MANUAL NO.

14A
SOFTWARE VERSION
3.3 AND HIGHER

Model ETR-9090
Microprocessor Based
SMARTER LOGIC® Auto Tune PID Controller

MARTER®
S
LLO
OGGIIC
C

INSTRUCTION MANUAL
 INSTRUCTION MANUAL SM
ARTER ®

FOR ETR-9090 LLO

OGGIIC
C

Section 1: INTRODUCTION

This manual contains information for the installation and C/F and security codes are held in a non-volatile
operation of the Ogden Model ETR-9090 auto-tuning memory and retained for ten years if the unit is left
micro-processor based controller with Smarter Logic®. unpowered. Batteries are not necessary.
Ease of use is an essential feature on this versatile The auto-tuning function determines the correct
controller. Four touch keys are used to select sensor proportional band, rate and reset values to provide
type, control mode, control parameters, alarm mode, accurate control with minimal overshoot and tempera-
degrees C/F, auto-manual mode, and to lock the ture oscillation. This is accomplished without the need
parameters from the prevention of unauthorized for expensive and time consuming procedures for
tampering. Two large 4-digit displays show process set-up of control parameters. In case of a power failure
and set point values at a glance. Precise 14 slope or temporary shutdown, the instrument retains the
sensor linearization, self-diagnostic capability, cold correct parameters. This instrument also has manual
junction compensation and 3-mode PID calculations are override capabilities that allow the operator to bypass
automatically executed by the single chip microproces- the auto-tuning parameters. Required fine tuning
sor. The wide selection of parameters, values, sensor adjustments can then be made.
types, set points, control modes, alarm modes, degrees

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

64 West Seegers Road © Ogden Manufacturing Co. 1999

OGDEN, ETR, ETR-9090 and
Arlington Heights, IL 60005 SMARTER LOGIC are
(847) 593-8050 • Fax: (847) 593-8062 Registered Trademarks of
Ogden Manufacturing Co.
MARCA REGISTRADA

Printed in U.S.A. 7/99 Specifications subject to change without notice.

Section 2: CATALOG NUMBERING SYSTEM

ETR-9090- 1 2 3 LINE TWO–CONTROL OUTPUT:

LINE ONE–SIGNAL INPUT: 1.) None

2.) Relay rated 3A/240VAC/VDC resistive, 2400VA
1.) Thermocouple J, K, T, E, B, R, S, N 3.) Pulsed voltage to drive SSR, 3-32VDC
2.) RTD PT100 ohms, Alpha = 0.00385/DIN43760 4.) Internal Triac rated 1A, 240VAC
3.) RTD PT100 ohms, Alpha = 0.00392/JIS 5.) Isolated 4-20mA linear
4.) Voltage - 10 to 60 mV, current or special order 6.) Isolated 0-20mA linear
7.) Isolated 0-10V linear
8.) Special order

LINE THREE–ALARM:

1.) With alarm relay rated 2A/240VAC

2.) No alarm

Example:
Standard Model: ETR-9090-1 2 1
Thermocouple Type J, K, T, E, B, R, S, N, heating relay, with alarm

NOTE: A “-3” after the 9090 indicates 20-32VAC/VDC operation.

A” -4” after the 9090 indicates 10-16VDC operation.

Section 3: SPECIFICATIONS

Line Voltage: 90-264 VAC, 50-60 Hz, 20-32VAC/DC and 10-16VDC available.
Input: Type: J, K, R, T, B, E, S, N
thermocouple, PT100 ohm
RTD (DIN) 43760/BS1904
or JIS) and –10 to 60mV
(given span).
Power consumption: Less than 5VA.
Accuracy: ±.1%, ± least significant digit.

Maximum Temperature Ranges:

Sensor 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°C
K Chromel/Alumel –58 to 2500°F ±3.6°F –50 to 1370°C ±2°C
T Copper/Constantan –454 to 752°F ±3.6°F –270 to 400°C ±2°C
E Chromel/Constantan –58 to 1382°F ±3.6°F –50 to 750°C ±2°C
B Pt-30%RH/Pt-6% RH 32 to 3272°F ±5.4°F 0 to 1800°C ±3°C
R Pt-13%RH/Pt 32 to 3182°F ±3.6°F 0 to 1750°C ±2°C
S Pt-10%RH/Pt 32 to 3182°F ±3.6°F 0 to 1750°C ±2°C
N Nicrosil/Nisil –58 to 2372°F ±3.6°F –50 to 1300°C ±2°C
RTD PT 100 ohms (DIN) –328 to 752°F ±0.72°F –200 to 400°C ±0.4°C
RTD PT 100 ohms (JIS) –328 to 752°F ±0.72°F –200 to 400°C ±0.4°C
Linear Voltage or Current –1999 to 9999 ±0.05% –1999 to 9999 ±0.05%
SPECIFICATIONS EMC Emission: EN500081-1, EN55011
Operating ambient for 14-120°F (-10 to 50°C) EMC Immunity: IEC801-2, 801-3, IEC801-4
rated accuracy: °F/°C: External keypad selection
Storage Temperature: -4 to 160°F (-20 to 70°C) Auto/Manual operation: External keypad selection
Humidity: 5 to 90%RH (non-condensing Linearization: Software driven
Dimensions: Front panel: H-17⁄8” (48mm) Outputs: Heating and/or alarm
W-17⁄8” (48mm) Output modules
D-33⁄4” (95mm) –Current output: 4-20mA isolated, max. load
Depth behind panel: 33⁄8” 500 ohms
(86mm) –Voltage output: 0-10V isolated, minimum
Panel cutout: 125⁄32” x 125⁄32” (45 x 45mm) impedance 500K ohms
Weight: 7 oz. (198 grams) –Pulsed voltage: 24VDC, unisolated max.
Normal mode rejection: 60dB current 20mA
Common mode rejection:120dB –Relay: 3A/240V, Resistive load for
Thermocouple break heating, 2A/240V, Resistive
protection: Operator selectable load for alarm.
Display: Process .4” red LED Control Action: Heating (relay closed on
Set point .3” green LED temperature rise) or cooling
(relay open on temperature
Display update rate: 4 times per second rise) front panel selectable.

NON-VOLATILE MEMORY
• Retains process parameters when power is off

EXTERNAL LOCKOUT CODE AUTOMATIC TUNING

• Prevents accidental or • Eliminates complicated and
unauthorized changes time consuming manual
tuning procedures
• Smarter Logic practically
STATUS INDICATORS eliminates overshoot and
• Indicate output and alarm temperature variations
condition
CON: Control Output
ALM: Alarm Output SET POINT DISPLAY VALUE
• All control parameter and set
points displayed
• Output Percentage
4 PUSHBUTTONS • Calibration parameters
• For ease of control set-up

TOUCH KEY, Sealed mylar front panel

• Splash and chemical resistant
• Tactile feedback, pressure sensitive buttons

MODEL ETR-9090
Section 4: INSTALLATION
Wiring Precautions:
WARNING!
• Before wiring, verify the label for correct model num-
RISK OF ELECTRIC SHOCK - Dangerous and poten- ber and options. Switch off the power when checking.
tially fatal voltages are present when working on this • Care must be taken to ensure that maximum voltage
equipment. Before installation or beginning any ratings specified in Section 3 on previous page are
troubleshooting procedures, the electric power to this not exceeded.
equipment must be disconnected and locked out as • It is recommended that power to these instruments
described by OSHA Standards. Units suspected of be protected by fuses and circuit breakers rated at
being faulty must be removed and returned to Ogden for the minimum value possible.
inspection and/or repair. They contain no user service-
• All units should be installed inside a suitably ground-
able components.
ed metal enclosure to prevent live parts being acces-
WARNING! sible to human hands and metal tools.
• All wiring must conform to appropriate standards of
To help minimize the possibility of fire or shock hazards, good practice, national and local codes and regula-
do not expose this instrument to rain or excessive tions. Wiring must be suitable for the maximum volt-
moisture. This control is not to be used in hazardous age, current, and temperature ratings expected in the
locations as defined in Articles 500 and 505 of the system.
National Electric Code. • Both solderless terminals or “stripped” leads as
specified in Figure 4.2 below can be used for power
CAUTION! ! leads. Only “stripped” leads should be used for ther-
mocouple connections to prevent compensation and
Do not use this instrument in areas subject to resistance errors.
hazardous conditions such as excessive shock,
vibration, dirt, moisture, corrosive gases or oil. The • Take care not to over-tighten the terminal screws.
ambient temperature of the areas should not exceed • Unused control terminals should not be used as
the maximum rating specified in Section 3, on previous jumper points as they may be internally connected,
page. causing damage to the unit.
• Verify that the ratings of the output devices and the
Unpacking: inputs as specified in Table 4.2 on Page 8 are not
exceeded.
Upon receipt of the shipment remove the instrument
from the carton and inspect the unit for shipping dam- • Electric power in industrial environments contains a
age. If any damage due to transit is noticed, report and certain amount of noise in the form of transient volt-
file a claim with the carrier. Write down the model num- ages and spikes. This electrical noise can enter and
ber, serial number, and date code for future reference adversely affect the operation of microprocessor-
when corresponding with our service center. The serial based controls. For this reason we strongly recom-
number (S/N) and date code (D/C) are located inside mend the use of shielded thermocouple extension
the control. wire which connects from the sensor to the controller.
This wire is a twisted-pair construction with foil wrap
Mounting: and drain wire. The drain wire is to be attached to
Make panel cutout to dimensions shown below. Insert earth ground at the control end only. We carry both
the controller into the panel cutout. The maximum type J and type K in our stock.
panel thickness is 1⁄8" (3mm). NOTE: 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.

9/16"

1-25/32"
(45mm)

5/16"
1-25/32"
(45mm)

SPADE TONGUE
Panel Cutout CONNECTOR FOR
Panel NO. 6 STUD 20 AWG
3/8"

3-3/8"
(86mm)
3-3/4"
(95mm)

Figure 4.1 Mounting Dimensions Figure 4.2 Lead Termination

Power Wiring:
Connect terminals as shown in Figure 4.3. The power codes. Refer to Figures 4.4, 4.5 and 4.6 on following
switch S1 and Fuse F1 are included for illustrative purpose pages for sample wiring diagrams.
only. All wiring must conform to national and local electrical

Optional
F1 S1 DC
Alarm
Common 1 6 Supply
+
Alarm Power
N/O 2 7 –
C Current.
3 8 Control + Voltage
RTD NO – Pulsed
Sensor – – 4 9 O/P Voltage
+ +V NC

T/C mA V
5 10
Figure 4.3 Rear Terminal Connections

Input Wiring: specified by the instrument. Extension wires must be

Connect appropriate sensors to terminals 3, 4, or 5 as the same alloy and polarity as the thermocouple. The
illustrated in Figure 4.3 above. Verify that the instru- total lead resistance should not exceed 100 ohms for
ment is selected for the correct sensor and the correct accurate measurements. One hundred ohms of lead
polarity is observed at both the sensor-end and instru- resistance will introduce a 1°F (0.5°C ) error.
ment-end of the cable. Do not run sensor cables in the For wiring 3 wire RTD (Resistance Temperature
same conduit or wiring trough as power lines because Detector) all leads connecting the RTD to the controller
the low level signal is noise sensitive. must be the same gauge and material. If the RTD is a
When wiring the thermocouple, check the thermocouple 3 wire device, install the two common wires of the RTD
and extension wire (compensating cable) to make sure to terminals 4 and 5. If a 2 wire RTD is to be used,
they conform to the appropriate thermocouple type install a jumper between terminals 4 and 5.

Table 4.1 Thermocouple Cable Color Codes

Thermocouple Cable American British German French

Type Material ANSI BS DIN NFE
1843 43710 18001
+ white + yellow + red + yellow
J Iron/Constantan - red - blue - blue - black
* black * black * blue * black

+ yellow + brown + red + yellow

K Chromel/Alumel - red - black - green - purple
* yellow * red * green * yellow

+ blue + white + red + yellow

Copper - brown - blue
T - red - blue
Constantan * brown * blue
* blue * blue

+ black + white + red + yellow

R - white - green
Platinum/Rhodium - red - blue
S * white * green
* green * green

+ grey + red
B Platinum/Rhodium - red - grey
* grey * grey

* Color of overall sheath Chromel® and Alumel® are registered trademarks of Hoskins Mfg. Co.
 Fuse
5A
1 6 Incoming
Power
CAUTION
SHOCK 2 Internal 7
HAZARD Relay
3 8
Red –
Thermocouple
4 9
Heater
+ 5 10 3 Amps
Maximum
360W/120V
720W/240V
Maximum
A 3
Heater
Load
B 4
B 5 Figure 4.4
Example of wiring connections for
RTD Sensor Connections ETR-9090-122 with Relay Output.

Control
Fuse
1A
1 6 Control
Power
2 7
3 + 8 Heater
Fuse
Red –
Thermocouple
4 – 9 Heater
Power
+ 5 10
Heaters
1 2
Solid State
Relay
+
4 3
This diagram can also be used
for controls with 4-20mA output.

Figure 4.5
Example of wiring connections for
ETR-9090-132 with Pulsed Voltage Output
for Solid State Relay

Note control label for incoming power requirements.

 Alarm
2 Amps Control
Maximum Fuse
1 Alarm
Relay
6 Incoming
Power
2 7
3 Heater
Relay
8
Red –
Thermocouple
4 9
White + 5 10

Coil

o o Three
Phase
o o o Heater
Three Phase o o Power
Delta Heater
Load 3-Pole Heater
Magnetic Fuses
Contactor
NEMA
o o or
DP

Figure 4.6
ETR-9090-121 with Relay Output.
Heaters connected in 3-Phase to Contactor.
With Alarm option.

Note control label for incoming power requirements.

 Table 4.2 Heating Output Wiring

Function Internal Device: Terminals: External Connection:

1. Relay (Isolated). 8 To line 240VAC max.

Relay contact is closed during
ON phase of output cycle. LOAD MAX 3A
(CTRL lamp ON) 9

2. Current (Isolated. Input impedance of control

4-20mA 8
Reverse acting current (The + device, MAX. 500 ohms.
function of CTRL lamp ON
lasts longer during decreasing
0-20mA 9
–
process value).

3. Voltage (Isolated). Input impedance of control

Reverse acting voltage (The 8 device, MIN. 500K ohms.
Flashing of CTRL lamp ON
0-10V + +
lasts longer during decreasing
V
– –
process value). 9

4. Pulsed Voltage. To drive solid state relay

8
The non-isolated logic signal + + or other isolated control
goes high during ON phase of device 24 VDC/20mA
output cycle. (CTRL lamp ON). – – MAX.
9

Output Wiring: heater. In processes where the heat demand is

Four different types of output devices can be used from variable, the probe should be closer to the work area.
output one. Relay, current, voltage and pulsed voltage Some experimenting with probe location is often
provide a variety of control applications, Verify that the required to find this optimum position.
output device is correctly selected to meet your
application requirements and make certain the ratings In a liquid process, addition of a stirrer will help to
of the output devices are not exceeded before wiring eliminate thermal lag. Since the thermocouple is
the system. basically a point measuring device, placing more than
one thermocouple in parallel will provide an average
The external connections depend on what type of temperature reading and produce better results in most
output is installed. Pulsed voltage output is not isolat- air heated processes.
ed from the internal circuits of the instrument.
Proper sensor type is also a very important factor in
Alarm obtaining precise measurements. The sensor must
This instrument offers 14 different alarm modes. Each have the correct temperature range to meet the
one can be selected by pressing the keypads on the process requirements. In special processes the sensor
front panel. The detailed descriptions are shown on might have to have different requirements such as
Table 5.3, Page 11 and on Table 5.7, Page 16. leak-proof, anti-vibration, antiseptic, etc.

Sensor Placement Standard sensor limits of error are ± 4 degrees F (±2

Proper sensor placement can eliminate many problems degrees C) or 0.75% of sensed temperature (half that
in a control system. The probe should be placed so for special) plus drift caused by improper protection or
that it can detect any temperature change with minimal over-temperature occurance. This error is far greater
thermal lag. In a process that requires fairly constant than controller error and cannot be corrected at the
heat output, the probe should be placed close to the sensor except by proper selection and replacement.
Section 5: OPERATION

Front Panel Adjustments

Table 5.1 Keypad Operation

TOUCHKEYS DESCRIPTION FUNCTION

Scroll Key Advances the index display to the desired position.

Indexes advanced continuously and cyclically by
pressing this keypad.

Up Key Increases the parameter. (Set point or other)

Down Key Decreases the parameter. (Set point or other)

Return Key Resets the controller to its normal status. Also stops
auto-tuning, output percentage monitoring and manual
mode operation.

Long Scroll Allows more parameters to be inspected or changed.

Press

for 6 seconds

Long Return 1. Executes auto-tuning function.

Press
2. Calibrates control when in calibration level.
for 6 seconds

Output Percentage Allows the set point display to indicate the control
Press and Monitoring output value in percent.

Press and Manual Mode Execution Allows the controller to enter the manual mode.
This can be used if the sensor fails.
for 6 seconds

PROCESS VALUE

SET VALUE

SCROLL KEY RETURN KEY

 PROCESS VALUE DISPLAY
SET VALUE DISPLAY Level 1
AND ADJUSTMENT
Long
(6 seconds)

Table 5.2 Control Function

and Display Flow Chart

Level 2

Long
(6 seconds)

The "return" key ( )can be pressed at any time.

This will prompt the display to return to the Level 3
Process Value/Set Value.
Power Applied:
1. . Displayed for 4 seconds
(Software Version 3.3 or higher)

2. LED test.
All LED segments must be lit for 4 seconds.

3. Process value and set point indicated.

Long
(6 seconds)

WARNING: Do not enter Level 4 unless you have proper calibration

instruments. Refer to Page 19 for further information.
Level 4
Table 5.3 Index Code (Menu) Descriptions:
(Do not disconnect power for at least 12 seconds after changing any control values.
NOTE: Further parameter definitions
This allows the parameters to be entered into memory.) on pages 12 and 13

Index Description *Default Index Description *Default

Code —Adjusting Range Setting Code —Adjusting Range Setting
Set Point of control Alarm Mode Selection**
SV – Low Limit to High Limit Value 0: Process High Alarm
1: Process Low Alarm
Alarm Set Point Value 2: Deviation High Alarm
2
– Low limit to high limit (If ALAI=0,1,4 or 5) 3: Deviation Low Alarm
–0-3600 minutes (If ALAI=12 or 13) 18°F 4: Inhibited Process High Alarm
5: Inhibited Process Low Alarm
–Low limit minus set point high limit minus 6: Inhibited Deviation High Alarm
set point (IF ALAI=2, 3, 6 or 11) 7: Inhibited Deviation Low Alarm
Ramp Rate for the process value. 8: Outband Alarm
9: Inband Alarm
Limits an abrupt change of the
10: Inhibit Outband Alarm
process temperature. (Soft start) 11: Inhibit Inband Alarm
0.0
– 0-360°F 0-200°C/minute (If in=0-90) 12: Alarm Relay OFF as Dwell Time Out
– 0-3600°/minute (If in = 10) 13: Alarm Relay ON as Dwell Time Out
Offset Value for Manual Reset Hysteresis of Alarm
0.5
Only used if integral is 0. 0.0 – 0 to 20.0% of SPAN
– 0 to 100% °C/°F Selection
Offset shift for process value – 0 to 1 0
– 199 count to 199 count 0.0 0:°F, 1:°C
See page 18 for instructions Resolution Selection
Proportional Band – 0 to 3
0 - 360°F 0: No Decimal Point Used
18.0
For ON-OFF control set to 0 1: 1 Digit Decimal
See instructions below. 2: 2 Digit Decimal 0
Integral (Reset) Time, TI 3: 3 Digit Decimal
120 sec. 2 and 3 can only be used for
– 0 to 3600 seconds
Linear Voltage or Current
Derivative (Rate) Time, TD (IN=10)
30 sec.
– 0 to 1000 seconds
Control Action
Local Mode – 0 to 1
– 0 to 1- 1
0: Direct (cooling) Action
0: No Control Parameters can be 1 1: Reverse (heating) Action
changed.
1: Control Parameters can be Error Protection
changed. – 0 to 3
0: Control OFF, Alarm OFF
Following parameters will be 1
1: Control OFF, Alarm ON
upgraded to Level 1 2: Control ON, Alarm OFF
– 0 to 7 3: Control ON, Alarm ON
0: None 4: 0
1: 5: Hysteresis of ON-OFF control
0.5%
2: 6: – 0 to 20.0% of SPAN
3: 7: Low Limit of Range (SPAN)
Proportional Cycle Time, Heating & Adjust for your process –58
Cooling – 0 to 120 seconds – See Instructions on Page 13.
Relay 20 High Limit of Range (SPAN)
3-32VDC Pulsed Voltage 1 Adjust for your process 1832
Linear Voltage, 4-20ma Current 0 – See Instructions of Page 13
Input Mode Selection, IN Low Calibration parameter
T/C 0 32
– 0 to 10 5: R Type T/C – Refer to Section 6.
0: J Type T/C 6: S Type T/C High Calibration parameter
RTD 8 1112
1: K Type T/C 7: N Type T/C – Refer to Section 6.
2: T Type T/C 8: PT100 DIN
3: E Type T/C 9: PT100, JIS
Linear 10
4: B Type T/C 10: Linear Voltage
or Current
NOTE: T/C - Close solder gap G5. RTD - Open G5 ON-OFF CONTROL:
Located on P.C.B. A909F For on-off control action the following parameters must
be set to zero (0): Proportional band, Integral, Derivative,
Cycle time, Offset. The hysteresis (deadband) adjust-
*Factory set before shipping.
ment must now be used to determine the process oscil-
**Process alarms are at fixed temperature points.
lations from set point. Setting the hysteresis to a larger
Deviation alarms move with set point value. number will cause the contactor (or other equipment, to
For convenience, values used can be recorded on the next page. switch less often, but the process will oscillate farther
Long Scroll from the set point.
Table 5.4 Parameter Chart PARAMETER DEFINITIONS:
PV - Process Value - This is the temperature (or other
CONTROL process variable) as measured at the sensor. This will indi-
NO.
cate a value within the range between the low scale value
DA (LLiE) and High scale value (HLiE). This indication will read
TE
PARAMETER an error code if the temperature (process variable) goes out
of the preset span. Note items 4 and 5 of the troubleshoot-
SV ing guide on page 21 for the error code descriptions.
SET POINT VALUE SV - Set Point Value - This parameter is the desired set
point of the process. It can be adjusted within the range
defined by the low scale (LLiE) and high scale value (HLiE).
ALARM SET POINT The span adjustments can be used to limit the set point set-
ting of the controller.
RAMP RATE ASP1 - Alarm Set Point Value or Dwell Time - This sets
the point at which the alarm will energize if ALAI (alarm
mode selection) is set for an alarm function. If ALAI is
OFFSET selected for the dwell timer function (setting 11 or 12), then
this becomes the timer setting in minutes. The dwell timer
starts counting when the process value reaches the set
DISPLAY SHIFT point value. Note page 17 for more information.
rr - Ramp Rate - This controls the heat-up and cool-down
rate of the process. This setting is in degrees per minute.
PROPORTIONAL BAND
Note page 15 for more information.
oFST - Offset Value - This parameter is only functional if
INTEGRAL the integral time (Ti) is set to zero. The oFST than func-
tions the same as manual reset to correct the process tem-
perature to the set point temperature. If the process tem-
DERIVATIVE perature stabilizes below the set point, set a positive
amount of oFST. If the process temperature stabilizes
above the set point, set a negative amount of oFST. Wait
LOCK OUT for the system to stabilize and make further adjustments as
required. The number observed in this parameter can be
ignored if you have a number greater than 1 entered in the
SELECT
integral setting (Ti).
ShiF - Display Shift - A value entered here will be added to
CYCLE TIME or subtracted from the Process Value. This offset can be
used as a correction factor if the sensor does not read the
same temperature as the item being sensed. It can also be
INPUT TYPE used to correct for calibration. Note page 18 for more infor-
mation.
Pb, Ti and Td - PID Values - Proportional band (Pb),
ALARM TYPE Integral (Ti) and Derivative (Td) time constants. These
must be set as close as possible to the process application
requirements. During auto-tuning, these parameters will be
ALARM HYSTERESIS
adjusted. Note pages 13, 14 and 15 for more information.
LoCL - Local Mode - Used to disable the up and down but-
DEGREES C OR F tons to prevent tampering.
SEL - Select - Used to upgrade commonly used parame-
ters to Level 1.
RESOLUTION
CT - Proportional Cycle Time - This sets the proportional
cycle time for the control output. This should be set accord-
CONTROL ACTION ing to the type of output device used. For mechanical
relays, cycle times of 15 to 20 seconds are used. For solid-
state relays, set this adjustment to 1 or 0. For 4-20mA or
ERROR PROTECTION other linear outputs, adjust to 0.
in - Input Mode Selection - This parameter is used to pro-
gram the control to the type of input sensor used.
CONTROL HYSTERESIS
ALAI - Alarm Mode Selection - This adjustment sets the
type of alarm (or dwell timer) to be used: deviation alarm,
LOW RANGE band alarm or process alarm. Refer to page 16 for more
information.
(Continued on next page.)
HIGH RANGE
Long Scroll
AHY1 - Hysteresis of Alarm - The value entered here ErPr - Error Protection - Sets the control and alarm
defines the deadband for the alarm. The alarm will not output to be used in case of sensor failure.
change state until the temperature is outside of the hYSE - Hysteresis of On-Off Control - This parameter
deadband. defines the deadband when on-off control is used and
CF - Degrees Selection - Sets the indication to PID control has been disabled. For on-off control, set
degrees Celsius or Fahrenheit. Pb, Ti and Td to 0. The output on a relay control will
rESO - Display Resolution - This parameter is used to not change state until the temperature is outside of the
place a decimal point in the process and set point val- deadband. Note page 13 for more information.
ues. A two-place decimal point can only be used if the LLiE, HLiE - Low Scale/High Scale Range - The para-
“in” adjustment is set to 10; ;linear voltage or current. meters are used to define the range (span) of the con-
ConA - Control Action - This parameter selects heat- trol. These should be set for the requirements and
ing (reverse) or cooling (direct) action for the control safety of your process. Refer to “Span Adjustment” on
output. page 13 for further information.

Operating Procedure: ON-OFF Control:

When the control has been wired, you can apply power. On-off control action is recommended when continuous
The display will indicate the model number, software cycling of the load cannot be used. Examples are
version and LED lamp test. The temperature as mechanical solenoids, large contactors and valves.
measured at the sensor should now be indicated by the For on-off control, set the following parameters to zero:
PV display. The thermocouple is wired in reverse if the proportional band; integral; derivative and offset
indicated temperature decreases as the temperature at (oFSE). The hysteresis (hySE) adjustment is now used
the thermocouple increases. The set point should be to set the deadband. The larger the hysteresis is set,
lowered to a value (eg. 30°F) so the heaters will not be the larger the deadband will be. A large deadband will
energized. This will allow time to enter and make any cause the contactor (or other device) to switch less
adjustments of the parameters. The process will not often, but the process will oscillate farther from the set
heat-up. point. This setting is measured in degrees.
Span Adjustment: Adjusting PID Parameters:
During this initial set-up, alarm points and any other set- The PID parameters can be reviewed by operating the
tings can now be made. The low limit and high limit scroll key and noting whether the values are reason-
range settings (LLiE) and (HLiE) should be adjusted to able or not. Examine the controller’s result. Modify the
your process. This sets the range (SPAN) of the con- PID parameters, if necessary, according to Table 5.5 on
trol. The set point cannot be adjusted out of this range. page 15 until the control quality is acceptable.
For plastics processing and packaging, a span of 0- PID Control
800°F is common. If oils are used, a lower span such
as 0-300°F should be entered. For various applications, the controller can be used as
P control only (set integral = 0, derivative - 0); PI con-
Automatic Tuning Procedure trol (set derivative = 0), PD control (set integral = 0),
When the settings have been made, you can return to and PID control.
the PV/SV level. Do not enter the calibration level. Figure 5.3 on page 14 represents the response of a
Adjust the required process temperature set point. The typical control system using various modes of control.
green “output” lamp should turn on indicating the
heaters have been energized. You can auto-tune the 1.) P control results in a response showing a devia-
control to the set point by depressing the return ( ) tion (offset), a high overshoot and a moderate period of
button for six seconds, then release. This matches the oscillation. In addition, a significant length of time is
control’s PID values to your process requirements. The required before the system ceases to oscillate.
lower decimal point will flash, indicating the control is in 2.) PI control has no offset, but elimination of offset
the auto-tune mode. No other adjustments can be comes at the expense of higher overshoot, larger peri-
made while the control is auto-tuning. During auto-tun- od of oscillation and a longer time required for
ing, the process will take approximately twenty-five per- oscillations to cease compared with other modes of
cent longer to heat-up than it normally takes. After auto- control.
tuning, the correct PID values will be entered into the 3.) PD control generally brings the system to steady
control’s memory. state in the shortest time with the lease oscillation.
Auto-tuning will not function if the control has been con- However, it still has offset.
figured from PID to ON-OFF. For electric heating, PID is 4.) PID control is essentially a compromise between
usually recommended. the advantages of PI and PD control. Offset is elimi-
Auto-tuning may not give satisfactory results and hold a nated by the integral action. The derivative action
close temperature on all applications. If this occurs, you serves to lower offshoot and to eliminate some of the
can change the PID values manually using the three oscillation realized with PI control.
charts in Figure 5.1 on the top of the next page and
Table 5.5 for a guide. It is recommended to change
only one parameter at a time, so the results of that
change can be clearly noted.
 PROPORTIONAL ACTION INTEGRAL ACTION DERIVATIVE ACTION
Proportional Band Too Low Integral Too High (Too long for recovery)
Derivative Too Low
PV PV PV
Perfect Perfect

SP SP SP

Perfect
Integral Too Low
Proportional Band Too High Derivative Too High

TIME
TIME TIME

FIG 5.1 Effects of PID Adjustment on Process Response

The proportional band (Pb) is a temperature band oscillations then gradually decrease the propor-
expressed in degrees. When the controller is within this tional band until steady cycling is observed.
band, the time proprtioning functions are active. Record this important proportional band percent-
age (Pc).
Integral action (automatic reset) corrects for offset (load
error) for load variations. Reset wind-up inhibition prevents PV
integral action from occurring outside of the proportional
PV (Process value)
band. Software antisaturation minimizes process oscilla- Tc
tions when the load changes.

Derivative action is adjusted to match the response time of

the process and to compensate the integral action. P Band (Pb) = 1.7 Pc
Correct adjustment provides power output compensation Integral Time (ti) = Tc
for process load variations. It also minimizes overshoot Derivative Time (td) = 0.125 Tc
and oscillations at start up or in large process upsets.
Refer to Figure 5.1 for additional adjustment instructions. TIME
Fig. 5.2 Steady State Cycling

Manual Tuning Procedures:

For some systems it is difficult to execute automatic tuning Step 5: Time the period of steady cycling. Record this crit-
or the automatic tuning results are not satisfactory. The ical period Tc. The PID parameters are deter-
following steps can then be used for initial tuning of a mined as:
three-mode control:
This method was developed by Ziegler and Nichols.
Step 1: Adjust the integral and derivative values to 0. This
inhibits the rate and reset action. If you are unfamiliar with tuning PID Controllers, we sug-
Step 2: Set an arbitrary value of proportional band and gest that you obtain and become familiar with the following
monitor the control results. reference material: Tuning of Indusrial Control Systems
Step 3: If the original setting introduces a large process by A.R. Corripio ISBN: 1-55617-253-2-Q. Available from:
oscillation then gradually increase the proportional ISA Publications and Training Aids, phone: 919-549-8411.
band until the oscillation disappears.
This method should be performed with a temperature
Step 4: If the original setting does not introduce process chart recorder.
Fig. 5.3 Response of a Typical Control System Using Various Modes of Control
PV
UPPER PB
PI
PID

SET POINT
OFFSET PROPORTIONAL BAND

LOWER PB

PD P

TIME
Table 5.5 Tuning Guide
ADJUSTMENT SEQUENCE: SYMPTOM: SOLUTION:
1.) Proportional Band Slow Response Decrease Proportional Band (Pb)
High Overshoot or Oscillations Increase Proportional 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)

RAMP RATE ADJUSTMENT Manual Mode Operation:

The purpose of this adjustment is to control the rate at It is suggested to use Manual Mode (open loop operation)
which the process temperature can change. This feature during the time the controller’s sensor is not functioning
would be used when rapid temperature changes could and the control is unable to display the correct process
damage the product being controlled. When used, the value. This can also be used when automatic control
ramp rate is in effect at all times, during heat-up, set point (closed loop) is not possible or during the time required to
changes and cool-down. test the characteristics of a process.

The ramp rate ( ) is expressed in degrees/minute In order to enter the manual mode operation press both
the “Scroll” key and the “Return” key for longer than 6
seconds and release. Now the control will display the out-
EXAMPLE 1: The process temperature cannot change
put percentage with a range of –100% to 100%. A posi-
more than 5 degrees per minute.
tive value for heating output percentage and a negative
value for cooling output percentage. Press the UP or
Adjust =5 DOWN key to adjust the output percentage. Zero output
percentage disables the heating output.
EXAMPLE 2: The process temperature cannot change
more than 60 degrees per hour.
Table 5.6 Parameter Lockout

Adjust =1 There are 5 levels of parameter security protection.

They are shown below in the order of protection.
Also refer to table 5.2 on page 10.
The ramp rate is not functional if is set to zero.
LEVEL 1 LOCL = 0 No changes can be made
LEVEL 1 LOCL = 1 Only set point can be changed
LEVEL 2 LOCL = 1 Long scroll at Process Valve
LEVEL 3 LOCL = 1 Long scroll at
LEVEL 4 LOCL = 1 Long scroll at

Set Point
Process Temperature
Temperature

Ramp Rate Ramp Rate

TIME

Figure 5.4 Ramp Rate Diagram

Table 5.7 Code Assignments and Description of Alarm Modes

ALARM SV = SET POINT VALUE =ALARM SET POINT VALUE

=0 =1 =2 =3
PROCESS HIGH ALARM PROCESS LOW ALARM DEVIATION HIGH ALARM DEVIATION LOW ALARM

ASP1 ASP1
moves
SV SV SV SV
with SV
ASP1 ASP1
moves
with SV

=4 =5 =6 =7
INHIBITED INHIBITED INHIBITED INHIBITED
PROCESS HIGH ALARM PROCESS LOW ALARM DEVIATION HIGH ALARM DEVIATION LOW ALARM

ASP1 Alarm is not Alarm is not

ASP1
active the active the
SV SV moves
SV first incident SV first incident
with SV

Alarm is not ASP1 Alarm is not ASP1

active the active the
first incident first incident

=8
OUTBAND ALARM INBAND ALARM
=9 = 10
INHIBIT OUTBAND ALARM

SV + ASP1 ASP1 ASP1

SV SV SV

SV - ASP1 SV - ASP1 ASP1

Alarm is not
active the
first incident

= 11 = 12 = 13
INHIBIT INBAND ALARM DWELL TIME OUT RELAY OFF DWELL TIME OUT RELAY ON
SOAK CONTROL SOAK CONTROL

ASP1
SV Once set point Once set point
is reached. is reached.
ASP1 SV timer is activated SV timer is activated

= MINUTES = MINUTES
Alarm is not active the first incident See Ramp Example on Page 17 See Ramp Example on Page 17
Table 5.7 (Continued)

Descriptions of Alarms

Process High Alarm: Alarm is actuated whenever the process value rises above the alarm set point. Changing
the control set point does not affect the process alarm trip point.

Process Low Alarm: Alarm is actuated whenever the process value falls below the alarm set point. Changing
the control set point does not affect the process alarm trip point.

Deviation High Alarm: Alarm is actuated whenever the process value goes above the control set point by a
predetermined (alarm Value) amount. Changing the control set point changes the alarm set point value
maintaining the same deviation from the control set point.

Deviation Low Alarm: alarm is actuated whenever the process value falls below the control set point by a
predetermined (alarm Value) amount. Changing the control set point changes the alarm set point value
maintaining the same deviation from the control set pint. This alarm value is a negative number.

Inhibited alarms do not energize the alarm relay the first the alarm area, the Inhibited Alarm offers ON as a nor-
time the process temperature enters the alarm area. mal alarm. For some systems, it is useful to bypass the
From the second time the process temperature enters first alarm section while the system is heating up.

Ramp and Soak Function

The ETR-9090 can be programmed as either a fixed set control has opened. The cycle will repeat each time the
point controller or as a two segment ramp and soak control is energized. Note Diagram No. 2 below.
control. The ramp-up rate is determined by the “rr”
setting. This setting can be adjusted in the range of
0-360°F (200°C) per minute. The ramp rate function is
disabled if the “rr” is set to 0. The soak function is Process Value
°F
accomplished by configuring the alarm relay to act as
timer. To use this function, set ALA1 to 12. The alarm 175
= 12
relay will be closed at start-up and it will stay closed
150 = 30
until the process temperature has remained at the set
point temperature for the time period set in ASP1. The 125
ASP1 setting is in minutes. When the alarm relay 30 Minutes
100
opens, the process temperature will drop at an Alarm Relay
uncontrolled rate. The heater power must be wired in 75 ON
OFF
series from the main relay through the alarm relay. The
control will now operate as a guaranteed soak control.
Please note the following example: The ramp rate “rr” 0 10 20 30 40 50 60 70 80 90
TIME/Minutes
is set to 5°F per minute. The ALA1 is set to 12, and the
ASP1 is set to 30 (minutes). When the unit is turned DIA. 1 Ramp and Soak
on, the process will climb at 5°F per minute to the set
point of 175°F. Once the set point has been reached,
the timer will activate. After 30 minutes, the alarm
Process Value
relay will open. The process temperature falls. The °F
process will repeat every time power has been switched Set point
175
off and on to the controller. See Diagram 1 at right.
150 = 13
Single Event Function = 30
125
The single event function may be used to control
30 Minutes Alarm Relay
external devices such as lights, bells or locks. It could 100
also be used to alert the operator when a guaranteed ON
soak time has been reached. To use this function, set 75 OFF

ALA1 to 13. The alarm relay will now operate as a

timer. The relay will be open at start-up. Once the set
0 10 20 30 40 50 60 70 80 90
point temperature has been reached and the time
TIME/Minutes
period set in ASP1 has elapsed, the alarm relay will
DIA. 2 Single Event
close. The relay will remain closed until power to the
Display Shift
In certain applications it is desirable to shift the con- controlling value or the temperature at the sensor must be
trollers indicated value from its actual value. This can be 375 degrees F. Due to the design and position of the
easily accomplished with this control by using the dis- components of the system, the sensor could not be
play shift function. Cycle the control to the para- placed any closer to the work.
meter by using the “Scroll” pushbutton. The number you Thermal gradients (different temperatures) are common
adjust here, either positive or negative, will be the and necessary to an extent in any thermal system for
amount that the process value (PV) will be shifted from heat to be transferred from one point to another.
the actual value. This amount will be the same across
the entire range of the control. Note the example stated The difference between the two temperatures is 45
below. degrees F. You should input –45 as to subtract 45
degrees from the actual process value (PV). Cycle the
The desired temperature at the part to be heated is 330 control back to the process value after making this
degrees F. In order to achieve that temperature, the adjustment.

DISPLAY BEFORE DISPLAY AFTER DISPLAY AFTER SHIFT AND SV

INPUT SHIFT. INPUT SHIFT. ADJUSTMENT
ADJUST SV TO 330.

HEAT TRANSFER
HEAT SOURCE MEDIUM
Figure 5.5 Display Shift

MOLD SENSOR PART BEING HEATED

375°F OR "WORK" 330°F
Section 6: CALIBRATION PROCEDURE

Changing these values can make the control useless because it can be put out of calibration. Do not
WARNING! attempt to re-calibrate this temperature controller unless you have an adequate calibration instrument
available. This must be used to simulate the sensor input.

The controller must operate under power for at least 45 3.) Press the scroll button again and the high calibration
minutes before starting the calibration procedure. This parameter ( ) will be displayed. Adjust the input sim-
allows the internal components to reach the proper ulator to the high calibration (span) value as indicated in
operating temperature. Connect the calibrating instru- the chart. Adjust the controller to the same value. Press
ment to the ETR control and power leads. the button for exactly 6 seconds to calibrate the
STEP: high (or SPAN) calibration point.
1.) Press and release the scroll key ( ) cycling 4.) The calibration is now complete. Press the scroll but-
through the parameters to make certain they are cor- ton again and process value and setpoint value will
rect. Note the display flow chart on pages 10 & 11. Long appear.
scrolls (pressing the button for 6 seconds) must be used Check intermediate values to test mid-range calibration
where indicated. Check parameters such as ,input accuracy. The procedure can be repeated again if the
type, degrees C or degrees F and resolution. The span accuracy of the controller is not acceptable. Also you
of the control ( ) and ( ) must be extended out can easily add an arbitrary offset value if desired during
to their maximum values. Example: when using a type the calibration procedure by changing the simulator
“J” thermocouple the low range value must be –58 value.
degrees F (–50 deg. C) and the high range value Calibration can be recorded in the accompanying chart.
must be 1832 degrees F (1000 deg. C). These values
are listed in the chart on page two for other sensor
types. The span of the control can be narrowed to your CALIBRATION VALUES
preferred range after the calibration procedure is com- T/C Type ‘J’ RTD DIN
pleted. SENSOR SENSOR
2.) Press the scroll button again for a long scroll and the 32°F 32°F
low calibration parameter ( ) will be displayed. 1112°F 752°F
Adjust the input simulator to the value indicated in the
chart to the right. This value must also match the value NOTE: The above values must be used for correct cali-
in the controls display. Correct if necessary. Press the bration.
button for exactly 6 seconds to calibrate the low (or
zero) calibration point.

:Low Calibration parameter

:High Calibration parameter

CALIBRATION RECORD
Control Date Calibrated Date Next
No.: Calibrated: By: Calibration Due:
Section 7: TROUBLESHOOTING

THIS PROCEDURE REQUIRES ACCESS TO THE CIRCUITRY OF A LIVE POWER UNIT.

WARNING! 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 and
Table 7.1 on the next page for some of the other common causes of failures:

Incorrect parameters entered in menu. Short across terminals.

Excessive electrical interference. Open or shorted heater circuit.
Line wires are improperly connected. Open coil in external contactor.
No voltage between line terminals. Burned out line fuses.
Incorrect voltage between line terminals. Burned out relay inside control.
Connections to terminals are open, missing or loose. Defective solid-state relays.
Thermocouple (or RTD) is open at tip. Defective line switches.
Thermocouple (or RTD) lead is broken. Burned out contactor.
Shorted thermocouple (or RTD) leads. Defective circuit breakers.

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

Return control to:

OGDEN MANUFACTURING COMPANY
ATTN: REPAIR DEPARTMENT
64 WEST SEEGERS ROAD
ARLINGTON HEIGHTS, IL 60005

NOTE:
Control can be removed from housing by pushing in
latch located on bottom of bezel and pulling control
from housing. Power must first be disconnected.
 Table 7.1 Troubleshooting

Symptom Probable Cause(s) Solution(s)

1.) LED’s will not light. —No power to instrument. —Check power line connections.
—Power supply defective. —Replace power supply board.
2.) Some segments of the display or —LED display or LED Lamp defec- —Replace LED display or LED lamp.
LED lamps not lit or lit erroneous- tive.
ly. —Related LED driver defective. —Replace the related transistor or IC
chip.
3.) Process Display shows: —Sensor break error. —Replace RTD or sensor.
—Use manual mode operation.
4.) Process Display shows: —Process value beyond the low —Re-adjust value.
range setpoint.
5.) Process Display shows: —Process value beyond the high —Re-adjust value.
range setpoint.
6.) Process Display shows: —Analog hybrid module damage. —Replace module. Check for outside
source of damage such as tran-
sient voltage spikes.
7.) Process Display shows: —Incorrect operation of auto tune —Repeat procedure. Increase Prop.
procedure. Prop. Band set to 0. Band to a number larger than 0.
8.) Process Display shows: —Manual mode is not allowable for —Increase proportional band.
an ON-OFF control system.
9.) Process Display shows: —Check sum error, values in memory —Check and reconfigure the control
may have changed accidentally. parameters.
10.) Display Unstable —Analog portion or A-D converter —Replace related components or
defective. board.
—Thermocouple, RTD or sensor —Check thermocouple, RTD or sen-
defective. sor.
—Intermittent connection of sensor —Check sensor wiring connections.
wiring
11.) Considerable error in tempera- —Wrong sensor or thermocouple —Check sensor or thermocouple type
ture indication. type. Wrong input mode selected. and if proper input mode was
selected.
—Analog portion A-D converter —Replace related components or
defective. board.
12.) Display goes in reverse direction —Reversed input wiring of sensor. —Check and correct.
(counts down scale as process
warms).
13.) No heat or output —No heater power (output), incorrect —Check output wiring and output
output device used. device.
—Output device defective. —Replace output device.
—Open fuse outside of the instru- —Replace output fuse.
ment.
14.) Heat or output stays on but indi- —Output device shorted, or power —Check and replace.
cator reads normal. service shorted.
15.) Control abnormal or operation —CPU or EEPROM (non-volative —Check and replace.
incorrect. memory) defective. Key switch
defective.
—Operation of control incorrect. —Read the operation procedure care-
fully.
16.) Display blinks, entered values —Electromagnetic interference (EMI), —Suppress arcing contacts in system
change by themselves. or Radio Frequency Interface (RFI). to eliminate high voltage spike
sources. Separate sensor and con-
troller wiring from “dirty” power
lines, ground heaters.
—EEPROM defective. —Replace EEPROM.