Tempco PCM10086 - Portable Control Console

Specifications

Temperature Controller: Model TEC-9400, 1/16 DIN Dual Display with PID Auto-tuning

Sensor Input: Type "J" thermocouple

Connector Body: Black

Power Cord/Voltage Input: 240VAC, 50/60 HZ, 20 amps

Heater Output: 16 amps Max, 3840 watts max.

Output Device: Mechanical Relay

Main Power Switch: Located on front panel

Fuse Main Power: Buss ABC-20-R (located on back panel)

Fuse Control Power: Buss ABC-1-R (located on back panel)

Warnings

1. Dangerous voltage capable of causing injury or death is present within this console. Power to all equipment must be disconnected before installation or beginning any troubleshooting procedures. Heater output wiring and component replacement must be made by qualified personnel only.

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

3. Do not use this console in areas where hazardous conditions exist such as excessive shock, vibration, dirt, corrosive gases, oil or where explosive gases or vapors are present.

4. It is strongly recommended that a process should incorporate a Limit Control like a Tempco TEC-910 which will shut down the equipment at a preset process condition in order to avoid possible damage to products or systems.

Wiring

(For safety, disconnect all power sources prior to wiring)

1. Attach the leads from your type "J" thermocouple to the mini-plug provided. Take care to note the correct polarity. The red lead is (-) negative.
2. The heater output current is sourced directly through the line cord. The rear console output receptacle and mating Hubbell plug provides live controlled power for direct connection to your heater(s). Connect one lead from your heater to one prong of the Hubbell plug (not ground). Connect the other lead from your heater to the other prong. Connect heater ground (if applicable) to the ground connection (G) on the plug.

Operation

1. Verify the power switch is in the off position. Plug your heater & thermocouple into the rear connectors. Plug the provided line cord from the console into a standard 240V, 20A outlet. Switch on the console.
2. Set your desired temperature setpoint by using the up and down arrow buttons on the TEC-9400 temperature controller.
3. Refer to the following pages for complete operation and page 4 for auto-tuning of the TEC-9400 temperature controller.

Spare/Replacement Parts

NOTE: For all fuses, use listed BUSS part numbers or equivaliant.

TEC-9400 Front Panel Keys and Display

The TEC-9400 controller features a digital display and several keys for operation and parameter adjustment.

Keypad Operation

• SCROLL KEY: This key is used to scroll through a menu to select a parameter to be viewed or adjusted.
• UP KEY: This key is used to increase the value of the selected parameter.
• DOWN KEY: This key is used to decrease the value of the selected parameter.
• RESET KEY: This key is used to:
  1. Revert the display to the home screen.
  2. Reset a latching alarm once the alarm condition is removed.
  3. Stop manual control mode, Auto-Tuning mode or calibration mode.
  4. Clear an Auto-Tuning or communication error message.
  5. Restart the dwell timer when the dwell timer has timed out.
  6. Enter the manual control menu if failure mode occurs.
• ENTER KEY: Press and hold for 5 seconds or longer to:
  1. Enter the setup menu. The display will show SEE.
  2. Enter manual control mode. Press and hold the ENTER key for 6.2 seconds, then let go, to select manual control mode. The display will show HAND.
  3. Enter Auto-Tuning mode. Press and hold the ENTER key for 7.4 seconds, then let go to select Auto-Tuning mode. The display will show A-t.
  4. Perform calibration of a selected parameter during the calibration procedure. Press and hold the ENTER key for 8.6 seconds, then let go to select calibration mode.

During power-up, the upper display will show PROG and the lower display will show the Firmware version for 6 seconds.

The front panel includes indicators for Process Unit, Output, Manual Mode, Alarm, and Communication. It also shows Process Value (PV), Set Point (SV), Auto-tuning Indicator, Set Point or Control Output, and Lock Indicator. Four user access buttons are provided for menu access and set point adjustment.

Menu Flowchart

The menu is divided into 5 groups:

• User Menu
• Setup Menu
• Manual Mode Menu
• Auto-Tuning Mode Menu
• Calibration Mode Menu (not recommended)

Navigation involves pressing the SCROLL key to move between parameters and the UP/DOWN keys to adjust values. Specific functions are accessed by holding the ENTER key for defined durations (e.g., 5 seconds for User Menu, 6.2 seconds for Manual Mode, 7.4 seconds for Auto-Tuning, 8.6 seconds for Calibration).

The flowchart illustrates the path from the User Menu to other modes via the ENTER key, with specific time durations indicated for entering Setup Menu (5 sec), Manual Control Mode (6.2 sec), Auto-Tuning Mode (7.4 sec), and Calibration Mode (8.6 sec).

User Menu

The User Menu provides access to parameters such as:

• PV,SV
• SP1, SP2, SP3, SP4, SP5, SP6, SP7
• SFtR
• CT1R, CT2R
• DTMR
• PASS, RUN
• CYCR, STEP, TIMR
• SEL1 through SEL8

Pressing the SCROLL key advances to the next parameter, while pressing SCROLL and RESET simultaneously returns to the previous parameter.

Setup Menu

The setup menu is categorized into eight sections:

• Basic Menu
• Output Menu
• Alarm Menu (marked with *)
• Event Input Menu (marked with *)
• User Select Menu (marked with *)
• Communication Menu (marked with *)
• Current Transformer Menu (marked with *)
• Profile Menu (Ramp and Soak) (marked with *)

To access the Basic Menu (bASE), navigate to "SET" in the upper display and use the UP/DOWN keys to select bASE in the lower display. The SCROLL key cycles through the parameters.

Basic Menu (bASE) Parameters

This section details parameters like OFS1, OFS2, OFS3, INPT, UNIT, DP, INLO, INHI, SP1L, SP1H, FILT, DISP, PB, TI, TD, RAMP, RR, RETY, RELO, REHI, RMSP, RINL, RINH, CODE, OFSTL, OFSTH, CALO, CAHI, SFT, SFL1, SFL2, SFtH.

Note: Some parameters marked with an asterisk (*) may not apply to this console.

Output Menu (oUT) Parameters

This section details parameters related to output control, including:

• OUT1, O1TY, O1FT, O1HY, CYC1, OFST
• OUT2, O2TY, O2FT, CYC2, CPB, DB
• PL1L, PL1H, PL2L, PL2H

Access is similar to the Basic Menu, selecting "SET" and then "oUT".

Manual Mode Menu

This mode is used for temporary operation if the sensor fails. To enter Manual Mode:

1. Press and hold the ENTER key for approximately 6 seconds until "HAND" appears in the upper display.
2. Press and hold the ENTER key for an additional 5 seconds until the "MANU" indicator flashes.
3. Use the SCROLL key to cycle through options.

In this mode, the user can manually set the output to be energized from 0-100% of the cycle time. "Hx.xx" adjusts output 1, and "Cx.xx" adjusts output 2.

To exit Manual Mode, press and hold the RESET key.

The diagram shows pressing ENTER for 5 seconds to access HAND, then ENTER for 5 seconds to access MANU, followed by SCROLL to cycle through MV1, MV2, and FILE. Pressing ENTER for 5 seconds executes the selected default program.

Auto-Tuning Mode

This mode tunes PID parameters to your application. To enter Auto-Tuning Mode:

1. Press and hold the ENTER key for approximately 7 seconds until "A-T" appears in the upper display.
2. Press and hold the ENTER key for 5 seconds to activate Auto-Tuning Mode.
3. Continue to hold the ENTER key for an additional 3 seconds, otherwise the display will revert to a "User Menu" parameter.

Auto-tuning allows the controller to find its optimal control parameters (PID) by measuring the speed of your thermal process.

Parameter Description

This section details various parameters available in the controller.

Basic Menu Parameters

Output Menu Parameters

Programming

To enter the setup menu, press and hold the ENTER key for 5 seconds, then release. Press and release the SCROLL key to cycle through parameters. The upper display shows the parameter symbol, and the lower display shows the selected value.

User Security

The lockout program is controlled by two parameters: PASS (password) and CODE (security code).

Signal Input

INPT: Select the desired sensor type or signal type for the signal input. This is factory set and should NOT be changed.

UNIT: Select the desired process unit. Options are °C, °F, or PU (Process unit). If the unit is neither °C nor °F, it is set to PU.

DP: Select the desired resolution (decimal points) for the process value.

Control Output

There are 4 kinds of control modes:

2.3.1 Heat Only ON-OFF Control (Used for Solenoids and Valves)

Select REVR for OUT1, Set PB to 0. O1HY is used to adjust hysteresis for ON-OFF control. The output 1 hysteresis (O1HY) setting is only available when PB = 0. The heat only ON-OFF control function is illustrated by a diagram showing PV, SP1, SP1-O1HY, Dead band (O1HY), and OUT1 Action (ON/OFF) over time.

ON-OFF control can cause process oscillations. If ON-OFF control is used (PB = 0), parameters like TI, TD, CYC1, OFST, CYC2, CPB, DB become inapplicable. Auto-Tuning and Bumpless transfer are not possible in this mode.

2.3.2 Heat only P or PD Control (Used for Electric Heaters)

Select REVR for OUT1, set TI = 0. OFST adjusts the control offset (manual reset). If PB is not 0, O1HY is hidden. OFST is measured in % (0-100.0%). For example, if the process value is 5°F below the setpoint and PB is 20.0, this 5°F represents 25% of the PB. Increasing OFST by 25% adjusts the control output to coincide with the setpoint.

With Proportional (P) control (TI = 0), Auto-Tuning is unavailable. Manual tuning of PB and TD is recommended. Manual reset (OFST) requires constant adjustment due to load changes, which PID control avoids.

2.3.3 Heat only PID Control (Default for Electric Heaters)

Select REVR for OUT1. PB and TI should not be zero. Perform Auto-Tuning for initial startup. If results are unsatisfactory, use manual tuning or re-run Auto-Tuning.

2.3.4 Cool only Control

ON-OFF, Proportional, and PID control can be used for cooling. Set "OUT1" to DIRT (direct action).

NOTE: ON-OFF control may cause overshoot/undershoot. Proportional control may cause deviation from the set point. PID control is recommended for stable heating or cooling.

The availability of parameters depends on the controller configuration.

Ramp

The ramping function occurs during power up or when the set point changes. Use "MINR" (ramp in minutes) or "HRR" (ramp in hours) for the "RAMP" setting. The ramp rate is set by "RR". Ramping is disabled in Failure, Manual Control, Auto-Tuning, or Calibration modes.

2.4.1 Ramping Example without Dwell Timer

Example: Set RAMP to "MINR", RR to 10. Starting temperature is 30°C, setpoint is 200°C. After warm-up, the setpoint is changed to 100°C after 30 minutes. The process behavior is shown in a graph illustrating PV over time, with points at 30°C, 100°C, and 200°C at specific times.

Note: The lower display shows the current ramping value, reverting to the set point when keys are touched. Ramping starts at power-on or set point change. Setting RR to zero disables ramping.

User Calibration - Display Offset

Factory calibration is stable, but user calibration allows field modification to meet user standards, match other equipment, suit installation characteristics, or correct long-term drift.

Parameters OFTL (Offset Low) and OFTH (Offset High) adjust process value errors. CALO and CAHI are for sensor input values.

To calibrate:

1. Refer to section 1.6 for key operation and section 1.7 for the operation flowchart.
2. Press and hold the ENTER key until the Setup Menu is displayed.
3. Press and release the SCROLL key to navigate to the OFTL parameter.
4. Send the low signal to the sensor input. Press and release the ENTER key.
5. If the displayed process value differs from the input signal, use the UP/DOWN keys to adjust OFTL until the process value matches the desired value.
6. Press and hold the ENTER key for 5 seconds to complete low point calibration (display blinks).
7. Repeat for high scale calibration (OFTH).

The diagram illustrates Two Point User Calibration, showing how OFTL and OFTH create a straight line, with "Offset introduced" indicated.

After calibration, the input type is stored. Changing the input type may cause a calibration error (error code CAEr).

Digital Filter

A programmable low-pass filter can improve readability of unstable process values. The filter is a first-order filter with a time constant set by the FILT parameter (0 to 60 seconds). A factory default of 0.5 seconds is used. 0 seconds means no filter.

The filter is available only for the process value (PV) and affects the displayed value. The controller uses an unfiltered signal for control. A lagged signal may cause unstable processes. The "Filter Characteristics" diagram shows PV over time with FILT=0, FILT=1, and FILT=30.

Failure Transfer

The controller enters failure mode due to conditions like sensor break (SBER error), low input current/voltage, or A-D converter failure (ADER error).

Output 1 Failure Transfer

If activated, Output 1 failure transfer performs as follows:

1. If proportional control (PB≠0) and BPLS is selected for O1FT, Output 1 performs a Bumpless transfer using the previous average output value.
2. If proportional control (PB≠0) and a value of 0 to 100.0% is set for O1FT, Output 1 performs failure transfer using the O1FT value.
3. If ON-OFF control (PB=0), Output 1 transfers to OFF if OFF is set for O1FT, or to ON if ON is set for O1FT.

Auto-Tuning - When using PID Control

Auto-Tuning is performed at the set point (SP1). The process may oscillate around the set point. Set a lower set point if overshooting can cause damage. It's best to perform Auto-Tuning at the expected operating set point with the process running normally.

Auto-Tuning is generally applied for:

• Initial setup for a new process.
• Substantial set point changes since the last Auto-Tuning.
• Unsatisfactory control results.

2.8.1 Auto-Tuning Operation Steps

1. Ensure the system is set up for real-world conditions.
2. PB and TI settings should not be zero.
3. The LOCK parameter should be set to NONE.
4. Set the set point to a normal operating value, or a lower value if overshooting could cause damage.
5. Press and hold the ENTER key until "A-t" appears. Continue holding for 3 more seconds, or the display reverts to "User Menu".
6. Press and hold the ENTER key until the TUNE indicator flashes.
7. Auto-Tuning begins.

NOTE: During Auto-Tuning, the output stays on until the Process Value reaches the setpoint, potentially causing overshoot. The output then remains off until the PV falls below the setpoint. This cycle repeats at least twice as the controller learns.

Procedures: Auto-Tuning can be done during warming (Cold Start) or steady state (Warm Start). Upon completion, the TUNE indicator stops flashing, and PID control resumes with new values stored in nonvolatile memory.

2.8.2 Auto-Tuning Error

An ATER message appears if Auto-Tuning fails due to:

• PB exceeding 9000 (9000 PU, 900.0°F or 500.0°C).
• TI exceeding 1000 seconds.
• Setpoint change during Auto-Tuning.

2.8.3 Solution for an Auto-Tuning Error

1. Try Auto-Tuning again.
2. Avoid changing the set point during Auto-Tuning.
3. Ensure PB and TI are not zero (avoiding On-Off Control).
4. Use manual tuning.
5. Touch RESET key to clear the ATER message.

Manual Tuning

If Auto-Tuning is inadequate or the process is too slow, manual tuning can be used. If control performance remains unsatisfactory after Auto-Tuning, use the following guidelines:

PID Parameter Adjustment Guide

The "Effects of PID Adjustment" diagrams illustrate how PV changes over time with different PB, TI, and TD settings (e.g., "PB too low", "PB too high", "TI too high", "TI too low", "TD too low", "TD too high").

Manual Control

To enable manual control, ensure the LOCK parameter is set to NONE.

1. Press and hold the ENTER key until HAND (Hand Control) appears.
2. Press and hold the ENTER key until the "MANU" indicator flashes. The lower display shows H for output 1 and C for output 2.

Use the UP/DOWN keys to adjust percentage values for heating/cooling output. This percentage is based on CYC1 and CYC2 settings, determining how long the output stays on.

Example: If CYC1 is 20 seconds and the controller is set to "H50.0", the output is on for 10 seconds, then off for 10 seconds.

The controller performs open-loop control, ignoring the input sensor in manual mode.

2.10.1 Exit Manual Control

Pressing the RESET key returns the controller to normal display mode.

Setting Controller to Factory Default

Controller parameters can be reset to factory defaults. Follow these steps:

1. Ensure the LOCK parameter is set to NONE.
2. Press and hold the ENTER key until HAND (Hand Control) appears.
3. Press and release the SCROLL key to cycle through the manual mode menu to reach "FILE".
4. Press and hold the ENTER key for 5 seconds, or until the upper display shows "FILE" flashing.

Error Code

This section describes error codes and corrective actions.

6.5 Mode

The Value of the Mode Register is as below:

Returns

No product returns can be accepted without a completed Return Material Authorization (RMA) form.

Technical Support

Technical questions and troubleshooting help are available from Tempco. When calling or writing, please provide as much background information on the application or process as possible.

E-mail: techsupport@tempco.com

Phone: 630-350-2252

Toll Free: 800-323-6859

Note: Information in this manual was deemed correct at the time of printing. Tempco's policy is continuous development and product improvement, and specifications and designs may be modified without prior notice. Not responsible for typographical errors.

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