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1. oA Jc gt OA 5 ex Jc 5 OA Jc 5 cx c C DOA KS DOA n d Hand Manual cx for 3 seconds c BE 3c 5 93x Control gc 563 E C 206 Mode A BIC 2E a aes C 5 9x
2. Al A2 C F Lid y LI 5 2 gd A Y e IBicl BTC 9300 A1 A2 C F LI L L1 III d C All segments of display and indicators are left off for 0 5 second All segments of display and indicators are lit for 2 seconds Display program code of the product for 2 5 seconds The left diagram shows program no 1 for BTC 9300 with version 35 Display Date Code and Serial number for 2 5 seconds The left diagram shows Year 1998 Month July 7 Date 31 st and Serial number 192 This means that the product is the 192 th unit produced on July 31 st 1998 Note that the month code A stands for October B stands for November and C stands for December Display the used hours for 2 5 seconds The left diagram shows that the unit has been used for 23456 2 hours since production UM93001C Figure 1 5 Display Sequence of Initial Message Program Code I Program Version a UN E Program No Date Code ii UA a Date 31 st Month December Year 1999 1 5 Menu Overview PV Value User Svane Menu
3. Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value N type thermocouple L type thermocouple PT 100 ohms DIN curve PT 100 ohms JIS curve 4 20 mA linear current input IN1 Sensor Type Selection D etu 0 20 mA linear current input D 7 0 1V linear Voltage input g 5 fag 0 5V linear Voltage input 1 54 1 5V linear Voltage input a i ig 0 10V linear Voltage input SPEL Special defined sensor curve ar Degree C unit IN1 Unit Selection OF Degree F unit i Pu Process unit nocd No decimal point IN1 Decimal Point Selection i dP een 1 C dP 2 decimal digits 3 J F 3 decimal digits IN1 Low Scale Value Low 19999 High 45536 0 IN1 High Scale Value Low 19999 High 45536 1000 0 nan E IN2 no function 1 Lt Current transformer input 4 20 mA linear current input 0 20 mA linear current input IN2 Signal Type Selection 0 1V linear voltage input 1 0 5V linear voltage input 1 5V linear voltage input 7 0 10V linear voltage input IN2 Unit Selection Same as IN1U 2 IN2 Decimal Point Selection Same as DP1 1 IN2 Low Scale Value Low 19999 High 45536 0 IN2 High Scale Value Low 19999 High 45536 1000 or E L Reverse heating control action Output 1 Function 0 1 gi cr t Direct cooling control action 0 EL 1j Relay output 1 r Solid state relay drive output 2 amp 45 Solid state relay ou
4. Qe Max 247 units can be linked Vs Qv Os Qe UM93001C Terminator 220 ohms 0 5W TX2 TX1 36 2 16 RS 232 88688969 9909090QG TX1 TX2 COM 9 pin RS 232 port FREI g CC94 1 Note f the BTC 9300 is configured for RS 232 communication the El Event Input is disconnected internally The unit can no longer perform event input function EIFN When you insert a RS 232 module CM94 2 to the connectors on CPU board C930 the jumper JP22 on terminal board T930 must be modified as following J1 must be shorted and J2 must be cut and left open Location of JP22 is shown in the following diagram If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable must PC be modified according to the following circuit diagram BTC 9300 9 T2 10 cow Q4 89M Female DB 9 UM93001C To DTE PC RS 232 Port 1 DCD 2 RD 3 TD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI Figure 2 19 RS 232 Wiring Figure 2 20 Location of Jumper JP22 Figure 2 21 Configuration of RS 232 Cable 37 2 17 Analog Retransmission Or Qe O Q Qe oOo Qe Load Retransmit Voltage
5. 87 5 5 Heat Cool Control 88 5 6 Ramp amp Dwel a 90 5 7 Remote Set Point lt ss saa se eee 92 5 8 Differential Control 93 5 9 Dual Set Point PID 94 5 10 RS 485 96 5 11 RS 232 esee ee eee 98 5 12 Retransmit 7 99 Chapter 6 Calibration 100 Chapter 7 Error Codes amp Troubleshooting 104 Chapter 8 Specifications 107 Appendix A 1 Menu Existence Conditions 110 A 2 Factory Menu Description 113 A 3 Glossary 115 AA Index cc EA 122 A 5 Memo 125 A 6 Warranty 127 Chapter 1 Overview 1 1 Features High accuracy 18 bit input A D High accuracy 15 bit output D A Fast input sample rate 5 times second Two function complexity levels User menu configurable xx Pump control Fuzzy PID microprocessor based control Automatic programming Differential control x Auto tune function Self tune function x Sleep mode function Soft start ramp and dwell timer Programmable inputs thermocouple RTD mA VDC Analog input for remote set point and CT Event input for changing f
6. Press A Sleep Key Peter enters the sleep mode if the sleep function SLEP is enabled for at least 3 seconds selec By entering correct security code to allow execution of engineering programs Press A Factory Key This function is used only at the factory to manage the diagnostic reports The user should never attempt to operate this function Alarm 1 Indicator How to display a 5 digit number Alarm 2 Output 2 Indicator For a number with decimal point the Process Value Indicator display will be shifted one digit right Process Unit Indicator 199 99 will be displayed by 199 9 r Upper Display 4553 6 will be displayed by 4553 to display process value m menu symbol and error For a number without decimal point Li J code etc the display will be divided into two Set point LI alternating phases Value r Lower Display l i Indicator to display set point value 19999 will be displayed by parameter value or control d output value etc g g g 3 Silicone Rubber Buttons BTC 9300 for ease of control setup Figure 1 4 Front Panel Description 274 set point adjustment 45536 will be displayed by Table 1 3 Display Form of Characters CN 4 5536 9999 will be displayed by N z s be he pe B C C D 7 Confused Character UM93001C 9 10 IBicl BTC 9300 Al A2 PV C F io LLLLLLLI
7. 0 5V Chart Recorder Figure 5 18 Retransmission Application 20 30 C 2 40 50 SP1L and SP1H are used to limit the adjustment range of set point UM93001C 99 Chapter 6 Calibration A Do not proceed through this section unless there is a definite need to re calibrate the controller Otherwise all previous calibration data will be lost Do not attempt recalibration unless you have appropriate calibration equipment If calibration data is lost you will need to return the controller to your supplier who may charge you a service fee to re calibrate the controller Entering calibration mode will break the control loop Make sure that if the system is allowable to apply calibration mode Equipments needed before calibration 1 A high accuracy calibrator Fluke 5520A Calibrator recommended with following functions 0 100 mV millivolt source with 0 005 accuracy 0 10 V voltage source with 0 005 96 accuracy 0 20 mA current source with 0 005 96 accuracy 0 300 ohm resistant source with 0 005 96 accuracy 2 A test chamber providing 25 C 50 C temperature range 3 A switching network SW6400 optional for automatic calibration 4 A calibration fixture equipped with programming units optional for automatic calibration 5 A PC installed with calibration software BC Net and Smart Network Adaptor SNA10B optional for automatic calibration The calibration procedures described in the following
8. DB Apply Auto tuning at 120 C for a new system to get an optimal PID values See Section 3 19 Adjustment of CPB is related to the cooling media used If water is used as cooling media instead of oil the CPB is set at 250 If air is used as cooling media instead of oil the CPB is set at 100 Adjustment of DB is dependent on the system requirements More positive value of DB will prevent unwanted cooling action but will increase the temperature overshoot while more negative value of DB will achieve less temperature overshoot but will increase unwanted cooling action UM93001D 89 5 6 Ramp amp Dwell Example 1 Temperature cycling Chamber A chamber is used to test the temperature cycling effect on the personal computers An external cycle timer is used to control the event input for switching the set point The products under test are required to stay at 60 C for 1 hour and 10 C for 30 minutes The transition interval between high low temperature is required to be 5 minutes Make the following setup EIFN SPP2 A1FN TIMR OUT1 REVR Relay Output OUT2 COOL 4 20mA Output SPMD MINR IN1U C DP1 1 DP The circuit diagram and its temperature profile are shown below Chamber C Freezer RTDB Heater 3PAC ie rea Inverter ELS mans TT AC Relay MIZUNE s 88608080 Lool BTC 9300 TIME 60 0 minutes
9. The pressure gauge is switched ON as it senses a higher pressure Connect the output contacts of the pressure gauge to the event input SP1 is set with a normal temperature and SP2 is set with a higher temperature Choose ACTU for SP2F Application 2 An oven is required to be heated at 300 C from eight o clock AM to six o clock PM After six o clock PM it is desirable to be maintained at 80 C Use a programmable 24 hours cycle timer for this purpose The timer output is used to control event input Set SPMD SP1 2 and EIFN SP2 or SPP2 if the second PID is required to be used for the second set point SP1 is set with 300 C and SP2 is set with 80 C Choose ACTU for SP2F After six o clock PM the timer output is closed The event input function will select SP2 80 C to control the process Refer to Section 4 1 for more descriptions about SP2F function UM93001C SP2F Format of SP2 Value ACTU SP2 is an actual value DEVI SP2 is a deviation value Apply Signal To Event input 3 Event input Setup EIFN choose SP2 or SPP2 Availability SPMD choose Or ni mi or Aro Format of SP2 Value SP2F choose C wu Actual Value or d amp Deviation Value 69 4 3 Second PID Set In certain applications the process characteristics is strongly related to its process value The BTC 9300 provides two set of PID values When the process is changed to different set point the PID values can
10. 38 The total effective resistance of serial loads can t exceed 500 ohms Indicators PLC s Recorders Data loggers Inverters etc Figure 2 22 Analog Retransmission Wiring The total effective resistance of parallel loads should be greater than 10K Ohms Indicators PLC s Recorders Data loggers Inverters etc UM93001C 2 18 Programming Port See Figure 1 3 in Section 1 3 to find the programming port location Programmer connector and ATE connector inserted here Xe Access hole on the bottom view Programmer P10A Figure 2 23 Programming Port Wiring Switch Unit SW6400 HP 34401A Calibrator Fluke 5520A NOTE The programming port is used for off line automatic setup and testing procedures only Don t attempt to make any connection to these jumpers when the unit is used for a normal control purpose UM93001C 39 Chapter 3 Programming the Basic Function This unit provides an useful parameter FUNC which can be used to select If you don t need the function complexity level before setup If the Basic Mode FUNC BASC 1 Second setpoint is selected for a simple application then the following functions are ignored 2 Second PID and deleted from the full function menu 3 Event input RAMP SP2 PB2 TI2 TD2 PL1 PL2 COMM PROT ADDR BAUD DATA 4 Soft start RAMP PARI STOB AOFN AOLO AOH
11. Failure Transfer Setup 1 O1FT 2 O2FT 3 ATFT 4 A2FT 3 17 Bumpless Transfer The bumpless transfer function is available for output 1 and output 2 provided that OUT2 is configured as COOL Bumpless Transfer is enabled by selecting BPLS for O1FT and or O2FT and activated as one of the following cases occurs 1 Power starts within 2 5 seconds 2 The controller enters the failure mode See Section 3 16 for failure mode descriptions 3 The controller enters the manual mode See Section 3 22 for manual mode descriptions 4 The controller enters the calibration mode See Chapter 6 for calibration mode descriptions As the bumpless transfer is activated the controller will transfer to open loop control and uses the previous averaging value of MV1 and MV2 to continue control Without Bumpless Transfer PV J Power interrupted on break Large deviation Set point Time Since the hardware and software need time to be initialized the control is abnormal as the power is recovered and results in a large disturbance to the process During the sensor breaks the process loses power With Bumpless Transfer PV Power interrupted Sensor break Set point Load varies Small deviation After bumpless transfer configured the correct control variable is applied immediately as the power is recovered the disturbance is small During the sensor breaks
12. Jc Sak JC BOBA c DIOR cc 5 amp 9 amp c C DRIES C gt ex c C 5 ela c 5 tA C Pela Auto tuning N EJ C 5 9 Sc gt a A s A aide sep bec scent Ber Press amp for 3 seconds to enter gc 53A gc 5 9E the auto tuning mode gc 5 3x 3 C DIES 5 ex ex Jc SRK cc t X PIOA KA DIES c C 5 amp AJ cc DEES G Jc 5 c ax Display ec SERE Mode eC 5 9A Jc 5 9x c 2 9A cc 5 89A Jc 5 OA X mC zh 2892 Display Go Home c9 C 5 9 Sc BE The menu will revert to Defaul 2 BICIA OKA 06 PV SV display after keyboard efault e gc 2 is kept untouched for Setting FILE eic Sma P a2 2 minutes except Display Mode to gc EIE Sic sae Mode Menu and Manual 3 seconds Fel C PIGIA gc gt 06 Mode Menu However the To execute the e z AKA 0A menu can revert to PV SV default setting e C 5 9A display at any time by program QC De gc 0A Gc pressing and Calibration 2 lc 29 Jc 5 etx Mode SE ADO ec 2 E365 ej C ADG De C 5 amp Xx e Viel QC 2 amp a HL OG sc 206 E CJG cC 5 eA REF1 2 955 JC SR1 5 9x 2 CM AiG 98 1 The flow chart shows a complete listing of all parameters cc V2G 5 IES For actual application the number of available parameters 2 Cag AoG QB depends on setup conditions and should be less 5 than that shown in the flow chart See Appendix A 1 for the existence conditions of each parameter Apply these modes will
13. Perform step 10 to calibrate offset of cold junction compensation if required The DIP switch is set for T C input Step 10 Setup the equipments according to the following diagram for DIP Switch Position 102 calibrating the cold junction compensation Note that a K type ON TCi thermocouple must be used i A A A input 5520A 12 Calibrator BTC 9300 ae Figure 6 2 Cold Junction Calibration Setup Stay at least 20 minutes in still air room room temperature 25 3 C The 5520A calibrator is configured as K type thermocouple output with internal compensation Send a 0 00 C signal to the unit under calibration UM93001C The unit under calibration is powered in a still air room with temperature 25 x 3 C Stay at least 20 minutes for warming up The DIP Switch is located at TC input Perform step 1 stated above then press scroll key until the display shows Apply up down key until value 0 00 is obtained Press scroll key at least 3 seconds The display will blink a moment anda new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 5 00 or 40 00 then the calibration fails x Perform step 11 to calibrate gain of cold junction compensation if required otherwise perform step 11N to use a nominal value for the cold junction gain if a test chamber for calibration is not available Step 11 Setup the equipments same as step 10 The unit under calibratio
14. S 105 105 105 ON T 105 105 P b x 100 100 95 95 UM93001C 2 Types of Deviation Band Alarms DB HI DB LO Deviation Band Alarm 1 Setup A1FN A1MD Adjust SP1 A1DV Trigger levels SP1 A1DV Deviation Band Alarm 2 Setup OUT2 A2FN A2MD Adjust SP1 A2DV Trigger levels SP1 A2DV Error Code Figure 3 13 Normal Deviation Band Alarm 105 100 Figure 3 14 95 Latching Deviation Band Alarm 105 Figure 3 15 i Holding Deviation Band Alarm 105 100 Figure 3 16 95 Latching Holding Deviation Band Alarm 51 3 11 Heater Break Alarm A current transformer parts No CT94 1 should be installed to detect the Heater Break Alarm 1 heater current if a heater break alarm is required The CT signal is sentto Setup IN2 CT input 2 and the PV2 will indicate the heater current in 0 1 Amp resolution AIFN PV2 L The range of current transformer is 0 to 50 0 Amp ATMD NORM For more detailed descriptions about heater current monitoring please see AIHY 0 1 Section 3 24 Adjust A1SP Trigger levels ATSP x 1 2 A1HY Heater Break Alarm 2 Example Setup IN2 CT A furnace uses two 2KW heaters connected in parallel to warm up the process A2FN PV2 L The line voltage is 220V and the rating current for each heater is 9 09A If we A2MD NORM want to detect any one heater break set A1SP 13 0A A1HY 0 1 A2HY 0 1 A1FN PV2 L AIMD NOR M then Adjust A2SP Trigger levels A2SP 1 2 A2HY Limitation
15. 0 and TH or TI2 0 should use reverse mode heating action otherwise don t use OUT2 for cooling control Illegal setup values been used unequal IN1U and IN2U or Check and correct setup values of IN1U IN2U DP1 DP2 unequal DP1 and DP2 while P1 2 or P2 1 is used for PVMD PVMD SPMD A1FN or A2FN Same unit and decimal point or PV1 or PV2 is used for SPMD or P1 2 H P1 2 L D1 2 H should be used if both PV1 and PV2 are used for PV SV or D1 2 L are used for A1FN or A2FN alarm 1 or alarm 2 Illegal setup values been used OUT2 select AL2 but Check and correct setup values of OUT2 and A2FN OUT2 A2FN select NONE will not perform alarm function if A2FN select NONE Illegal setup values been used Dwell timer TIMR is Check and correct setup values of A1FN and A2FN Dwell selected for both A1FN and A2FN timer can only be properly used for single alarm output Correct the communication software to meet the protocol requirements Communication error bad function code Communication error register address out of range Don t issue an over range register address to the slave Communication error access a non existent parameter Don t issue a non existent parameter to the slave Communication error attempt to write a read only data Don t write a read only data or a protected data to the slave Communication error write a value which is out of range to a register Don t write an over range data to the slave reg
16. 40 57 58 65 75 97 98 108 Manual tuning 43 45 60 61 105 Menu overview 11 Mini jumper and DIP switch 8 Mold 88 95 Mounting 21 MV1 19 53 56 57 65 66 68 75 77 108 MV2 19 56 57 65 66 68 75 77 108 O1FT 11 16 56 57 83 86 89 O1HY 11 13 43 44 45 87 O1TY 11 15 16 41 43 45 67 83 85 86 87 89 93 O2FT 11 16 56 57 89 O2TY 11 16 41 45 67 85 89 OFST 11 13 18 42 43 45 On off control 13 43 44 45 56 58 59 60 65 75 87 Ordering code 7 64 77 OUT1 11 15 22 41 43 44 45 65 75 82 83 85 86 87 88 89 90 92 93 105 UM93001C OUT2 11 16 22 41 45 48 50 51 58 54 56 57 64 65 75 82 83 85 88 89 90 105 Output 1 7 9 13 14 15 16 17 19 30 40 41 43 45 56 57 65 66 67 68 75 82 85 87 101 107 108 Output 2 7 9 13 14 16 17 19 32 40 41 45 50 56 57 64 65 66 67 68 75 82 85 101 107 108 Oven 5 69 86 91 92 104 Parameter description 3 13 14 15 16 17 18 19 PARI 5 11 14 40 76 85 97 98 108 PB 11 19 46 58 60 62 66 105 108 PB1 11 13 17 18 42 43 45 46 56 58 59 61 62 65 68 70 75 81 83 87 94 95 105 PB2 11 13 17 18 40 42 46 58 59 62 65 68 70 94 95 105 P or PD control 4 12 13 18 40 43 57 65 80 81 PID adjustment 62 63 PID control 5 6 40 43 44 45 58 59 60 68 91 PL1 11
17. E gt 4 20 mA E T Water pa m Xx ontro Motor Pump 3h AC AC gt Inverter t Water The water pressure is required to be controlled at 10 Kg cm to achieve this the following devices are used for this example Inverter To supply a variable frequency AC voltage to the motor Motor A 3 induction motor Pump An economical type Pressure Sensor A three wire or two wire type pressure transducer with 0 20 Kg cm range Pressure Reservoir Providing a smoother pressure for the system BTC 9300 4137XX Order a BTC 9300 with standard input 4 20 mA output 1 20V DC output 2 for sensor power 82 UM93001C Set the following parameters in the setup menu FUNC FULL COMM optional IN1 4 20 INTU PU DP1 2 DP IN1L 0 IN1H 20 00 IN2 NONE OUT1 REVR O1TY 4 20 O1FT 0 OUT2 DCPS A1FN optional EIFN NONE PVMD PV1 FILT 1 SELF NONE SLEP NONE SPMD PUMP SP1L 5 00 SP1H 15 00 SP2F DEVI Adjust the following parameters in the user menu A1SP optional Key menu REFC 3 SPMD PB1 10 00 SP2F TH 21 REFC TD120 2 ane SP2 0 50 PL1 100 Also refer to Section 4 12 for more details UM93001C 5 2 Variable Period Full Wave SSR VPFW SSR VPFW SSR is a variable period full wave solid state relay It can provide a zero cross output with superior controllability compared to a conventional SSR with a fixed time base The block diagram of VPFW SSR is shown as follows AC AC Input Output ti rr Figure 5 2 Block Diagram of
18. Figure 3 23 Manual Tuning Procedure 0 8PB1 gt PB1 Wait and Examine the Process Is steady state reached the process oscillate Yes PB1 PBu Oscillating period Tu Load new PID values 1 7 PBu PB1 Tu TH 0 3 Tu TD1 END NOTE The final PID values can t be zero If PBu 0 then set PB1 1 If Tu lt 1 sec then set Tl1 1 sec The above procedure may take a long time before reaching a new steady state since the P band was changed This is particularly true for a slow process So the above manual tuning procedures will take from minutes to hours to obtain optimal PID values UM93001C 61 The PBu is called the Ultimate P Band and the period of oscillation Tu is called the Ultimate Period in the flow chart of Figure 3 23 When this occurs the process is called in a critical steady state Figure 3 24 shows a critical steady state occasion If PB PBu the process sustains to oscillate Figure 3 24 Critical Steady Set point 7 State j Time If the control performance by using above tuning is still unsatisfactory the following rules can be applied for further adjustment of PID values ADJUSTMENT SEQUENCE SYMPTOM SOLUTION Slow Response Decrease PB1 or PB2 1 Proportional Band P PB1 and or PB2 High overshoot or increase PB1 or PB2 Oscillations Slow Response Decrease TI1
19. Refer to Section 5 9 for more details 70 UM93001C Apply Signal To Event input 3 Event input Setup EIFN choose PID2 or SPP2 EIFN SPP2 EIFN PID2 Alarm output Controls the Event input See Section 5 9 4 4 Ramp amp Dwell Ramp The ramping function is performed during power up as well as any time the set point is changed Choose MINR or HRR for SPMD the unit will perform the ramping function The ramp rate is programmed by using RAMP which is contained in user menu Example without Dwell Timer Select MINR for SPMD IN1U selects C DP1 selects 1 DP Set RAMP 10 0 SP1 is set to 200 C initially and changed to 100 C after 30 minutes since power up The starting temperature is 30 C After power up the process is running like the curve shown below minutes Note When the ramp function is used the lower display will show the current ramping value However it will revert to show the set point value as soon as the up or down key is touched for adjustment The ramping value is initiated to process value either power up or RAMP and or set point are changed Setting RAMP to zero means no ramp function at all Dwell The Dwell timer can be used separately or accompanied with a Ramp If A1FN selects TIMR the alarm 1 will act as a dwell timer Similarly alarm 2 will act as a dwell timer if A2FN selects TIMR The timer is programmed by using TIME which is contained in user menu The Timer starts
20. SP1 60 0 C SISISISISISTS 1 SP2 10 0 C CPB 100 ee Cycle Timer RAMP 14 0 C minute 90 UM93001C Figure 5 8 A Temperature Cycling Chamber 60 minutes 60 minutes al 60 C 60 C Figure 5 9 Temperature Profile of Chamber 39 minutes 5 minutes 65 minutes BTC 9300 provides 4 20 mA signal to control the speed of the Inverter SPP2 being chosen for EIFN is for the purpose of accomplishing a dual PID control You can perform auto tuning twice at SP1 and SP2 for initial setup to the dual PID values Refer Sections 3 19 and 4 3 30 minutes Example 2 Programmable Bread Baking Oven Bread is baked in batches A ramp is incorporated to control the thermal gradient to suit for making the bread A dwell timer is used to shut off the oven power and announce the baker The system is configured as shown in the following diagram AC Relay 220VAC Mains Terminal O use Form B Relay Figure 5 10 A Bread Baking Oven Order a form B relay for Alarm 1 Push ON switch to start a batch The temperature will rise with a ramp rate determined by RAMP value Bread is baked with the set point temperature for a definite time which is programmed by TIME value and then the power is shut off The temperature profile is shown in the following Figure 40 A1FN TIMR ou SPMD MINR Figure 5 11 B 180 C Time 40 0 minutes Temperature Profile RAMP 30 0 C
21. the controller continues to control by using its previous value If the load doesn t change the process will remain stable Thereafter once the load changes the process may run away Therefore you should not rely on a bumpless transfer for a longer time For fail safe reason an additional alarm should be used to announce the operator when the system fails For example a Sensor Break Alarm if configured will switch to failure state and announces the operator to use manual control or take a proper security action when the system enters failure mode UM93001C Bumpless Transfer Setup 1 O1FT BPLS 2 O2FT BPLS Bumpless Transfer Occurs as 1 Power Starts within 2 5 seconds 2 Failure mode is activated 3 Manual mode is activated 4 Calibration mode is activated Figure 3 21 Benefits of Bumpless Transfer Warning After system fails never depend on bumpless transfer for a long time otherwise it might cause a problem to the system to run away 57 3 18 Self tuning The Self tuning which is designed by using an innovative algorithm provides an alternative option for tuning the controller It is activated as soon as SELF is selected with YES When Self tuning is working the controller will change its working PID values and compares the process behavior with previous cycle If the new PID values achieve a better control then changing the next PID values in the same direction otherwise changing the next PID valu
22. 20 mA and O 10 volts BTC 9300 is fully programmable for PT100 thermocouple types J K T E BB R S N L O 20mA 4 20mA and voltage signal input with no need to modify the unit The input signals are digitized by using a 18 bit Ato D converter Its fast sampling rate allows the BTC 9300 to control fast processes such as pressure and flow Self tune is incorporated The self tune can be used to optimize the control parameters as soon as undesired control result is observed Unlike auto tune Self tune will produce less disturbance to the process during tuning and can be used any time 4 UM93001D Unique Valuable Digital communications RS 485 RS 232 or 4 20 mA retransmission are available as an additional option These options allow BTC 9300 to be integrated with supervisory control system and software or alternatively drive remote display chart recorders or data loggers Three kinds of method canbe used to program BTC 9300 1 Use keys on front panel to program the unit manually 2 Use a PC and setup software to program the unit via RS 485 or RS 232 COMM port and 3 Use P10A a hand held programmer to program theunit via programming port In last nearly a hundred years although PID control has been used and proved to be an efficient controlling method by many industries yet the PID is difficult to deal with some sophisticated systems such as second and higher order systems long time lag systems during set point change
23. Low 19999 High 45536 E TYPE LEYPE Signal Type of Special Sensor Low 0 High 3 DATE oALE Manufacturing Date of Product Low 0 High 3719 NO mo Serial Number of Product Low 1 High 999 These parameters are available only if IN1 selects SPEC UM93001C 113 Parameter Notation Display Format Parameter Description Range Default Value HOUR HRLO Hour Working Hour Value Fractional Hour Value Historical Error Record 1 Historical Error Record 2 High 65535 Hours High 0 9 Hour High FFFF High FFFF ASCII Input Delimiter Low 0000 High 007F 000A Bb PL OUT1 Bumpless Transfer Value Low O0 High 100 00 OUT2 Bumpless Transfer Value Low 0 High 100 00 Sense Voltage of Cold Junction Calibration Low High 40 320 mV 114 UM93001C A 3 Glossary Abosolute zero The lowest theoretical temperature At absolute zero a body would have no molecular motion of heat energy Absolute zero is the zero point on the Rankine and Kelvin scale 273 15 C or 459 67 F AC Alternating Current an electric current that reverses direction at regularly occurring intervals Accuracy Calibration accuracy The potential error of a device compared to a physical constant or agency standard Control accuracy Maintaining a process at the desired setting The errors or combination of errors in
24. Output Direct Drive 31 2 12 Output 2 Wiring Max 2A Resistive Load gt 120V 240V Mains Supply 4 6 7 8 STSISISISIS IS IS Relay Output Direct Drive Figure 2 15 Output 2 Wiring OQOOOQOOOQO 9 10 11 12 13 14 15 16 120V 240V Mains Supply 1 2 4 6 T 8 OQOOOOOQO Q P IIIS 04 9 0 0 Three op 5 o gt o Phase Heater O4 0 0 2 Power Three Phase No Fuse Relay or Triac SSR gt Delta Contactor Breaker Output to Drive Heater QKEOERKNSNOE ee Contactor 9 10 11 12 13 14 15 16 120V 240V Mains Supply Internal Circuit 30mA 5V 5v Pulsed Pulsed Voltage to Drive SSR Voltage 33 4 i 33 3 Www OONO QOQO d x 9 10 11 12 13 14 15 16 32 UM93001C P88 88888 0 1V 0 5V 1 5V 0 10V Maximum Load 500 ohms SSO89OSo OOOOOO9 Q 9 10 11 12 13 14 15 1 ez Max 1A 240V IIIS Triac eQ an oO un m INS I co m A m jor m lo Minimum Load 10 K ohms 120V 240V Mains Supply UM93001C Linear Current Linear Voltage Triac SSR Output Direct Drive 33 2 13 Alarm 1 Wiring Max
25. P2 1 SPMD SP1 2 Figure 4 4 Relation between PV1 and PV2 for a Differential Control Error Message ma 6 NN 4 7 Output Power Limits In certain system the heater or cooler is over designed such that the process is too heavily heated or cooled To avoid an excessive overshoot and or undershoot you can use the Power Limit function PL1 Output 1 power limit PL1 is contained in User Menu If output 2 is not used for PL2 cooling that is COOL is not selected for OUT2 then PL2 is hidden If the controller is used for ON OFF control then both PL1 and PL2 are hidden Operation Press for 3 seconds then press fe several times to reach PL1 and PL2 The PL1 and PL2 are adjusted by using up down keys with range 0 100 Menu Example OUT2 COOL PB1 10 0 C CPB 50 PL1 50 PL2 80 The output 1 and output 2 will act as following curves MV1 100 Figure 4 5 50 Power Limit Function MV2 10096 8096 OUT2 NOTE The adjusting range of MV1 H and MV2 C for manual control and or failure transfer are not limited by PL1 and PL2 UM93001C 4 8 Data Communication Two types of interface are available for Data Communication These are RS 485 and RS 232 interface Since RS 485 uses a differential architecture to drive and sense signal instead of a single ended architecture which is used for RS 232 RS 485 is less sensitive to the noise and suitable for a longer distanc
26. VPFW SSR Pulsed Voltage Control Input Unlike a conventional SSR the VPFW SSR always give the output an even number of half cycles full wave as shown in the following diagram VPFW SSR Conventional SSR comes Lo I Lf LI LE Power Input AALS AAA AAR AAA Figure 5 3 VPFW SSR l i vs Conventional SSR l i i l i f i Power Output Af f A The VPFW switches the load without DC current hence minimize the harmonic NOTES current and stress on the load The load life is prolonged 1 The VPFW SSR can be used to drive resistant load and some types of inductance load such as relay contactor magnetic switch solenoid valve etc However it can not drive Motor and Capacitance Load 2 Only AC power can supply VPFW SSR otherwise it will not operate properly As the duty cycle ie output power level of the control input is small the off period will be extended to keep the output resolution so that the conversion error is minimized As low as 0 1 of timing error can be achieved Hence VPFW SSR is particularly suitable for a smoother control 84 UM93001C The advantages of VPFW SSR over conventional SSR are summarized as following table VPFW SSR Conventional SSR Zero Cross Switching Proportional Timing Error e i Pn Table 5 1 cycle time Function Comparison between Control Achievement Good Conventional SSR and VPFW SSR The output 1 and output 2 of BTC 9300 can be connected to VPFW SSR directly prov
27. a range expressed in the same units as the range Specific gravity The ratio of mass of any material to the mass of the same volume of pure water at 4 C Specific Heat The ratio of thermal energy required to raise the temperature of a particle 1 degree to the thermal energy required to raise an equal mass of water 1 degree SSR Solid state relay see relay solid state Stability The ability of an instrument or sensor to maintain a constant output when a constant input is applied 120 Surge current A current of short duration occurring when power is initially applied to capacitive or resistive loads usually lasting no more than several cycles Temperature gradient The range of temperature variations at various physical locations throughout a thermal system Tera The prefix for one trillion T Thermal expansion An increase in size due to an increase in temperature expressed in units of an increase in length or increase in size per degree i e inches inch degree C Thermal lag The time delay in the distribution of heat throughout a thermal system Thermal system A regulated environment consisting of a heat source heat transfer medium sensing device and a process variable control instrument Thermistor A temperature sensing probe made of a mixture of metal oxides and encapsulated in epoxy or glass A large change in resistance is exhibited proportional to a change in temperature The resistance usually de
28. and IN2H should be set with values higher than the set point range used 92 UM93001C 5 8 Differential Control In certain applications it is desirable to control a second process such that its process value always deviates from the first process with a constant value Water tank 1 is 5 12 meters height and water tank 2 level is desirable to be maintained at 1 meter lower than tank 1 level Set the following parameters in the setup menu FUNC FULL IN1 INTL INTH According to Sensor 1 signal IN1U PU DP1 2 DP IN2 IN2L IN2H According to Sensor 2 signal IN2U PU DP2 2 DP OUT1 REVR O1TY 4 20 PVMD P1 2 SPMD SP1 2 From Controller Output Water Tank 1 Level Sensor 1 5 12 M Height Outlet gt SV 1 00 PV 1 00 PV1 5 12 PV2 4 12 4 20 mA Valve Control Output Water Tank 2 OUT1 Adjust SP1 here is 1 00 to control the difference between PV1 and PV2 Choosing P1 2 for PVMD the PV display will show the difference value PV1 PV2 between PV1 and PV2 and this value will be stabilized to the set point here is 1 00 If you need PV1 or PV2 instead of PV you can use the Display Mode to select PV1 or PV2 to be displayed See Section 3 23 The above diagram indicates PV2 instead of PV UM93001C 4 12 M Height Figure 5 13 Differential Control Example Level Sensor 2 Outlet 93 5 9 Dual Set Point PID The BTC 9300 will switch
29. at set point 2 If the process no longer consumes material the controller will shut off the pump as long as possible 3 The controller will restart the pump to control the pressure at set point as soon as the material is demanded again while the pressure falls below a predetermined value ie SP1 SP2 80 UM93001C Programming Guide 1 Perform auto tuning to the system under such condition that the material ie pressure is exhausted at typical rate A typical value for PB1 is about 10 Kg cm TI1 is about 1 second TD1 is about 0 2 second 2 If the process oscillates around set point after auto tuning then increase PB1 until the process can be stabilized at set point The typical value of PB1 is about half to two times of the range of pressure sensor 3 Increase FILT Filter can further reduce oscillation amplitude But a value of FILT higher than 5 seconds is not recommended A typical value for FILT is 0 50r1 4 Close the valves and examine that if the controller can shut off the pump each time The value of REFC is adjusted as small as possible so that the controller can shut off the pump each time when all the valves are closed A typical value for REFC is between 3 and 5 5 An ordinary pump may slowly lose the pressure even if the valves are completely closed Adjust SP2 according to the rule that a more negative value of SP2 will allow the pump to be shut off for a longer time as the valves are closed A typical v
30. can be avoided but an excessive overshoot over the set point will occur If more negative value of DB greater overlap is used an excessive overshoot over the set point can be minimized but an unwanted cooling action will occur It is adjustable in the range 36 0 to 36 0 of PB1 or PB2 if PB2 is selected A negative DB value shows an overlap area over which both outputs are active A positive DB value shows a dead band area over which neither output is active 46 UM93001D 3 7 Dwell Timer Alarm 1 or alarm 2 can be configured as dwell timer by selecting TIMR for A1FN or A2FN but not both otherwise Er07 will appear As the dwell timer is configured the parameter TIME is used for dwell time adjustment Error Code The dwell time is measured in minute ranging from 0 to 6553 5 minutes Once the process reaches the set point the dwell timer starts to count from zero until time out The timer relay will remain unchanged until time out The dwell timer operation is shown as following diagram Figure 3 4 Dwell Timer Function OFF T Timer starts If alarm 1 is configured as dwell timer A1SP A1DV A1HY and A1MD are hidden Same case is for alarm 2 Example Set A1FN TIMR or A2FN TIMR but not both Adjust TIME in minutes A1MD if A1FN TIMR or A2MD if A2FN TIMR is ignored in this case If a form B relay is required for dwell timer then order form B alarm 1 and configure A1FN Form B relay is not available f
31. can control one process in relation to the difference of a second process DIN Deutsche Industrial Norms A German agency that sets engineering and dimensional standards that now has worldwide recognition Drift A change in a value over a long period due to changes in factors such as ambient temperature time or line voltage Droop In time proportioning controls the difference in temperature between the set point and where the system temperature stabilizes Corrected by automatic or manual reset Dual output The primary output will regulate the process temperature A secondary output will be utilized for process cooling or as an alarm Duty cycle Percentage of load ON time relative to total cycle time Efficiency The amount of useful output versus energy input Electrical interference Electrical noise induced upon the signal wires that obscures the wanted information signal Electromagnetic Compatibility EMC A system meets three requirements 1 It does not cause interference with other systems 2 It is not susceptible to emissions from other systems and 3 It does not cause interference with itself Electromagnetic interference EMI An electrical and magnetic noise which can be generated when switching inductive devices lightning radio wave radiation electrostatic discharge etc emf Electromotive force A rise in electrical potential energy The principal unit is the volt Emissivity The ratio of
32. cease to flash and the unit revert to PID control by using its new PID values During pre tune stage the PID values will be modified if any unstable phenomenon which is caused by incorrect PID values is detected Without pre tune stage like other conventional controller the tuning result will be strongly related to the time when the auto tuning is applied Hence different values will be obtained every time as auto tuning is completed without pre tune It is particularly true when the auto tuning are applied by using cold start and warm start UM93001C Applicable Conditions PB1 0 TH 40 if PB1 TH TD1 assigned PB2 0 TI2 0 if PB2 TI2 TD2 assigned Pre tune Function Advantage Consistent tuning results can be obtained 59 Auto tuning Auto tuning Begins Complete Warm up Waiting Cycle E ycle pla Learning Cycle E New PID Cycle 2 Integral i Time PV Figure 3 22 Auto tuning Procedure Set Point Pre tune Stage Post tune Stage ON OFF Control PID Control PID Control Time Cold Start Auto tuning Auto tuning Begins Complete Pre4tune Stage Waiting Cycle Learning Cycle New PID Cycle e a 8 2 Integral Time Pre tune Stage Post tune Stage OP PID Control ON OFF Control PID Control PV Set Point Warm Start Ts If the auto tuning begins near the set point warm start the unit pas
33. or TI2 2 Integral Time 1 E TH and or T12 Instability or Increase TH or TI2 Table 3 2 PID Adjustment Guide Oscillations Slow Response or D TD4 or TD2 3 Derivative Time D Oscillations Sorcas or TD1 and or TD2 High Overshoot Increase TD1 or TD2 Figure 3 25 shows the effects of PID adjustment on process response P action PV PB too low Perfect Set point Figure 3 25 Effects of PID Adjustment PB too high Time 62 UM93001C action TI too high PV Set point Perfect TI too low Time D action py TD too low Perfect Set point TD too high Time UM93001C Figure 3 25 Continued Effects of PID Adjustment 63 3 21 Signal Conditioner DC Power Supply Three types of isolated DC power supply are available to supply an external transmitter or sensor These are 20V rated at 25mA 12V rated at 40 mA and 5V rated at 80 mA The DC voltage is delivered to the output 2 terminals Two line Transmitter Set Three line Transmitter or sensor NE COM IN OUT2 DC Power Supply Figure 3 26 NE DC Power Supply Applications WWOOQOOO 9 10 11 12 13 14 15 16 Bridge Type Sensor Qu Qe Caution Don t use the DC power supply beyond its rating curren
34. the entire system including the sensor control power load and design inefficiencies affect control accuracy Display accuracy The amount of potential error between a measured value and the control s displayed value Set point accuracy The potential error between a measured value and the control setting Alarm A control condition or function indicating that the process is a predetermined amount above or below the set point Alpha a The average percent change in resistance per degree of a pure metal resistance device between 0 and 100 C Usually designated by the Greek letter alpha a with units of ohm ohm C The common alpha for a platinum RTD is 0 00385 ohm ohm C Ambient compensation The design of an instrument such that changes in ambient temperature do not affect the readings of the instrument Ambient temperature The average or mean temperature of the surrounding air which comes in contact with the equipment and instruments under test Ampere amp A unit used to define the rate of flow of electricity current in a circuit units are one coulomb 6 25 x 107 electrons per second Analog indication A meter with graduated scale and a pointer that moves to indicate process condition Analog output A voltage or current signal that is a continuous function of the measure parameter Analog set point Potentiometer adjustment of the control setting ANSI American National Standards Institute Anti res
35. the control variable MV1 has reached to its maximum or minimum value within the detecting time interval a loop break alarm if configured will be actuated Heater Sensor Figure 3 18 Switching Loop Break Sources Controller Loop Break Sources Sensor Controller Heater Switching Device Device Loop Break Alarm if configured occurs when any following condition happens 1 Input sensor is disconnected or broken 2 Input sensor is shorted 3 Input sensor is defective 4 Input sensor is installed outside isolated from the process 5 Controller fails A D converter damaged 6 Heater or generally chiller valve pump motor etc breaks or fails or uninstalled 7 Switching device used to drive heater is open or shorted UM93001C 53 3 13 Sensor Break Alarm Alarm 1 or alarm 2 can be configured as sensor break alarm by selecting SENB Sensor Break Alarm 1 5Enb for ATFN or A2FN If alarm 2 is required for sensor break alarm then Setup ATFN SENB OUT2 should be selected with AL2 A1MD NOR M LTCH The sensor break alarm is activated as soon as failure mode occurs Refer to Hidden TIME A1SP A1DV Section 3 16 for failure mode conditions Note that A D failure also creates a A1HY sensor break alarm TIME A1SP A1DV and A1HY are hidden if alarm 1 is configured as a sensor break alarm Similarly TIME A2SP A2DV and A2HY are Sensor Break Alarm 2 hidden if alarm 2 is configured as a
36. will perform bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 2 If OUT2 selects COOL and a value of 0 to 100 0 is set for O2FT then output 2 will perform failure transfer Thereafter the value of O1FT will be used for controlling output 2 Alarm 1 Failure Transfer is activated as the controller enters failure mode Thereafter the alarm 1 will transfer to the ON or OFF state preset by A1FT Exception If Loop Break LB alarm or sensor Break SENB alarm is configured for A1FN the alarm 1 will be switched to ON state independent of the setting of A1FT If Dwell Timer TIMR is configured for A1FN the alarm 1 will not perform failure transfer Alarm 2 Failure Transfer is activated as the controller enters failure mode Thereafter the alarm 2 will transfer to the ON or OFF state preset by A2FT Exception If Loop Break LB alarm or sensor Break SENB alarm is configured for A2FN the alarm 2 will be switched to ON state independent of the setting of A2FT If Dwell Timer TIMR is configured for A2FN the alarm 2 will not perform failure transfer 56 UM93001C Failure Mode Occurs as 1 SB1E 2 SB2E 3 ADER Failure Transfer of outout 1 and output 2 OCCUIS as 1 Power start within 2 5 seconds 2 Failure mode is activated 3 Manual mode is activated 4 Calibration mode is activated Failure Transfer of alarm 1 and alarm 2 OCCUIS as 1 Failure mode is activated
37. you may select other value for DP1 to alter the resolution 3 2 OUT1 amp OUT2 Types O1TY Selects the signal type for Output 1 The selection should be consistent with the output 1 module installed The available output 1 signal types are RELY Mechanical relay Formula PV1 INIL INTH IN1L SSRD Pulsed voltage output to drive SSR O1TY SSR _ Isolated zero switching solid state relay 4 20 4 20 mA linear current output 0 20 0 20mA linear current output 0 1V 0 1V linear voltage output O2TY 0 5V 0 5V linear voltage output 1 5V 1 5V linear voltage output 0 10V 0 10 V linear voltage output O2TY Selects the signal type for Output 2 The selection should be consistent with the output 2 module installed The available output 2 signal types are the same as for O1TY The range for linear current or voltage may not be very accurate For 0 96 output the value for 4 20 mA may be 3 8 mA to 4 mA while for 100 96 output the value for 4 20 mA may be 20 mA to 21 mA However this deviation will not degrade the control performance at all UM93001C 41 3 3 Rearrange User Menu The conventional controllers are designed with a fixed parameters scrolling If you need a more friendly operation to suit your application the manufacturer will say sorry to you The BTC 9300 has the flexibility for you to select those parameters which are most significant to you and put these parameters in the front of display sequen
38. 0 F 5 i Parameter OFST put ahead Select 1 st Parameter 8 er EFL Parameter REFC put ahead 0 9 SH F Parameter SHIF put ahead 10 Ah Parameter PB1 put ahead E Parameter TI1 put ahead E cl Parameter TD1 put ahead L P b Parameter CPB put ahead gh Parameter DB put ahead Pg Parameter SP2 put ahead h Parameter PB2 put ahead Parameter TI2 put ahead oc Parameter TD2 put ahead Select 2 nd Parameter Same as SEL1 0 Select 3 rd Parameter Same as SEL1 0 Select 4 th Parameter Same as SEL1 0 Select 5 th Parameter Same as SEL1 0 Calibration Mode Menu 18 A to D Zero Calibration Coefficient Low 360 A to D Gain Calibration Coefficient Low 199 9 e SESS ee Voltage Input 1 Gain Calibration Coefficient Cold Junction Low Temperature Calibration Coefficient UM93001D Low 199 9 40 00 C Table 1 4 Parameter Description continued 7 7 Contained in Calibration Mode Menu Display Mode Menu Basic Parameter Function Notation Display Parameter Format Description Cold Junction Gain Calibration Coefficient Range High 199 9 Reference Voltage 1 Calibration Coefficient for RTD 1 High 199 9 Serial Resistance 1 4 Calibration Coefficient for High 199 9 RTD 1 d Gain High 199 9 Y Galbeation Coefficient High 199 9 Y Ta Inputa Gain Calibration High 199 9 A Hist
39. 08 Failure transfer 16 17 40 56 75 101 FILT 11 17 40 78 80 81 83 108 Flow 4 11 61 62 Freezer 54 88 90 FUNC 9 11 13 40 73 74 76 77 79 80 83 86 87 89 92 93 94 95 97 98 99 Furnace 52 94 95 Fuzzy logic 4 5 108 Fuzzy PID 4 Heat cool control 40 45 88 Heater break 4 7 40 52 Heater current 28 52 67 Humidity 99 109 Idle state 80 IN1 11 14 15 16 18 19 20 40 41 54 71 72 73 74 77 82 83 86 87 88 89 93 99 105 IN1H 11 15 41 54 73 74 83 93 IN1L 11 15 41 54 73 74 83 93 IN1U 11 15 40 41 71 72 73 74 71 83 86 87 89 90 93 99 105 IN2 11 14 15 16 18 19 20 40 52 67 73 74 77 83 92 93 105 IN2H 11 15 40 73 74 92 93 IN2L 11 15 40 73 74 92 93 IN2U 11 15 40 73 74 77 93 105 Input 1 3 7 8 18 19 26 27 40 41 56 66 73 74 77 101 102 105 107 Input 2 7 19 26 27 40 52 56 66 67 73 74 77 92 102 105 107 Installation 21 23 24 98 Inverter 38 82 90 91 Keys and displays 9 Level 4 12 13 40 48 50 51 52 68 84 93 Linear current 15 26 27 31 33 41 Linear DC input wiring 26 Linear output 43 45 52 67 107 108 Linear voltage 15 26 27 31 33 41 Lockout 4 8 40 81 101 107 Loop break 4 16 40 53 56 58 108 Loop break alarm 4 16 40 53 108 MA1G 11 19 MA2G 11 19 Manual control hand control mode 9
40. 1 5 V is selected if PV1 P1 2 or P2 1 is selected for PVMD or PV1 is selected for SPMD 2 SB2E occurs due to the input 2 sensor break or input 2 current below 1mA if 4 20 mA is selected or input 2 voltage below 0 25V if 1 5 V is selected if PV2 P1 2 or P2 1 is selected for PVMD or PV2 is selected for SPMD 3 ADER occurs due to the A D converter of the controller fails The output 1 and output 2 will perform the failure transfer function as one of the following conditions occurs 1 During power starts within 2 5 seconds 2 The controller enters the failure mode 3 The controller enters the manual mode 4 The controller enters the calibration mode Output 1 Failure Transfer if activated will perform 1 If output 1 is configured as proportional control PB1 7 0 and BPLS is selected for O1FT then output 1 will perform bumpless transfer Thereafter the previous averaging value of MV1 will be used for controlling output 1 2 If output 1 is configured as proportional control PB1 0 and a value of 0 to 100 0 96 is set for O1FT then output 1 will perform failure transfer Thereafter the value of O1FT will be used for controlling output 1 3 If output 1 is configured as ON OFF control PB1 0 then output 1 will be driven OFF if O1FN selects REVR and be driven ON if O1FN selects DIRT Output 2 Failure Transfer if activated will perform 1 If OUT2 selects COOL and BPLS is selected for O1FT then output 2
41. 10 A1FN 11 16 17 20 42 43 47 48 49 50 51 52 53 54 56 70 71 72 83 86 90 91 94 95 105 A1FT 11 17 56 86 A1HY 11 13 47 48 49 50 51 52 53 54 94 A1MD 11 16 17 47 48 49 50 51 52 53 54 70 94 A1SP 11 13 18 20 47 48 49 50 51 52 53 54 70 83 94 A2DV 11 13 18 45 48 50 51 53 54 A2FN 11 17 20 42 43 45 47 48 50 51 52 53 54 56 71 72 105 A2FT 11 17 56 A2MD 11 17 45 47 48 50 51 52 53 54 A2SP 11 13 18 20 45 48 50 51 52 53 54 ADO 11 18 Adaptive 5 ADDR 11 14 40 76 97 98 105 ADG 11 18 Alarm 1 7 9 13 16 17 34 40 47 48 49 50 51 52 53 56 68 70 71 91 94 105 107 Alarm 2 7 9 13 16 17 35 40 47 48 49 50 51 52 53 54 56 68 71 72 105 107 108 AOFN 11 14 40 77 99 AOHI 11 14 40 77 92 99 AOLO 11 14 40 77 92 99 Auto tune 4 9 40 122 Auto tuning 11 12 43 45 46 58 59 60 61 68 70 81 86 89 91 94 97 98 105 108 Automatic calibration 100 103 Automatic programming 4 8 Baud 14 76 108 BAUD 11 14 40 76 97 98 BC Net 7 96 97 98 100 Bumpless transfer 4 40 43 56 57 65 Calibration mode 8 12 56 57 100 101 Chamber 90 91 100 103 CJCT 11 19 66 CJG 11 19 CJTL 11 18 Colour codes 25 COMM 5 11 13 14 40 76 77 83 92 97 98 99 Communication 4 5 7 13 37 40 76 98 105 108 C
42. 13 40 43 75 83 94 95 PL2 11 13 40 75 Power wiring 23 Pressure 4 41 69 80 81 82 108 Process alarm 45 48 49 Programming port 5 8 39 103 108 PROT 4 11 13 40 76 97 98 Pulsed voltage 7 30 32 41 84 85 107 Pump pressure control 4 18 40 80 81 82 108 123 PVHI 9 11 19 66 PV1 11 13 17 19 20 40 41 45 48 49 55 56 66 70 73 74 77 78 80 83 92 93 94 95 99 105 108 PV1 shift 13 40 55 PV2 11 17 19 20 48 52 56 66 67 73 74 77 92 93 105 108 PVLO 9 11 19 66 PVMD 11 17 20 40 56 73 74 80 83 92 93 94 95 105 PVR 11 19 66 PVRH 11 19 66 PVRL 11 19 66 RAMP 11 13 18 40 42 71 72 90 91 94 95 Ramp 4 13 18 40 42 58 59 69 71 72 90 91 94 95 97 98 108 Ramp amp Dwell 71 72 90 Rearrange user menu 42 Recorder 5 38 99 REF1 11 19 102 REFC 11 13 18 42 80 81 83 Refrigerator 87 Relay 4 7 15 30 32 34 35 40 41 43 45 47 68 69 70 84 90 91 104 107 108 Reload default value 40 67 Remote lockout 4 40 81 107 Remote set point 4 40 58 59 73 92 108 Retransmission 4 5 7 13 38 40 77 92 99 108 RS 232 4 5 7 13 36 37 69 76 96 98 108 RS 485 4 5 7 13 36 76 77 96 108 RTD input wiring 26 124 Second PID 40 68 69 70 94 95 Second set point 69 107 SEL1 4 8 11 18 42 SEL2 8 11 18 42 SEL3 11 18
43. 2 A1HY For alarm 2 Trigger levels SP1 A2DV 1 2 A2HY A1SP and or A2SP are hidden if alarm 1 and or alarm 2 are set with deviation alarm One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2 These are Normal alarm Latching alarm Holding alarm and Latching Holding alarm See Section 3 8 for descriptions of these alarm modes Examples A1FN DE HI A1MD NORM SP1 100 A1DV 10 A1HY 4 Process Process proceeds x x 112 112 ON 112 112 112 108 108 108 108 OFF 108 100 100 100 100 100 A1FN DE HI A1MD LTCH SP1 100 A1DV 10 A1HY 4 Process proceeds x x x 112 108 100 112 112 ON 112 108 108 108 100 100 100 A1HY DE LO A1MD HOLD SP1 100 A1DV Process Process proceeds 10 ATHY 4 x x p D d A E 100 Bes 92 OFF 88 ON Error Code 2 Types of Deviation Alarms DE HI DE LO Deviation Alarm 1 Setup ATFN A1MD Adjust SP1 A1DV A1HY Trigger levels SP1 A1DV 1 2A1HY Deviation Alarm 2 Setup OUT2 A2FN A2MD Adjust SP1 A2DV A2HY Trigger levels SP1 A2DV 2A2HY Figure 3 9 Normal Deviation Alarm Figure 3 10 Latching Deviation Alarm Figure 3 11 Holding Deviation Alarm A1HY DE LO A1MD LT HO SP1 100 A1DV 10 A1HY 4 Process proceeds x 100 100 100 100 100 Figure 3 12 92 2A 92 92 92 Latching Holding 88 88 88 88 ON Deviation Alarm 50 UM93001C J 00 E 00 3 10 Deviation Band Alarm A deviation ban
44. 26 2 8 Linear DC Input Wiring 26 2 9 CT Heater Current Input Wiring 28 2 10 Event Input wiring 29 2 11 Output 1 Wiring 30 2 12 Output 2 Wiring 32 2 13 Alarm 1 Wiring 34 2 14 Alarm 2 Wiring saan ran 35 2 15 RS 485 36 2 16 HS 232 sao sean cera casas 37 2 17 Analog Retransmission 38 2 18 Programming Port 39 Chapter 3 Programming the Basic Function Sal Input Sona sesess season ee Soa 40 3 2 OUT1 amp OUT2 Types 41 3 3 Rearrange User Menu 42 3 4 Heat Only Control 43 3 5 Cool Only Control 44 3 6 Heat Cool Control 45 3 7 Dwell Timer 47 3 8 Process Alarms 48 3 9 Deviation Alarms 50 3 10 Deviation Band Alarms 51 3 11 Heater Break Alarm 52 3 12 Loop Break Alarm 53 3 13 Sensor Break Alarm 54 3 14 SP1 Range 54 3 15 PV1 Shift 55 3 16 Fail re anster A 56 3 17 Bumples
45. 2A Resistive Load gt 120V 240V Mains Supply 4 6 7 8 OOOO eTS IS Relay Output Direct Drive Figure 2 16 Alarm 1 Wiring OQOOQOOOQOC 9 10 11 12 13 14 15 16 120V 240V da Mains Supply 1 2 4 6 T 8 OOOO o oo Three 6 0 o o o Phase D Heater 90 9 Power Three Phase No Fuse LOW Delta Contactor Breaker Heater OQOOOOOOQCCO Load 9 160 ii i 73 i4 15 16 oa Relay Output to Drive Contactor Note Both Form A and B contacts are available for alarm 1 relay Order a correct form for alarm 1 to suit for your application 34 UM93001C 2 14 Alarm 2 Wiring Max 2A Resistive Load gt 120V 240V gt Mains Supply 4 6 7 8 STSTSTS SISTI Relay Output Direct Drive Figure 2 17 Alarm 2 Wiring OQOOOQOOOQO 9 10 11 12 13 14 15 16 120V 240V de Mains Supply 1 2 4 6 T 8 OOOO o oo Three 6 0 o o o Phase 5 Heater 90 0 9 Power Three Phase No Fuse HE Delta Contactor Breaker Heater OQOOOOOQCCO Me 9 10 11 12 13 14 15 16 oa Relay Output to Drive Contactor UM93001C 35 2 15 RS 485 Figure 2 18 RS 485 Wiring RS 485 to RS 232 network adaptor SNA10A or SNA10B Qe PC C TX1 TX2 RS 485 Twisted Pair Wire N gt lt TX1
46. 3002000 X1 plus a SNA10B Smart Network Adaptor and BC Net PC based software for this purpose The system is installed as shown in the following diagram Kiln 1 Figure 5 17 RS 485 Applications Control Room PC BC Net RS 232 SNA10B Twisted pair wire max distance 1 Km 96 UM93001C Setup Enters the setup mode to configure each BTC 9300 Choose FULL for FUNC 485 for COMM RTU for PROT and select an unequal address ADDR for each unit Use the same values of BAUD DATA PARI and STOP for BTC 9300 s SNA10B and BC Net Also refer to Section 2 15 and Section 4 8 Taking the advantage of BC Net software the operator can monitor the process on the PC screen program the set point as well as other control parameters such as PID values down load the ramp and soak profile to the controllers execute the manual control or trigger an auto tuning etc and print out a report as required The historical data can be saved in the floppy disc hard disc or a CD for permanent storage purpose UM93001C Setup Menu FUNC COMM PROT ADDR BAUD DATA PAR STOP 97 5 11 RS 232 Suppose a chemical experiment is performed in a laboratory And an engineer Setup Menu desires to find out the relation between the chemical reaction and temperature FUNC He uses a BTC 9300 to control the temperature of the solution under test A COMM testing report co
47. 418 F 2372 F 300 C 9007C 328 F 1652 F 2 C 22MO 210 C 700 C 346 F 1292 F 200 C 600 C 328 F 1112 F 8mV 70mV_ 0 05 22M9 3mA 27mA 0 05 7050 1 3V 11 5V 0 05 302 K2 UM93001C 0 C 1820 C 32 F 3308 F 2 2 MQ 2 C 2 2 MQ 2 C 2 2 MQ 0 4 C 1 3KQ 0 4 C 1 3KQ Input 2 Resolution 18 bits Sampling Rate 1 66 times second Maximum Rating 2 VDC minimum 12 VDC maximum Temperature Effect 1 5uV C for all inputs except mA input 3 0uV C for mA input Common Mode Rejection Ratio CMRR 120dB Normal Mode Rejection Ratio NMRR 55dB Sensor Break Detection Below 1 mA for 4 20 mA input below 0 25V for 1 5V input unavailable for other inputs Sensor Break Responding Time 0 5 second Characteristics Accuracy Input R Type c 25 C Impedance 2 CT94 1 0 50 0A of Reading 302 KQ 0 2A 0 8V mA 3mA 27mA 0 05 059 put current V 1 3V 11 5V x 0 05 302 KQ Input 3 Event Input Logic Low 10V minimum 0 8V maximum Logic High 2V minimum 10V maximum External pull down Resistance 400 KQ maximum External pull up Resistance 1 5 MQ minimum Functions Select second set point and or PID reset alarm 1 and or alarm 2 disable output 1 and or output 2 remote lockout Output 1 Output 2 Relay Rating 2A 240 VAC life cycles 200 000 for resist
48. 42 SEL4 11 18 42 SEL5 4 8 11 18 42 SELF 11 17 43 45 58 80 83 86 89 Self tune 4 40 58 Self tuning 43 45 46 58 61 68 108 Sensor installation guidelines 24 Sensor break 4 16 40 54 56 57 58 105 107 108 Sensor break alarm 4 40 54 57 108 Setup menu 4 8 11 12 48 54 58 68 69 73 74 76 77 78 79 80 83 86 89 92 93 94 95 97 98 99 SHIF 11 13 18 42 55 Sleep mode 4 9 12 17 40 58 79 108 SLEP 9 11 17 40 79 83 Smart network adaptor 7 96 SNA10A 7 36 76 SNA10B 7 36 76 96 97 100 Soft start 4 SP1 8 13 17 18 40 43 44 45 47 48 49 50 51 54 68 69 71 72 74 75 80 86 89 90 91 92 93 94 95 99 SP1H 11 13 18 54 83 87 99 SP1L 11 13 18 54 83 87 99 SP1 range 40 54 UM93001C SP2 11 13 17 18 20 40 42 48 68 69 72 74 80 81 83 90 91 95 SP2F 11 18 40 69 80 83 SPMD 11 18 40 56 68 69 71 72 79 74 80 883 90 91 92 93 94 95 105 SR1 11 19 102 SSR 4 7 30 31 32 33 40 41 43 45 67 84 85 108 SSRD 40 41 43 45 67 85 STOP 11 14 40 76 97 98 System modes 12 TD 11 19 37 63 66 TD1 11 13 17 18 42 43 45 58 59 61 62 68 70 81 83 94 95 TD2 11 13 17 18 40 42 58 59 62 68 70 94 95 Thermocouple input wiring 25 Tl 11 19 58 60 63 66 105 T11 11 13 17 18 42 43 45 53 59 61 62 68 70
49. 5 205 ON 205 205 205 195 195 195 195 195 Figure 3 6 Latching Process Alarm A1SP 200 A1HY 10 0 SP1 210 A1MD HOLD A1FN PV1 L Process proceeds I X 210 210 210 210 205 205 205 205 205 OFF f 205 195 195 195 195 ON 195 195 l Figure 3 7 Holding Process Alarm A1SP 200 A1HY 10 0 SP1 210 A1MD LT HO A1FN PV1 L Process proceeds M vv X X 210 210 210 210 205 205 205 205 205 205 195 195 195 195 on gt 195 195 Figure 3 8 Latching Holding Process Alarm Although the above descriptions are based on alarm 1 the same conditions can be applied to alarm 2 UM93001C 49 3 9 Deviation Alarm OUT2 can be configured as alarm 2 by selecting AL2 If OUT2 selects AL2 then output 2 will perform alarm 2 function Now A2FN can t be selected with NONE otherwise Er06 will appear A deviation alarm alerts the user when the process deviates too far from set point The user can enter a positive or negative deviation value A1DV A2DV for alarm 1 and alarm 2 A hysteresis value A1HY or A2HY can be selected to avoid interference problem of alarm in a noisy environment Normally A1HY and A2HY can be set with a minimum 0 1 value Trigger levels of alarm are moving with set point For alarm 1 Trigger levels SP1 A1DV 1
50. 5 0 mm depth behind panel Weight 150 grams Approval Standards Safety UL873 11 th edition 1994 CSA C22 2 No 24 93 EN61010 1 IEC1010 1 Protective Class NEMA 4X IP65 front panel indoor use IP 20 housing and terminals EMC EN61326 UM93001C 109 A 1 Menu Existence Coditions Menu Existence Conditions Table Menu Parameter Existence Conditions Notation Exists unconditionally TIME Exists if ATFN selects TIMR or A2FN selects TIMR A1SP Exists if ATFN selects PV1H PV1L PV2H PV2L P12H P12L D12H or D12L Exists if ATFN selects DEHI DELO DBHI or DBLO A2SP Exists if A2FN selects PV1H PV1L PV2H PV2L P12H P12L D12H or D12L A2DV Exists if A2FN selects DEHI DELO DBHI or DBLO Exists if T11 is used for control depends on Event input and EIFN selection but TI1 0 and OFST PB1 0 or if TI2 is used for control depends on Event input and EIFN selection but TI2 0 and PB2z0 REFC Exists if SPMD selects PUMP SHIF Exists unconditionally PB1 ue TH EM Exists if PB14 0 TD1 CPB DB Exists if OUT2 select COOL Exists if EIFN selects SP2 or SPP2 or if SPMD selects PUMP Exists if EIFN selects PID2 or SPP2 Exists if EIFN selects PID2 or SPP2 provided that PB24 0 TI2 TD2 O1HY If PID2 or SPP2 is selected for EIFN then O1HY exists if PB1 0 or PB2 O If PID2 or SPP2 is not selected for EIFN then O1HY exists if PB1 0 A1HY Exists if ATFN selects DEHI DELO PV1H P
51. 55 96 100 Heating Cooling Dead Band Tm Y DB db Negative Value Overlap Low 36 0 High 36 0 0 37 8 C SP2 5 Pg Set point 2 See Table 1 5 1 8 100 0 F sap 200 0 10 0 PB2 Ph Proportional Band 2 Value Low 0 High 900 0 F 18 0 F TI2 E g Integral Time 2 Value Low 0 High 1000 sec 100 TD2 Edd Derivative Time 2 Value Low 0 High 360 0 sec 25 0 Output 1 ON OFF Control n 55 6 C Y OiHY o 1HY Hysteresis Low 0 1 High 300 0 gt F 0 1 4 A1HY A IHY Hysteresis Control of Alarm 1 Low 0 1 High 18 0 i 0 1 4 A2HY HgH Hysteresis Control of Alarm 2 Low 0 1 High 18 0 e 0 1 PL1 PL Output 1 Power Limit Low 0 High 100 100 PL2 PL gZ Output 2 Power Limit Low 0 High 100 96 100 0 A l Basic Function Mode 4 FUNC F nL Function Complexity Level b 5 1 1 FL L Full Function Mode 0 ann E No communication function 1 YES RS 485 interface 2 PsA Rs 232 interface 3 H H 4 20 mA analog retransmission S output etu ee Man COMM Conn Communication Interface 4 eu 0 20 mA analog retransmission 1 Type output 5 t amp 0 1V analog retransmission output 6 M C LI 0 5V analog retransmission Ue output 7 l 5 LI 1 5V analog retransmission output 8 M 1f1 0 10V analog retransmission Ho IU output PROT Prak COMM Protocol Selection 0 uy Modbus protocol RTU mode 0 UM93001D 13 Table 1 4 Parameter Description continued 2 7 Contained 14 Basic AD
52. 81 83 94 95 105 TI2 11 13 17 18 40 42 58 59 62 68 70 94 95 105 TIME 11 13 18 42 43 47 53 5A 71 72 86 90 91 95 Triac 4 7 30 31 32 33 108 User menu 4 8 9 11 12 42 48 71 75 80 83 87 94 95 Ultimate p band 62 Ultimate period 62 Unpacking 21 V1G 11 18 V2G 11 19 Valve control 93 VPFW SSR 84 85 Water tank 93 Use the following Table as a master copy for your settings e Feces Pon seo SP1 TIME E AE A1SP A 5P A1DV A ig A2sP Hg5P A2DV Hgg RAMP AAP OFST oF 5E REFC EFL SHIF 5H F PB1 Pb uu TH Ei i TDi Eg CPB Ph DB db SP2 5pg PB2 Pbg TI2 Eid TD2 kde O1HY o IHY A1HY A IHH A2HY ACHY PLI PL PL2 PLA Setup FUNC E pr Menu rune Contained in Setup Menu oe Ao COMM oA PROT Prot ADDR Addr BAUD bHud DATA HHEH PARI PHr STOP 5E oF AOFN HafFn AOLO Aolo AOHI Ha H IN1 ime INTU n lu DP1 dF i INIL n iL INTH n iH IN2 nc IN2U new DP2 gPg IN2L nek IN2H ngH OUT a uL O1TY io iE H cvci YE O1FT 5 IFE UM9300 125 Contained Parameter Display Your setting Contained Parameter Display Your setting in Notation Format in Notation Format autc ADO AdO prr ADG Ad amp LYLE
53. 93001C Accessory Installed CT94 1 Setup IN2 CT O1TY or O2TY RELY SSRD or SSR CYC1 or CYC2 gt 1 sec Limitations 1 Linear output type can t be used 2 CYC1 or CYC2 should select 1 second or longer to detect heater current reliably 3 Only full wave AC current can be detected FILE 0 C Default File FILE 1 F Default File 67 Chapter 4 Programming the Full Function 4 1 Event Input Refer to Section 2 10 for wiring an event input The Event input accepts a digital type signal Three types of signal 1 relay or switch contacts 2 open collector pull low and 8 TTL logic level can be Terminals used to switch the event input Event input One of ten functions can be chosen by using 4 EIFN contained in 3 Event input setup menu NONE Event input no function If chosen the event input function is disabled The controller will use PB1 TI EIFN and TD1 for PID control and SP1 or other values determined by SPMD for the set point 0 NONE 1 SP2 SP2 If chosen the SP2 will replace the role of SP1 for control 2 PID2 PID2 If chosen the second PID set PB2 TI2 and TD2 will be used to replace 3 SPP PB1 TI1 and TD1 for control 4 RS M SPP2 If chosen the SP2 PB2 TI and TD2 will replace SP1 PB1 TI and 9 Hue TD1 for control 6 R A1 2 7 D O1 NOTE If the second PID set is chosen during Auto tuning and or Self tuning 8 DO procedures the new PID values will be stored in P
54. Alarm PV1 PV2 High Low Alarm Loop Break Alarm Sensor Break Alarm Alarm Mode Normal Latching Hold Latching Hold Dwell Timer 0 6553 5 minutes Data Communication Interface RS 232 1 unit RS 485 up to 247 units Protocol Modbus Protocol RTU mode Address 1 247 Baud Rate 0 3 38 4 Kbits sec Data Bits 7 or 8 bits Parity Bit None Even or Odd Stop Bit 1 or 2 bits Communication Buffer 50 bytes Analog Retransmission Functions PV1 PV2 PV1 PV2 PV2 PV1 Set Point MV1 MV2 PV SV deviation value Output Signal 4 20 mA 0 20 mA 0 1V 0 5V 1 5V 0 10V 108 UM93001D Resolution 15 bits Accuracy 0 05 96 of span 3 0 0025 C Load Resistance 0 500 ohms for current output 10 K ohms minimum for voltage output Output Regulation 0 01 96 for full load change Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC min Integral Linearity Error 0 005 96 of span Temperature Effect 0 0025 of span C Saturation Low 0 mA or OV Saturation High 22 2 mA or 5 55V 11 1V min Linear Output Range 0 22 2mA 0 20mA or 4 20m4A 0 5 55V 0 5V 1 5V 0 11 1 V 0 10V User Interface Dual 4 digit LED Displays Upper 0 4 10 mm Lower 0 3 8 mm Keypad 3 keys Programming Port For automatic setup calibration and testing Communication Port Connection to PC for supervisory control Control Mode Output 1 Reverse he
55. B2 TI2 and TD2 9 DO12 10 LOCK RS A1 Reset Alarm 1 as the event input is activated However if alarm 1 condition is still existent the alarm 1 will be retriggered again while the event input is released RS A2 Reset Alarm 2 as the event input is activated However if alarm 2 condition is still existent the alarm 2 will be retriggered again while the event input is released R A1 2 Reset both Alarm 1 and Alarm 2 as the event input is activated However if the alarm 1 and or alarm 2 are still existent the alarm 1 and or alarm 2 will be triggered again while the event input is released The RS A1 RS A2 and R A1 2 are particularly suitable to be used for a Latching and or Latching Holding alarms D O1 Disable Output 1 as the event input is activated The output 1 control variable MV1 is cleared to zero D O2 Disable Output 2 as the event input is activated The output 2 control variable MV2 is cleared to zero D O1 2 Disable both Output 1 and Output 2 by clearing MV1 and MV2 values as soon as the event input is activated When any of D O1 D O2 or D O1 2 is selected for EIFN the output 1 and or output 2 will revert to their normal conditions as soon as the event input is released LOCK All parameters are locked to prevent from being changed See Section 4 13 for more details 68 UM93001C SP2F Function Define format of SP2 value If SP2F in the setup menu is selected with ACTU the event input function will use SP2
56. C and common contacts These contacts will open when the relay coil is energized The contacts will close when power is removed from the control Form C Single Pole Double Throw Utilizes the N O N C and common contacts The user has the option of wiring for a Form A or Form B contact Refer to the Form A and Form B above for more information UM93001C fpm Flow velocity in feet per minute fps Flow velocity in feet per second Freezing point The temperature at which the substance goes from the liquid phase to the solid phase Frequency The number or event occurrences or cycles over a specified period of time Fuse A device that interrupts power in a circuit when an overload occurs Fuzzy logic An artificial intelligence technique that allows control decisions to be made upon approximate or incomplete information Fuzzy logic is a continuous decision making function that can prevent initial overshoot and set point differentials Gain The amount of amplification used in an electrical circuit GIGA The prefix for one billion G gph The volumetric flow rate in gallons per hour gpm The volumetric flow rate in gallons per minute Ground 1 The electrical neutral line having the same potential as the surrounding earth 2 The negative side of dc power supply 3 Reference point for an electrical system Grounded junction A thermocouple junction in which the sheath and conductors are welded together forming
57. Cool ON OFF NORM sx NORM X NORM x NORM x NORM X Heat PID Cool PID OUT1 OUT2 REVR COOL x X 0 40 x w x x x x X Don t care xx Adjust to meet process requirements Table 3 1 Heat Cool Control Setup NOTE The ON OFF control may result excessive overshoot and undershoot problems in the process The P or PD control will result in a deviation process value from the set point It is recommended to use PID control for the Heat Cool control to produce a stable and zero offset process value Other Setup Required O1TY CYC1 O2TY CYC2 A2SP A2DV O1TY amp O2TY are set in accordance with the types of OUT1 amp OUT2 installed CYC1 amp CYC2 are selected according to the output 1 type OTTY amp output 2 type O2TY Generally selects 0 5 2 sec for CYC1 if SSRD or SSR is used for O1TY 10 20 sec if relay is used for O1TY and CYC1 is ignored if linear output is used Similar condition is applied for CYC2 selection If OUT2 is configured for ON OFF control by selecting AL2 the OUT2 acts as alarm output and the process alarm as well as deviation alarm see section 3 8 amp 3 9 can be used Adjust A2SP to change set point if process alarm is used and adjust SP1 with preset A2DV to change set point if deviation alarm is used Examples Heat PID Cool ON OFF Set OUT1 REVR OUT2 AL2 A2FN PV1 H A2MD NORM A2HY 0 1 PB1 40 TI1 50 TD1 0 and
58. D and PVMD an Z2 Error Code will appear You should not use these cases otherwise the BTC 9300 will not control properly UM93001C Setup FUNC FULL SPMD PV2 PVMD PV1 or SPMD PV1 PVMD PV2 Error Message 73 4 6 Differential Control In certain applications it is desirable to control a second process such that its process value always deviates from the first process with a constant value To achieve this set the following parameter in the Setup menu FUNC FULL IN1 IN1L IN1H are set according to input 1 signal IN2 IN2L IN2H are set according to input 2 signal IN1U DP1 IN2U DP2 are set according to input 1 and input 2 signal PVMD P1 2 or P2 1 SPMD SP1 2 The response of PV2 will be parallel to PV1 as shown in the following diagram i PV1 PV2 PV PV1 PV2 or PV2 PV1 Set point 2 SP1 or SP2 Set point Time The PV display will indicate PV1 PV2 value if P1 2 is chosen for PVMD or PV2 PV1 value if P2 1 is chosen for PVMD If you need PV1 or PV2 to be displayed instead of PV you can use the Display Mode to select PV1 or PV2 to be viewed See Section 3 23 Error Messages If PVMD selects P1 2 or P2 1 while SPMD selects PV1 or PV2 an Error Code will appear In this case the signals used for input 1 and input 2 should be the same unit and same decimal point that is INTU IN2U DP1 DP2 otherwise E 7 5 Error Code will appear 74 UM93001C Setup PVMD P1 2 or PVMD
59. DR Addr Parameter Display Parameter Range Default Function Notation Format Description Value Address Assignment of Digital inh Im COMM High 255 0 3 Kbits s baud rate 0 6 Kbits s baud rate 1 2 Kbits s baud rate 2 4 Kbits s baud rate 4 8 Kbits s baud rate Baud Rate of Digital COMM 9 6 Kbits s baud rate 5 14 4 Kbits s baud rate 19 2 Kbits s baud rate 28 8 Kbits s baud rate 38 4 Kbits s baud rate Data Bit count of Digital 7 data bits 1 COMM 8 data bits Even parity Parity Bit of Digital COMM Odd parity 0 No parity bit Stop Bit Count of Digital One stop bit 0 COMM Two stop bits Retransmit IN1 process value Retransmit IN2 process value Retransmit IN1 IN2 difference process value Retransmit IN2 IN1 difference process value Analog Output Function Retransmit set point value 0 Retransmit output 1 manipulation value Retransmit output 2 manipulation value g Retransmit deviation PV SV Value Analog Output Low Scale m 0 C Valua Low 19999 High 45536 32 0 3 Analog Output High Scale inh 100 0 Valua Low 19999 High 45536 212 0 F IN1 Sensor Type Selection UM93001C 0 1 mor re ke wm cr r3 P303 D 08 09 P Btype thermocouple J type thermocouple K type thermocouple T type thermocouple E type thermocouple 0 R type thermocouple S type thermocouple Table 1 4 Parameter Description continued 3 7
60. Hence Self tuning can be used for ramping set point control as well as remote set point control where the set point is changed from time to time Operation The parameter SELF is contained in setup menu Refer to Section 1 5 to obtain SELF for initiating a self tuning 58 UM93001C Self tune Menu Selects Disable Self tuning or Enable Self tuning Default SELF NONE Benefits of Self tune 1 Less disturbance to the process 2 Perform PID control during tuning period 3 Available for ramping set point control and remote set point control 3 19 Auto tuning A The auto tuning process is performed at set point The process will oscillate around the set point during tuning process Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage The auto tuning is applied in cases of Initial setup for a new process The set point is changed substantially from the previous auto tuning value The control result is unsatisfactory Operation 1 The system has been installed normally 2 Use the default values for PID before tuning The default values are PB1 PB2 18 0 F Tl1 Tl2 100 sec TD1 TD2 25 0 sec Of course you can use other reasonable values for PID before tuning according to your previous experiences But don t use a zero value for PB1 and TI1 or PB2 and TI2 otherwise the auto tuning program will be disabled 3 Set the set point to a normal oper
61. I IN2 IN2U DP2 IN2L IN2H EIFN PVMD 5 Remote set point FILT SLEP SPMD and SP2F 6 Complex process value 7 Output power limit 8 Digital communication 9 Analog retransmission 10 Power shut off Sleep Mode 11 Digital filter 12 Pump control 13 Remote lockout then you can use Basic Mode Basic Mode capabilities 1 Input 1 Thermocouple RTD Volt mA 2 Input 2 CT for heater break detection 3 Output 1 Heating or Cooling Relay SSR SSRD Volt mA 4 Output 2 Cooling Relay SSR SSRD Volt mA DC Power supply 5 Alarm 1 Relay for Deviation Deviation Band Process Heater Break Loop Break Sensor Break Latch Hold or Normal Alarm 6 Alarm 2 Relay for Deviation Deviation Band Process Heater Break Loop Break Sensor Break Latch Hold or Normal Alarm 7 Dwell Timer 8 Heater Break Alarm 9 Loop Break Alarm 10 Sensor Break Alarm 11 Failure Transfer 12 Bumpless Transfer 13 PV1 Shift 14 Programmable SP1 Range 15 Heat Cool control 16 Hardware Lockout 17 Self Tune 18 Auto Tune 19 ON OFF P PD PI PID Control 20 User Defined Menu SEL 21 Manual Control 22 Display Mode 23 Reload Default Values 24 Isolated DC Power Supply 3 1 Input 1 Press to enter Setup Mode Press to select parameter The upper display indicates the parameter symbol and the lower display indicates the selection or the value of parameter IN1 Selects the sensor type and signal
62. N1 or IN2 process value high P CH alarm d 3 11 P gl IN1 or IN2 process value low alarm 12 i IN1 IN2 difference process value d cH high alarm P 13 lc Ll IN1 IN difference process value d ieu low alarm P 14 L h Loop break alarm 15 5Enb Sensor break or A D fails morn Normal alarm action Lich Latching alarm action Alarm 1 Operation Mode 0 UM93001D HaL d Hold alarm action LtHa Latching amp Hold action Table 1 4 Parameter Description continued 5 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value A IFE Alarm 1 Failure Transfer 0 oFF Alarm output OFF as unit fails 1 cm Alarm output ON as unit fails HgF n Alarm 2 Function Same as A1FN 2 Agag Alarm 2 Operation Mode Same as A1MD 0 Herr Alarm 2 Failure Transfer Same as A1FT 1 0 nn E Event input no function 1 5 Pe SP2 activated to replace SP1 2HBD de pBa ue ane activated to replace SP Pc opace SPI PBT TID 7 5H Reset alarm 1 output Event Input Function r 5 Hg Reset alarm 2 output 1 rH Lg Reset alarm 1 amp alarm 2 7 i4 Disable Output 1 8 dna e Disable Output 2 9 da le Disable Output 1 amp Output 2 10 L oc Lock All Parameters 0 JU Use PV1 as process value IP Use PV2 as process value PV Mode Selection Use PV1 PV2 difference as 0 process value plots ale difference as J 0 second time constant He 0 2 sec
63. PBi 0 TD1 Setup PID OUT O1TY CYC1 if RELAY SSRD or SSR is selected for O1TY SELF NONE or YES Adjust SP1 TIME if enabled PB1 0 TH 0 Tdi Auto tuning Used for new process during initial tuning Self tuning Used for a process any time Manual Tuning May be used if self tuning and auto tuning are inadequate 43 3 5 Cool Only Control ON OFF control P PD control and PID control can be used for cool control Setup Cool Control Set OUT1 to DIRT direct action The other functions for cool only ON OFF OUT1 control cool only P PD control and cool only PID control are same as descriptions in section 3 4 for heat only control except that the output variable and action for the cool control is inverse to the heat control such as the following diagram shows PV A SP1 O1HY 2 SP1 on band O1HY SP1 O1HY 2 t Ld OUT1 Action Time A Figure 3 3 Cool Only OFF ON OFF Control Time Refer to section 3 4 in which similar descriptions for heat only control can be applied to cool only control 44 UM93001C 3 6 Heat Cool Control The Heat Cool Control can use one of 6 combinations of control modes Setup of parameters for each control mode are shown in the following table Setup Values Uses OUT1 OUT2 O1HY OFST DB A2FN A2MD A2HY Control Modes Heat ON OFF
64. User s Manual BTC 9300 Self Tune Fuzzy PID Process Temperature Controller Bie BRAINCHILD UM93001F Warning Symbol N The Symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in personal injury or damage to or destruction of part or all of the product and system Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met Use the Manual e Installers Read Chapter 1 2 e Basic Function User Read Chapter 1 3 5 e Enhanced Function User Read Chapter 1 3 4 5 e System Designer Read All Chapters Expert User Read Page 11 UM93001C CONTENTS Page No Chapter 1 Overview 1 1 Features 4 1 2 Ordering Code 7 7 1 3 Programming Port and DIP Switch 8 1 4 Keys and Displays 9 1 5 Menu Overview 11 TB Systemi MOdEs ecc 12 1 7 Parameter Description 13 Chapter 2 Installation 2 1 Unpacking 21 2 2 MOUNING 21 2 3 Wiring Precautions 22 2 4 Power Wiring 23 2 5 Sensor Installation Guidelines 24 2 6 Thermocouple Input Wiring 25 2 7 RTD Input Wiring
65. V1L PV2H PV2L P12H P12L D12H or D12L A2HY Exists if A2FN selects DEHI DELO PV1H PV1L PV2H PV2L P12H P12L D12H or D12L PL1 If PID2 or SPP2 is selected for EIFN then PL1 exists if PB14 O or PB2 O If PID2 or SPP2 is not selected for EIFN then PL1 exists if PB1z 0 Exists if OUT2 selects COOL 110 UM93001D Menu Existence Conditions Table continued 2 3 Menu Parameter Existence Conditions Notation FUNC Exists unconditionally COMM Exists if FUNC selects FULL Exists if COMM selects 485 or 232 Exists if COMM selects 4 20 0 20 0 1V 0 5V 1 5V or 0 10 Exists if COMM selects 4 20 0 20 0 1V 0 5V 1 5V or 0 10 and AOFN is not MV1 and MV2 Exists unconditionally Exists if IN1selects 4 20 0 20 0 1V 0 5V 1 5V or 0 10 Exists if FUNC selects FULL Exists if IN2 selects 4 20 0 20 0 1V 0 5V 1 5V or 0 10 Exists unconditionally Exists if OUT2 selects COOL UM93001C 111 Menu Existence Conditions Table continued 3 3 Menu Parameter Existence Conditions Notation AIFN Exists unconditionally Exists if ATFN selects DEHI DELO DBHI DBLO PV1H PV1L PV2H PV2L P12H P12L D12H D12L LB or SENB ATFT Exists if ATFN is not NONE A2FN Exists unconditionally Exists if A2FN selects DEHI DELO DBHI DBLO PV1H PV1L PV2H PV2L P12H P12L D12H D12L LB or SENB A2FT Exists if A2FN is not NONE EIFN A1MD A2MD PVMD Exists if FUNC selects FULL Setup Men FILT SELF Exists un
66. a completely sealed integrated junction Heat Thermal energy expressed in Calories Btu s or Joules Heat of fusion The amount of energy required to change one pound of a material from a solid to a liquid without an increase in temperature Expressed in Btu lb Heat of vaporization The amount of energy required to change one pound of a material from a liquid to a vapor without an increase in temperature Expressed in Btu lb Heat sink 1 Thermodynamic A body which can absorb thermal energy 2 Practical A finned piece of metal used to dissipate the heat of solid state components mounted on it Heat transfer The process of thermal energy flowing from a body of high energy to a body of low energy Means of transfer are Conduction the two bodies in contact Convection a form of conduction where the two bodies in contact are of different phases i e solid and gas Radiation all bodies emit infrared radiation Heat treating A process for treating metals where heating to a specific temperature and cooling at a specific rate changes the properties of the metal Hertz Hz Unit in which frequency is expressed Synonymous with cycles per second 117 Hi Pot test To apply a high voltage to an electrical conductor to test the surrounding insulation Hysteresis In ON OFF control the temperature change necessary to change the output from full ON to full OFF Hunting Oscillation or fluctuation of process temperature betwe
67. abled Refer to section 3 20 manual tuning for the adjustment of PB1 and TD1 Manual reset adjust OFST is not practical because the load may change from time to time and often need to adjust OFST repeatedly The PID control can avoid this situation Heat only PID control Selecting REVR for OUT1 SP1 is used to adjust set point value TIME is used to adjust the dwell timer enabled by selecting TIMR for A1FN or A2FN PB1 and TI1 should not be zero Adjust CYC1 according to the output 1 type O1TY Generally CYC1 0 5 2 sec for SSRD and SSR CYC1 10 20 sec for relay output CYC1 is ignored if linear output is selected for O1TY In most cases the self tuning can be used to substitute the auto tuning See Section 3 18 If self tuning is not used select NONE for SELF then use auto tuning for the new process or set PB1 TI1 and TD1 with historical values See Section 3 19 for auto tuning operation If the control result is still unsatisfactory then use manual tuning to improve the control See Section 3 20 for manual tuning BTC 9300 contains a very clever PID and Fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is properly tuned UM93001C Setup ON OFF OUT PB1 0 Adjust SP1 O1HY TIME if enabled Figure 3 2 Heat Only ON OFF Control Setup P OUT TH 0 CYC1 if RELAY SSRD or SSR is selected for O1TY Adjust SP1 OFST TIME if enabled
68. across its input terminals NPT National Pipe Thread Offset The difference in temperature between the set point and the actual process temperature Also referred to as droop ohm The unit of electric resistance On off controller A controller whose action is fully on or fully off Open Loop Conirol A control system with no sensing feedback Overshoot Excursion of temperature above the set point Phase A time based relationship between a periodic function and a reference In electricity it is expressed in angular degrees to describe the voltage or current relationship of two alternating waveforms Phase proportioning A form of temperature control where the power supplied to the process is controlled by limiting the phase angle of the line voltage PID Three mode temperature control proportional integral automatic reset derivative rate Polarity In electricity the quality of having two oppositely charged poles one positive and one negative Potentiometer 1 A variable resistor often used to control a circuit 2 A balancing bridge used to measure voltage Primary standard NBS The standard reference units and physical constants maintained by the National Bureau of Standards upon which all measurement units in the United States are based Process alarm A fixed alarm or secondary set point value independent of the primary set point Should a process value exceed this value an alarm condition wo
69. alue for SP2 is about 0 50 Kg cm An Example is given in Section 5 1 for pump control 4 13 Remote Lockout The parameters can be locked to prevent from being changed by using either Remote Lockout Hardware Lockout see Section 1 3 or Remote Lockout or both If you need 1 Connect external switch to terminal the parameters to be locked by using an external switch remote lockout 3 and 3 function then connect a switch to terminals 13 and 14 see Section 2 10 and Set LOCK for EIFN choose LOCK for EIFN see Section 4 1 3 Lock all parameters If remote lockout is configured all parameters will be locked as the external Switch is closed When the switch is left open the lockout condition is determined by internal DIP switch hardware lockout see Section 1 3 Hardware Lockout Can be used only during initial setup Remote Lockout Can be used any time UM93001C 81 Chapter 5 Applications 5 1 Pump Pressure Control A regulated water supply system is widely used in residence water plant PUMP A Cost Effective chemical plant electrical plant semiconductor plant etc Taking the yet Perfect Solution advantage of PUMP function the BTC 9300 can be used for these applications to achieve an economical yet versatile solution Here is an example BTC 9300 4137XX Kg cm Pressure Reservoir Figure 5 1 I Pressure A water Supply System e e Sensor IB c BTC 9300 OUTI mT OUT2 w 4
70. an be used Relay mechanical An electromechanical device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other Relay solid state A solid state switching device which completes or interrupts a circuit electrically with no moving parts Repeatability The ability of a probe or instrument to give the same output or reading under repeated identical conditions Resistance The resistance to the flow of electric current measured in ohms Q For a conductor resistance is a function of diameter resistivity an intrinsic property of the material and length Resolution sensitivity The amount of temperature change that must occur before the control actuates It may be expressed in temperature or as a percentage of the control s scale Response time Time constant The time required by a sensor to reach 63 2 of a step change in temperature under a specified set of conditions Five time constants are required for the sensor to stabilize at 99 3 96 of the step change value Retransmit output Analog output scaled to the process or the set point value 119 RFI Radio frequency interference RS232 or RS485 output signal A serial interface suitable for connection between a digital control and a personal computer a host computer or printer RTD A temperature sensing probe of finely wound platinum wire that displays a linear resistance change for a corresponding temper
71. and or load disturbance circumstance etc The PID principle is based on amathematic modeling which is obtained by tuning the process Unfortunately many systems are too complex to describe in numerical terms precisely In addition these systems may be variable from time to time In order to overcome the imperfection of PID control the Fuzzy Technology is introduced What is the Fuzzy Control It works like a good driver Under different speeds and circumstances he can control a car well with experiences he had before and does not require the knowledge of kinetic theory of motion The Fuzzy Logic is a linguistic control which is different from the numerical PID control It controls the system by experiences and does not need to simulate the system precisely as been controlled by PID PID FUZZY CONTROL Fuzzy Rule Language information igi m Fuzzy Inference igi Digital _ Fuzzifier I y Defuzzifier Digital information Engine information The function of Fuzzy Logic is to adjust PID parameters internally in order to make manipulation output value MV more flexible and adaptive to various processes The Fuzzy Rule may work like these If temperature difference is large and temperature rate is large then MV is large If temperature difference is large and temperature rate is small then MV is small PID Fuzzy Control has been proven to be an efficient method to improve the control stability as shown b
72. are set to map to output signal LOW SL e g 4mA and output signal High SH e g 20mA respectively The analog output signal AOS corresponding to an arbitrary value of parameter AOV is determined by the following curve Output Signal SH AOS SL Parameter Value AOLO AOV AOHI SH SL Formula MM ormula AOS SL AOV AOLO c SG AOHI AOLO AOV AOLO AOS SL SH SL Notes The setup values used for AOHI and AOLO must not be equal otherwise incorrect value will happen However AOHI can be set either higher or lower than AOLO If AOHI is set higher than AOLO it could result in a direct conversion If AOHI is set lower than AOLO it could result in a reverse conversion Example A control uses 4 20 mA analog output to retransmit difference value between input 1 and input 2 PV1 PV2 It is required that if the difference value is 100 4mA will be exported and if the difference value is 100 20mA will be exported Make the following Setup for BTC 9300 INTUZPU DP1 NODP IN2U PU DP2 NODP FUNC FULL COMM 4 20 AOFN P1 2 AOLO 100 AOHI 100 UM93001C Setup Menu Funt FUNC Cana COMM Harn AOFN AOLO H AOHI 3B za DN za m la Terminals AO 40 AO Figure 4 6 Conversion Curve for Retransmission NOTES AOHIZAOLO AOHI gt AOLO Direct Conversion AOHI lt AOLO Reverse Conversion 77 4 10 Digital Filter In certain application the process value is too unstab
73. ating or direct cooling action Output 2 PID cooling control cooling P band 1 25596 of PB ON OFF 0 1 100 0 F hysteresis control P band 0 P or PD 0 100 0 offset adjustment PID Fuzzy logic modified Proportional band 0 1 900 0 F Integral time O 1000 seconds Derivative time 0 360 0 seconds Cycle Time 0 1 100 0 seconds Manual Control Heat MV1 and Cool MV2 Auto tuning Cold start and warm start Self tuning Select None and YES Failure Mode Auto transfer to manual mode while sensor break or A D converter damage Sleep Mode Enable or Disable Ramping Control 0 900 0 F minute or 0 900 0 F hour ramp rate Power Limit O 100 6 output 1 and output 2 Pump Pressure Control Sophisticated functions provided Remote Set Point Programmable range for voltage or current input Differential Control Control PV1 PV2 at set point Digital Filter Function First order Time Constant 0 0 2 0 5 1 2 5 10 20 30 60 seconds programmable Environmental amp Physical Operating Temperature 10 C to 50 C Storage Temperature 40 C to 60 C Humidity 0 to 90 RH non condensing Insulation Resistance 20 Mohms min at 500 VDC Dielectric Strength 2000 VAC 50 60 Hz for 1 minute Vibration Resistance 10 55 Hz 10 m s for 2 hours Shock Resistance 200 m s 20 g Moldings Flame retardant polycarbonate Dimensions 50 7mm W X 50 7mm H X 88 0mm D 7
74. ating value or a lower value if overshooting beyond the normal process value is likely to cause damage 4 Press until appears on the display 5 Press for at least 3 seconds The upper display will begin to flash and the auto tuning procedure is beginning NOTE Any of the ramping function remote set point or pump function if used will be disabled once auto tuning is proceeding Procedures The auto tuning can be applied either as the process is warming up Cold Start or as the process has been in steady state Warm Start See Figure 3 22 If the auto tuning begins apart from the set point Cold Start the unit enters Warm up cycle As the process reaches the set point value the unit enters waiting cycle The waiting cycle elapses a double integral time TI1 or TI2 dependent on the selection see Section 4 1 then it enters a learning cycle The double integral time is introduced to allow the process to reach a stable state Before learning cycle the unit performs pre tune function with a PID control While in learning cycle the unit performs post tune function with an ON OFF control Learning cycle is used to test the characteristics of the process The data are measured and used to determine the optimal PID values At the end of the two successive ON OFF cycles the PID values are obtained and automatically stored in the nonvolatile memory After the auto tuning procedures are completed the process display will
75. ature change The resistance increases as the temperature rises A base resistance of 100 ohms at 32 F is the industry DIN standard Saturation temperature The boiling temperature of a liquid at the existing pressure SCFM Volumetric flow rate in cubic feet per minute at 60 F 15 C and standard atmospheric pressure SCR Silicone Controlled Rectifier Secondary standard A standard of unit measurement derived from a primary standard Sensitivity The minimum change in input signal to which an instrument can respond Set point Control setting to achieve or maintain temperature Sheath thermocouple A thermocouple made out of mineral insulated thermocouple cable which has an other metal sheath Shield Material surrounding a conductor s to prevent electrostatic or EMI from external sources Slide wire feedback A potentiometer that varies the resistance to control a valve position Soak To raise the temperature of a metal object in a heated environment to produce a metallurgical change Soft start Reduces voltage on initial start up which reduces power to the heaters If heater has accumulated moisture internally during a shut down soft start will allow heater to dry before full voltage is applied so as to extend heater life Solid State Relay SSR A solid state switching device which completes or breaks a circuit electrically with no moving parts Span The difference between the upper and lower limits of
76. auto tuning mode and normal control mode are in the same priority level The sleep mode is in the highest priority 12 UM93001C Mode 1 7 Parameter Description Table 1 4 Parameter Description Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value m 100 0 C 4 SP1 Set point 1 Low SP1L High SP1H 212 0 F Y TIME E AE Dwell Time Low 0 High 6553 5 minutes 0 0 4 A1SP A ISP Alarm 1 Set point See Table 1 5 1 6 212 0 E m 200 0 C 200 0 C 10 0 C EIE 4 A1DV A ig Alarm 1 Deviation Value Low 360 0 F High 360 0 F 18 0 F v A2SP ACP Alarm 2 Set point See Table 1 5 1 7 E i zm 200 0 C 200 0 C 10 0 C 4 A2DV Figg Alarm 2 Deviation Value Low 360 0 F High 360 0 F 18 0 F a 500 0 RAMP AnP Ramp Rate Low 0 High 900 0 F 0 0 4 OFST oF SE Offset Value for P control Low 0 High 100 0 96 25 0 Reference Constant for Sh REFC r EFL Specific Function Low 0 High 60 2 200 0 C imh 200 0 C Y SHIF SH F PV1 Shift offset Value Low 360 0 F High 360 0 F 0 0 High 500 0 C 10 0 C 4 PB1 Ph Proportional Band 1 Value Low 0 igh 900 0 F 18 0 F User 4 TH LE Integral Time 1 Value Low 0 High 1000 sec 100 Menu 4 TD1 Ed Derivative Time 1 Value Low 0 High 360 0 sec 25 0 v CPB CP ooling Proportional Band Low 1 High 2
77. be switched to another set to achieve an optimum condition Auto tuning Second PID The optimal PID values for a process may vary with its process value and set point Hence if a process is used for a wide range of set point dual PID values are necessary to optimize the control performance If the first PID set is selected event input is not applied during auto tuning procedure the PID values will be stored in PB1 TI1 and TD1 Similarly if the second PID set is selected event input is applied while PID2 or SPP2 is selected for EIFN during auto tuning the PID values will be stored in PB2 Tl2 and TD2 as soon as auto tuning is completed Application 1 Programmed by Set Point Choose SPP2 for EIFN then both set point and PID values will be switched to another set simultaneously The signal applied to event input may come from a Timer a PLC an Alarm Relay a Manual Switch or other devices Application 2 Programmed by Process Value If the process value exceeds a certain limit 500 C for example it is desirable to use another PID values to optimize the control performance You can use a process high alarm to detect the limit of the process value Choose PV1H for A1FN A1MD selects NORM adjust A1SP to be equal to 500 C and choose PID2 for EIFN If the temperature is higher than 500 C then alarm 1 is activated The alarm 1 output is connected to event input the PID values will change from PB1 TI1 and TD1 to PB2 TI2 and TD2
78. between the two PID sets based on the process value the set point or either of the event input As the control ramps up to the higher process value the process characteristics changes As this happens the original PID values are no longer valid To achieve optimal control over the entire range a second PID set is used Example 1 Single Set Point Dual PID A heat treating furnace is used over the range of 400 C to 1200 C 1 Set the following parameters in the Setup menu FUNC FULL A1FN PV1H A1MD NORM EIFN PID2 PVMD PV1 SPMD MINR 2 Adjust the following parameters in the User menu A1SP 800 C A1HY 1 0 C PL1 100 RAMP According to the process requirement SP1 According to the process requirement 3 Tune first PID set at SP1 500 C and tune second PID set at SP1 1100 C or set the proper values for PB1 TI1 TD1 PB2 TI2 and TD2 directly according to the previous records to eliminate auto tuning sequence The circuit diagram and its temperature profile are shown as follows AC power 4 6 7 8 Figure 5 14 Dual PID Furnace O lt To NS Heater Furnace O 4 Power po Heater Input QOO 9 10 11 Alarm 1 controls Event input ga Process Value 800 4 N Figure 5 15 Dual PID Crossover Use PID 1 PID Crossover Value Use PID 2 Time 94 UM93001C Exa
79. ble 1 6 Range Determination for A1SP same as range of If A2FN PV1 H PV1 L PV2 H PV2 L rA IA Table 1 7 Range Determination for A2SP Range of A2SP sane aprangeot IM me INN Na If PVMD P1 2 P2 1 Range of SP2 i kei range of IN1 IN2 Table 1 8 Range Determination for SP2 Exception If any of A1SP A2SP or SP2 is configured with respect to CT input its adjustment range is unlimited 20 UM93001C Chapter 2 Installation AN Dangerous voltages capable of causing death are sometimes present in this instrument Before installation or beginning any troubleshooting procedures the power to all equipment must be switched off and isolated Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair Component replacement and internal adjustments must be made by a qualified maintenance person only A To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture AN Do not use this instrument in areas under hazardous conditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 8 2 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If any damage due to transit report and claim with the carrier Write down th
80. break the control loop and change 2 You can select at most 5 parameters put in front of the user some of the previous setting data Make sure that if the system menu by using SEL1 to SEL5 contained at the bottom of is allowable to use these modes setup menu UM93001D 11 1 6 System Modes The controller performs close loop control under its normal control mode condition The controller will maintain its normal control mode when you are operating user menu setup menu or display mode reloading default values or applying event input signal Under certain conditions the normal control mode will transfer to an Exception Mode The exception modes include Sleep Mode Manual Mode Failure Mode Calibration Mode and Auto tuning Mode All these modes perform in an open loop control except the auto tuning mode which performs ON OFF plus PID close loop control The mode transfer is governed by the priority conditions A lower priority mode can not alter a higher priority mode as shown in Figure 1 6 System Modes Sleep Mode See Section 4 11 Manual Mode See Section 3 22 Failure Mode See Section 3 16 Calibration Mode See Chapter 6 Auto tuning Mode See Section 3 19 Normal Control Mode See Section 3 23 3 25 4 1 Priority High No Sleep Mode Yes Manual Mode is Figure 1 6 xs System Mode Priority Failure Mode Low Request Request Request Calibration Auto tuning Normal Mode Mode Control The calibration mode
81. can accept a switch signal as well as an open collector signal The event input function EIFN is activated as the switch is closed or an open collector or a logic signal is pulled down Also refer to Section 4 1 for event input function UM93001C 29 2 11 Output 1 Wiring Max 2A Resistive Load 120V 240V Mains Supply III Relay Output Direct Drive Figure 2 14 Output 1 Wiring eQ bak Io m un m INS I co m MH m o mm lo 120V 240V de 1 2 4 6 1 8 SISTSISISISIS IS a tr d Phase ae Heater 0 0 0 o power Three Phase No Fuse Relay or Triac SSR E Delta Contactor Breaker Output to Drive QKOQKKQKKNOE E Contactor 9 10 11 12 13 14 15 16 120V 240V Mains Supply Internal Circuit 30mA 5V 5V Pulsed Voltage 33 6 i Pulsed Voltage to Drive SSR 33 5 AN OQOOQOOOQOC dd J 9 10 11 12 13 14 15 16 30 UM93001C Maximum Load 500 ohms 0 1V 0 5V 1 5V 0 10V OSOD ISI Minimum Load 10 K ohms 28928822 Max 1A 240V o 120V 240V Mains Supply 888800 Triac 28928822 UM93001C Linear Current Linear Voltage Triac SSR
82. ce SEL1 Selects the most significant parameter for view and change SEL2 SEL3 SELA SEL5 Selects the 2 nd significant parameter for view and change Selects the 3 rd significant parameter for view and change Selects the 4 th significant parameter for view and change Selects the 5 th significant parameter for view and change Range NONE TIME A1 SB A1 DV A2 SP A2 DV RAMP OFST REFC SHIF PB1 TH TD1 C PB DB SP2 PB2 TI2 TD2 When using the up down key to select the parameters you may not obtain all of the above parameters The number of visible parameters is dependent on the setup condition The hidden parameters for the specific application are also deleted from the SEL selection Example A1FN selects TIMR A2FN selects DE HI PB1 10 Ti 0 SEL1 selects TIME SEL2 selects A2 DV SEL3 selects OFST SELA selects PB1 SEL5 selects NONE Now the upper display scrolling becomes 42 UM93001D un i r r xum Un mm r Mu N un uhi FI uj un len rl ed Daa un A ied un C 3 4 Heat Only Control Heat Only ON OFF Control Select REVR for OUT1 Set PB1 to 0 SP1 is used to adjust set point value O1HY is used to adjust dead band for ON OFF control TIME is used to adjust the dwell timer enabled by selecting TIMR for A1FN or A2FN The output 1 hysteresis O1HY is enabled in case of PB1 0 The heat only on off control function is shown in the following diagra
83. conditionally SLEP Exists if FUNC selects FULL SPMD SP1L Exists unconditionally SP1H SP2F Exists if EIFN selects SP2 or SPP2 or if SPMD selects PUMP Exists unconditionally 112 UM93001C A 2 Factory Menu Description Default Value Parameter Display P D ipti R Notation Format arameter Description ange EROR Eror Current Error Code High 40 r Program Identification Code Contains Program igh PROG DRE Number and Version Number High 15 99 0 0 Contains Lockout Status Code and Current System Low 0 High 3 5 _ 0 Job Job Password High 65535 Warm up Drift Calibration Factor j High 5 0 C A to D Zero Calibration Coefficient High 360 A to D Gain Calibration Coefficient i High 199 9 U Voltage Input 1 Gain Calibration Coefficient i High 199 9 Cold Junction Low Temperature Calibration TEN o EL Coetticient High 40 00 C Cold Junction Gain Calibration Coefficient High 199 9 r L ER 4 3 CJG r A I m Reference Voltage 1 Calibration Coefficient for RTD 1 Low 199 9 High 199 9 Serial Resistance 1 Calibration Coefficient for RTD 1 Low 199 9 High 199 9 mA Input 1 Gain Calibration Coefficient Low 199 9 High 199 9 31 SES SET eie x Voltage Input 2 Gain Calibration Coefficient Low 199 9 High 199 9 nu Ci cc I Tn nu mA Inp
84. creases as temperature rises Thermocouple A temperature sensing probe consisting of the junction of two dissimilar metals which has a millivolt output proportional to the difference in temperature between the hot junction and the lead wires cold junction Thermocouple break protection Fail safe operation that assures output shutdown upon an open thermocouple condition Thermowell A closed end tube designed to protect temperature sensors from harsh environments high pressure and flows They can be installed into a system by pipe thread or welded flange and are usually made of corrosion resistant metal or ceramic material depending upon the application Transducer A device which converts the parameter being measured into another form which is its output For example a thermocouple transforms heat into a millivolt output Transmitter two wire A device which is used to transmit temperature data from either a thermocouple or RTD via a two wire current loop The loop has an external power supply and the transmitter acts as a variable resistor with respect to its input signal Triac A solid state switching device used to switch alternating current wave forms Triple point water The thermodynamic state where all three phases solid liquid and gas may all be present in equilibrium The triple point of water is at 01 C UM93001C TTL Transistor to transistor logic A form of solid state logic which uses only transi
85. d alarm presets two reference levels relative to set point Two types of deviation band alarm can be configured for alarm 1 and alarm 2 These are deviation band high alarm A1FN or A2FN select DB HI and deviation band low alarm A1FN or A2FN select DB LO If alarm 2 is required then select AL2 for OUT2 Now A2FN can t be selected with NONE otherwise Er06 will appear A1SP and A1HY are hidden if alarm 1 is selected with deviation band alarm Similarly A2SP and A2HY are hidden if alarm 2 is selected with deviation band alarm Trigger levels of deviation band alarm are moving with set point For alarm 1 trigger levels SP1 x A1DV For alarm 2 trigger levels SP1 A2DV One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2 These are Normal alarm Latching alarm Holding alarm and Latching Holding alarm See Section 3 8 for descriptions of these alarm modes Examples A1FN DB HI ATMD NORM SP1 100 A1DV 5 Process Process proceeds N ps 105 105 105 ON 105 OFF 105 100 ps 100 100 100 L 95 OFF gt 95 95 95 A1FN DB LO A1MD LTCH SP1 100 A1DV 5 Process proceeds sl vl sv vv vv XX XX 70 XX X s 105 105 105 105 105 100 100 100 100 100 95 ON 95 95 95 95 A1FN DB HI A1MD HOLD SP1 100 A1DV 5 Process Process proceeds 105 105 105 ON 105 OFF 105 m 100 95 ON gt A1FN DB HI A1MD LT HO SP1 100 A1DV 5 Process Process proceeds E Xy XC xc S
86. e communication RS 485 can communicate without error over 1 km distance while RS 232 is not recommended for a distance over 20 meters Using a PC for data communication is the most economic way The signal is transmitted and received through the PC communication Port generally RS 232 Since a standard PC can t support RS 485 port a network adaptor such as SNA10A SNA10B has to be used to convert RS 485 to RS 232 for a PC if RS 485 is required for the data communication But there is no need to be sad Many RS 485 units up to 247 units can be connected to one RS 232 port therefore a PC with 4 comm ports can communicate with 988 units It is quite economic Setup Enters the setup menu Select FULL Full function for FUNC Select 485 for COMM if RS 485 is required or 232 if RS 232 is required Select RTU ie Modbus protocol RTU mode for PROT Set individual address as for those units which are connected to the same port Set the Baud Rate BAUD Data Bit DATA Parity Bit PARI and Stop Bit STOP such that these values are accordant with PC setup conditions NOTE If the BTC 9300 is configured for RS 232 communication the El Event Input is disconnected internally The unit can no longer perform event input function EIFN When you insert a RS 232 module CM94 2 to the connectors on CPU board C930 you also need to modify the jumper JP22 on terminal board according to Section 2 16 If you use a c
87. e model number serial number and date code for future reference when corresponding with our service center The serial number S N and date code D C are labeled on the box and the housing of control 2 2 Mounting Make panel cutout to dimension shown in Figure 2 1 Take both mounting clamps away and insert the controller into panel cutout Install the mounting clamps back Gently tighten the screws in the clamp till the controller front panels is fitted snugly in the cutout MOUNTING 45 27 gt 5 05 Panel cutout 13 5mm gt EC 75 0 mm 11 0mm UM93001C Figure 2 1 Mounting Dimensions 21 2 3 Wiring Precautions Before wiring verify the label for correct model number and options Switch off the power while checking Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded Itis recommended that power of these units to be protected by fuses or circuit breakers rated atthe minimum value possible All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools All wiring must conform to appropriate standards of good practice and local codes and regulations Wiring must be suitable for voltage current and temperature rating of the system The stripped leads as specified in Figure 2 2 below are used for power and sensor connect
88. eferred to as the hot junction that is used to measure an unknown temperature Mechanical relay An electromechanical device that completes or breaks a circuit by opening or closing electrical contacts Mega The prefix for one million M 10 Melting point The temperature at which a substance transforms from a solid phase to a liquid phase Mico The prefix for one millionth 10 Microamp 10 amps one millionth of an amp Micron 10 meters one millionth of a meter Microprocessor The central processing unit CPU that performs the logic operations in a micro computer system The microprocessor in a process or instrument control decodes instructions from the stored program performs algorithmic and logic functions and produces signals and commands Milli The prefix for one thousandth 10 Milliamp 10 amps one thousandth of an amp Millivolt 10 volts one thousandth of a volt NEC National Electrical Code NEMA National Electrical Manufacturer s Association NEMA 4X A front panel rating designating the control as washdown capable and corrosion resistance NIST National Institute of Standards and Technology United states Department of Commerce Noise Undesirable electrical interference on the signal wires Noise suppression A device used to reduce electrical interference Normal mode rejection ratio The ability of an instrument to reject interference usually of line frequency 50 60 Hz
89. elect HRR for SPMD IN1U selects PU DP1 select 2 DP Set RAMP 60 00 A2FN selects TIMR Set TIME 20 0 As power is applied the process value starts from 0 00 and set SP1 30 00 SP2 40 00 The timer output is used to control event input PV 40 00 30 00 Figure 4 3 Ramp Accompanied with a Dwell Timer Time minutes 0 30 50 60 l Alarm 2 ON Alarm 2 OFF 72 UM93001C 4 5 Remote Set Point SPMD selecting PV1 or PV2 will enable the BTC 9300 to accept a remote set point signal If PV1 is selected for SPMD the remote set point signal is sent to Input 1 and Input 2 is used for process signal input If PV2 is selected for SPMD the remote set point signal is sent to Input 2 and Input 1 is used for process signal To achieve this set the following parameters in the Setup menu Case 1 Use Input 2 to accept remote set point FUNC FULL IN2 IN2U DP2 IN2L IN2H are set according to remote signal PVMD PV1 IN1 IN1U DP1 are set according to the process signal IN1L IN1H if available are set according to the process signal SPMD PV2 Case 2 Use Input 1 to accept remote set point FUNC FULL IN1 INTU DP1 IN1L IN1H are set according to remote signal PVMD PV2 IN2 IN2U DP2 are set according to the process signal IN2L IN2H if available are set according to the process signal SPMD PV1 Note If PV1 are chosen for both SPMD and PVMD anl Zi i Error Code will appear If PV2 are chosen for both SPM
90. em to eliminate high voltage spike sources Separate sensor and controller wiring from dirty power lines ground heaters Replace EEPROM Chapter 8 Specifications Power 90 264 VAC 47 63 Hz 15VA 7W maximum 11 26 VAC VDC 15VA 7W maximum Input 1 Resolution 18 bits Sampling Rate 5 times second Maximum Rating 2 VDC minimum 12 VDC maximum 1 minute for mA input Temperature Effect 1 5uV C for all inputs except mA input x 3 0uV C for mA input Sensor Lead Resistance Effect T C 0 2uV ohm 3 wire RTD 2 6 C ohm of resistance difference of two leads 2 wire RTD 2 6 C ohm of resistance sum of two leads Burn out Current 200 nA Common Mode Rejection Ratio CMRR 120dB Normal Mode Rejection Ratio NMRR 55dB Sensor Break Detection Sensor open for TC RTD and mV inputs below 1 mA for 4 20 mA input below 0 25V for 1 5 V input unavailable for other inputs Sensor Break Responding Time Within 4 seconds for TC RTD and mV inputs 0 1 second for 4 20 mA and 1 5 V inputs Characteristics Accurac Input Type Range 25 C ae 120 C 1000 C 184 F 1832 F 200 C 1370 C 328 F 2498 F 250 C 400 C 418 F 752 F 100 C 900 C 148 F 1652 F 2 C 2 2 MQ 2 C 2 2MQ 2 C 2 2 MQ 2 C 2 2 MQ 2 C 200 C 22Ma 1820 C 0 C 1767 8 C 4 50 32 F 3214 F 0 C 1767 8 C 32 F 3214 F 250 C 1300 C
91. en set point and process variable IAE Integrated absolute error Ice point The temperature at which pure water freezes 0 C 32 F 273 16K IE Integrated error Impedance The total opposition in a circuit to the flow of electrical current Measured in ohms and represented by Z Infrared Or radiation is the exchange of energy by electromagnetic waves The infrared spectrum extends from the deep red end of the visible spectrum to the microwave region of the radio spectrum the portion adjacent to the visible spectrum is of importance to heating Radiant heat transfer can be very efficient in directing energy from the heat source to an object Integral See Automatic Reset Interchangeability error A measurement error that can occur if two or more probes are used to make the same measurement It is caused by a slight variation in characteristics of different probes Intrinsically safe An instrument which will not produce any spark or thermal effects under normal or abnormal conditions that will ignite a specified gas mixture IPTS 68 International Practical Temperature Scale of 1968 Fixed points in thermometry set by the 1968 General Conference of Weights and Measures ISA Instrument Society of America ISE Integrated squared error Isolation Electrical Separation Isothermal A process or area that maintains a constant temperature ITS 90 International Temperature Scale of 1990 Joule The basic unit of
92. energy emitted by an object to the energy emitted by a blackbody at the same temperature The emissivity of an object depends upon its material and surface texture a polished metal surface can have an emissivity around 0 2 anda piece of wood can have an emissivity around 0 95 Endothermic Absorbs heat A process is said to be endothermic when it absorbs heat Error The difference between the correct or desired value and the actual reading or value taken Event input A programmable On Off input used to signal peripheral equipment or a process Event output A programmable On Off output used to signal peripheral equipment or a process Exothermic Gives off heat A process is said to be exothermic when it releases heat Fahrenheit A temperature scale with 32 F defined as the ice point and 212 F as the boiling point of water at sea level Filter A low pass filter designed to minimize display fluctuations Flow rate speed or velocity of fluid movement FM Factory Mutual Research Corp An organization which sets industrial safety standards FM approved An instrument that meets a specific set of specifications established by Factory Mutual Research Corp Form A Single Pole Single Throw relay that only utilizes the N O and common contacts These contacts close when the relay coil is energized The contacts open when power is removed from the control Form B Single Pole Single Throw relay that only utilizes the N
93. es in reverse direction When an optimal condition is obtained the optimal PID values will be stored in PB1 Tl1 TD1 or PB2 TI2 TD2 which is determined by Event Input conditions See Section 4 1 When Self tuning is completed the value of SELF will be changed from YES to NONE to disable self tuning function When the Self tuning is enabled the control variables are tuned slowly so that the disturbance to the process is less than auto tuning Usually the Self tuning will perform successfully with no need to apply additional auto tuning Exceptions The Self tuning will be disabled as soon as one of the following conditions occurs 1 SELF is selected with NONE 2 The controller is used for on off control that is PB 0 3 The controller is used for manual reset that is TI 0 4 The controller is under loop break condition 5 The controller is under failure mode e g sensor break 6 The controller is under manual control mode 7 The controller is under sleep mode 8 The controller is being calibrated If the self tuning is enabled the auto tuning can still be used any time The self tuning will use the auto tuning results for its initial values Benefits of Self tuning 1 Unlike auto tuning Self tuning will produce less disturbance to the process 2 Unlike auto tuning Self tuning doesn t change control mode during tuning period It always performs PID control 3 Changing set point during Self tuning is allowable
94. et windup This is a feature in a three mode PID controller which prevents the integral auto reset circuit from functioning when the temperature is outside the proportional band ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materials Automatic reset Integral The integral function of a control that automatically compensates for the difference between the set point and the actual process temperature A signal moves the proportional band up or down to correct for the droop or offset error Automatic tuning of control parameters A control that calculates the optimum PID parameters with a built in software algorithm to eliminate manual tuning efforts AWG American Wire Gauge Bandwidth A symmetrical region around the set point in which proportional control occurs Baud rate In serial communications the rate of information transfer in bits per second Blackbody A theoretical object that radiates the maximum amount of energy at a given temperature and absorbs all the energy incident upon it A blackbody is not necessarily black The name blackbody was chosen because the color black is defined as the total absorption of light energy Boiling point The temperature at which a substance in the liquid phase transforms to the gaseous phase commonly refers to the boiling point of water which is 100 C 212 F at sea level Btu British Thermal Unit The quantity of thermal ener
95. etic contactor O1TY selects RELY A small temperature oscillation is tolerable hence use ON OFF control to reduce the over all cost To achieve ON OFF control PB1 is set with zero and O1HY is set at 0 1 C Setup Summary Refrigerator FUNC BASC IN1 PT DN INTU C DP1 1 DP OUT1 DIRT O1TY RELY SP1L 10 C SP1H 0 C User Menu Mains PB1 0 C Supply O1HY 0 1 C Al A2 PV C Lri Figure 5 6 Cooling Control Example SV li OUT l Ll A Y C e p IB C BTC 9300 UM93001D 87 5 5 Heat Cool Control An injection mold required to be controlled at 120 C to ensure a consistent quality for the parts An oil pipe is buried in the mold Since plastics is injected at higher temperature e g 250 C the circulation oil needs to be cooled as its temperature rises Here is an example Injection Mold 120 C Plastics Figure 5 7 Heat Cool Control Example Oil Tank Freezer SV I0 n1 OUT 6h LLLI A Y D Bic BTC 9300 88 UM93001C The PID Heat Cool is used for the above example To achieve this set the following parameters in the Setup Menu Key Menu FUNC BASC FUNC IN1 PT DN i i IN1U C DP1 DP1 1 DP OUTI OUT1 REVR O1TY O1TY RELY CYC1 CYC1 218 0 sec O1FT O1FT BPLS OUT2 OUT2 COOL O2TY O2TY 4 20 O2FT O2FT BPLS SELF SELF STAR SP1 CPB Adjust SP1 at 120 0 C CPB at 125 and DB at 4 0
96. f any value obtained for SR1 and REF1 is equal to 199 9 or 199 9 then the calibration fails Perform step 7 to calibrate mA function if required for input 1 Step 7 Step 8 Step 9 Change the DIP switch for mA input Press scroll key until the display DIP Switch Position shows n H iL Send a 20 mA signal to terminals 12 and 13 in ON correct polarity Press scroll key for at least 3 seconds The display mA input will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform step 8 to calibrate voltage as well as CT function if required for input 2 Press scroll key until the display shows Send a 10 V signal to terminals 15 and 16 in correct polarity Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform step 9 to calibrate mA function if required for input 2 Press scroll key until the display shows Send a 20 mA signal to terminal 15 and 16 in correct polarity Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails
97. free of charge or refund of purchase price within the warranty period specified This warranty does not apply to damage resulting from transportation alteration misuse or abuse RETURNS No products return can be accepted without a completed Return Material Authorization RMA form UM93001C 127 Bic BRAINCHILD Electronic Co Ltd 6F No 209 Chung Yang Rd Nan Kang Dist Taipei Taiwan R O C Tel 886 2 27861299 Fax 886 2 27861395 web site http www bcmfg com http www brainchild com tw
98. g point of water at sea level cfm The volumetric flow rate of a liquid or gas in cubic feet per minute Chatter The rapid cycling on and off of a relay in a control process due to insufficient bandwidth in the controller Closed loop control A control system in which process temperature changes are detected by a sensor The feedback from the sensor allows the control make adjustments for accurate system regulation Cold junction compensation A temperature sensitive device that prevents changes in the ambient temperature from affecting the cold junction of a thermocouple Common mode rejection ratio The ability of an instrument to reject interference from a common voltage at the input terminals with relation to ground Expressed in dB decibels Control loop The basic control loop of any automatic control system consists of 1 variable process 2 sensor 3 error detector of control 4 control 5 final control element relay SSR SCR 6 temperature indication Control mode The method in which the control restores the system temperature to set point On Off proportional and PID are the most common control modes CT Current Transformer Current proportioning A 4 20 milliamp typical current output which provides a current proportional to the amount of control required Current transformer A transformer intended for measuring purposes designed to generate a current at its secondary winding which is propo
99. gnal conditioner measures the heater current during the heater is powered and the current value will remain unchanged during the heater is unpowered The PV2 will indicate the heater current About how to read PV2 value please refer to Section 3 23 NOTES If the heater to be measured is controlled by output 1 then CYC1 should select 1 second or longer and O1TY should use RELY SSRD or SSR Similarly if the heater to be measured is controlled by output 2 then CYC2 should select 1 second or longer and O2TY should use RELY SSRD or SSR to provide an adequate time for A to D converter to measure the signal Since CT94 1 can detect a full wave AC current only a DC or half wave AC cant be measured 3 25 Reload Default Values The default values listed in Table 1 4 are stored in the memory as the product leaves the factory In certain occasions it is desirable to retain these values after the parameter values have been changed Here is a convenient tool to reload the default values Operation Press several times until Then press The upper display will show Use up down key to select 0 to 1 If C unit is required select O for FILE and if F unit is required select 1 for FILE Then Press ce for at least 3 seconds The display will flash a moment and the default values are reloaded CAUTION The procedures mentioned above will change the previous setup data Before doing so make sure that if it is really required UM
100. gy required to raise one pound of water 1 F at or near its maximum density 39 1 F Bumpless transfer The smooth automatic transition from automatic control closed loop to manual control open loop The control output is maintained during the transfer Burst proportioning A fast cycling output form on a time proportioning controller typically adjustable from 2 to 4 seconds used in conjunction with a solid state relay to prolong the life of heaters by minimizing thermal stress Calender van Dusen equation An equation that defines the resistance temperature value of any pure metal that takes the form of R Ro 1 AT BT for values between the ice point 0 C and the freezing point of antimony 630 7 C and the form Rz Ro 1 AT BT C T 100 T between the oxygen point 183 0 C and the ice point 0 C Calibration The process of adjusting an instrument so that the indication is accurate compared to the actual value Calorie The quantity of thermal energy required to raise one gram of water 1 C at 15 C Cascade Control in which the output of a secondary or inner control loop is the set point for a primary or outer loop The primary loop in turn determines the control action UM93001C 115 CE A mark that designates compliance with European Union EU requirements for products sold in Europe Celsius Centigrade A temperature scale with 0 C defined as the ice point and 100 C as the boilin
101. ided that a pulsed voltage drive output BTC 9300 XX2XXX or BTC 9300 XXX2XX is ordered Here is an example BTC 9300 XX22XX OUT1 REVR O1TY SSRD CYC1 1 0 sec Figure 5 4 OUT2 COOL VPFW SSR Application Example O2TY SSRD CYC2 1 0 SEC VPFW SSR AC Power Three phase VPFW SSR s are also available upon request UM93001C 85 5 3 Heat Only Control An oven is designed to dry the products at 150 C for 30 minutes and then stay unpowered for another batch A BTC 9300 equipped with dwell timer is used for this purpose The system diagram is shown as follows Set SP1 150 0 TIME 30 0 A1 A2 IZ l sv OUT i Figure 5 5 Heat Control Example 2 Bic Mains Supply Timer ALM1 To achieve this function set the following parameters in the setup menu FUNC BASC Basic function IN1 K_TC INTU C DP1 1_DP OUT1 REVR O1TY RELY CYC1 18 0 O1FT BPLS A1FN TIMR A1FT ON SELF NONE Auto Tuning is performed at 150 C for a new oven 86 UM93001C 5 4 Cool Only Control A BTC 9300 is used to control a refrigerator at temperature below 0 C To ON OFF control avoid the set point adjustment beyond the interesting range SPiLis setat Direct Control Action 10 C and SP1H is set at O C The temperature is lower than the ambient a cooling action is required Hence select DIRT for OUT1 Since output 1 is used to drive a magn
102. igure 2 7 Input 1 Linear Voltage Wiring 0 1V 0 5V 1 5V 0 10V 26 UM93001C E i 2 4 6 7 jae OOOO o gt Figure 2 8 DIP Switch Input 1 Linear Current Wiring Q 0 20mAor 4 20mA e Figure 2 9 Input 2 Linear Voltage Wiring 0 1V 0 5V p 1 5V 0 10V 4 6 7 8 SSSOSQGG Figure 2 10 I Input 2 Linear Current Wiring 9999999 9 10 11 12 13 14 15 1 0 20mA or B 4 20mA UM93001C 27 2 9 CT Heater Current Input Wiring Heater 1 Contactor Heater Supply Current Transformer Tee CT94 1 ee E DIN Rail Figure 2 11 me CT Input Wiring for Single Phase Heater CT Signal Input Contactor RT j Three Phase o 9 Heater Power 0 0 o OO Current Transformer 1 Mains go T o o supply Bilis CT94 1 1 2 sile Figure 2 12 CT Input Wiring for J Three Phase Heater CT Signal Input DIN Rail Make sure that the total current through CT94 1 not exceed 50A rms 28 UM93001C 2 10 Event Input wiring STSTSTSSISISTS QOQQQO 10 11 12 13 14 15 1 lo Open Collector Input SSOSSO8GG Figure 2 13 m Event Input Wiring 9 909o9QQQQO Switch Input The event input
103. igure 7 1 Refer to Table 7 2 for some probable causes and actions D Press both sides of the latch located on rear terminal block Hold tightly and remove the terminal block from the housing 2 Expand the rear edge of the housing by using a tool Pull out the PCB from the housing Figure 7 1 Dismantling the Controller 104 UM93001C Table 7 1 Error Codes and Corrective Actions Error Display Code Symbol Error Description Corrective Action Illegal setup values been used PV1 is used for both PVMD Check and correct setup values of PVMD and SPMD PV and SPMD It is meaningless for control and SV can t use the same value for normal control Illegal setup values been used PV2 is used for both PVMD and SPMD It is meaningless for control Illegal setup values been used P1 2 or P2 1 is used for Check and correct setup values of PVMD and SPMD PVMD while PV1 or PV2 is used for SPMD Dependent Difference of PV1 and PV2 can t be used for PV while PV1 values used for PV and SV will create incorrect result or PV2 is used for SV of control 1 Curt 4 eros Same as error code 1 Illegal setup values been used Before COOL is used for Check and correct setup values of OUT2 PB1 PB2 TI1 OUT2 DIRT cooling action has already been used for TI2 and OUT1 IF OUT2 is required for cooling control the OUT1 or PID mode is not used for OUT1 that is PB1 or control should use PID mode PB 0 TI 0 and OUT1 PB2
104. ions Beware 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 the inputs as specified in Chapter 8 are not exceeded Electric power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes This electrical noise can enter and adversely affect the operation of microprocessor based controls For this reason we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the controller This wire is a twisted pair construction with foil wrap and drain wire The drain wire is to be attached to ground at one end only m 4 5 7 0 mm 0 18 0 27 Uri z ALN Es ALMI gt 2 9 900999 90 264VAC Ew ros VAC 2A 240VAC JB 47 63HZ 15VA 2A a 240 VAC EI Act TC c PTA PTB PTB COM e 6 aT O E car i 22 UM93001C Figure 2 2 Lead Termination Figure 2 3 Rear Terminal Connection Diagram 2 4 Power Wiring The controller is supplied to operate at 11 26 VAC VDC or 90 264VAC Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller Fuse 90 264 VAC or o gt 11 26 VAC VDC SSOSSOse Fig
105. is added to SP1 to obtain the set point for idle state Since the pump can t produce any more pressure at lower speed the pump Pump Control Features may not stop running even if the pressure has reached the set point If this 1 Minimum oscillation of pressure happens the pump will be over worn out and waste additional power To avoid Rapidly stabilized this the BTC 9300 provides a Reference Constant REFC in the user menu If 3 Guaranteed pump stop PUMP is selected for SPMD the controller will periodically test the process by 4 Programmable pump stopping using this reference constant after the pressure has reached its set point If the interval test shows that the pressure is still consumed by the process the controller will continue to supply appropriate power to the pump If the test shows that the pressure is not consumed by the process the controller will gradually decrease the power to the pump until the pump stops running As this happens the controller enters idle state The idle state will use a lower set point which is obtained by adding SP2 to SP1 until the pressure falls below this set point The idle state is provided for the purpose of preventing the pump from been restarted too frequently The value of SP2 should be negative to ensure a correct function The pump functions are summarized as follows 1 If the process is demanding material ie lose pressure the controller will precisely control the pressure
106. ister 1 The PID values obtained after auto tuning procedure are out of range Retry auto tuning 2 Don t change set point value during auto tuning Fail to perform auto tuning function procedure 3 Don t change Event input state during auto tuning procedure 4 Use manual tuning instead of auto tuning EEPROM can t be written correctly Return to factory for repair Input 2 IN2 sensor break or input 2 current below 1 mA if 4 20 mA is selected or input 2 voltage below 0 25V if Replace input 2 sensor 1 5V is selected Input 1 IN1 sensor break or input 1 current below 1 mA 39 5h iE if 4 20 mA is selected or input 1 voltage below 0 25V if Replace input 1 sensor 1 5V is selected 40 E Ato D converter or related component s malfunction Return to factory for repair UM93001C 105 Table 7 2 Common Failure Causes and Corrective Actions Symptom Probable Causes Corrective Actions 1 Keypad no function 2 LED s will not light Bad connection between PCB amp keypads No power to instrument Power supply defective Clean contact area on PCB Replace keypads Check power line connections Replace power supply board 3 Some segments of the display or LED lamps not lit or lit erroneously LED display or LED lamp defective Related LED driver defective Replace LED display or LED lamp Replace the related transistor or IC chip 4 Display Uns
107. ive load Pulsed Voltage Source Voltage 5V current limiting resistance 66 Q Linear Output Characteristics Dips Selen To ance Cay 4 20 mA 3 8 4 mA 20 21 mA 5009 max 0 20 mA OmA 20 21 mA 5009 max 0 5V OV 5 5 25V 10KQ min 1 5V 0 95 1V 5 5 25V 10 KQ min 0 10V OV 10 10 5V 10KQ min 107 Linear Output Resolution 15 bits Output Regulation 0 01 for full load change Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC Temperature Effect 0 0025 96 of SPAN C Triac SSR Output Rating 1A 240 VAC Inrush Current 20A for 1 cycle Min Load Current 50 mA rms Max Off state Leakage 3 mA rms Max On state Voltage 1 5 V rms Insulation Resistance 1000 Mohms min at 500 VDC Dielectric Strength 2500 VAC for 1 minute DC Voltage Supply Characteristics Installed at Output 2 Max Output Ripple Isolation Current Voltage Barrier 20V 0 5V 25mA 0 2Vp p 500 VAC 12V 500 VAC 5V 0 15V 80 mA 0 05 Vp p 500 VAC Type Tolerance Alarm 1 Alarm 2 Alarm 1 Relay Form A or Form B Max Rating 2A 240VAC life cycles 100 000 for resistive load Alarm 2 Relay Form A Max rating 2A 240VAC life cycles 200 000 for resistive load Alarm Functions Dwell timer Deviation High Low Alarm Deviation Band High Low Alarm PV1 High Low Alarm PV2 High Low Alarm PV1 or PV2 High Low
108. le A process is equipped with a heater a sensor and a subject to be warmed up Due to the design and position of the components in the system the sensor could not be placed any closer to the part Thermal gradient different temperature is common and necessary to an extent in any thermal system for heat to be transferred from one point to another If the difference between the sensor and the subject is 35 C and the desired temperature at the subject to be heated is 200 C the controlling value or the temperature at the sensor should be 235 C You should input 35 C as to subtract 35 C from the actual process display This in turn will cause the controller to energize the load and bring the process display up to the set point value i idi Subject Heater Heat Heat o Transfer Transfer Transfer 165 C 165 C 200 C 200 C oro Sensor C J ce un nu C3 C3 35 C temperature Adjust SHIF difference is observed SHIF 35 C SHIF 0 Supply more heat Figure 3 20 PV1 Shift Application UM93001C Subject ae Heat 235 C Display is stable SHIF 35 C PV SV 55 3 16 Failure Transfer The controller will enter failure mode as one of the following conditions occurs 1 SB1E occurs due to the input 1 sensor break or input 1 current below 1mA if 4 20 mA is selected or input 1 voltage below 0 25V if
109. le to be read To improve Menu this a programmable low pass filter incorporated in the BTC 9300 can be used F 1E FILT This is a first order filter with time constant specified by FILT parameter which is contained in setup menu The default value of FILT is 0 5 sec before shipping Adjust FILT to change the time constant from 0 to 60 seconds O Filter is used to stabilize the second represents no filter is applied to the input signal The filter is process display characterized by the following diagram PV1 FILT 0 1 sec ES 2n Figure 4 7 Filter Characteristics FILT 30 ieee Time Note The Filter is available only for PV1 and is performed for the displayed value only The controller is designed to use unfiltered signal for control even if Filter is applied A lagged filtered signal if used for control may produce an unstable process 78 UM93001C 4 11 Sleep Mode To Enter Sleep Mode FUNC selects FULL to provide full function SLEP selects YES to enable the sleep mode Press for 3 seconds the unit will enter its sleep mode During sleep mode 1 Shut off all display except a decimal point which is lit periodically 2 Shut off all outputs and alarms To Exit Sleep Mode 1 Press A zz to leave the sleep mode 2 Disconnect the power Sleep Function can be used to replace a power switch to reduce the system cost Default SLEP NONE Sleep mode is disabled Note If the Sleep mode is n
110. m PV A SP1 O1HY 2 SP1 on band O1HY SP1 O1HY 2 T t OUT1 Action Time A we Lt LE LT OFF T ae Time The ON OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest If ON OFF control is set ie PB1 0 TH TD1 CYC1 OFST CPB and PL1 will be hidden and have no function to the system The manual mode auto tuning self tuning and bumpless transfer will be disabled too Heat only P or PD control Select REVR for OUT1 set TI1 to 0 SP1 is used to adjust set point value TIME is used to adjust the dwell timer enabled by selecting TIMR for A1FN or A2FN OFST been enabled in case of TI1 0 is used to adjust the control offset manual reset Adjust CYC1 according to the output 1 type O1TY Generally CYC1 0 5 2 sec for SSRD and SSR CYC1 10 20 sec for relay output CYC1 is ignored if linear output is selected for O1TY O1HY is hidden if PB1 is not equal to 0 OFST Function OFST is measured by 96 with range 0 100 0 96 In the steady state ie process has been stabilized if the process value is lower than the set point a definite value say 5 C while 20 C is used for PB1 that is lower 25 96 then increase OFST 25 96 and vice versa After adjusting OFST value the process value will be varied and eventually coincide with set point Using the P control TI1 set to 0 the auto tuning and self tuning are dis
111. ments such as leak proof anti vibration antiseptic etc Standard sensor limits of error are x 4degrees F 2degrees C or 0 75 of sensed temperature half that for special plus drift caused by improper protection or an over temperature occurrence This error is far greater than controller error and cannot be corrected on the sensor except by proper selection and replacement 24 UM93001C 2 6 Thermocouple Input Wiring Thermocouple input connections are shown in Figure 2 5 The correct type of thermocouple extension lead wire or compensating cable must be used for the entire distance between the controller and the thermocouple ensuring that the correct polarity is observed throughout Joints in the cable should be avoided if possible If the length of thermocouple plus the extension wire is too long it may affect the temperature measurement A 400 ohms K type or a 500 ohms J type thermocouple lead resistance will produce 1 degree C temperature error approximately E0 VEN m Figure 2 5 M Thermocouple Input Wiring DIP Switch The colour codes used on the thermocouple extension leads are shown in Table 2 1 Table 2 1 Thermocouple Cable Colour Codes Thermocouple Cable British American German French Type Material BS ASTM DIN NFE Copper Cu white blue t red yellow T Constantan blue red brown blue Cu Ni blue blue brown blue Iron Fe yellow whi
112. min of Baking Oven Alarm 1 Form B Relay PV 40 jae 180 C 30 C min t Restart a new batch i Time 3 J Cooling minutes 30 C UM93001C 91 5 7 Remote Set Point An on line multiple zone oven is used to dry paint Since heat demand is various at different position in the production line multiple zones with individual controls should be used to ensure a consistent temperature profile If you order a BTC 9300 with a retransmission unit for the master controller and retransmit its set point to the input 2 of the rest of slave controllers each zone will be synchronized with the same temperature Here is an example To Control To Control To Control To Control Zone 1 Heater Zone 2 Heater Zone 3 Heater Zone 4 Heater Figure 5 12 Remote Set Point Application Master Slave Slave Slave Set the following parameters in the setup menu For master unit For slave units FUNC FULL FUNC FULL COMM 1 5V IN22 1 5V AOLO 0 C IN2L 09C AOHI 300 C IN2H 300 C PVMD PV1 PVMD PV1 SPMD SP1 2 SPMD PV2 If a voltage signal such as the above example is sent to slave units the slave inputs are connected in parallel If a current signal e g 4 20 mA is sent to slave units the slave inputs should be connected in series The current retransmission is used widely since it can transmit to a longer distance without voltage drop Note AOHI
113. mple 2 Dual Set Point PID A heat treating furnace is required to harden the mold at a high temperature 1000 C for 30 minutes then the mold is cooled down with a programmable ramp 20 C minute toward a lower set point 200 C Use the dual set point PID and ramp dwell functions for this application 1 Set the following parameters in the Setup menu FUNC FULL A1FN TIMR EIFN SPP2 PVMD PV1 SPMD MINR 2 Adjust the following parameters in the User menu TIME 30 0 Minutes RAMP 20 0 C Minute SP1 1000 C SP2 200 C PL1 100 96 3 Set the proper values for PB1 TI1 TD1 PB2 TI2 and TD2 directly according to the previous records For a new system tune first PID set at SP1 800 C and tune second PID set at SP2 400 C The circuit diagram is same as shown in Figure 5 14 The temperature profile is shown as below C 30 40 minutes minutes 5 d NES Figure 5 16 Dual Set Point PID Profile 1000 200T7 dq Use SP1 PID1 EM Use SP2 PID2 Time Minutes UM93001C 95 5 10 RS 485 A tile making plant has 5 production lines Each production line is equipped with 16 units of BTC 9300 to control the temperature for the kiln They are desirable to program the controllers and monitor the process in the control room for the purpose of improving the quality and productivity A cost effective solution for the above application is to use 80 units of BTC 9
114. n is powered in a still air room with temperature 50 8 C Stay at least 20 minutes for warming up The calibrator source is set at 0 00 C with internal compensation mode Perform step 1 stated above then press scroll key until the display shows 45 Apply up down key until value 0 0 is obtained Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails This setup is performed in a high temperature chamber hence it is recommended to use a computer to perform the procedures Step 11N Perform step 1 stated above then press scroll key until the display shows Apply up down key until value 0 1 is obtained Press scroll key for at least 3 seconds The display will blink a moment and the new value 0 0 is obtained Otherwise the calibration fails Caution It is not recommended to use this step 11N since the cold junction gain is not able to achieve rated accuracy by this step Final step Step 12 Set the DIP switch to your desired position refer to Section 1 3 Automatic Calibration Procedures The programming port See Section 2 18 of BTC 9300 can be used for automatic calibration The equipments required for automatic calibration are available upon request UM93001C 103 Chapter 7 Error Codes amp Troubleshooting This procedure requires access t
115. n the non alarm condition and energized in an alarm condition Latching Alarm A1MD LTCH If a latching alarm is selected once the alarm output is energized it will remain unchanged even if the alarm condition is cleared The latching alarms are disabled when the power is shut off or if event input is applied with proper selection of EIFN Holding Alarm ATMD HOLD A holding alarm prevents an alarm from power up The alarm is enabled only when the process reaches the set point value may be SP1 or SP2 See Section 4 1 event input Afterwards the alarm performs same function as normal alarm Latching Holding Alarm A1MD LT HO A latching holding alarm performs both holding and latching function Examples A1SP 200 A1HY 10 0 A1MD NORM A1FN PV1 H Process proceeds r x x 205 205 ON 205 205 205 195 195 195 195 Qorr 195 48 UM93001C Error Code 8 Types of Process Alarms PV1 H PV1 L PV2 H PV2 L P1 2 H P1 2 L D1 2 H D1 2 L Process Alarm 1 Setup A1FN A1MD Adjust ATSB A1HY Trigger level A1SP 1 2 A1HY Process Alarm 2 Setup OUT2 A2FN A2MD Adjust A2SP A2HY Trigger level A2SP 1 2 A2HY Reset Latching alarm 1 Power off 2 Apply Event input in accordance with proper selection of EIFN Figure 3 5 Normal Process Alarm 3 8 2 nd page A1SP 200 A1HY 10 0 A1MD LTCH A1FN PV1 H Process proceeds _ x xo 0X 20
116. ned in Setup menu Parameters been selected are then allocated at the beginning of the user menu 8 UM93001F Figure 1 3 Access Hole Overview Table 1 1 DIP Switch Configuration 1 4 Keys and Displays The unit is programmed by using three keys on the front panel The available key functions are listed in following table Table 1 2 Keypad Operation TOUCHKEYS FUNCTION DESCRIPTION AJ Us Ke Press and release quickly to increase the value of parameter piney Press and hold to accelerate increment speed xz Down Ke Press and release quickly to decrease the value of parameter aNd y Press and hold to accelerate decrement speed Co Scroll Key Select the parameter in a direct sequence Press CO for at least 3 seconds Allow access to more parameters on user menu also used to Enter manual Enter Key mode auto tune mode default setting mode and to save calibration data during calibration procedure Press Start Record Key Reset historical values of PVHI and PVLO and start to record the peak process for at least 6 seconds value Press C9 A Reverse Scroll Key Select the parameter in a reverse sequence during menu scrolling Press 2 x Mode Key Select the operation Mode in sequence Reset the front panel display to a normal display mode also used to leave Press A IY Reset Key the specific Mode execution to end up the auto tune and manual control execution and to quit the sleep mode
117. ntaining the relation between the concentration and PROT temperature is particularly interested ADDR i RT BAUD For a single unit application it is adequate to order a BTC 9300 00002 with RS 232 communication and a BC Net software By using the BC Net software DATA the temperature data can be viewed and stored in a file The user can PARI program the temperature as well as other control parameters such as PID STOP values He can setup the controller down load a ramp and soak profile also execute the manual control or auto tuning procedure etc The results can be printed out or stored in a file for the future reference Refer to Section 2 16 for installation and Section 4 8 for setup procedure 98 UM93001C 5 12 Retransmit An air conditioned room uses two units of BTC 9300 to control its temperature and humidity The temperature and humidity are required to be recorded on a chart recorder The interesting ranges for these two quantity are 20 C to 30 C and 40 RH to 6096 RH The recorder inputs accept 0 5 V signal To achieve this set the following parameters in the Setup menu UNIT 1 UNIT 2 FUNC FULL FUNC FULL COMM 0 5V COMM 0 5V AOFN PV1 AOFN PV1 AOLO 20 0 C AOLO 40 0 96 AOHI 30 0 C AOHI 60 0 96 IN1 PTDN IN1 0 1 V According to humidity sensor INTU C INTU PU DP1 1 DP DP1 1 DP SP1 25 0 SP1 50 0 SP1L 20 0 SP1L 40 0 SP1H 30 0 SP1H 60 0 IBIc 9 Retransmission Output
118. o the circuitry of a live power unit Dangerous accidental contact with line voltage is possible Only qualified personnel are allowable to perform these procedures Potentially lethal voltages are present Troubleshooting Procedures 1 If an error message is displayed refer to Table 7 1 to see what cause it is and apply a corrective action to the failure unit 2 Check each point listed below Experience has proven that many control problems are caused by a defective instrument Line wires are improperly connected No voltage between line terminals Incorrect voltage between line terminals Connections to terminals are open missing or loose Thermocouple is open at tip Thermocouple lead is broken Shorted thermocouple 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 3 If the points listed on the above chart have been checked and the controller does not function properly it is suggested that the instrument be returned to the factory for inspection Do not attempt to make repairs without qualified engineer and proper technical information It may create costly damage Also it is advisable to use adequate packing materials to prevent damage in transportation 4 Dismantle the controller according to F
119. ond time constant G5 0 5 second time constant 1 second time constant Filter Damping Time e 2 seconds time constant Constant of PV 5 5 seconds time constant 1l 10 seconds time constant C 20 seconds time constant 3 30 seconds time constant 5 D 60 seconds time constant Self Tuning Function Self tune function disabled Selection Self tune function enabled j Sleep mode Function Sleep mode function disabled Selection Sleep mode function enabled UM93001C 17 Table 1 4 Parameter Description continued 6 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value Use SP1 or SP2 depends on EIFN as set point Use minute ramp rate as set point Use hour ramp rate as set point Set point Mode Selection 0 Use IN1 process value as set point Use IN2 process value as set point Selected for pump control igh 0 C SP1 Low Scale Value Low 19999 High 45536 32 0 F igh 1000 0 C SP1 High Scale Value Low 19999 High 45536 1832 0 F 0 ACHE iy Set point 2 SP2 is an actual value Format of set point 2 Value m m 0 1 d LI Set point 2 SP2 is a deviation _ gt value 0 momE No parameter put ahead 1 E AE Parameter TIME put ahead 2 H 5 Parameter A1SP put ahead 3 Af gj Parameter A1DV put ahead He D Parameter A2SP put ahead Ae dU Parameter A2DV put ahead r Hj B Parameter RAMP put ahead 7
120. ontactor 28 30 32 34 35 84 87 104 Control 4 5 6 7 8 9 11 12 13 15 16 18 21 22 23 24 25 39 40 41 42 48 44 45 53 55 56 57 58 59 60 61 62 65 66 67 68 69 70 72 73 74 75 77 78 80 81 82 84 85 86 87 88 89 90 91 92 93 94 96 97 98 99 100 101 102 104 105 106 108 Cooling control 16 105 108 CPB 11 13 18 37 42 45 46 75 89 90 DB 11 13 42 45 46 51 76 89 107 108 110 Critical steady state 62 UM93001D CT 4 20 22 28 40 52 67 102 Current transformer 7 15 28 52 67 CYC1 11 16 43 45 52 67 85 86 89 CYC2 11 16 45 67 85 DATA 11 14 40 76 97 98 DC power supply 4 16 40 64 Dead band 13 43 44 46 Default 8 9 11 12 13 14 15 16 17 18 19 40 58 59 67 78 79 Deviation alarm 45 50 Deviation band alarm 51 Differential control 4 74 93 108 Digital filter 4 40 78 108 Display mode 9 11 12 40 66 74 93 DP1 11 15 40 41 71 72 73 74 77 83 86 87 89 90 93 99 105 DV 11 13 18 19 42 45 47 48 50 51 53 54 66 Dwell timer 4 16 40 43 47 56 71 72 86 91 105 108 EIFN 11 17 18 29 37 40 48 68 69 70 76 80 81 83 90 91 94 95 Error code 47 48 50 51 72 73 74 104 105 Event input 4 7 12 17 29 37 40 48 58 60 65 68 69 70 72 76 90 94 105 107 Exception mode 12 Failure mode 12 54 56 57 58 65 1
121. ontrol value for the output 1 fF _ _ _ control value for the output 2 shows shows the percentage DV shows the difference value between process and set point ie PV SV This value is used to control the output 1 and output 2 PV1 shows the process value of input 1 on the upper display PV2 shows the process value of input 2 on the upper display PB shows the current proportional band value used for control TI shows the current integral time used for control TD shows the current derivative time used for control Since the controller is performing FUZZY control the values of PB TI and TD may change from time to time CJCT shows the temperature at the cold junction measured in C independent of the unit used PVR Shows the changing rate of the process in C F or PU per minute It may be negative if the process is going down PVRH PVRL The maximum and minimum changing rate of the process since power up are measured in C F or PU per minute PVRH is a positive value while PVRL is a negative value NOTE The controller will never revert to its PV SV display from Display Mode unless you press the keys 66 UM93001C PVHI PVLO MV1 MV2 DV PV1 PV2 PB TI TD CJCT PVR PVRH PVRL 3 24 Heater Current Monitoring A current transformer CT94 1 should be equipped to measure the heater current Select CT for IN2 The input 2 si
122. onventional 9 pin RS 232 cable instead of CC94 1 the cable should be modified for proper operation of RS 232 communication according to Section 2 16 76 UM93001C RS 485 Benefits Long distance Multi units RS 232 Benefits Direct Connection to a PC Order BTC 9300 XXXXX1 for RS 485 Order BTC 9300 XXXXX2 for RS 232 RS 485 Setup FUNC FULL COMM 485 PROT RTU ADDR Address BAUD Baud Rate DATA Data Bit Count PARI Parity Bit STOP Stop Bit Count RS 485 Terminals 1 TX2 RS 232 Setup FUNC FULL COMM 232 PROT RTU ADDR Address BAUD Baud Rate DATA Data Bit Count PARI Parity Bit STOP Stop Bit Count RS 232 Terminals 9 X1 9 Tx2 4 COM 4 9 Analog Retransmission The Analog Retransmission is available for model number BTC 9300 XXXXXN Where N 3 4 or 5 See Ordering Code in Section 1 2 Setup Select FULL for FUNC in the setup menu COMM selects a correct output signal which should be accordant with the retransmission option used Five types of retransmission output are available These are 4 20 mA 0 20mA 0 5V 1 5V and 0 10V There are 8 types of parameters that can be retransmitted according to the Analog Function AOFN selected These are PV1 PV2 PV1 PV2 PV2 PV1 SV MV1 MV2 and PV SV Refer to Table 1 4 for a complete description AOLO selects a value corresponding to output zero and AOHI selects a value corresponding to output SPAN How to Determine Output Signal AOLO and AOHI
123. or alarm 2 UM93001C 47 3 8 Process Alarms There are at most two independent alarms available by adjusting OUT2 If AL2 is selected for OUT2 then OUT2 will perform alarm 2 function Now A2FN can t be selected with NONE otherwise Er06 will be displayed A process alarm sets an absolute trigger level or temperature When the process could be PV1 PV 2 or PV1 PV2 exceeds that absolute trigger level an alarm occurs A process alarm is independent from set point Adjust A1FN Alarm 1 function in setup menu One of 8 functions can be selected for process alarm These are PV1 H PV1 L PV2 H PV2 L P1 2 H P1 2 L D1 2 H D1 2 L When the PV1 H or PV1 L is selected the alarm examines the PV1 value When the PV2 H or PV2 L is selected the alarm examines the PV2 value When the P1 2 H or P1 2 L is selected the alarm occurs if the PV1 or PV2 value exceed the trigger level When the D1 2 H or D1 2 L is selected the alarm occurs if the PV1 PV2 difference value exceeds the trigger level The trigger level is determined by A1SP Alarm 1 set point and A1HY Alarm 1 hysteresis value in User Menu for alarm 1 The hysteresis value is introduced to avoid interference action of alarm in a noisy environment Normally A1HY can be set with a minimum 0 1 value A1DV and or A2DV are hidden if alarm 1 and or alarm 2 are set with process alarm Normal Alarm ATMD NORM When a normal alarm is selected the alarm output is de energized i
124. orical Maximum Value of 19999 High 45536 s Eu ent Minimum Value of High 45536 4 Current Output 1 Value High 100 00 A MV2 _ _ _ Current Output 2 Value Low 0 High 100 00 v DV aia Low 12600 High 12600 z 4 PV1 PY IN1 Process Value Low 19999 High 45536 4 PV2 PY IN2 Process Value Low 19999 High 45536 T PB Ph cd Proportional Band Low 0 High om Ro E 4 Current Integral Time Value Low 0 High 4000 sec i B vr Derivative Time Low 0 High 1440 sec a T CJE E29 unction Compensation Low 40 00 c High 90 00 C 4 PVR P Current Process Rate Value Low 16383 High 16383 4 PVRH P r H Maximum Process Rate Value Low 16383 High 16383 4 PVRL PY L Minimum Process Rate Value Low 16383 High 16383 2 UM93001C 19 420 C 200 C 250 C 100 C 0 C 0 OC 184 F 328 F 418 F 148 F 32 F 32 F 32 F Range High 1000 C 1370 C 400 C 900 C 1820 C 1767 87C 1767 8 C 1832 F 2498 F 752 F 1652 F 3308 F 3214 F 3214 F Input Type PT DN PT JS EISE EM mA 250 C 200 C 210 C 200 C 418 F 328 F 346 F 328 F 219999 ant 1300 C 900 C 700 C 600 C Range Hight 2372 F 1652 F 1292 F 1112 F SCAMP 45536 Table 1 5 Input IN1 or IN2 Range If A1FN PV1 H PV1 L PV2 H PV2 L P 2 H P1 2 D1 2 H D1 2 L A Ta
125. ot required by your system the SLEP should select NONE to disable sleep mode against undesirable occurrence UM93001C Sleep Mode Features Shut off display Shut off outputs Green Power Replace Power Switch Setup Menu FUNC FULL SLEP YES 79 4 12 Pump Control Pump Control function is one of the unique features of BTC 9300 Using this PUMP A Cost Effective function the pressure in a process can be controlled excellently The pressure yet Perfect Solution in a process is commonly generated by a pump driven by a variable speed motor The complete system has the following characteristics which affects the control behavior 1 The system is very noisy 2 The pressure is changed very rapidly 3 The pump characteristics is ultra nonlinear with respect to its speed 4 The pump cant generate any more pressure as its speed is lower than half of its rating speed 5 An ordinary pump may slowly lose the pressure even if the valves are completely closed Obviously a conventional controller can t fulfill the conditions mentioned above Only the superior noise rejection capability in addition to the fast sampling rate owned by BTC 9300 can realize such application To achieve this set the following parameters in the setup menu FUNC FULL Key menu EIFN NONE SPMD PVMD PV1 SP2F FILT 0 5 SELF NONE tei SPMD PUMP SP2F DEVI and program the following parameters in the user menu REFC Reference constant SP2 A negative value
126. rtional to the current at the primary winding Cycle time The time usually expressed in seconds for a controller to complete one on off cycle Data logging Recording a process variable over an extended period of time DC Direct Current An electric current flowing in one direction and constant in value 116 UM93001C Dead band 1 For chart recorders the minimum change of input signal required to cause a deflection in the pen position 2 For temperature controllers the temperature band where heat is turned off upon rising temperature and turned on upon falling temperature expressed in degrees The area where no heating or cooling takes place Default parameters The parameters or programmed instructions permanently stored in microprocessor software to provide a data base Derivative See Rate Deviation The difference between the value of the controlled variable and the value at which it is being controlled Deviation alarm An offset value that follows the set point If the set point is 350 F and the Deviation alarm value is 4 20 F the alarm value would be 350 F plus 20 F or 370 F See Process alarm Dielectric strength An amount of voltage that an insulating material can withstand before an electrical breakdown occurs Differential In an on off control the temperature difference expressed in degrees between where the control switches off and the control switches on Differential control A controller
127. s 1 Linear output can t use heater break alarm No heater breaks 1 heater breaks 2 heaters breaks 2 CYC1 should use 1 second or SE diana S Alem longer to detect heater current reliably 20 30 20 30 20 30 Figure 3 17 n P ir a w S Heater Break Alarm 0 50 0 50 0 50 52 UM93001C 3 12 Loop Break Alarm A1FN selects LB if alarm 1 is required to act as a loop break alarm Similarly if Loop Break Alarm 1 alarm 2 is required to act as a loop break alarm then set OUT2 with AL2 and Setup A1FN LB A1FN with LB A1MD NORM LTCH TIME A1SP A1DV and A1HY are hidden if alarm 1 is configured as a loop break alarm Similarly TIME A2SP A2DV and A2HY are hidden if alarm 2 is configured Loop Break Alarm 2 as a loop break alarm Setup OUT2 AL2 One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2 These A2FN LB are Normal alarm Latching alarm Holding alarm and Latching Holding alarm A2MD NORM LTCH However the Holding mode and Latching Holding mode are not recommended to be chosen for loop break alarm since loop break alarm will not perform holding function even if it is set with holding or latching holding mode See Section 3 8 for the descriptions of these alarm modes Loop Break Conditions are detected during a time interval of 2TI1 double of integral time but 120 seconds maximum Hence the loop break alarm doesn t respond quickly as it occurs If the process value doesn t increase or decrease while
128. s Transfer 57 3 15 Seung Se a 58 3 19 Auto tuning 59 3 20 Manual TUNING 61 UM93001C Page No 3 21 Signal Conditioner DC Power Supply 64 3 22 Manual Control 65 3 23 Display Mode 66 3 24 Heater Current Monitoring 67 3 25 Reload Default Values 67 Chapter 4 Programming the Full Function 4 1 Event Input 68 4 2 Second Set Point 69 4 3 Second PID Set 70 4 4 Ramp amp Dwell 71 4 5 Remote Set Point 73 4 6 Differential Control 74 4 7 Output Power Limits 75 4 8 Data Communication 76 4 9 Analog Retransmission 77 4 10 Digital Filter 78 4 11 Sleep Mode eeoeeoeeeiooeooeeeeoeeee eoo ee eol 79 Z2 PU CONTO Seen eee eneReee emere nenne 80 4 13 Remote Lockout 81 Chapter 5 Applications 5 1 Pump Pressure Control 82 5 2 Variable Period Full Wave SSR VPFW SSR 84 5 3 Heat Only Control 86 5 4 Cool Only Control
129. s configured as ON OFF control ie PB1 0 if PB1 is assigned or PB2 0 if PB2 is assigned by event input the controller will never perform manual control mode Exit Manual Control To press keys the controller will revert to its previous operating mode may be a failure mode or normal control mode UM93001C 344 Means MV1 38 4 96 for OUT1 or Heating Means MV2 7 63 96 for OUT2 or Cooling 65 3 23 Display Mode Operation Press several times until Display appears on the display Then press ce to enter the display mode You can select more parameters to view by pressing or pressing in reverse sequence The system mode of the controller and its operation will remain unchanged Entering the Display Mode the upper display will show the parameter value and the lower display will show the parameter symbol except and shows the percentage value for output 1 and _ shows the percentage value for output 2 on the lower display while the upper display shows the current process value PVHI PVLO show the historical extreme maximum or minimum values of the process on the upper display The historical extreme values are saved in a nonvolatile memory even if it is unpowered Press for at least 6 seconds to reset both the historical values PVHI and PVLO and begin to record new peak process values MV1 MV2 show the process value on the upper display and 5 the percentage c
130. se if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform step 4 to calibrate voltage function if required for input 1 Step 4 Change the DIP switch for the Voltage input Press scroll key until the display shows Send a 10 V signal to terminals 12 and 13 in correct polarity Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform both steps 5 and 6 to calibrate RTD function if required for input 1 Step 5 Change the DIP switch for the RTD input Press scroll key until the display shows F J Send a 100 ohms signal to terminals 11 12 and 13 according to the connection shown below 100 ohms wo BTC 9300 Press scroll key for at least 3 seconds The display will blink a moment otherwise the calibration fails UM93001C DIP Switch Position MEDD T C input DIP Switch Position LI 0 10V input 1 2 3 4 DIP Switch Position f RTD input Figure 6 1 RTD Calibration 101 Step 6 Press scroll key and the display will show Change the ohm s value to 300 ohms Press scroll key for at least 3 seconds The display will blink a moment and two values are obtained for SR1 and REF 1 last step Otherwise if the display didn t blink or i
131. section are a step by step manual procedures Since it needs 30 minutes to warm up an unit before calibration calibrating the unit one by one is quite inefficient An automatic calibration system for small quantity as well as for unlimited quantity is available upon request 100 UM93001C Manual Calibration Procedures Perform step 1 to enter calibration mode Step 1 Set the lockout DIP switch to the unlocked condition both switches 3 and 4 are off Press both scroll and down keys and release them quickly The operation mode menu will appear on the display Repeat the operation several times until E EL appear on the display Press scroll key for at least 3 seconds the display will show and the unit enters calibration mode The output 1 and output 2 use their failure transfer values to control Perform step 2 to calibrate Zero of Ato D converter and step 3 to calibrate gain of A to D converter The DIP switch is set for T C input Step 2 Short terminals12 and 13 then press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 360 or 360 then the calibration fails Step 3 Press scroll key until the display shows Ati Send a 60mv signal to terminals 12 and 13 in correct polarity Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwi
132. sensor break alarm Setup OUT2 AL2 One of 4 kinds of alarm modes can be selected for sensor break alarm These A2FN SENB are Normal alarm Latching alarm Holding alarm and Latching Holding alarm A2MD NOR M LTCH However the Holding alarm and Latching Holding alarm are not recommended Hidden TIME A2SP A2DV to be chosen for sensor break alarm since sensor break alarm will not perform A2HY holding function even if it is set with holding or latching holding mode See Section 3 8 for the descriptions of these alarm modes 3 14 SP1 Range SP1L SP1 low limit value and SP1H SP1 high limit value in setup menu are used to confine the adjustment range of SP1 Setup SP1L SP1H Example A freezer is working in its normal temperature range 10 C to 15 C In order to avoid an abnormal set point SP1L and SP1H are set with the following values SPiL 15 C SP1H 10 C Now SP1 can only be adjusted within the range from 10 C to 15 C IN1H or sensor range high SP1H sei Figure 3 19 SP1 Range SPIL IN1L or sensor range low 54 UM93001C 3 15 PV1 Shift In certain applications it is desirable to shift the controller display value from its actual value This can be easily accomplished by using the PV1 shift function Press the scroll key to the parameter SHIF The value you adjust here either positive or negative will be added to the actual value The SHIF function will alter PV1 only Here is an examp
133. ses the warm up cycle and enters the waiting cycle Afterward the procedures are same as that described for cold start Auto Tuning Error If auto tuning fails an ATER message will appear on the upper display in cases of Auto Tuning Error e f PB exceeds 9000 9000 PU 900 0 F or 500 0 C or if Tl exceeds 1000 seconds e or if set point is changed during auto tuning procedure e or if event input state is changed so that set point value is changed Solutions to 1 Try auto tuning once again 2 Don t change set point value during auto tuning procedure 3 Don t change event input state during auto tuning procedure 4 Use manual tuning instead of auto tuning See Section 3 20 5 Touch any key to reset message 60 UM93001C 3 20 Manual Tuning In certain applications very few using both self tuning and auto tuning to tune a process may be inadequate for the control requirement then you can try manual tuning Connect the controller to the process and perform the procedures according to the flow chart shown in the following diagram Use initial PID values to control the process cc Wait and Examine the Process Is steady state reached 0 Flag lt 0 5PB1 gt PB1 2PB1 gt PB1 o Wait and Examine the Process steady state the process No oscillate Yes Yes 1 6PB1 gt PB1
134. set appropriate values for O1TY and CYC1 Heat PID Cool PID set OUT1 REVR OUT2 COOL CPB 100 DB 4 0 PB1 0 TI1 0 TD1 0 and set appropriate values for O1TY CYC1 O2TY CYC2 If you have no idea about a new process then use self tuning program to optimize the PID values by selecting YES for SELF to enable the self tuning program See Section 3 18 for self tuning description You can use the auto tuning program for the new process or directly set the appropriate values for PB1 TI1 amp TD1 according to the historical records for the repeated systems If the control behavior is still inadequate then use manual tuning to improve the control See Section 3 20 for manual tuning UM93001D 45 CPB Programming The cooling proportional band is measured by of PB with range 1 255 Initially set 100 for CPB and examine the cooling effect If cooling action should be enhanced then decrease CPB if cooling action is too strong then increase CPB The value of CPB is related to PB and its value remains unchanged throughout the self tuning and auto tuning procedures Adjustment of CPB is related to the cooling media used For air is used as cooling media adjust CPB at 100 For oil is used as cooling media adjust CPB at 125 For water is used as cooling media adjust CPB at 250 DB Programming Adjustment of DB is dependent on the system requirements If more positive value of DB greater dead band is used an unwanted cooling action
135. solated 12V 40 mA DC Example 9 Special order Output Power Supply BTC 9300 411111 9 Isolated 5V 80mA DC e 90 264 operating voltage Output Power Supply e nput Standard Input e Output 1 Relay e Output 2 Relay e Alarm 1 Form A Relay e RS 485 Communication Interface Accessories CT94 1 0 50 Amp AC Current Transformer OM95 3 Isolated 4 20 mA 0 20 mA Analog Output Module OM95 4 Isolated 1 5V 0 5V Analog Output Module OM95 5 Isolated 0 10V Analog Output Module OM94 6 Isolated 1A 240VAC Triac Output Module SSR OM94 7 14V 40mA SSR Drive Module DC94 1 Isolated 20V 25mA DC Output Power Supply DC94 2 Isolated 12V 40mA DC Output Power Supply DC94 3 Isolated 5V 80mA DC Output Power Supply CM94 1 Isolated RS 485 Interface Module CM94 2 Isolated RS 232 Interface Module CM94 3 Isolated 4 20 mA 0 20 mA Retransmission Module CM94 4 Isolated 1 5V 0 5V Retransmission Module CM94 5 Isolated 0 10V Retransmission Module CC94 1 RS 232 Interface Cable 2M CC91 3 Programming Port Cable UM93001F BTC 9300 User s Manual UM93001F C Pulsed voltage to drive SSR 14V 40mA A Special order Range set by front keyboard Alternative between RS 232 and El Need to order an accessory CT94 1 if Heater Break detection is required Related Products SNA10A Smart Network Adaptor for Third Party Software Converts 255 channels of RS 485 or RS 422 to RS 232 Net
136. stors to form the logic gates UL Underwriters Laboratories Inc An independent laboratory that establishes standards for commercial and industrial products Ultraviolet That portion of the electromagnetic spectrum below blue light 880 nanometers Undershoot Excursion of temperature below set point Ungrounded junction A thermocouple junction fully insulated from the sheath Viscosity The inherent resistance of a substance to flow Volt The electrical potential difference between two points in a circuit The fundamental unit is derived as work per unit charge V W Q One volt is the potential difference required to move one coulomb of charge between two points in a circuit while using one joule of energy Voltage An electrical potential which is measured in volts VPFW SSR A type of Solid State Relay with Variable Period and Full Wave switching characteristics Wattage A measurement of electrical power In a resistive circuit VI W See Ohms Law formulas Working standard A standard of unit measurement calibrated from either a primary or secondary standard which is used to calibrate other devices or make comparison measurements Zero voltage switching The making or breaking of circuit timed such that the transition occurs when the voltage waveform crosses zero voltage typically it is only found in solid state switching devices UM93001C 121 A 4 Index A1DV 11 13 18 47 48 50 51 53 54 1
137. t to avoid damage Purchase a correct voltage to suit your external devices See ordering code in Section 1 2 64 UM93001C 3 22 Manual Control The manual control may be used for the following purposes 1 To test the process characteristics to obtain a step response as well as an impulse response and use these data for tuning a controller 2 To use manual control instead of a close loop control as the sensor fails or the controller s A D converter fails NOTE that a bumpless transfer can not be used for a longer time See Section 3 17 3 In certain applications it is desirable to supply a process with a constant demand Operation Press until Hand Control appears on the display Press for 3 seconds then the upper display will begin to flash and the lower display will show H _ The controller now enters the manual control mode Pressing c9 the lower display will show f _ _ _ and alternately where indicates output 1 or heating control variable value MV1 and i indicates output 2 or cooling control variable value MV2 Now you can use up down key to adjust the percentage values for H or C Li n The controller performs open loop control as long as it stays in manual control mode The H value is exported to output 1 OUT1 and C value is exported to output 2 provided that OUT2 is performing cooling function ie OUT2 selects COOL Exception If OUT1 i
138. table Analog portion or A D converter defective Thermocouple RTD or sensor defective Intermittent connection of sensor wiring Replace related components or board Check thermocouple RTD or sensor Check sensor wiring connections 5 Considerable error in temperature indication 6 Display goes in reverse direction counts down scale as process warms Wrong sensor or thermocouple type wrong input mode selected Analog portion of A D converter defective Reversed input wiring of sensor Check sensor or thermocouple type and if proper input mode was selected Replace related components or board Check and correct 7 No heat or output No heater power output incorrect output device used Output device defective Open fuse outside of the instrument Check output wiring and output device Replace output device Replace output fuse 8 Heat or output stays on but indicator reads normal 9 Control abnormal or operation incorrect Output device shorted or power service shorted CPU or EEPROM non volatile memory defective Key switch defective Incorrect setup values Check and replace Check and replace Read the setup procedure carefully 10 Display blinks entered values change by themselves 106 Electromagnetic interference EMI or Radio Frequency interference RFI EEPROM defective UM93001C Suppress arcing contacts in syst
139. te red yellow J Constantan blue red blue black Cu Ni black black blue black E brown yellow t red yellow K Nickel Aluminum a se jc a im Ni Al re y g y R Pt 13 Rh Pt white iy black red yellow S Pt 10 Rh Pt blue red white green scade green green white green B Pt 30 Rh Use pe ah Use Pt 6 Rh Copper Wire grey grey Copper Wire Colour of overall sheath UM93001C 25 2 7 RTD Input Wiring RTD connection are shown in Figure 2 6 with the compensating lead connected to terminal 12 For two wire RTD inputs terminals 12 and 13 should be linked The three wire RTD offers the capability of lead resistance compensation provided that the three leads should be of same gauge and equal length Two wire RTD should be avoided if possible for the purpose of accuracy A 0 4 ohm lead resistance of a two wire RTD will produce 1 degree C temperature error NW ale Figure 2 6 SEN RTD Input Wiring CNN QOOQOQOOQQ QOOOGOOOCOGO ES 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 E DIP Switch RTD RTD Three wire RTD Two wire RTD 2 8 Linear DC Input Wiring DC linear voltage and linear current connections for input 1 are shown in Figure 2 7 and Figure 2 8 DC linear voltage and linear current connections for input 2 are shown in Figure 2 9 and Figure 2 10 DIP Switch F
140. thermal energy 1 Joule equals 1 ampere passed through a resistance of 1 ohm for 1 second Junction A thermocouple junction is the point at which two alloys are joined A typical thermocouple circuit would have a measuring and a reference junction Kelvin The unit of absolute or thermodynamic temperature scale Zero Kelvin is absolute zero where all molecular activity stops No o symbol is used 0 C 273 15K 100 C 373 15K 118 UM93001C Kilo The prefix for one thousand K Kilowatt kw 1000 watts or 3412Btu per hour Lag 1 A time delay between the output of a signal and the response of the instrument to which the signal is sent 2 A time relationship between two waveforms where a fixed reference point on one wave occurs after the same point of the reference wave Least Significant Digit LSD The digit farthest to the right in a display Linearity The deviation of an instrument s response from a straight line Load The electrical demand of a process expressed as power watts current amps or resistance ohms Manual reset The adjustment on a proportional control which shifts the proportional band in relation to the set point to eliminate droop of offset errors Maximum operating temperature The maximum temperature at which an instrument or sensor can be safely operated Maximum power rating The maximum power in watts that a device can safely handle Measuring junction The thermocouple junction r
141. to count as soon as the process reaches its set point and triggers an alarm as time out Here is an example Example without Ramp Select TIMR for A1FN IN1U selects F DP1 selects NODP Set TIME 30 0 SP1 is set to 400 F initially and corrected to 200 F before the process reaches 200 F As the process reaches set point ie 200 F the timer starts to count The TIME value can still be corrected without disturbing the Timer before time out The TIME is changed to 40 0 after 28 minutes since the process reached its set point The behavior of process value and alarm 1 are shown below SP1 changed to 200 F PV reaches set point A Pu changed to 40 0 200 F I I I 28 1 c PV minutes l Alarm 1 ON Alarm 1 OFF l l l gt Time minutes K 40 1 l minutes l UM93001C SPMD Choose ri rue Unit minute or Hra Unit hour Adjust 7 Ha H RAMP Figure 4 1 RAMP Function A1FN or A2FN Choose TIMER Adjust kiat TIME Figure 4 2 Dwell Timer 71 Once the timer output was energized it will remain unchanged until power down or an event input programmed for resetting alarm is applied Note The TIMR can t be chosen for both A1FN and A2FN simultaneously Error Code otherwise an error code will produce Ramp amp Dwell A ramp may be accompanied with a dwell timer to control the process Here is an example Example with Ramp amp Dwell S
142. tput Output 1 Signal Type 3 4 gi 4 20 mA current module 0 UM93001C 15 Table 1 4 Parameter Description continued 4 7 Contained In 16 Setup Menu Basic Parameter Display Parameter Default Function Notation Format Description Value 0 20 mA current module 0 1V voltage module Output 1 Signal Type 0 5V voltage module 0 1 5V voltage module 0 10V voltage module Output 1 Cycle Time High 100 0 sec 18 0 i Select BPLS bumpless transfer or 0 0 100 0 Output 1 Failure Transfer to continue output 1 control function as the unit BPLS oue fails power starts or manual mode starts 0 mome Output 2 no function 1 Coo PID cooling control Output 2 Function 0 P 2 H L Perform alarm 2 function 3 dL P5 DC power supply module installed Output 2 Signal Type Same as O1TY 0 Output 2 Cycle Time Low 0 1 High 100 0 sec 18 0 Select BPLS bumpless transfer or 0 0 100 0 Wa 2 Failure Transfer to continue output 2 control function as the unit BPLS ode fails power starts or manual mode starts onon E Noalarm function 1 t n i Dwell timer action 2 pj EH Deviation high alarm 3 dEL i Deviation low alarm 4 rji Hi Deviation band out of band alarm 5 gh m Deviation band in band alarm 6 py iH IN1 process value high alarm 7 Peer 11 IN1 process value low alarm Alarm 1 Function a d P 2 8 PYEH IN2 process value high alarm 9 UC IN2 process value low alarm 10 2L I
143. type for Input 1 Range Thermocouple J TC K TC T TC E TC B TC R TC S TC IN1 N TC L TC RTD PT DN PT JS Linear 4 20 0 20 0 1V 0 5V 1 5V 0 10 Default J TC if F is selected K TC if C is selected IN1U Selects the process unit for Input 1 INTU Range C F PU process unit If the unit is neither C nor F then selects PU Default C or F DP1 Selects the location of the decimal point for most not all process DP1 related parameters dP 1 Range For T C and RTD NO DP 1 DP For Linear NO DP 1 DP 2 DP 3 DP Default 1 DP 40 UM93001C IN1L Selects the low scale value for the Linear type input 1 IN1L Hidden if T C or RTD type is selected for IN1 n dL IN1H Selects the high scale value for the Linear type input 1 IN1H Hidden if T C or RTD type is selected for IN1 How to use IN1L and IN1H If 4 20 mA is selected for IN1 let SL specifies the input signal low ie 4 mA SH specifies the input signal high ie 20 mA S specifies the current input signal value the conversion curve of the process value is shown as follows process value IN1H a Figure 3 1 Conversion Curve for Linear Type Process Value IN1L input signal S SL SH SL 5 Example A 4 20 mA current loop pressure transducer with range 0 15 kg cm is connected to input 1 then perform the following setup IN1 4 20 IN1L 0 0 INTU PU IN1H 15 0 DP1 1 DP Of course
144. uld register Process variable The parameter being controlled or measured such as temperature relative humidity flow level pressure etc Proportional band A temperature band in degrees within which a control s proportioning function is active UM93001C Proportional control mode When process temperature approaches set point and enters the proportional band the output is switched on and off at the established cycle time The change in power to the load provides a throttling action which results in less temperature overshoot Ramp A programmed rise or fail in temperature at a constant rate Range An area between two limits in which a measurement or control action takes place Typically expressed in upper and lower limits Rankine R An absolute temperature scale based upon the Fahrenheit scale with 180 between the ice point and boiling point of water 459 69 R 0 F Rate derivative A control function that measures the rate of increase or decrease of the system temperature and brings the control into an accelerated proportioning action This mode prevents an overshoot condition at initial heat up and with system disturbances Rate time The interval over which the system temperature is sampled for the derivative function Reference junction The cold junction in a thermocouple circuit which is held at a stable known temperature The standard reference temperature is 0 C 32 F however other temperatures c
145. unction amp set point Programmable digital filter Hardware lockout remote lockout protection Loop break alarm Heater break alarm Sensor break alarm Bumpless transfer RS 485 RS 232 communication Analog retransmission Signal conditioner DC power supply A wide variety of output modules available Safety UL CSA IEC1010 1 EMC CE EN61326 Front panel sealed to NEMA 4X amp IP65 BTC 9300 Fuzzy Logic plus PID microprocessor based controller incorporates a bright easy to read 4 digit LED display indicating process value The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time with the minimum of overshoot during power up or external load disturbance The units are housed in a 1 16 DIN case measuring 48 mm x 48 mm with 75 mm behind panel depth The units feature three touch keys to select the various control and input parameters Using a unique function you can put at most 5 parameters in front of user menu by using SEL1 to SEL5 contained in the setup menu This is particularly useful to OEM s as it is easy to configure menu to suit the specific application BTC 9300 is powered by 11 26 VAC VDC or 90 264 V AC supply incorporating a 2 amp control relay output and dual 2 amp alarm relays output as standard whereby second alarm can be exceptionally configured into second output for cooling purpose or dwell timer Alternative output options include SSR drive triac 4
146. ure 2 4 Power Supply Connections WOOOOOO 9 10 11 12 13 14 15 16 AN This equipment is designed for installation in an enclosure which provides adequate protection against electric shock The enclosure must be connected to earth ground Local requirements regarding electrical installation should be rigidly observed Consideration should be given to prevent from unauthorized person access to the power terminals UM93001C 23 2 5 Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a control system The probe should be placed so that it can detect any temperature change with minimal thermal lag In a process that requires fairly constant heat output the probe should be placed closed to the heater In a process where the heat demand is variable the probe should be closed to the work area Some experiments with probe location are often required to find this optimum position In a liquid process addition of a stirrer will help to eliminate thermal lag Since the thermocouple is basically a point measuring device placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes Proper sensor type is also a very important factor to obtain precise measurements The sensor must have the correct temperature range to meet the process requirements In special processes the sensor might need to have different require
147. ut 2 Gain Calibration Coefficient Low 199 9 High 199 9 Point 1 Signal Value of Special Sensor Low 19999 High 45536 IND1 mg Point1 Indication Value of Special Sensor Low 19999 High 45536 5 Lg Point 2 Signal Value of Special Sensor Low 19999 High 45536 s t mgg Point 2 Indication Value of Special Sensor Low 19999 High 45536 5 GJ Point 3 Signal Value of Special Sensor Low 19999 High 45536 1 mg J Point3 Indication Value of Special Sensor Low 19999 High 45536 5 LGH Point 4 Signal Value of Special Sensor Low 19999 High 45536 1 nd Point 4 Indication Value of Special Sensor Low 19999 High 45536 5 L5 Point 5 Signal Value of Special Sensor Low 19999 High 45536 1 ad Point 5 Indication Value of Special Sensor Low 19999 High 45536 G GG Point 6 Signal Value of Special Sensor Low 19999 High 45536 1 ndE Point 6 Indication Value of Special Sensor Low 19999 High 45536 Point 7 Signal Value of Special Sensor Low 19999 High 45536 1 nd 1 Point7 Indication Value of Special Sensor Low 19999 High 45536 5 GA Point 8 Signal Value of Special Sensor Low 19999 High 45536 1 mg Point 8 Indication Value of Special Sensor Low 19999 High 45536 5 G9 Point9 Signal Value of Special Sensor Low 19999 High 45536 Point 9 Indication Value of Special Sensor
148. value for its second set point If SP2F is selected with DEVI the SP1 value will be added to SP2 The sum of SP1 and SP2 SP1 SP2 will be used by the event input function for the second set point value In certain applications it is desirable to move second set point value with respect to set point 1 value The DEVI function for SP2 provides a convenient way in this case Modification from RS 232 to Event input Because of limitation of pin number pin 14 is used for both Event input and RS 232 If you want to change function of BTC 9300 from RS 232 to event input you must modify jumper JP22 on terminal board by opening jumper J1 and shorting jumper J2 Refer to Section 2 16 for the location of JP22 4 2 Second Set Point In certain applications it is desirable to change the set point automatically without the need to adjust the set point You can apply a signal to event input terminals pin 14 and pin 13 The signal applied to event input may come from a Timer a PLC an Alarm Relay a Manual Switch or other devices Select SP2 for EIFN which is contained in setup menu This is available only with the case that SP1 2 MIN R or HR R is used for SPMD where MIN R and HR R are used for the ramping function See Section 4 4 Application 1 A process is required to be heated at a higher temperature as soon as its pressure exceeds a certain limit Set SPMD SP1 2 EIFN SP2 or SPP2 if the second PID is required for the higher temperature too
149. viG ib og FE Calibra CJTL JEL A Fn Mode CHG CIE A ind Menu REF EF H FE SR1 Sri AEF nA MA1G 5 H IL Hend V2G vel HeFtE MA2G n HL E Fn PVHI PY 1 Pag PVLO PYL a Pree MV1 H SELF MV2 L SLEC DV dz 5Png Display PV1 b SP IL Mode PV2 pug SP IH Menu pb Pb PeF TI Li BEL TD Ed SELE CJCT L JEE SELI PVR Per SEL H PVRH FY H SELS PVRL PY rb 126 UM93001C A 6 Warranty WARRANTY Brainchild Electronic Co is pleased to offer suggestions on the use of its various products However Brainchild makes no warranties or representations of any sort regarding the fitness for use or the application of its products by the Purchaser The selection application or use of Brainchild products is the Purchaser s responsibility No claims will be allowed for any damages or losses whether direct indirect incidental special or consequential Specifications are subject to change without notice In addition Brainchild reserves the right to make changes without notification to Purchaser to materials or processing that do not affect compliance with any applicable specification Brainchild products are warranted to be free from defects in material and workmanship for two years after delivery to the first purchaser for use An extended period is available with extra cost upon request Brainchild s sole responsibility under this warranty at Brainchild s option is limited to replacement or repair
150. work SNA10B Smart Network Adaptor for BC Net Software Converts 255 channels of RS 485 or RS 422 to RS 232 Network SNA12A Smart Network Adapter for programming port to RS 232 interface BC Set Configuration Software 1 3 Programming Port and DIP Switch Access Hole Rear Terminal Front Panel The programming port is used to connect to SNA12A for automatic programming also can be connected to ATE system for automatic testing amp calibration DIP Switch Won j orr TC RTD mV Input 1 Select 0 1V 0 5V 1 5V 0 10V 0 20 mA 4 20 mA All parameters are Unlocked Only SP1 SEL1 SEL5 are unlocked Lockout Only SP1 is unlocked All Parameters are locked mH Factory Default Setting Bi The programming port is used for off line automatic setup and testing procedures only Don t attempt to make any connection to these pins when the unitis used for anormal control purpose When the unit leaves the factory the DIP switch is set so that TC amp RTD are selected for input 1 and all parameters are unlocked Lockout function is used to disable the adjustment of parameters as well as operation of calibration mode However the menu can still be viewed even under lockout condition SEL1 SEL5 represent those parameters which are selected by using SEL1 SEL2 SEL5 parameters contai
151. y the comparison curves below UM93001C Figure 1 1 Fuzzy PID System Block PID control with properly tuned PID Fuzzy control Temperature Set point Figure 1 2 Fuzzy PID Enhances Control Load Disturbance Stability Time 6 UM93001C 1 2 Ordering Code BTC 9300 4 Power Input 1 2 3 4 90 264 VAC 50 60 HZ 5 11 26 VAC or VDC 9 Special Order Signal Input 1 Standard Input Input 1 Universal Input Thermocouple J K T E B R S N L RTD PT100 DIN PT100 JIS Current 4 20mA 0 20 mA Output 1 LI E 5 6 Alarm 1 Communications 0 None 0 None 1 Form A Relay 1 RS 485 i BBC 3 Retransmit 4 20mA 0 20mA 9 Special order 4 Retransmit 1 5V 0 5V ae 5 Retransmit 0 10V 9 Special order Voltage 0 1V 0 5V 1 5V 0 None Output 2 Alarm 2 0 10V 1 Relay rated 2A 240VAC 0 None Input 2 CT and Analog Input 2 Pulsed voltage to 1 Form A Relay 2A 240VAC CT 0 50 Amp AC Current drive SSR 5V 30mA 2 Pulsed voltage to Transformer 3 Isolated drive SSR 5V 30mA Analog Input 4 20 mA 4 20mA 0 20mA 3 Isolated 4 20mA 0 20mA 0 20mA 0 1V 0 5V 4 Isolated 1 5V 0 5V 4 Isolated 1 5V 0 5V 1 5V 0 10V 5 Isolated 0 10V 5 Isolated O 10V Input 3 Event Input El 6 Triac Output 6 Triac Output 1A 240VAC SSR 9 Special Order 1A 240VAC SSR 7 Isolated 20V 25mA DC C Pulsed voltage to Output Power Supply drive SSR 14V 40mA 8 I

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