etr-9200 automatic tuning smarter logic¨ controller · manual no. 25 software version 1.8 and...

MANUAL NO. 25SOFTWARE VERSION

1.8 and HIGHER

Model ETR-9200AUTOMATIC TUNING

SMARTER LOGIC® Controller

SMARTERSMARTER

LOGICLOGICLOGIC

®

INSTRUCTION MANUAL

INSTRUCTION MANUALFOR ETR-9200

CONTENTS

Failure of devices, such as the thermocouple-RTD sensor, heater output relay or temperature control can result insevere damage to a product while in process, melting of the heater or a damaging fire. An over-temperature protec-tion device must be installed in your process that will remove all power from the heating circuit if the above failureoccurs. We recommend that this device be classified as a safety control and carry FM, U.L. and CSA Listing orCertification. Failure to install high-limit temperature control protection where a potential hazard exists, could resultin damage to equipment and property, and fatal injury to personnel.

WARNING!

Section 1: INTRODUCTION

This manual contains information for the installation andoperation of the Ogden Model ETR-9200 auto-tuningmicro-processor based controller.Ease of use is an essential feature on this versatilecontroller. Three touch keys are used to select sensortype, control mode, control parameters, alarm mode,degree C/F, auto-manual mode, and to lock the para-meters from the prevention of unauthorized tampering.Two large 4-digit displays show process and set pointvalues at a glance. Precise 14 slope sensor lineariza-tion, self-diagnostic capability, cold junction compensa-tion and 3-mode PID calculations are automatically exe-cuted by the single chip microprocessor. The wideselection of parameters, values, sensor types, setpoints, control modes, alarm modes, degrees C/F and

security codes are held in a non-volatile memory andretained for ten years if the unit is left unpowered.Batteries are not necessary.The auto-tuning function determines the correct propor-tional band, rate and reset values to provide accuratecontrol with minimal overshoot and temperature oscilla-tion. This is accomplished without the need for expen-sive and time consuming procedures for set-up of con-trol parameters. In case of a power failure or temporaryshutdown, the instrument retains the correct parame-ters. This instrument also has manual override capabili-ties that allow the operator to bypass the auto-tuningparameters. Required fine tuning adjustments can thenbe made.

SMARTERSMARTER

LOGICLOGICLOGIC

®

64 West Seegers RoadArlington Heights, IL 60005(847) 593-8050 • Fax: (847) 593-8062www.ogdenmfg.com • [email protected]

Printed in U.S.A. 9/99

© Ogden Manufacturing Co. 1999OGDEN, SMARTER LOGIC, ETR and

ETR-9200 are Registered Trademarks of Ogden Manufacturing Co.

MARCA REGISTRADA

Specifications subject to change without notice.

Section 2: CATALOG NUMBERING SYSTEM

ETR-9200-

Signal Input1 Thermocouple J, K,

T, E, B, R, S, N2 RTD PT100 ohms,

Alpha = .00385/DIN3 RTD PT100 ohms

Alpha = .00392/JIS4 Other Voltage

(up to 10VDC)or current(up to 20mA)

Control Output1 None2 Relay rated

3A/240VAC resistive3 Pulsed voltage to

drive SSR, 3-32VDC4 Triac rated

1A/240VAC 5 Isolated 4-20mA

linear6 Isolated 0-20mA

linear7 Isolated 0-10VDC

linear8 Special order

Alarm Outputs1 None2 With alarms A1 and

A2, relays rated 3A/240VAC resistive

3 SSR,3-32VDC4 Special Order

Example:ETR-9200-1221• Thermocouple type*

J, K, T, E, B, R, S, N• Relay Output• With Alarm Option* NOTE: True universal input can bere-programmed in field

□ □ □ 1

41 2 3

Sensor SensorSensor Input Type Max. Range F° Accuracy F° Max. Range C° Accuracy C°

J Iron/Constantan –58 to 1832°F ±3.6°F –50 to 1000°C ±2°CK Chromel/Alumel –58 to 2500°F ±3.6°F –50 to 1370°C ±2°CT Copper/Constantan –454 to 752°F ±3.6°F –270 to 400°C ±2°CE Chromel/Constantan –58 to 1382°F ±3.6°F –50 to 750°C ±2°CB Pt-30%RH/Pt-6%RH 32 to 3272°F ±5.4°F 0 to 1800°C ±3°CR Pt-13%RH/Pt 32 to 3182°F ±3.6°F 0 to 1750°C ±2°CS Pt-10%RH/Pt 32 to 3182°F ±3.6°F 0 to 1750°C ±2°CN 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°CRTD PT 100 ohms (JIS) –328 to 752°F ±0.72°F –200 to 400°C ±0.4°C

Linear 4 - 20 mA –1999 to 9999 ±0.05% –1999 to 9999 ±0.05%Linear 0 - 20 mA -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%Linear 0 - 1 VDC -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%Linear 0 - 5 VDC -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%Linear 1 - 5 VDC -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%Linear 0 - 10 VDC -1999 to 9999 ±0.05% -1999 to 9999 ±0.05%

Maximum Temperature Ranges:

Chromel® and Alumel® are Registered Trademarks of Hoskins Manufacturing Company.

NOTE: If a low voltage power source is used, place a number ”3” beforethe Signal Input for 20-32VAC/VDC operation.

Communications1 None2 RS-4853 Retransmission4 RS-232C

NON-VOLATILE MEMORYRetains process parameters when power is off

EXTERNAL LOCKOUT CODE• Prevents accidental or

unauthorized changes

PROCESS DISPLAY• Process display updated 5

times per second• Menu and error codes

STATUS INDICATORS• Output and alarm condition

3 PUSHBUTTONS• For ease of control set-up

AUTOMATIC TUNING• Eliminates complicated and

time consuming manual tuning procedures

• Smarter Logic practically eliminates overshoot and temperature variations

• Universal input

SET VALUE DISPLAY (SV)• All control parameters and

set point displayed• Output Percentage* Calibration parameters

NEMA 4X/IP65 FRONT PANEL• Water and corrosion resistant

Line Voltage: 90-264VAC, 50-60Hz,20-32VAC/DC optional

Consumption: Less than 5VA.Input: Thermocouple Type: J, K, T,

E, B, R, S, NRTD 2 or 3 wire PT-100DIN @ = .00385 orJIS @ = .00392 0 – 10VDC, 0 - 20mA

Linear Voltage Input Impedance: 100k ohmsCold Junction Compensation: .1C/C ambient typicalSensor Break Protection: Operator selectableExternal Resistance: 100 ohms max.Sample Rate: 5 samples per secondAccuracy: ±.1%, ±least significant digitNormal Mode Rejection: 60dbCommon Mode Rejection: 120dbOperating Ambient for

Rated Accuracy: 14 - 120°F (-10 - 50°C)Storage Temperature: -4 - 160°F (-20 - 70°C)Humidity: 5 - 90% RH (non-condensing)Insulation: 20M ohms min. (500VDC)Breakdown: 2000V (AC), 50/60Hz,

1 minuteShock: 200m/s2 (20g)Weight: 4 oz. (110 grams)EMC Emission: EN50081-1, EN61326,

(EN55011 class B, EN61000-3-2, EN61000-3-3)

EMC Immunity: EN50082-2, EN61326(EN61000-4-2, EN61000-4-3,EN61000-4-4, EN61000-4-5,EN61000-4-6, EN61000-4-11)

Section 3: SPECIFICATIONS

Dimensions: Front Panel H - 17⁄8” (48mm)W - 17⁄8”(48mm)

D - 33⁄8” (86mm)Depth Behind Panel:27⁄8” (73mm)

Panel Cutout: 125⁄32” x 125⁄32” (45 x 45mm)Proportional Band: 0 - 360°F (0 - 200°C)Integral (Reset): 0 - 3600 secondsDerivative (Rate): 0 - 1000 secondsRamp Rate: 0- 99.99°F (0 - 55.55°C)

/minuteDwell: 0 - 9999 minutesOn-Off: Adjustable hysteresisProportional Cycle Time: 0 - 99 seconds°F/°C: External keypad selectableLinearization: Software drivenOutputs: Heating (and cooling) or

alarmsOutput Modules:

–Current Output: 4-20mA isolated, max. load 500 ohms

–Voltage Output: 0 - 10V isolated, minimum impedance 500K ohms

–Pulsed Voltage: 24VDC, unisolated Max. current 20mA

–Relay: 3A/240V, resistive load for heating, 2A/240V, resistive load for alarm

Control Actions: Heating (relay closed on temperature rise) or cooling (relay open on temperature rise) front panel selectable

RISK OF ELECTRIC SHOCK - Dangerous and poten-tially fatal voltages are present when working on thisequipment. Before installation or beginning any trou-bleshooting procedures, the electric power to this equip-ment must be disconnected and locked out as describedby OSHA Standards. Units suspected of being faultymust be removed and returned to Ogden for inspectionand/or repair. They contain no user serviceable compo-nents.

To help minimize the possibility of fire or shock hazards,do not expose this instrument to rain or excessivemoisture. This control is not to be used in hazardouslocations as defined in Articles 500 and 505 of theNational Electric Code.

Do not use this instrument in areas subject tohazardous conditions such as excessive shock,vibration, dirt, moisture, corrosive gases or oil. Theambient temperature of the areas should not exceedthe maximum rating specified in Section 3, on previouspage.

Unpacking:Upon receipt of the shipment remove the instrumentfrom the carton and inspect the unit for shipping dam-age. If any damage due to transit is noticed, report andfile a claim with the carrier. Write down the model num-ber, serial number, and date code for future referencewhen corresponding with our service center. The serialnumber (S/N) and date code (D/C) are located insidethe control.

Mounting:Make panel cutout to dimensions shown below right.Insert the controller into the panel cutout. The maxi-mum panel thickness is 1⁄8" (3.2mm).

Wiring Precautions:• Before wiring, verify the label for correct model num-

ber and options. • Care must be taken to ensure that maximum voltage

ratings specified in Section 3 on previous page arenot exceeded.

• It is recommended that power to these instrumentsbe protected by fuses or circuit breakers rated at theminimum value possible.

• All units should be installed inside a suitably ground-ed metal enclosure to prevent live parts being acces-sible to human hands and metal tools.

• All wiring must conform to appropriate standards ofgood practice, national and local codes andregulations. Wiring must be suitable for the maximumvoltage, current, and temperature ratings expected inthe system.

• Only “stripped” leads should be used for thermocou-ple connections to prevent compensation andresistance errors.

• Take care 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 theinputs as specified on page 3 are not exceeded.

• Electric power in industrial environments contains acertain amount of noise in the form of transient volt-ages and spikes. This electrical noise can enter andadversely affect the operation of microprocessor-based controls. For this reason we strongly recom-mend the use of shielded thermocouple extensionwire which connects from the sensor to the controller.This wire is a twisted-pair construction with foil wrapand drain wire. The drain wire is to be attached toearth ground at the sensor end only. We carry bothtype J and type K in our stock.

NOTE: The use of motor starters in place of magnetic contactors should be avoided. They have very largeinductive loads that can damage the controller's relay.

Section 4: INSTALLATION

1 25/32"(45mm)

1 25/32"(45mm)

PANEL CUTOUT 2 7/8"(73mm)

3 3/8"(86mm)

Mounting Bracket

2 7/8"(73mm)

3 3/8"(86mm)

Mounting Screws

.080" max. (2.0mm)

1/4" (6.4mm)

20 Ga. Wire

Fig. 4.2 Mounting DiagramFig. 4.1 Lead Termination

Controls are supplied with either a mounting bracket or mounting screws.The mounting screws are to be used in applications that require

NEMA 4X rating.

!

WARNING!

CAUTION!

WARNING!

Power Wiring:Connect terminals as shown in Figure 4.3. The powerswitch S1 and Fuse F1 are included for illustrativepurpose only. Refer to Figures 4.4, 4.5, 4.6, 4.7, 4.8,4.9, and 4.10 on the following pages for sample wiringdiagrams.

Input Wiring:Connect the appropriate sensor to terminals 12, 13, 14,15 or 16 as illustrated in Figure 4.3. Verify that theinstrument is selected for the correct sensor and thecorrect polarity is observed at both the sensor-end andinstrument-end of the cable. Do not run sensor cablesin the same conduit or wiring trough as the power lines,because the low level signal is noise sensitive.When wiring the thermocouple, check the thermocoupleand extension wire (compensating cable) to make surethey conform to the appropriate thermocouple typespecified by the instrument. Extension wires must bethe same alloy and polarity as the thermocouple. Thetotal lead resistance should not exceed 100 ohms foraccurate measurements. One hundred ohms of leadresistance will introduce a 1°F (0.5°C ) error. For wiring 3 wire RTD (Resistance TemperatureDetector) all leads connecting the RTD to the controllermust be the same gauge and material. If the RTD is a3 wire device, install the two common wires of the RTDto terminals 13 and 14. If a 2 wire RTD is to be used,install a jumper between terminals 13 and 14.See page 22 for instructions to re-range the input tovolts, milli-volts or milli-amps.

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

+

+

+

+

–

–

–

0-20mA4-20mA

V0-10V

RTD

AB B

T/C

PTATC–MV–

TC+COM+ mA– V–

MV

90-264VAC

50/60Hz

ALARM 2OUTPUT 2 ALARM 1 OUTPUT 1

PowerInput:

S1

F1

VPulsedVoltage

Current

+

+

–

–

VPulsedVoltage

Current

N L

Relay

(or)Low Voltageon Specific

Models

–

Polarity makes no difference

(or Triac)

OptionalRetransmission

Output.Refer to page 21 for

Instructions.

Figure 4.3 Rear Terminal Connections

Thermocouple Cable American British German French

Type Material ANSIBS DIN NFE

1843 43710 18001

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

TCopper/Constantan

+ white- blue* blue

+ blue- red* blue

+ red- brown* brown

+ yellow- black* black

RS

Platinum/Rhodium+ white- blue* green

+ black- red* green

+ red- white* white

+ yellow- green* green

B Platinum/Rhodium+ grey- red* grey

+ red- grey* grey

Table 4.1 International Thermocouple Cable Color Codes

* Color of overall sheath Chromel® and Alumel® are registered trademarks of Hoskins Mfg. Co.

(Red) – +

T/C

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16OUT 1

Load3 Amp/240VACMax. for Relay.

1A for Triac.

Power Input Hot

Fuse

Neutral

(Red) – +

T/C

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16OUT 1

Power Input

ALM 2 ALM 1

Load3A/240VAC

Max. for Relay.1A for Triac.

Alarms 1 & 2 - 3A/240VAC Max

Hot

Fuse

Neutral Alarm 2 Alarm 1

Figure 4.4Example of wiring connections forETR-9200-1211 Single Relay Output

No Alarms

Figure 4.5Example of wiring connections for

ETR-9200-1221 Heating Outputwith dual alarms

Typical Wiring Diagrams

12 13 14A B B

3-WireRTD Connection

12 13 14A B B


CAUTIONSHOCK

HAZARD

(Red) – +

T/C

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16OUT 1

Power Input

CoolingDevice

2A/240VAC

Max

OUT 2 ALM 1

Load3A/240VAC

Max. for Relay.1A for Triac.

Alarm3A/240VAC maxHot

Fuse

Neutral

(Red) – +

T/C

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16OUT 1

Power Input

ALM 2 ALM 1

o

o o

ooo

ooo

Coil

Three PhaseHeaters

HeaterFuses

ThreePhasePower

Fuse

Alarms 1 & 2 - 3 A/240VAC max

HotNeutral Alarm 2 Alarm 1

Three Pole DPMagneticContactor


ETR-9200-1221 Heating andCooling with alarm

Figure 4.7Example of wiring connections forETR-9200-1221 with three phase

Delta heater loadNOTE: The use of motor starters in place of magnetic contactors should be avoided.

They have very large inductive loads that can damage the controller’s relay.

12 13 14A B B


12 13 14A B B


(Red) – +

T/C

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16OUT 1

Power Input

+ –

ALM 2 ALM 1

Alarm 2 Alarm 1

Alarms 1 & 2 - 3A/240VAC max

1 2

34+

Solid StateRelay

Load

NLHeater Power

Neutral Hot

Fuse

HeaterFuse


ETR-9200-1321 with SSR outputwith dual alarms

(Red) – +

T/C

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16OUT 1

Load3 Amp/240VAC

Max

Power Input

Hot

FuseNeutral

ALM 1ALM 2

Figure 4.9Ramp and Soak

12 13 14A B B


12 13 14A B B


Output Wiring:Four different types of output devices can be used fromoutput one. Relay, current, voltage and pulsed voltageprovide a variety of control applications, Verify that theoutput device is correctly selected to meet yourapplication requirements and make certain the ratingsof the output devices are not exceeded before wiringthe system.

The external connections depend on what type ofoutput is installed. Pulsed voltage output is notisolated from the internal circuits of the instrument.

Sensor PlacementProper sensor placement can eliminate many problemsin a control system. The probe should be placed sothat it can detect any temperature change with minimalthermal lag. In a process that requires fairly constantheat output, the probe should be placed close to theheater. In processes where the heat demand isvariable, the probe should be closer to the work area.Some experimenting with probe location is often

required to find this optimum position.In a liquid process, addition of a stirrer will help toeliminate thermal lag. Since the thermocouple isbasically a point measuring device, placing more thanone thermocouple in parallel will provide an averagetemperature reading and produce better results in mostair heated processes.

Proper sensor type is also a very important factor inobtaining precise measurements. The sensor musthave the correct temperature range to meet theprocess requirements. In special processes the sensormight have to have different requirements such asleak-proof, anti-vibration, antiseptic, etc.

Standard thermocouple sensor limits of error are ± 4degrees F (±2 degrees C) or 0.75% of sensed temper-ature (half that for special) plus drift caused by improp-er protection or over-temperature occurance. Thiserror is far greater than controller error and cannot becorrected at the sensor except by proper selection andreplacement.

(Red) – +

T/C

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16OUT 1

Power Input

ALM 1ALM 2

Load3A/240VAC

Max

Hot

Fuse

Neutral

Alarm, Lights orother Devices

Fig. 4.10Dwell Function

When installation has been completed, the clear protectivefilm can be removed from the faceplate.

12 13 14A B B


TOUCHKEYS FUNCTION DESCRIPTION

Scroll Key Advances the display to the desired parameter.Parameters advance continuously and cyclically by pressing this key.

Up Key 1. Increases the value of a numerical parameter.2. Selects a desired item in the engineering level.

Down Key1. Decreases the value of a numerical parameter. 2. Selects a desired item in the engineering level.

To change the parameter, tap the or key quickly. This will brighten the individual digit of the display. Once the desired digit is brighter, simply hold down the or key to increase or decrease the value.

PressLong Scroll/ 1. Selects the parameters in higher security level.

longer than 4 Enter Key 2. Actuates the selected program when in engineering level.

seconds

Reverse Scroll/ 1. Selects the parameters in a reverse direction during parameter

Press and Calibration scrolling.

Verification Key 2. Verifies the display accuracy for various input types during calibration.

Press andDisables keypad operation to protect all parameters from being

longer than 4 Lock Keytampered with.

seconds

Press andEngineering Selects the Engineering level. Scrolls through the Engineering Programs.Level Key

1. Resets the control to its normal status.

Press andReset (Exit) Key 2. Unlocks keypad operation.

Unlock Key 3. Exits the engineering level program.4. Stops the Autotuning function.

Press andlonger than 4 Autotune Key Starts the Autotune function.

seconds

ETR-9200 TOUCH KEY DESCRIPTIONS:To move from one level of parameters toanother. Scroll to the end of the level. Holddown the key, the display will flash, oncethe display stops flashing, release the key.

To return from any parameter to the processand set point values, press the andkeys simultaneously.

SCROLL KEY

UP KEY

SETPOINTVALUE

Section 5: OPERATION

Table 5.1 Keypad Operation

DEGREES COR FINDICATORS

PROCESS VALUEALARM OUTPUT

INDICATORS

CONTROLOUTPUT

PROCESSVALUE

DOWNKEY

PROCESS VALUESET POINT VALUE

SecurityLevel 2

Security Level 1

SecurityLevel 0

Hold until displaystops strobing (4 seconds)

Hold until displaystops strobing (4 seconds)

Table 5.2 Control Functionand Display Flow Chart

(OPERATOR LEVEL)

Engineering Level can be entered at any time by pressing theand keys.

NOTE: Control will return to ProcessValue in 25 seconds if no entry is made.

Short Scroll returns to PV/SV

Short Scroll advances step by step through parameters in forward direction

Short Scroll advances step by step through parameters in forward direction

Short Scroll advances step by step through parameters inforward direction


(See page 14.)


Views parameters step by step in reverse order

Exits parameters and returnsto process and set point values.

1) 9200/ /Software Version displayed for 4 seconds.

2) LED check/all LED segments lit for 4 seconds

POWER APPLIED:

SecurityLevels Display Code: Description: Adjusting Range:

SV Set point Value of Control

Alarm 1 Set Point Value. Dwell Time

Ramp Rate

Offset Value for Manual Reset(Integral Time TI = 0)

Alarm 2 Set Point Value

Display Shift

Proportional Band of Output 1

Integral (Reset) Time of Output 1

Derivitive (Rate) Time of Output 1

Hysteresis of Alarm 1

Hysteresis of Alarm 2

Hysteresis of ON-OFF control

Low Scale of Range. Adjust foryour process

High Scale of Range. Adjust foryour process

Power Limit of Output 1

Power Limit of Output 2

Input Type Selection

Display Units

Resolution

Control Action of Output 1

Alarm 1 Mode

Alarm 1 Special Function

Alarm 2 Mode

Alarm 2 Special Function

Proportional Cycle Time of Output 1

Cooling Cycle Time

Cooling P Band

Dead Band for pB and CPB

Low scale to high scale value

Trip Point within High/Low scale or 0 - 9999 minutes (for Dwell Time)

0 - 99.99°F/minute (0 - 55.55°C/minute)

0 - 100%Only functional if Integral is set to 0.

Trip Point within High/Low scale

-199° to 199°F (-111 - 111°C) (Refer to page 21)

0 - 360°F (0-200.0 °C)O: for ON-OFF control (Refer to Page 17)

0 - 3600 seconds

0 - 1000 seconds

0 - 19°F (0 - 11 °C)

0 - 19°F (1 - 11 °C)

0 - 19°F (1 - 11 °C)

0 - 40

Minimum value for the selected Input (INPT) to High Scale (HISC)

Low Scale (LOSC) to maximum value for the selected Input (INPT)

0 - 100%

0 - 100%

= J Type T/C

= E Type T/C

= S Type T/C= PT100 JIS0 - 1V = 1 - 5V

= K Type T/C= B Type T/C

= N Type T/C= 4-20 mA= 0-5V

T Type T/CR Type T/C

PT100 DIN

= 0-20 mA

0 - 10V

= degree C = degree F = process units (Engineering Units)

= No decimal point used= 2 Digit decimal (only for Linear Voltage or Current Input)

= 1 Digit decimal

= Direct (Cooling) Action = Reverse (Heating) Action

0

= Deviation High Alarm= Deviation Band High Alarm= Full Scale High Alarm

= Deviation Low Alarm= Deviation Band Low Alarm= Full Scale Low Alrm

= No Special Function= Alarm with Hold Function= Dwell Timer ON as Time Out

= Alarm with Latch Function= Alarm with Latch & Hold Function= Dwell Timer OFF as Time Out

Same as Alarm Mode 1

= No Special Function= Alarm w/Hold

= Alarm w/Latch = Alarm w/Latch & Hold

0 - 99 Seconds, 0 for Linear current/voltage output

0 - 99 Seconds, 0 for Linear current/voltage output

0 - 360°F (0 - 200°C)

-199 - 199°F (-111 - 111°C)

1

2

DefaultSetting:

18°F(10°C)

0.00

0.0

18°F(10°C)

18°F(10.0°C)

120

40

0

0

0

0

100%

100%

20For Relay Output

20For Relay Output

0

= Output 2 cooling

= or /Minutes

0

0

999

18°F(10.0°C)

212

Interface Address

Table 5.3 Index Code (Menu) Descriptions (OPERATOR LEVEL)

Long Scroll For convenience, parameters can be recorded on the next page.

SET POINT VALUE

ALARM SET POINT 1

SV

RAMP RATE

OFFSET

ALARM SET POINT 2

DISPLAY SHIFT

PROPORTIONAL BAND/HEAT

INTEGRAL TIME

DERIVATIVE TIME

HYSTERESIS ALARM 1

HYSTERESIS ALARM 2

HYSTERESIS ON/OFF

ADDRESS

LOW LIMIT OF RANGE

HIGH LIMIT OF RANGE

POWER LIMIT OUTPUT 1

POWER LIMIT OUTPUT 2

INPUT TYPE

UNIT TYPE

RESOLUTION

CONTROL ACTION

ALARM MODE 1

ALARM 1 SPECIAL FUNCTION

ALARM MODE 2

ALARM 2 SPECIAL FUNCTION

PROPORTIONAL CYCLE TIME

COOLING CYCLE TIME

COOLING PROPORTIONAL BAND

DEADBAND

CONTROL NO.

PARAMETER

DATE

Table 5.4 Parameter Record Sheet (OPERATOR LEVEL)

Long Scroll

Table 5.5 Engineering LevelThe engineering level can be entered at any time bypressing the keys. This level contains sixparameters for control configuration and options. Theparameters are defined as:

Manual Mode (hand control) – This feature is used ifthe sensor fails. The control can now be used as anon-off proportional timer to control the load until a newsensor can be installed. The setting for heating or cool-ing is 0 - 100% of the proportional cycle time.

Peak Process Values – The minimum and maximumpeak values of the process are indicated here.

Calibrate A-D Converter – This parameter is usedduring the calibration procedure.

Fail Safe – This defines the status of the outputs if thesensor fails.

Lock Parameters – Levels 0, 1 or 2 in the operatorslevel can be locked-out to prevent unauthorizedtampering.

Configuration Level – This feature allows parametersto change levels (0, 1 or 2) in the operators level. Thepurpose of this is to allow only selected parameters tobe adjustable and all the others to be locked-out. Forexample, if only the set point is to remain un-locked, allthe other parameters in level 0 can be moved to level 1.Then lock out level 1 and 2.

Press the keys to exit the engineering level.

Manual Mode(hand control). Used ifsensor fails.

Peak Process Value. Stored minimum andmaximum values.

CalibrateA-D Converter

Indicates the percentage power of output 1. (Heating)

Long

Long

Indicates the percentage power of output 2. (Cooling)

or

Indicates the maximum (peak) process value.

Indicates the minimum (peak) process value.

or

or

or

Adjusts the Cold junction compensation code.(Range -19.9 to 42.7)

Adjusts the Drift compensation code.(Range -6.6 to 6.6)

The percentage of on-time for output 1 can be adjusted by using the keys. Range: 0 - 100%

(Not functional with ETR-9200)

Long

LongResets the maximum process value.

Resets the minimum process value.

Long

Long

Long

Calibrate the A-D converter and enterthe Cold-Junction compensation code.

Calibrate the 0 � 4-20mA and enter it.

Enter the drift compensation code

(Also note the calibration procedure on page 23.)

(Continued on next page)

(Engineering Level continued)

Parameter levels can belocked-out to preventunauthorized tampering.

ConfigureSecurity levels(Parameters can be moved from onelevel to another)

: Security LEVEL.

: Places the parameter in LEVEL 0.



= 0

= 1

= 2

FAIL SAFE

Long

Long

Long

Long

or

or

or

or

Select the status for Output 1. : Output 1 ON * : Output 1 OFF

or

or

or

or

or

Changes the value of security level of theselected parameter.


Displays the rest of the parameters accordingto the standard sequence.


Enters the selection.



or

Enters the updated security level of ASP1.

Enters the updated security level of RAMP.

Enters the updated security level of DB.

Defines the status of the outputs if the sensor fails.

Select the status for Alarm 1.* : Alarm 1 ON : Alarm 1 OFF

Select the status for Alarm 2.* : Alarm 2 ON : Alarm 2 OFF

Select the status for Output 2.* : Output 2 ON : Output 2 OFF

Select Lock or Free for operator Security Level 0. Locks all the level 0 parameters.* : Allows all the Level 0 parameters to be adjustable.

Select Lock or Free for operator Security Level 1. : Locks all the level 1 parameters.* : Allows all the Level 1 parameters to be adjustable.

Select Lock or Free for operator Security Level 2. : Locks all the level 2 parameters.* : Allows all the Level 2 parameters to be adjustable.

Long

Long

Long

*Default Setting

(Not functional with ETR-9200)




Long

Long

Long

Press the keys to exit the engineering level.

Operator Level Parameter Definitions: PV - Process Value This is the temperature (or otherprocess variable) as measured at the sensor. This willindicate a value within the range between the low scale(Lo.SC) and high scale value (hi.SC). This indicationwill read an error code if the temperature (processvariable) goes out of the preset span. Note items 6 and7 of the troubleshooting guide on page 25 for the errorcode descriptions.SV - Set Point Value This parameter is the desired setpoint of the process. It can be adjusted within therange defined by the low scale (Lo.SC) and high scalevalue (hi.SC). The span adjustments can be used tolimit the set point of the controller.ASP1 - Alarm 1 Set Point Value or Dwell Time Thissets the points at which alarm 1 will energize if A1.SF(alarm 1 special function) is set for an alarm function.If A1.SF is selected for the dwell timer function (toon ortoof), then this becomes the timer setting in minutes.The dwell timer starts counting when the process valuereaches the set point value. Note page 20 for moreinformation.rAMP - Ramp Rate This controls the heat-up andcool-down rate of the process. This setting is indegrees per minute.oFSE - Offset Value This parameter is only functionalif the integral time (automatic reset) is set to zero. TheoFSE then functions the same as manual reset tocorrect the process temperature to the set point temper-ature. If the process temperature stabilizes below theset point, then set a positive amount of oFSE. If theprocess temperature stabilizes above the set point, seta negative amount of oFSE. Wait for the system tostabilize and make further adjustments as required.ASP2 - Alarm 2 Set Point Value This sets the pointsat which alarm 2 will energize if A2.SF (alarm 2 specialfunction) is set for an alarm function. If A2.SF isselected for cooling; the cooling cycle time, proportionalband and deadband are adjusted by parameters CCyC,C.pb and d-b. ASP2 will then have no effect. Notepage 20 for more information.ShiF - Display Shift A value entered here will beadded or subtracted from the process value. This offsetcan be used as a correction factor if the sensor doesnot read the same temperature as the item beingsensed. Note page 21 for more information.Pb, Ei and Ed - PID Values Proportional band,Integral (reset) and Derivative (rate) time constants.These must be set as close as possible to the processapplication requirements. Note page 17 for moreinformation.AhY1, AhY2 - Hysteresis of Alarm 1 and Alarm 2The values entered here define the deadbands for thealarms. The alarms will not change state until thetemperature is outside of the deadband.hySE - Hysteresis of On-Off Control This parameterdefines the deadband when on-off control is used andPID control has been disabled. For on-off control, set

Pb, Ei and Ed to 0. The output on a relay control willnot change state until the temperature is outside thedeadband. Note page 17 for further information.Addr - Interface Address For external communica-tions with a computer. Lo.SC, hi.SC - Low/High Scale Range Theseparameters are used to define the range (span) of thecontrol. These should be set for the requirements andsafety of your process. Refer to "Initial Operation" onpage 17 for further information. If inputs other thanthermocouples or RTDs are required, refer to page 22for reranging directions.PL.1, PL.2 - Power Limit These parameters are usedto limit the output percentage of power for heating orcooling. If the control has relay or pulsed voltageoutputs, then the percentage of “on” time will bedecreased. The actual output levels will be decreasedif the control has linear current (4-20mA) or linearvoltage outputs.inPE - Input Type This parameter is used to programthe control to the type of input sensor used.uniE - Process Units This parameter is used to setthe display in degrees F, C or blank for engineeringunits.rESo - Display Resolution This parameter is used toplace a decimal point in the process and set pointvalues. A two-place decimal point can only be set if theuniE adjustment is set to engineering units (PU).Con.A - Control Action of Output 1 This parameterselects heating (reverse) or cooling (direct) action foroutput 1.A1.Md, A2.Md - Alarm Mode Selection for Alarm 1and Alarm 2 This adjustment sets the type of alarmrequired: deviation alarm, band alarm or process alarm.Refer to page 20 for more information.A1.SF - Alarm 1 Special Function This selectsspecial functions required for use with alarm 1. Thespecial functions include latching alarms, hold(inhibited) function or dwell timer function. Refer topage 20 for more information on alarms.A2.SF - Alarm 2 Special Function This selects spe-cial functions for alarm 2. This includes latching func-tion, hold (inhibited) function or proportional cooling.CyC - Proportional Cycle Time of Output 1 This setsthe proportional cycle time for output 1. This should beset according to the type of output device used. Formechanical relays, cycle times of 15 to 20 seconds areused. For solid-state relays, set this adjustment to 1 or0. For 4-20mA or other linear outputs set this to 0.CCyC - Cooling Cycle Time Only used if A2.SF(alarm 2 special function) has been set for cooling. Usethe same settings as the above paragraph.C.Pb, d-b Cooling Proportional Band, CoolingDeadband Only used if A2.SF (alarm 2 specialfunction) has been set for cooling. Refer to page 22 forfurther information on the settings to be used for coolingoutput.

Initial Operation:When the control has been wired you can apply power.The display should indicate the model number, softwareversion and LED lamp illumination test. Thetemperature (or other process variable) as measured atthe sensor should be indicated by the PV display. Thethermocouple is wired in reverse if the indicatedtemperature decreases as the temperature at thethermocouple increases. While making initial settingsto configure the control, the set point should be loweredto a value (eg. 30°F) to assure the heaters will not beenergized. This will allow time to make any adjust-ments of the parameters in the operators or engineeringlevel.During this initial set-up, alarm points and other settingscan be made. The low limit and high limit range set-tings (Lo.SC) and (hi.SC) should be adjusted to yourprocess. This sets the range (span) of the control. Theset point cannot be adjusted out of this range.Generally, for plastics processing and packaging, aspan of 0 - 800°F is common. If oils are used, a lowerspan such as 0 -300°F should be entered.When the configuration settings have been made, youcan return to the PV/SV level. Adjust the requiredprocess set point. The red “out” lamp should illuminate,indicating the heaters have been powered.

Autotuning:The autotune function “teaches” the controller the maincharacteristics of the process. It “learns” by cycling theoutput on and off. The process will oscillate around theset point during autotuning. Note the diagram below:Adjust the set point to a lower value if overshootbeyond the normal process value may cause damage.The results are measured and used to calculate theoptimum PID values. It should not have to be repeatedon the same process. The autotune function starts by

depressing the and keys for 4 seconds; thenrelease. The process value display will flash on and offindicating the control is in the autotune mode. No otheradjustments can be made to the system while the con-trol is autotuning. The control will finish autotuning byitself and the correct PID values will be entered into thecontrol’s memory.Autotuning will not function if the control has been con-figured from PID to ON-OFF. For electric heating PID isusually recommended.Autotuning may not give satisfactory results and hold aclose temperature on all applications. If this occurs,you can change the PID values manually using thethree charts in Figure 5.2 on the top of the next pagefor a guide. It is recommended to change only oneparameter at a time, so the results of that change canbe clearly noted.

Adjusting PID Parameters:The PID parameters can be reviewed by operating thescroll key and noting whether the values are reasonableor not. Examine the controller’s result. Modify the PIDvalues until the control quality is acceptable.

ON-OFF Control:On-off control action is recommended when continuouscycling of the load cannot be used. Examples aremechanical solenoids, large contactors and valves. Foron-off control, set the following parameters to zero:proportional band; integral; derivative and offset (oFSE).The hysteresis (hySE) adjustment is now used to setthe deadband. The larger the hysteresis is set, thelarger the deadband will be. A large deadband willcause the contactor (or other device) to switch lessoften, but the process will oscillate farther from the setpoint. This setting is measured in degrees.

Initial PeriodProcess Oscillates

Verifying periodPID Control Smarter Logic + PID

Set PointValue

PB, TI, TDObtained

Autotune FinishedoFSE Value

Obtained

TE

MP

ER

AT

UR

E

TIME

Process Value

Figure 5.1 Autotuning

The proportional band ( ) adjustment is a percentage ofSPAN or RANGE value.

Integral action (automatic reset) corrects for offset (loaderror) for load variations. Reset wind-up inhibition preventsintegral action from occurring outside of the proportionalband. Software antisaturation minimizes process oscilla-tions when the load changes.

Derivative action is adjusted to match the response time ofthe process and to compensate the integral action.Correct adjustment provides power output compensationfor process load variations. It also minimizes overshootand oscillations at start up or in large process upsets.Refer to Figure 5.1 for additional adjustment instructions.

Manual Tuning Procedures:For some systems it is difficult to execute automatic tuningor the automatic tuning results are not satisfactory. Thefollowing steps can then be used for initial tuning of athree-mode control:Step 1: Adjust the integral and derivative values to 0. This

inhibits the rate and reset action.Step 2: Set an arbitrary value of proportional band and

monitor the control results.Step 3: If the original setting introduces a large process

oscillation then gradually increase the proportionalband until the oscillation disappears.

Step 4: If the original setting does not introduce process

oscillations then gradually decrease the propor-tional band until steady cycling is observed.Record this important proportional band percent-age (Pc).

Step 5: Time the period of steady cycling. Record this crit-ical period Tc. The PID parameters are deter-mined as:

This method was developed by Ziegler and Nichols.

If you are unfamiliar with tuning PID Controllers, we sug-gest that you obtain and become familiar with the followingreference material: Tuning of Indusrial Control Systemsby A.R. Corripio ISBA: 1-55617-253-20. Available from:ISA Publications and Training Aids, Phone: 919-549-8411.

This method should be performed with a temperaturechart recorder.

Fig. 5.2 Steady State CyclingTIME

PV (Process value)

PV

Tc

P Band (Pb) = 1.7 PcIntegral Time (ti) = TcDerivative Time (td) = 0.125 Tc

PVUPPER PB

SET POINT

LOWER PB

PIPID

PD P

OFFSETPROPORTIONALBAND

TIME

Perfect

Proportional Band Too Low

Proportional Band Too High

SP

PV

TIME

PROPORTIONAL ACTION

Derivative Too High

Perfect

Derivative Too Low

TIME

SP

PV

DERIVATIVE ACTIONINTEGRAL ACTION

PV

SP

Integral Too High (Too long for recovery)

Perfect

Integral Too Low

TIME

FIG 5.1 Effects of PID Adjustment on Process Response

Fig. 5.3 Response of a Typical Control System Using Various Modes of Control

The proportional band (Pb) is a temperature bandexpressed in degrees. When the process temperature iswithin this band, the time proportioning function isactive.

TE

MP

ER

AT

UR

E

Intergal action (automatic reset) corrects for offset (loaderror) for load variations. Anti-reset wind-up inhibitionprevents integral action from occuring outside of the pro-portinal band. Software antisaturation minimizes processoscillation when the load changes

Fig. 5.3 Steady State Cycling

Fig. 5.4 Response of a Typical Control Ststem Using Various Modes of Control

Fig. 5.2 Effects of PID Adjustment of Process Response

This method was developed by Ziegler and Nichols.

If you are unfamiliar with tuning PID Controllers, we sug-gest that you obtain and become familiar with the followingreference material: Tuning of Industrial Control Systemsby A.R. Corripio ISBN: 1-55617-253-2-Q. Available from:ISA Publications and Training Aids, Phone: 919-549-8411.

This method should be performed with a temperature chartrecorder.

PID Control (Proportional, Integral, Derivative):For various applications the controller can be used as Pcontrol only (set integral = 0, derivative = 0); PI control (setderivative = 0), PD control (set integral = 0), and PIDcontrol.Figure 5.4, on page 18, represents the response of atypical control system using various modes of control.1.) P control results in a response showing a deviation

(offset), a high overshoot and a moderate period ofoscillation. In addition, a significant length of time isrequired before the system ceases to oscillate.

2.) PI control has no offset, but elimination of offset comesat the expense of higher overshoot, larger period ofoscillation and a longer time required for oscillations tocease compared with other modes of control.

3.) PD control generally brings the system to steady statein the shortest time with the least oscillation. However,it still has offset.

4.) PID control is essentially a compromise between theadvantages of PI and PD control. Offset is eliminatedby the integral action. The derivative action serves tolower offshoot and to eliminate some of the oscillationsrealized with PI control.

Ramp and Soak Function:The ETR-9200 can be programmed as a two segmentramp and soak control. The ramp rate, in degrees perminute, is determined by the “ “ setting. The soakfunction is accomplished by configuring alarm 1 relay as atimer. The heater (or contactor coil) must be wired inseries through the alarm 1 relay and the “out 1” relay.Refer to wiring diagram figure 4.9 on page 8. To use this

feature, set A1.SF (alarm 1 special function) to . Setthe soak period at ASP1 (alarm 1 set point). The alarmrelay will be closed at start-up. It will remain closed untilthe process temperature has remained at the set pointtemperature for the time period (minutes) set in ASP1.Note the following example: The ramp rate is set to 20(degrees per minute), A1.SF is set to and ASP1 to30 (minutes). When the control is powered, the processwill climb at 20 degrees per minute to the set point of475°F. Once the set point temperature has been reached,the soak timer begins counting. After a time period of 30minutes has elapsed, the alarm relay 1 will open and theprocess temperature falls at an uncontrolled rate. Thisprocess will repeat every time power has been switchedoff and on to the controller. Note diagram 1 below.

Single Event (Dwell) Function:The single event (dwell) function may be used to controlexternal devices such as lights, bells or locks. It couldalso be used to alert the operator when a guaranteedsoak time has been reached. To use this feature, setASP1 (alarm 1 set point) to the time period (in minutes) ofthe timer. Set A1.SF (alarm 1 special function) to .The alarm 1 relay will now operate as a timer. Refer towiring diagram figure 4.10 on page 9. The alarm 1 relaywill be open at start-up. Once the set point temperaturehas been reached and the time period set in ASP1 haselapsed, the alarm 1 relay will close. This relay willremain closed until power to the control has been discon-nected. The cycle will repeat each time the control hasbeen energized. Other features such as ramp rate andalarm 2 can also be used. Note diagram 2 below. Theset point is 175°F and the dwell time has been set to 30minutes.

Table 5.6 Tuning Guide

ADJUSTMENT SEQUENCE: SYMPTOM: SOLUTION:1.) Proportional Band Slow Response Decrease P Band (Pb)

High Overshoot or Oscillations Increase P Band (Pb)2.) Integral Time (Reset) Slow Response Increase Reset (i.e. Decrease Integral Time)

Instability or Oscillations Decrease Reset (i.e. Increase Integral Time)3.) Derivative Time (Rate) Slow Response or Oscillations Decrease Rate (i.e. Decrease Derivative Time)

High Overshoot Increase Rate (i.e. Increase Derivative Time)

475

400

300

10075

0 20 40 60 80 90

°F

30 Minutes

Alarm Relay

OFF

TIME/Minutes

10 30 50 70

ON

Process Value

= 20

=

200

SET POINT = 475°F 175

150

125

100

75

0 20 40 60 80 90

°F

30 Minutes Alarm Relay

OFF

TIME/Minutes

10 30 50 70

ON

Process Value

Set point

=

Diagram 1: Ramp and Soak Diagram 2: Single Event

SV + ASP1 (2)

DEVIATIONHIGH ALARM

DEVIATIONLOW ALARM

SV

DEVIATIONIN-BAND ALARM

DEVIATIONOUT-BAND

ALARM

PROCESSLOW ALARM

PROCESSHIGH ALARM

SV - ASP1 (2)

SV + ASP1 (2)

SV - ASP1 (2)

SV - ASP1 (2)

SV

SVSV

SV + ASP1 (2)

ASP1 (2)

ASP1 (2)

( )

( )( )

( )( )

( )

Alarm Modes:There are two independent alarms available. The alarm modes are selected by designating the alarm types with theparameter: and . The alarm special functions ( and )can be implemented together withthe and modes that are selected.

• Latch Alarm: A1.SF (A2.SF) =When the latch mode is selected, the alarm will stay active until the power is reset.

• Inhibited Alarm: A1.SF (A2.SF) = This mode prevents an alarm at start up. The alarm is enabled only when the Process Value reaches the Set Point (SV).

• Latch and Inhibited Alarm: A1.SF (A2.SF) = When selected, the alarm will stay active until the power is reset. The alarm mode is only enabled when the Process Value reached the Set Point Value (SV).

• Cooling: A2.SF =Alarm 2 can be designated as a cooling output if heating and cooling operation is desired.

• Hysteresis (AHY1) EXAMPLE: No special function used with (SV) Deviation High Alarm.

SV = 100°F ASPI = 10°F AHY1 = 4°F

: Alarm ONSV = SETPOINT VALUE

= Alarm 1 Set Point = Alarm 2 Set Point

• ALARM SPECIAL FUNCTIONS: A1.SF (A2.SF)

SV + ASP1 = 100°F

112°F

108°F

= Alarm 1 Mode= Alarm 2 Mode

• Alarm Set Point Ranges– Low scale � High scale (Full scale Alarms)– -199 - 199°F (-111 - 111°C) Deviation alarms– 0-9999 minutes for (A1.SF = toon or toof) Dwell

Time

Table 5.7

DIRECTIONS FOR USING RETRANSMISSION (TRANSFER) OUTPUT:

The retransmission output of 4-20mA uses terminals #9 and 10. Terminal 9 is positive (+) and 10 is negative (—).

The interface parameter (Addr) is used to select which value is retransmitted. The possible selections are as follows:

Set the span of the control, low scale (Lo.SC) and high scale (hi.SC) to set the span of the retransmitted output.

FOR EXAMPLE: 0-1000, SPAN Lo.SC set to 0 and hi.SC set to 1000 would transmit 4MA AT 0 and 20MA at 1000.

Display ShiftIn certain applications it is desirable to shift the con-trollers indicated value from its actual value. This can beeasily accomplished with this control by using the dis-play shift function. Cycle the control to the para-meter by using the “Scroll” pushbutton. The number youadjust here, either positive or negative, will be theamount that the process value (PV) will be shifted fromthe actual value. This amount will be the same acrossthe entire range of the control. Note the example statedbelow.The desired temperature at the part to be heated is 330degrees F. In order to achieve that temperature, thecontrolled value or the temperature at the sensor mustbe 375 degrees F. Due to the design and position of thecomponents of the system, the sensor could not beplaced any closer to the work.

Thermal gradients (different temperatures) are commonand necessary to an extent in any thermal system forheat to be transferred from one point to another.The difference between the two temperatures is 45degrees F. You should input –45 as to subtract 45degrees from the actual process value (PV). Cycle the control back to the process value after makingthis adjustment.The display shift will alter the process value (PV) only.The set point must be manually adjusted to 330.

DISPLAY AFTER INPUT SHIFT.ADJUST SV TO 330

Figure 5.5 Display ShiftHEAT SOURCE

HEAT TRANSFERMEDIUM

SENSOR375°F

PART BEING HEATEDOR "WORK" 330°F

MOLD

DISPLAY AFTER INPUT SHIFTAND SV ADJUSTMENT

DISPLAY BEFOREINPUT SHIFT

192 Retransmit Process Value, 4-20mA193 Retransmit Set Point Value, 4-20mA194 Retransmit Alarm Value 1, 4-20mA195 Retransmit Alarm Value 2, 4-20mA

196 Retransmit Process Va,ue, 0-20mA197 Retransmit Set Point Value, 0-20mA198 Retransmit Alarm Value 1, 0-20mA199 Retransmit Alarm Value 2, 0-20mA

Cooling Deadband Adjustment:

This adjustment is used on the ETR-9200 to set the point at which the cooling set point is made. The heatingproportional band, cooling proportional band and deadband are described in the following chart. Please note thatAlarm 2 Special Function (A2.SF) must be set to cool.

90%80%70%60%50%40%30%20%

5%

A B C DPb C.Pbd-bSP

180°F 200°F 205°F 215°F

100%

ProcessValue

HEATING

OUTPUT PERCENTAGE

COOLING

An example of the settings of a typical system may be:Set Point = 200°FPb = 20°FC.Pb = 10°Fd-b = 5°F

Figure 5.6 Deadband Adjustment

The points on the chart are:A = SP - PbB = SPC = SP + d-b D = SP + d-b + C.Pb

SP = Set Point (SV)Pb = Heating Proportional Bandd-b = DeadbandC.Pb = Cooling Proportional Band

In this example the points on the chart would be:A = 180°F SP - Pb = 200 - 20 = 180B = 200°F SPC = 205°F SP + d-b = 200 + 5 = 205 D = 215°F SP + d-b + C.Pb = 200 + 5 + 10 = 215

Increasing the deadband (d-b) setting will increase the span between the heating and cooling set points. The rangeof this adjustment is from -199 - 199°F (-111 - 111°C).

Re-ranging for Linear Process Inputs:Select the type of input you wish to use from the(input type) list in the operators menu on page 12. Thiswould correspond to the output of the sensor or trans-mitter you are using. If the front display is to read inengineering units instead of temperature and if twodecimal places are required, then change the(display units) setting to (process units). In thissetting, the “F” and “C” indicators on the control’s facewill not illuminate. Define the control’s range by adjust-ing the low scale ( ) and high scale ( ) set-ting. Note the following example:The input type has been set to 4-20mA and the spanhas been set to read 0-100. At 12mA input, the process

value will read 50. If the input signal goes beyond therange of the low and high limit, an error message (or ) will be shown in the upper display. Note thecorrect input terminals on page 5 to use for the varioustypes of sensors and transmitters.

4 20

PV

100.0( )

0( )

INPUT SIGNAL (MA)

LLEr HHEr

Section 6: CALIBRATION PROCEDURE

Do not attempt to recalibrate unlessyou are absolutely sure that the con-

trol needs to be recalibrated and that the properequipment is available. Once this is preformed, allother calibration information will be lost!

WARNING!

Equipment Needed:1) Standard millivolt power source range 0-

100mV, accuracy ±0.01%2) Standard voltage power source range 0-10V,

accuracy ±0.01%3) Standard current power source range 0-20mA,

accuracy ±0.01%4) Standard ohm source range 0-300 ohm,

accuracy ±0.01%5) Standard thermometer range 0-50.0°C,

accuracy ±0.2°C6) A cooling fan may be needed to keep

equipment cool7) Thermocouple simulator8) Pushbutton switch

Calibration Set-up:1) Select Input type to J T/C, UNIT = C,

RESO = 1dp2) Turn power OFF3) Disconnect all wiring4) Connect wiring as shown below:

5) A fan should be used to keep the cold junction compensator cool. (Lower PCB rear)

+ –

12 13 14 15 16

V

V

– +

ETR-9200

40mV

200 ohm

10V

20mA

SWI

PTA TC-/MV- COM+ MA- V-

CalibrateA-D Converter or

or

or

Adjusts the Cold junction compensation code.(Range -19.9 to 42.7)

Adjusts the Drift compensation code.(Range -6.6 to 6.6)

Long

Long

Long

Calibrate the A-D converter and enterthe Cold-Junction compensation code.

Calibrate the 0 � 4-20mA and enter it.

Enter the drift compensation code

Calibration Steps:1) Enter the “Engineering Level” by pressing the

and keys simultaneously. Continue to pressthese keys until is displayed. (See flow chart below.)2) Press the key to view .3) Use the and keys to enter the room temperature on the upper display in degrees °C. Once the proper room temperature is entered, press the key for 4 seconds. After the key is released, the upper display will strobe, indicating that the new value has been loaded into the memory.4) Press the key to view .5) The upper display should read 0.00. Close SW1. The upper display should now read 20.00. Ifthe value is not 20.00, make sure that the current source is accurate. After a value of 20.00 is dis-played in the upper display, then the key should be pressed for 4 seconds. After the key is released, the upper display will strobe. This indicates that the new value is properly entered intothe controller memory.6) Press the key to view .7) The lower display should be 0.00. If it isn’t, change the value using the and keys. After 0.00 has been obtained, press the key for 4 seconds. When the key is released, the upper dis-play will strobe. This indicates that the new value has been properly entered into the memory. If the value was 0.00, there is no need to load the information into the memory again.8) Remove all connections. Now connect a thermocouple simulator accross terminals 13 and 14 and check calibration (controller must be pow-ered for 30 minutes). If a different input is used, check that input also. If the temperature is incor-rect, perform steps (2) and (3) above.9) If the controller is still not accurate the drift must be adjusted. Enter the Engineering Level and go to

. Press the key until is displayed. Use the and keys to enter the correction factor that will be shown in the lower dis-play. This number will be added or subtracted fromthe upper display. Once the values are correct, press the key for 4 seconds. This will load the new value into the memory. If the value is success-fully entered into the memory, the upper display willstrobe.

ENGINEERING LEVEL

Return control to:OGDEN MANUFACTURING COMPANY

ATTN: REPAIR DEPARTMENT64 WEST SEEGERS ROAD

ARLINGTON HEIGHTS, IL 60005

1) Press latches on each side to remove rear terminal block.

2) To remove PCB assembly from housing, insert twosmall screw drivers between the PCB and housing topand bottom. This will expand the housing and releasethe locking tabs. Then pull the PCB assembly out ofthe housing.

Section 7: TROUBLESHOOTING

THIS PROCEDURE REQUIRES ACCESS TO THE CIRCUITRY OF A LIVE POWER UNIT.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 chart below andTable 7.1 on the next page for some of the other common causes of failures:

WARNING!

Incorrect parameters entered in menu.Excessive electrical interference.Line wires are improperly connected.No voltage between line terminals.Incorrect voltage between line terminals.Connections to terminals are open, missing or loose.Thermocouple (or RTD) is open at tip.Thermocouple (or RTD) lead is broken.Shorted thermocouple (or RTD) leads.

Short across terminals. Open or shorted heater circuit.Open coil in external contactor.Burned out line fuses.Burned out relay inside control.Defective solid-state relays.Defective line switches.Burned out contactor.Defective circuit breakers.

If the points listed on the chart have been checked and the controller does not function, it is suggested that theinstrument be returned for inspection.Do not attempt to make repairs. Also, it is advisable to use adequate packing materials to prevent damage in shipment.

Table 7.1 Troubleshooting

Symptom

1.) LED’s will not light.

2.) Some segments of the display orLED lamps not lit or lit erroneous-ly.

3.) Process Display shows:







10.) Display Unstable

11.) Considerable error in tempera-ture indication.

12.) Display goes in reverse direction(counts down scale as processwarms).

13.) No heat or output

14.) Heat or output stays on but indi-cator reads normal.

15.) Control abnormal or operationincorrect.

16.) Display blinks, entered valueschange by themselves.

Probable Cause(s)

—No power to instrument.

—Power supply defective.

—LED display or LED Lamp defec-tive.

—Related LED driver defective.

—Sensor break error.

—Process value beyond the lowrange setpoint.

—Process value beyond the highrange setpoint.

—Analog hybrid module damage.

—Incorrect operation of auto tuneprocedure. Prop. Band set to 0.

—Manual mode is not allowable foran ON-OFF control system.

—Check sum error, values in memorymay have changed accidentally.

—Analog portion or A-D converterdefective.

—Thermocouple, RTD or sensordefective.

—Intermittent connection of sensorwiring

—Wrong sensor or thermocoupletype. Wrong input mode selected.

—Analog portion A-D converterdefective.

—Reversed input wiring of sensor.

—No heater power (output), incorrectoutput device used.

—Output device defective.

—Open fuse outside of the instru-ment.

—Output device shorted, or powerservice shorted.

—CPU or EEPROM (non-volativememory) defective. Key switchdefective.

—Operation of control incorrect.

—Electromagnetic interference (EMI),or Radio Frequency Interface (RFI).

—EEPROM defective.

Solution(s)

—Check power line connections.

—Replace power supply board.

—Replace LED display or LED lamp.

—Replace the related transistor or ICchip.

—Replace RTD or sensor.—Use manual mode operation.

—Re-adjust value.

—Re-adjust value.

—Replace module. Check for outsidesource of damage such as tran-sient voltage spikes.

—Repeat procedure. Increase Prop.Band to a number larger than 0.

—Increase proportional band.

—Check and reconfigure the controlparameters.

—Replace related components orboard.

—Check thermocouple, RTD or sen-sor.

—Check sensor wiring connections.

—Check sensor or thermocouple typeand if proper input mode wasselected.

—Replace related components orboard.

—Check and correct.

—Check output wiring and outputdevice.

—Replace output device.

—Replace output fuse.

—Check and replace.

—Check and replace.

—Read the operation procedure care-fully.

—Suppress arcing contacts in systemto eliminate high voltage spikesources. Separate sensor and con-troller wiring from “dirty” powerlines, ground heaters.

—Replace EEPROM.

etr-9200 automatic tuning smarter logic¨ controller · manual no. 25 software version 1.8 and...

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