attempt to
make any connection to these pins
when the unit is used for a normal
control purpose.
1–3 Programming Port
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 T C-9100 with version 12.
The program no. for T C-7100 is 13, for
T C-8100 is 11 and for T C-4100 is 12.

4
1–5 Menu Overview

5
1–6 Parameter Descriptions
Continued…

6
Parameter Descriptions, Continued…

7
Dangerous voltages capable of causing death are some-
times 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 replace-
ment and internal adjustments must be made by a qualified main-
tenance person only.
This instrument is protected throughout by double insula-
tion 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 con-
ditions such as excessive shock, vibration, dirt, moisture,
corrosive gases or oil. This control is not to be used in hazardous
locations as defined in Articles 500 and 505 of the National
lectrical Code. The ambient temperature of the area should not
exceed 122°F.
Remove stains from this instrument using a soft, dry
cloth. To avoid deformation or discoloration do not use
harsh chemicals, volatile solvent such as thinner, or strong deter-
gents to clean this instrument.
2–1 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 it and file a claim
with the carrier. Write down the model number, serial number,
and date code for future reference when corresponding with
Tempco. The serial number (S/N) and date code (D/C) are
labeled on the box and the housing of the control.
2–2 Mounting
Remove mounting clamps or screws and insert the controller into
the panel cutout. Reinstall the mounting clamps or screws.
Gently tighten the screws or clamp until the front panel of the
controller fits snugly in the cutout.
Figure 2.1 Mounting Dimensions
Chapter 2 Installation
NOT :
The T C-9100 Series may be supplied with either mounting
screws (2) or mounting clamps (2). The mounting clamps
are the newer type.
In clamp mounting, to remove the clamps before installation
lift under one of the edges and pull up (un-peel). To install
just snap back on and push the clamps towards the front of
the control until they are snug.

8
Before wiring, verify the correct model
number and options on the label. Switch
off the power while checking.
Care must be taken to ensure that the
maximum voltage rating specified on
the label is not exceeded.
It is recommended that the power for
these units be protected by fuses or cir-
cuit 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 appropriate
standards of good practice and local
codes and regulations. Wiring must be
suitable for the voltage, current, and
temperature rating of the system.
Beware not to over-tighten the terminal
screws. The torque should not exceed
1 n-m (8.9 in-lb.)
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 as specified in
chapter 6 are not exceeded.
xcept for the thermocouple wiring, all
wiring should be stranded copper with a
maximum gauge of 18 awg.
2–3 Wiring Precautions
*Or low voltage (11-26 VAC/VDC) when ordered as specified. Non-polarized.
NOTE: ASTM thermocouples (American) the
red colored lead is always negative.
II

9
Proper sensor installation can eliminate many problems in a con-
trol 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 experimentation
with probe location is often required to find the optimum position.
In a liquid process, the addition of agitation will help to eliminate
thermal lag. Since the 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.
Proper sensor type is also a very important factor in obtaining
precise measurements. The sensor must have the correct temper-
ature range to meet the process requirements. In special processes,
the sensor might have requirements such as leak-proof, anti-
vibration, antiseptic, etc.
Standard sensor limits of error are ±4°F (±2°C) or 0.75% of the
sensed temperature (half that for special) plus drift caused by
improper protection or an over-temperature occurrence. This
error is far greater than controller error and cannot be corrected
on the sensor except by proper selection and replacement.
Note: A 2-wire RTD temperature sensor can be used if a short is
placed across the “B” terminals.
xample: For a T C-9100 Controller, connect the 2-wire RTD to
terminals 4 & 5, and a short across terminals 5 & 6.
The controller is designed to operate at 11–26 VAC/VDC or
90–250 VAC. Check that the installation voltage corresponds to
the power rating indicated on the product label before connect-
ing power to the controller. The controller power input should be
equipped with a fuse and switch as shown below in figure 2.7
This equipment is designed for installation in an enclo-
sure which provides adequate protection against electric
shock. The enclosure must be connected to earth ground.
Local requirements regarding electrical installation should be
rigidly observed. Consideration should be given to prevent unau-
thorized personnel from accessing the power terminals.
2–4 Power Wiring
2–5 Sensor Installation Guidelines
2–6 Sensor Input Wiring 2–7 Control Output Wiring
Control Output Wiring, continued…

10
Control Output Wiring, continued…

11
2–9 Data Communication
2–8 Alarm Wiring
If you use a conventional 9-pin RS-232 cable instead
of T C 99014, the cable must be modified according
to the following circuit diagram.

12
Chapter 3 Programming
Press for 5 seconds and release to enter the setup menu.
Press to select the desired parameter. The upper display indi-
cates 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
IN T: Selects the sensor type or signal type for signal input.
Range: (thermocouple) J-TC, K-TC, T-TC, -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 nei-
ther °C nor °F, then it defaults to PU.
D : Selects the resolution of process value.
Range: (For T/C and RTD) NO.DP, 1-DP
(For linear) NO.DP, 1-DP, 2-DP, 3-DP
INLO: Selects the low scale value for the linear type input.
INHI: Selects the high scale value for the linear type input.
How to use the conversion curve for linear type
process values, INLO and INHI;
If 4–20mA is selected for INPT, SL specifies the input signal low
(i.e., 4mA), SH specifies the input signal high (i.e., 20mA), S
specifies the current input signal value, and the conversion curve
of the process value is shown as follows:
3–3 Control Outputs
There are four kinds of control modes that can be configured as shown in table 3.1.
SL = Setpoint Low Limit SH = Setpoint High Limit
Table 3.1 Heat-Cool Control Setup Value
Figure 3.1
Conversion Curve
for Linear Type
Process Value

13
The ON-OFF control may introduce excessive process oscillation
even if hysteresis is minimized. If ON-OFF control is set (i.e.,
PB=0), TI, TD, CYC1, OFST, CYC2, CPB, and DB will be hid-
den and have no function in the system. The auto-tuning and
bumpless transfer functions will be disabled as well.
Heat only (or D) control: Select R VR for OUT1, set TI to
0. OFST is used to adjust the control offset (manual reset). O1HY
is hidden if PB is not equal to 0. OFST function: OFST is meas-
ured by % with a range of 0–100.0%. In the steady state (i.e.,
process has been stabilized), if the process value is lower than the
set point by a definite value, say 5°C, while 20°C is used for PB,
that is lower by 25%, then increase OFST 25%, and vice-versa.
After adjusting OFST value, the process value will be varied and
eventually coincide with set point.
Refer to section 3-12 “manual tuning” for the adjustment of PB
and TD. Manual reset (adjust OFST) is not practical because the
load may change from time to time and OFST may need to be
adjusted repeatedly. PID control can avoid this situation.
Heat only ID control: If R VR is selected for OUT1, PB and
TI should not be zero. Perform auto-tuning for the new process,
or set PB, TI, and TD with historical values. See section 3-11 for
auto-tuning operation. If the control result is still unsatisfactory,
then use manual tuning to improve control. See section 3-12 for
manual tuning. The unit contains a very advanced PID and Fuzzy
Logic algorithm to create a very small overshoot and very quick
response to the process if it is properly tuned.
Control Outputs, continued…
Heat only ON-OFF control: Select R VR for OUT1. Set PB
(proportional band) to 0. O1HY is used to adjust dead band for
ON-OFF control. The output 1 hysteresis (O1HY) is enabled
in case PB=0. The heat only on-off control function is shown
in the following diagram:
3.3 & 3.4 Alarm Figures, next page…
Cool only control: ON-OFF control, P (PD) control, and PID
control can be used for cool control. Set OUT1 to DIRT (direct
action). The other functions for cool only ON-OFF control,
cool only P (PD) control, and cool only PID control are the
same as for heat only control except that the output variable
(and action) for cool control is inverse to heat control.
NOTE: ON-OFF control may result in excessive overshoot and
undershoot problems in the process. P (or PD) control will
result in a deviation of process value from the set point. It is
recommended to use PID control for heat-cool control to produce
a stable and zero offset process value.
Other setup required: O1TY, CYC1, O2TY, CYC2, O1FT
and O2FT are set in accordance with the types of OUT1 and
OUT2 installed. CYC1 and CYC2 are selected according to the
output 1 type (O1TY) and output 2 type (O2TY). Generally,
select 0.5~2 seconds for CYC1 if SSRD or SSR is used for
O1TY; 10~20 seconds if relay is used for O1TY. CYC1 is
ignored if a linear output is used. Similar conditions are applied
for CYC2 selection.
You can use the auto-tuning program for the new process or
directly set the appropriate values for PB, TI, and TD accord-
ing to historical records for the repeated systems. If the control
behavior is still inadequate, use manual tuning to improve the
control. See section 3-12 for manual tuning.
C B (Cooling roportional Band) rogramming: The cool-
ing proportional band is measured by % of PB with a range of
50-300. Initially set 100% for CPB and examine the cooling
effect. If the cooling action should be enhanced, then decrease
CPB, if the cooling action is too strong, then increase CPB. The
value of CPB is related to PB and its value remains unchanged
throughout the auto-tuning procedures.
Adjustment of CPB is related to the cooling medium used. If air
is used as the cooling medium, adjust CPB to 100%. If oil is
used as the cooling medium, adjust CPB to 125%. If water is
used as the cooling medium, adjust CPB to 250%.
DB (Heating-Cooling Dead Band) rogramming: The
adjustment of DB is dependent on the system requirements. If
a more positive value of DB (greater dead band) is used, an
unwanted cooling action can be avoided but an excessive over-
shoot over the set point will occur. If a more negative value of
DB (greater overlap) is used, an excessive overshoot over the
set point can be minimized, but an unwanted cooling action will
occur. It is adjustable in the range -36.0% to 36.0% of PB. A
negative DB value shows an overlap area over which both out-
puts are active. A positive DB value shows a dead band area
over which neither output is active.
Output 2 ON-OFF control (alarm function): Output 2 can
also be configured with an alarm function. There are four kinds
of alarm functions that can be selected for output 2. These are:
D .HI (deviation high alarm), D .LO (deviation low alarm),
PV.HI (process high alarm), and PV.LO (process low alarm).
Refer to figure 3.3 and figure 3.4 for descriptions of the devia-
tion alarm and the process alarm.

14
3.3 & 3.4 Alarm Figures 3–4 Alarm
The controller has one alarm output. There are six types of
alarm functions and one dwell timer that can be selected, and
four kinds of alarm modes (ALMD) are available for each
alarm function (ALFN). Output 2 can be configured as
another alarm in addition to the alarm output. But output 2
only provides four kinds of alarm functions and only normal
alarm mode is available for this alarm. When output 2 is used
as an alarm, SP2 sets the trigger point. SP3 sets the trigger
point for Alarm.
A process alarm sets absolute trigger levels. When the
process is higher than SP3, a process high alarm (PV.HI)
occurs, and the alarm is off when the process is lower than
SP3-ALHY. When the process is lower than SP3, a process
low alarm (PV.LO) occurs, and the alarm is off when the
process is higher than SP3+ALHY. A process alarm is inde-
pendent of the set point.
A deviation alarm alerts the user when the process deviates
from the set point. When the process is higher than SV+SP3,
a deviation high alarm (D .HI) occurs, and the alarm is off
when the process is lower than SV+SP3-ALHY. When the
process is lower than SV+SP3, a deviation low alarm
(D .LO) occurs, and the alarm is off when the process is
higher than SV+SP3+ALHY. The trigger level of the devia-
tion alarm moves with the set point.
A deviation band alarm presets two trigger levels relative to
the set point. The two trigger levels are SV+SP3 and SV-SP3
for alarm. When the process is higher than (SV+SP3) or
lower than (SV-SP3), a deviation band high alarm (DB.HI)
occurs. When the process is within the trigger levels, a devi-
ation band low alarm (DB.LO) occurs.
There are four types of alarm modes available for each alarm
function. These are: normal alarm, latching alarm, holding
alarm and latching/holding alarm. They are described as fol-
lows:
Normal alarm: ALMD=NORM
When a normal alarm is selected, the alarm output is de-ener-
gized in the non-alarm condition and energized in an alarm
condition.
Latching alarm: ALMD=LTCH
If a latching alarm is selected, once the alarm output is ener-
gized, it will remain unchanged even if the alarm condition
is cleared. The latching alarm is reset when the R S T key
is pressed after the alarm condition is removed.
Holding alarm: ALMD=HOLD
A holding alarm prevents an alarm when the control is pow-
ering up. The alarm is enabled only when the process reach-
es the set point value. Afterwards, the alarm performs the
same function as a normal alarm.
Latching/holding alarm: ALMD=LT.HO
A latching/holding alarm performs both holding and latching
functions. The latching alarm is reset when the R S T key
is pressed after the alarm condition is removed.
Alarm failure transfer is activated as the unit enters failure
mode. The alarm will go on if ALFT is set for ON and go off
if ALFT is set for OFF. The unit will enter failure mode when
a sensor break occurs or if the A-D converter of the unit fails.
Figure 3.4 Output 2 Process Low Alarm
Figure 3.3 Output 2 Deviation High Alarm

15
3–5 Configuring User Menu
Most conventional controllers are designed with a fixed order in
which the parameters scroll. The x100 series have the flexibility
to allow you to select those parameters which are most significant
to you and put these parameters at the front of the display
sequence.
SEL1~SEL8: Selects the parameter for view and change in the
user menu.
Range: LOCK, INPT, UNIT, DP, SHIF, PB, TI, TD, O1HY,
CYC1, OFST, RR, O2HY, CYC2, CPB, DB, ADDR, ALHY
When using the up and down keys to select the parameters, you
may not see all of the above parameters. The number of visible
parameters is dependent on the setup condition. The hidden
parameters for the specific application are also blocked from the
S L selection.
xample:
OUT2 set for D .LO PB= 100.0 S L1 set for INPT
S L2 set for UNIT S L3 set for PB S L4 set for TI
S L5~S L8 set for NON
Now, the upper display scrolling becomes:
3–6 Ramp
Ramp
The ramping function is performed during power up as well as
any time the set point is changed. If MINR or HRR is chosen for
RAMP, the unit will perform the ramping function. The ramp rate
is programmed by adjusting RR. The ramping function is dis-
abled as soon as failure mode, manual control mode, auto-tuning
mode or calibration mode is entered.
Example without dwell timer
Select MINR for RAMP, select °C for UNIT, select 1-DP for DP,
set RR=10.0. SV is set to 200°C initially, and changed to 100°C
30 minutes after power-up. The starting temperature is 30°C.
After power-up, the process runs like the curve shown below:
Note: When the ramp function is used, the lower display will
show the current ramping value. The ramping value is an artifi-
cially determined setpoint created and updated by the control to
match the ramp rate set by the user. However, it will revert to
show the set point value as soon as the up or down key is touched
for adjustment. The ramping value is initiated to process value
either on power-up or when RR and/or the set point are changed.
Setting RR to zero means no ramp function.
3–7 Dwell Timer
The alarm output can be configured as a dwell timer by selecting
TIMR for ALFN (alarm function). As the dwell timer is config-
ured, the parameter SP3 is used for dwell time adjustment. The
dwell time is measured in minutes ranging from 0.1 to 4553 min-
utes. Once the process reaches the set point the dwell timer starts
to count down to zero (time out). The timer relay will remain
unchanged until time out. For the dwell timer to control the
heater, the heater circuit (or contactor) must be wired in series
with the alarm relay. Note the following diagram located below
and also Figure 2.20.1 on page 11. When the dwell timer times
out, the heater will be turned off. The dwell timer operation is
shown in the following diagram.
After time out, the dwell timer can be restarted by pressing the
R S T key.
The timer stops counting during manual control mode, failure
mode, the calibration period and the auto-tuning period.
If the alarm is configured as a dwell timer, ALHY and ALMD are
hidden.
Dwell Timer Function Wiring Diagram
Figure 3.6 Dwell Timer Function
Figure 3.5 RAMP Function

16
3–8 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.
xample: 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 sys-
tem, 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.
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 sec-
onds 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 unfil-
tered 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 fail-
ure transfer function as the controller
enters failure mode.
Output 1 failure transfer, if activated,
will perform:
1. If output 1 is configured as proportion-
al control (PB≠ 0), and BPLS is select-
ed for O1FT, then output 1 will perform
bumpless transfer. Thereafter, the previ-
ous averaging value of MV1 will be
used for controlling output 1.
2. If output 1 is configured as proportion-
al 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 con-
trolling 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 control-
ling 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 trans-
fer. Thereafter, the value of O1FT will
be used for controlling output 2.
3. If OUT2 is configured as alarm func-
tion, and O2FT is set to OFF, then out-
put 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 3.7 PV Shift Application
Figure 3.8 Filter Characteristics