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UM91001G

1. UM91001D 4D 6D 63 21 4 tr oo 02 oo oo 00 64 SP1L 17 8 sP1H 537 8 SHIF 0 0 FILT 2 DISP 0 PB 10 0 00 64 oo Fa oo oo oo oo 4 tF oo ot Ti 100 TD 25 0 OUT1 0 O1TY 0 O1FT 0 O1HY 0 1 oo 84 oo F oo oo 00 oo 00 02 48 tF CYC1 18 0 OFST 25 0 RAMP 0 RR 0 0 OUT2 2 RELO 0 0 oo oo 45 1 oo ot oo sa 00 64 ae iF 02TY 0 oerr o ozhy o i cyca ts oj cPB 100 DB 0 oo 02 52 07 oo oo oo ot oo oo 00 ot ALFN 2 REHI 1000 ALMD 0 ALHY 0 1 ALFT 0 COMM 1 00101 ooloz oo 01 00 00 00 oo Joo c2 ADDR 1 BAUD 2 DATA 1 PARIZO STOP O SEL1 2 oo 03 00 04 oo 06 oo 07 oo o8 oo oa SEL2 3 SEL3 4 SEL4 6 SEL5 7 SEL6 8 SEL7 10 oo t1 Hi Lo SEL8 17 CRC16 74 Example 2 Read PV SV MV1 and MV2 Send the follovving message to the controller via the COMM port or programming port 03 Addr Func Starting Adar o of words Example 3 Perform Reset Function same effect as pressing CR key Query Data Hi Lo CRC16 Example 4 Enter Auto tuning Mode Query Jo oo Has Hea H28 Hi Lo Func Register Addr Data Hi Lo CRC16 Example 5 Enter Manual Control Mode Query 06 oo H48 H68 H27 Addr Func Register Addr Data Hi Lo CRC16 Example
2. User Setup Manual Auto tuning Calibration menu menu Mode A Mode AN Mode A 5 sec __ 6 2 sec 7 4 sec 8 6 sec 9 8 sec gt LPV SV SEE HHnd A E i AL all E je Release 9 s 2 a then press eq mka as for 5 seconds C eq to start e UN o stai ra cL BID ae UNIT o Tor c auto tuning cL RTDH z DP ce C INLO saa mode CILO OT ner e i Ba c TI g SPIL O OC 5 E Cs Press a 61 for 5 seconds Press for Laoon ad a to start 5 seconds to DT pg manual control 9 Gr perform calibration aq TD mks c OUNI A Apply these modes will break the control El O1TY s corr loop and change some of the previous M O1HY setting data Make sure that if the system E cL ore is allowable to apply these modes OFST BG RAMP SG Ex 41 The flow chart shows a complete listing ch OUTZ of all parameters For actual application c 22 the number of available parameters odd depends on setup conditions and should a4 CYC2 be less than that shown in the flow chart ze 6 8 ci sci XA 2 You can select at most 8 parameters put C7 MD in the user menu by using SEL1 SEL8 ac ALHY contained at the bottom of setup menu ALFT comm 3 Rel in for 2 d or Release 9 press c again for 2 seconds 624090 or longer but not longer than 3 seconds pata then release to enter the calibration menu C PARI E stop i i 6 The user menu
3. 3 18 9 120V 240VAC 4 9 10 Mains Supply Figure 2 9 Output 1 Relay or Triac SSR to Drive Load UM91001A 26 BTC 4100 BTC 8100 BTC 7100 BTC 9100 ES 7 8 9 120V 240V 4 9 10 o Mains Supply o o Three o Phase 5 6 Heater No Fuse Power las Chase Contactor Breaker Heater Load Figure 2 10 Output 1 Relay or Triac SSR to Drive Contactor BTC 4100 BTC 8100 BTC 7100 BTC 9100 SSR 3 8 9 9 120v maoy 4 9 10 _ 0 0 Mains Supply Internal Circuit Frege ee CE a 30mA 5V 1 5V Pulsed Voltage 33 n 33 i Wa OV m ea Figure 2 11 Output 1 Pulsed Voltage to Drive SSR 27 UM91001A BTC 4100 BTC 8100 BTC 7100 BTC 9100 de 3 8 9 Maximum Load 4 9 10 12 20mA 500 ohms Figure 2 12 Output 1 Linear Current BTC 4100 BTC 8100 BTC 7100 BTC 9100 3 8 9 0 1V 0 5V Load Minimum Load 4 9 10 1 5V 0 10V 10 K ohms Figure 2 13 Output 1 Linear Voltage BTC 4100 BTC 8100 BTC 7100 BTC 9100 Fl 5 6 11 100 12w2z0vac 6 7 Mains Supply tj 12 Figure 2 14 Output 2 Relay or Triac SSR to Drive Load UM91001A 28 BTC 4100 BTC 8100 BTC 7100 BTC 9100 m 5 6 1 1 120V 240V 6 7 12 o Mains Supply o Three o o Phase Heater No Fuse Power u De Phase Contactor Breake
4. 80410 H4 BTC 8100 BTC 9100 BTC 7100 TXI 7113 10 vja MEH am erminator 220 ohms 0 5W Figure 2 21 RS 485 Wiring 31 UM91001A RS 232 BTC 4100 BTC 8100 BTC 9100 RXD 14 ni com 15 9 pin RS 232 port sel 7 CC94 1 Figure 2 22 RS 232 Wiring If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable must be modified according to the following circuit diagram BTC 4100 BTC 8100 BTC 9100 To DTE PC RS 232 Port DD h3 H RXD nal COM 15 Female DB 9 Figure 2 23 Configuration of RS 232 Cable UM91001A 1DCD 2RD 310 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI Chapter 3 Programming Press for 5 seconds and release to enter setup menu Press to select the desired parameter The upper display indicates the parameter symbol and the lovver display indicates the selected value of parameter 3 1 Lockout There are four security levels can be selecied by using LOCK parameter f NONE is selected for LOCK then no parameter is locked f SET is selected for LOCK then all setup data are locked f USER is selected for LOCK then all setup data as well as user data refer to section 1 5 except set point are locked to prevent from being changed f ALL is selected for LOCK then all parameters are locked to prevent rom being changed 3 2 Signal Input INPT Selects the sensor type or signal type for signal input Ra
5. 77 UM91001A 3 Figures 8 Tables Figure 1 1 Fuzzy Control Advantage Figure 1 2 Programming Port Overview Figure 1 3 Front Panel Description Figure 1 4 Display of Initial Stage Figure 2 1 Mounting Dimensions Figure 2 2 Lead Termination for BTC 4100 BTC 8100 and BTC 7100 Figure 2 3 Lead Termination for BTC 9100 Figure 2 4 Rear Terminal Connection for BTC 4100 and BTC 8100 Figure 2 5 Rear Terminal Connection for BTC 7100 Figure 2 6 Rear Terminal Connection for BTC 9100 Figure 2 7 Power Supply Connections Figure 2 8 Sensor Input Wiring Figure 2 9 Output 1 Relay or Triac SSR to Drive Load Figure 2 10 Output 1 Relay or Triac SSR to Drive Contactor Figure 2 11 Output 1 Pulsed Voltage to Drive SSR Figure 2 12 Output 1 Linear Current Figure 2 13 Output 1 Linear Voltage Figure 2 14 Output 2 Relay or Triac SSR to Drive Load Figure 2 15 Output 2 Relay or Triac SSR to Drive Contactor Figure 2 16 Output 2 Pulsed Voltage to Drive SSR Figure 2 17 Output 2 Linear Current Figure 2 18 Output 2 Linear Voltage Figure 2 19 Alarm Output to Drive Load Figure 2 20 Alarm Output to Drive Contactor Figure 2 21 RS 485 Wiring Figure 2 22 RS 232 Wiring Figure 2 23 Configuration of RS 232 Cable Figure 3 1 Conversion Curve for Linear Type Process Value Figure 3 2 Heat Only ON OFF Control Figure 3 3 Output 2 Deviation High Alarm Figure 3 4 Output 2 Process Low Alarm Figure 3 5 RAMP Function Figure
6. ODADOA DN Output 1 0 None 1 Relay rated 2A 240VAC 2 Pulsed voltage to drive SSR 5V 30mA 3 Isolated 4 20mA 0 20mA 4 Isolated 1 5V 0 5V 5 Isolated O 10V 6 Triac output 1A 240VAC SSR C Pulsed voltage to drive SSR 14V 40mA 9 Special order L Options 0 Panel mount IP50 standard 1 Panel mount IP65 water resistant rubber installed 2 DIN Rail mount with IP50 for BTC 9100 only 3 DIN Rail mount with IP65 for BTC 9100 only Communications None RS 485 interface RS 232 interface not available for BTC 7100 Retransmit 4 20mA 0 20mA Retransmit 1 5 V 0 5V Retransmit 0 10V Special order oankO N o Alarm 0 None 1 Form C relay 2A 240VAC 9 Special order Output 2 0 None 1 Form A relay 2A 240VAC 2 Pulsed voltage to drive SSR 5V 30mA 3 Isolated 4 20mA 0 20mA 4 Isolated 1 5V 0 5V 5 Isolated 0 10V 6 Triac output 1A 240VAC SSR T 8 Isolated 20V 25mA transducer power supply Isolated 12V 40mA transducer power supply 9 Isolated 5V B0mA transducer power supply C Pulsed voltage to drive SSR 14V 40mA A Special order 8 UM91001E Accessories OM94 6 Isolated 1A 240VAC Triac Output Module SSR OM94 7 14V 40mA SSR Drive Module OM96 3 Isolated 4 20 mA 10 20 MA Analog Output Module OM96 4 Isolated 1 5V 0 5V Analog Output Module OM96 5 Isolated 0 10V Analog Output Module CM94 1 Isolated R
7. owing table for SP1 Non linear Linear input Linear input Linear input Linear input 5 The scale high low values are d O1HY RR O2HY and ALHY Conditions input DP 0 DP 1 DP DP 3 Scale low 1999 9 19999 1999 9 199 99 19 999 Scalehigh 4553 6 45536 45536 455 36 45 536 efined in the following table for PB Non linear Linear input Linear input Linear input Linear input Conditions input DP 0 DP 1 DP DP 3 Scale low 0 0 0 0 0 0 00 0 000 Scale high 6553 5 65535 6553 5 655 35 65 535 6 The scale high low values are defined in the following table for SP3 us ALFN 1 Non linear Linear input Linear input Linear input Linear input Conditions mma input pp Scale low 1999 9 1999 9 19999 1999 9 199 99 0 DP 1 DP DP 3 19 999 Scale high 4553 6 4553 6 45536 4553 6 455 36 45 536 For C21 and C91 Conditions TIMP input D 7 The scale high low values are defined in the following table for SP2 OUT2 1 Non linear Linear input Linear input Linear input Linear input P 0 DP 1 DP DP 3 Scale low 1999 9 1999 9 19999 1999 9 199 99 19 999 Scale high 4553 6 4553 6 45536 4553 6 455 36 45 536 UM91001D 72 For BTC 9100 BTC 8100 BTC 7100 and BTC 4100 Non linear IKAN Linear input IRAN mi inpu
8. Operating Temperature 10 C to 50 C Storage Temperature 40 C to 60 C Humidity O to 90 RH non condensing Altitude 2000m maximum Pollution Degree 2 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 BTC 4100 96mm W X 96mm H X 65mm D 53 mm depth behind panel BTC 7100 72mm W X 72mm H X 78 2mm D 65 mm depth behind panel BTC 8100 48mm W X 96mm H X 80mm D 65 mm depth behind panel BTC 9100 48mm W X 48mm H X 116mm D 105 mm depth behind panel Weight BTC 4100 250 grams BTC 7100 200 grams BTC 8100 210 grams BTC 9100 150 grams Approval Standards Safety UL61010C 1 CSA C22 2 No 24 93 EN61010 1 IEC1010 1 Protective Class IP65 for panel with additional option IP50 for panel without additional option IP20 for terminals and housing with protective cover All indoor use EMC EN61326 65 UM91001D Chapter 7 Modbus Communications This chapter specifies the Modbus Communications protocol as RS 232 or RS 485 interface module is installed Only RTU mode is supported Data is transmitted as eight bit binary bytes vvith 1 start bit 1 stop bit and optional parity checking None Even or Odd Baud rate may be set to 2400 4800 9600 14400 19200 28800
9. 4553 6 Date Code 0 65535 60 Serial Number 65535 VVorking hours of the controller 65535 UM91001D 70 Register Parameter Scale Scale Address Notation Parameter High Bumpless transfer of OP1 0 00 Bumpless transfer of OP2 0 00 Cold junction signal low 0 000 Process value Current set point value Read only unless in manual control OP1 control output value Read only unless in manual control OP2 control output value Remaining time of dwell timer Error code 1 Operation mode 8 alarm status 2 Program code 3 Command code Job code Job code Job code Cold Junction Temperature Reserved 78 Reserved 0 65535 79 Reserved 0 65535 1 The error code is show in the first column of Table A 1 2 Definition for the value of MODE register H 000X Normal mode H 010X Calibration mode H 020X Auto tuning mode H O30X Manual control mode H 040X Failure mode H OX00 Alarm status is off H Ox01 Alarm status is on The alarm status is shown in MV2 instead of MODE for models C21 and C91 71 UM91001D 3 The PROG Code is defined in the following table Where XX denotes the software version number For exam PROG 34 18 means that the controller is C91 with software version 18 44 The scale high low values are defined in the fol INLO INHI SP1L SP1H SHIF PV SV RELO and REHI ple
10. TD Derivative time value Low 0 High 360 0 sec 25 0 OUT1 Output 1 function Uu Reverse heating 9 E U control action 1 Direct cooling di rt control action O1TY Output 1 signal type Relay output 0 6 155rd 2 55r 34 00 40 06 jv Solid state relay drive output Solid state relay output 4 20 mA current module 0 20 mA current module 0 1V voltage module 0 5V voltage module 1 5V voltage module 0 10V voltage module 5 o QE 6 U 5 SE 7l n 1m 8 g LINI O1FT Qutput 1 failure transfer mode Select BPLS bumpless transfer or 0 0 100 0 to continue output 1 control function as the unit fails or select OFF 0 or ON 1 for ON OFF control O1HY Output 1 ON OFF control hysteresis Low 0 1 High 50 0 C 90 0 F 0 1 C 0 2 CYC1 Output 1 cycle time Low 0 1 High 90 0 sec 18 0 OFST Offset value for P control Low 0 High 100 0 96 25 0 RAMP Ramp function selection 0 non No Ramp Function 1 Use unit minute as Ramp Rate Use unit hour as Ramp Rate Ai e 2 Hrr 15 UM91001A Parameter Notation Parameter Description Range Default Value RR Ramp rate 500 0 C Low 0 900 0 F High 0 0 OUT2 Output 2 function 0 non Output 2 No Function 2 dEH 3 dELa 6 PYH Process High Alarm 7 PUL
11. the trigger levels a deviation band low alarm DB LO occurs In the above descriptions SV denotes the current set point value for control which is different from SP1 as the ramp function is performed There are four types of alarm modes available for each alarm function these are Normal alarm Latching alarm Holding alarm and Latching Holding alarm They are described as follows 39 UM91001A Normal Alarm ALMD NORM When a normal alarm is selected the alarm output is de energized in the non alarm condition and energized in an alarm condition Latching Alarm ALMD LTCH If a latching alarm is selected once the alarm output is energized it will remain unchanged even if the alarm condition is cleared The latching alarm is reset when the RESET key is pressed once the alarm condition is removed Holding Alarm ALMD HOLD A holding alarm prevents an alarm from power up The alarm is enabled only when the alarm condition is removed Afterwards the alarm performs same function as normal alarm Latching Holding Alarm ALMD LT HO A latching holding alarm performs both holding and latching function The latching alarm is reset when the RESET key is pressed once the alarm condition is removed Set Point Holding Alarm ALMD SPHO A set point holding alarm prevents an alarm from power up and or changing set point The alarm output is de energized whenever the set point is changed even if it is in an alarm condit
12. 3 6 Dwell Timer Function Figure 3 7 PV Shift Application Figure 3 8 Filter Characteristics Figure 3 9 Effects of PID Adjustment Figure 4 1 Heat Control Example Figure 4 2 Cooling Control Example Figure 4 3 Heat Cool Control Example Figure 5 1 RTD Calibration Figure 5 2 Cold Junction Calibration Setup Table 1 1 Display Form of Characters Table 3 1 Heat Cool Control Setup Value Table 3 2 PID Adjustment Guide Table A 1 Error Codes and Corrective Actions 4 UM91001A Chapter 1 Overview 1 1 General The Fuzzy Logic plus PID microprocessor based controller series incorporate two bright easy to read 4 digit LED displays indicating process value and set point 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 BTC 9100 is a 1 16 DIN size panel mount controller It can also be used for rail mount by adding a rail mount kit BTC 7100 is a 72X72 DIN size panel mount controller BTC 8100 is a 1 8 DIN size panel mount controller and BTC 4100 is a 1 4 DIN size panel mount controller These units are powered by 11 26 or 90 250 VDC INAC supply incorporating a 2 amp control relay output as standard The second output can be used as cooling control or an alarm Both outputs can select triac 5V
13. 38 3 4 Alarm The controller has one alarm output There are 6 types of alarm functions and one dwell timer can be selected and four kinds of alarm modes ALMD are available for each alarm function ALFN Besides the alarm output the output 2 can also be configured as another alarm But output 2 only provides 4 kinds of alarm functions and only normal alarm mode is avaiable for this alarm A process alarm sets two absolute trigger levels When the process is higher than SP3 a process high alarm PV HI occurs and the alarm is off as the process is lower than SP3 ALHY When the process is lower than SP3 a process low alarm PV LO occurs and the alarm is off as the process is higher than SP3 ALHY A process alarm is independent of set point A deviation alarm alerts the user when the process deviates too far from set point When the process is higher than SV SP3 a deviation high alarm DE HI occurs and the alarm is off as the process is lower than SV SP3 ALHY When the process is lower than SV SP3 a deviation low alarm DE LO occurs and the alarm is off as the process is higher than SV SP3 ALHY Trigger level of deviation alarm is moving with set point A deviation band alarm presets two trigger levels relative to set point The two trigger levels are SV SP3 and SV SP3 for alarm When the process is higher than SV SP3 or lower than SV SP3 a deviation band high alarm DB HI occurs When the process is within
14. C Setup Summary Refrigerator INPT PT DN UNIT C DP 1 DP OUT1 DIRT O1TY RELY Mains Supply User Menu PB 0 C 18 O1HY 0 1 C Figure 4 2 Cooling Control Example UM91001A 52 4 3 Heat Cool Control An injection mold required to be controlled at 120 Cto 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 Plastics Injection Mold LEG 00124 0 1 5 6 3 4 Son or INPT Ie t IC UU qt TUOD JAE R Figure 4 3 IBIG ercene Heat Cool Control Example UM91001A 53 The PID Heat Cool is used for the above example To achieve this set the following parameters in the Setup Menu INPT PT DN UNIT C DP 1 DP OUT1 REVR O1TY RELY CYC1 18 0 sec O1FT BPLS OUT2 COOL O2TY 4 20 O2FT BPLS Adjust SV at 120 0 C CPB at 125 96 and DB at 4 0 96 Apply Auto tuning at 120 C for anew system to get an optimal PID values See Section 3 11 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 96 If air is used as cooling media instead of oil the CPB is set at 100 Adjustment of DB is dependent on the system requ
15. ON OFF control O Adjust to met process is configured requirements UM91001A 34 Heat Only ON OFF Control Select REVR for OUT1 Set PB to O O1HY is used to adjust dead band for ON OFF control The output 1 hysteresis O1HY is enabled in case of PB 0 The heat only on off control function is shown in the following diagram PV A SP1 Dead band O1HY SP1 O1HY T T t ngi OUT1 Action Time A ON OFF Time Figure 3 2 Heat Only ON OFF Control The ON OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest If ON OFF control is set ie PB 0 TI TD CYC1 OFST CYC2 CPB DB will be hidden and have no function to the system The auto tuning mode and bumpless transfer will be disabled too Heat only P or PD control Select REVR for OUT1 set TI to 0 OFST is used to adjust the control offset manual reset O1HY is hidden if PB is not equal to 0 OFST Function OFST is measured by with range O 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 PB that is lower 25 35 UM91001A then increase OFST 25 96 and vice versa After adjusting OFST value the process value vvill be varied and eventually coincide vvith set point Using the P control TI set to O the auto tuning is disable
16. Other protocols are not available for the series 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 or RS 232 RS 485 is less sensitive to the noise and suitable for a longer distance 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 RTU for COMM 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 If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable should be modified for proper operation of RS 232 communication acc
17. and 38400 7 1 Functions Supported Only function 03 06 and 16 are available for this series of controllers The message formats for each function are described as follovvs Function 03 Read Holding Registers Query from master Response from slave Slave address 0 255 A Function code 3 a Starting address of register Hi 0 Byte count Starting address of register Lo 0 79 Data 1 Hi 128 131 Data 1 Lo No of words Hi 0 Data 2 Hi No of words Lo 1 79 Data 2 Lo CRC16 Hi CRC16 Lo E CRC16 Hi CRC16 Lo Function 06 Preset single Register Query from master Response from slave Slave address 0 255 Function code 6 Register address Hi 0 Register address Lo 0 79 128 131 Data Hi Data Lo CRC16 Hi CRC16 Lo Q UM91001B 66 Function 16 Preset Multiple Registers Query from master Slave address 0 255 Function code 16 Starting address of register Hi 0 Starting address of register Lo 0 79 128 131 No of vvords Hi 0 No of vvords Lo 1 79 Byte count 2 158 Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo CRC16 Hi CRC16 Lo 67 UM91001B Response from slave CRC16 Hi CRC16 Lo 7 2 Exception Responses If the controller receives a message which contains a corrupted character parity check error framing error etc or if the CRC16 check fails the controller ignores the message However
18. 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 Beware not to over tighten the terminal screws The torque should not exceed 1 N m 8 9 Lb in or 10 2KgF cm UM91001D 22 Unused control terminals should not be used as jumper points as they may be internally connected causing damage to the unit Verify that the ratings of the output devices and the inputs as specified in Chapter 6 are not exceeded x Except the thermocouple wiring all wiring should use stranded copper conductor with maximum gauge 18 AWG in 7 0mm max a Figure 2 2 Lead Termination for EL DA BTC 4100 BTC 8100 T and BTC 7100 pat Omm max i e Figure 2 3 Lead Termination Sommi LE for BTC 9100 9025040 PAY IL 500 max air ambient 47 63 Hz J Use copper conductors 12VA 2 N except on T C input ES c3 RS 485 4 No RETRANSMISSION 5 C Lad 7e 9 INC Guru 10 Figure 2 4 Rear Terminal Connection for BTC 4100 and BTC 8100 23 UM91001D 90 250VAC 11 1814 B car ii 47 63 Hz OPI 12VA 2JN 19 3 RE 10 TXT RS 485 or 4 Lo RE 7x2 RETRANSMISSION A puli ALM RTD Ka TC V 13 7 8 OP2 PTB mA Lt p FL Spero p PTB mA T TC V mA RID 50 C max air ambient Use copper conductors except o
19. either failure mode or manual control mode occurs UM91001D 46 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 VVarm Start After the auto tuning procedures are completed the AT indicator will cease to flash and the unit revert to PID control by using its new PID values The PID values obtained are stored in the nonvolatile memory HE E f Auto Tuning Error If auto tuning fails an ATER message will appear on the upper display in cases of 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 Solutions to Ht 1 Try auto tuning once again 2 Dont change set point value during auto tuning procedure 3 Dont set zero value for PB and TI 4 Use manual tuning instead of auto tuning See section 3 12 5 Touch RESET key to reset AL E message 3 12 Manual Tuning In certain applications very few using auto tuning to tune a process may be inadequate for the control requirement then you can try manual tuning If the control performance by using auto tuning is still unsatisfactory the following rules can be applied for further adjustment of PID values 47 UM91001A ADJUSTMENT SEQUENCE SYMPTOM SOLUTION Slow Response Decrease PB 1 Proportional Band PB High overs
20. if the controller receives a syntactically correct message which contains an illegal value it will send an exception response consisting of five bytes as follows slave address offset function code exception code CRC16 Hi CRC16 Lo Where the offset function code is obtained by adding the function code with 128 ie function 3 becomes H 83 and the exception code is equal to the value contained in the following table Exception Code Name Cause Function code is not supported 1 Bad function code by the controller Illegal data address Register address out of range Data value out of range or 3 Ilegal data value attempt to write a read only or protected data UM91001A 68 7 3 Parameter Table Register Parameter Address Notation Farameter Scale Scale Low High Notes 0 SP1 Set point 1 SP2 Set point 2 Set point 3 Lock code Input sensor selection Measuring unit Decimal point position Low scale value for linear input High scale value for linear input Low limit of SP1 PV shift value Filter time constant Display form for C21 P proportional band Integral time Derivative time Output 1 function Output 1 signal type 1 2 3 4 5 6 7 8 9 0 High limit of SP1 1 2 3 4 5 6 7 8 9 Output 1 failure transfer Output 1 ON OFF hysteresis Output 1 cycle time Offset value for P contro
21. shown in the flow chart is O REH corresponding to the default setting for ad SELI the SEL parameters SELI to SEL8 SP3 E SE vvill be hidden if NONE is selected for Ex ALFN SP2 will be hidden if alarm function d SELS is not selected for OUT2 The unused o c Ses parameter will be hidden even if it is ec selected by SEL parameters UM91001D 12 1 6 Parameter Descriptions Parameter anti Default Notation Parameter Description Range Value SP1 Set point for output 1 Low SPiL High SP1H 236 Set point for output 2 10 0 C SP2 when output 2 performs Low 19999 High 45536 48 op alarm function Set point for alarm or m 10 0 C SP3 dwell timer output Low 19999 High 45536 48 9 F 0 nonE No parameter is locked 1 SEE Setup data are Select parameters to be locked LOCK locked 2 uSEr Setup data and 0 User data except Set point are locked 3 FLL All data are locked O EE J type thermocouple 10 EC K type thermocouple 2L EC T type thermocouple 3 E EC E type thermocouple 4 b EC B type thermocouple 57 6 R type thermocouple 6 5 EC S type thermocouple 7 n EC N type thermocouple 8L EC Ltype thermocouple INPT Input sensor selection 9 PE dn PT 100 ohms DIN ibi curve 10 PE JS PT 100 ohms JIS curve 11 4 20 4 20 m linear current input 12 0 20 0 20 m linear current input 13 0 60 0 60 mV linear millivolt input 14 G 14 0 1V linear voltage input 15
22. stable to 99 9 Isolation Breakdown Voltage 1000 VAC Temperature Effect 0 01 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 UM91001B 62 DC Voltage Supply Characteristics Installed at Output 2 Type Tolerance Max Output Current Ripple Voltage Isolation Barrier 20V 1V 25 MA 0 2 Vp p 500 VAC 12V 0 6V 40 mA 0 1 Vp p 500 VAC 5V 0 25V 80 mA 0 05 Vp p 500 VAC Alarm Alarm Relay Form C Rating 2A 240VAC life cycles 200 000 for resistive load Alarm Functions Dwell timer Deviation High Low Alarm Deviation Band High Low Alarm PV High Low Alarm Alarm Mode Normal Latching Hold Latching Hold Dwell Timer 0 1 4553 6 minutes Data Communication Interface RS 232 1 unit RS 485 up to 247 units Protocol Modbus Protocol RTU mode Address 1 247 Baud Rate 2 4 38 4 Kbits sec Data Bits 7 or 8 bits Parity Bit None Even or Odd Stop Bit 1 or 2 bits Communication Buffer 160 bytes Analog Retransmission Output Signal 4 20 mA 0 20 mA 0 5V 1 5V 0 10V Resolution 15 bits Accuracy 0 05 96 of span 0 0025 C Load Resistance 0 500 ohms for current output 10 K ohms minimum fo
23. 0 C signal to the unit under calibration The unit under calibration is powered in a still air room with temperature 25 3 C Stay at least 20 minutes for warming up Perform step 1 stated above then press scroll key until the display shows Press up down key to obtain 40 00 Press scroll key for at least 5 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 5 00 or 40 00 then the calibration fails x Perform step 7 to calibrate gain of cold junction compensation if required Step 7 Setup the equipments same as step 6 The unit under calibration is powered in a still air room with temperature 50 3 C Stay at least 20 minutes for warming up The calibrator source is set at 0 00 C with internal compensation mode UM91001D 58 Perform step 1 stated above then press scroll key until the display shows E 4H Press scroll key for at least 5 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 x Input modification and recalibration procedures for a linear voltage or a linear current input 1 Remove R60 3 3K and install two 1 4 W resistors RA and RB on the control
24. 0 54 0 5V linear voltage input 16 54 1 5V linear voltage input 17 B 10 0 10V linear voltage input 13 UM91001A Default Parameter ipti Notation Parameter Description Range Value 0 Of Degree C unit UNIT Input unit selection 1 OF Degree F unit idi 2 Pu Process unit 0 nodP No decimal j point 1 l 1 decimal digit DP Decimal point selection i dP 1 2 gP 2decimal digits 3 3 gP 3decimal digits INLO In iah 17 8 C put low scale value Low 19999 High 45486 0 F 93 3 C INHI Input high scale value Low INLO 50 High 45536 200 0 F Low limit of set point 3 iate 17 8 C SPIL ue Low 19999 High 45536 High limit of set point ei 537 8 C SP1H value Low SPIL High 45536 1000 F SHIF PV shift offset value Low 2600 High 380 0 F 0 0 0 O second time constant 1 Lg 0 2 second time constant 2 16 0 5 second time constant 3 1second time constant 4 C 2 seconds time Filter damping time constant 2 FILT constant of PV 5 S 5 seconds time constant 6 7 10 seconds time constant 7 Qj 20 seconds time constant 8 73 30 seconds time constant 9 GO 60 seconds time constant UM91001A 14 Parameter Notation Parameter Description Range Default Value PB Proportional band value 500 0 C High 900 0 F Low 0 10 0 C 18 0 F TI Integral time value Low 0 High 3600 sec 100
25. 19 UM91001A Chapter2 Installation AN Dangerous voltages capable of causing death are sometimes present in this instrument Before installation or beginning any cleaning or 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 LN This instrument is protected throughout by Double Insulation 5 To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture A 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 6 AN Remove stains from this instrument using a soft dry cloth Don t use harsh chemicals volatile solvent such as thinner or strong detergents to clean the instrument in order to avoid deformation or discoloration 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 the model number serial number and date code for future reference when corresponding with our service center The serial number S N a
26. 2 O1FT O2FT 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 O1TY 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 UM91001A 36 You can use the auto tuning program for the new process or directly set the appropriate values for PB TI amp TD 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 12 for manual tuning CPB Programming The cooling proportional band is measured by 96 of PB with range 50 300 Initially set 10096 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 CPBis related to PB and its value remains unchanged throughout the 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 96 DB Programming Adjustment of DB is dependent on the system requirements If more positive value of DB greater dead band is used an unwanted cooli
27. 6 Read All Parameters Query os oo oo o uso Hi to Addr Func Starting Addr No of words CRC16 Example 7 Modify the Calibration Coefficient Preset the CMND register with 26669 before attempting to change the calibration coefficient 06 00 H48 H 68 H 9 Hi Lo Addr Func Register Addr Data Hi Lo CRC16 75 UM91001G Table A 1 Error Codes and Corrective Actions Displa S ced Symbol Error Description Corrective Action Illegal setup values been used Check and correct setup values of Before COOL is used for OUT2 OUT2 PB TI and 0011 IF OUT2 DIRT cooling action has already lis required for cooling control the been used for OUT1 or PID mode control should use PID mode PB 4 E 74 lis not used for OUTI thatisPB O TI 4 0 and OUT1 should 0 and or Tl 2 0 use reverse mode heating action otherwise don t use OUT2 for cooling control Communication error bad function Correct the communication 10 JE code software to meet the protocol requirements Communication error register Dont issue an over range njer ti address out of range register address to the slave Communication error attempt Dont write a read only data or a 14 14 to write a read only data or a protected data to the slave protected data Communication error write a Dont write an over range data 15 15 value which is out of range toa to the slave r
28. PSH 7P lo No alarm function Dwell timer action Deviation high alarm Deviation low alarm Deviation band out of band alarm Deviation band in band alarm Process value high alarm Process value low alarm ALMD Alarm operation mode 0norn 1LEch 2Hold 3LEHo 45PHo Normal alarm action Latching alarm action Hold alarm action Latching amp Hold action Set point holding alarm ALHY Hysteresis control of alarm Low 0 1 h 50 0 C High 90 0 F 0 1 C 0 2 F ALFT Alarm failure transfer mode 0 on 1 oFF Alarm output ON as unit fails Alarm output OFF as unit fails COMM Communication function 0 nonE 1 rtu 24 00 30 20 40 54 5 4 54 No communication Modbus RTU mode protocol 4 20mA retransmission output 0 20mA retransmission output 0 5V retransmission output 11 5V retransmission output 0 10V retransmission output 17 UM91001F Parameter ipti Default Notation Parameter Description Range Value Address assignment of T ADDR digital communication LOW 1 High 255 0 4 2 4 Kbits s baud rate 1 UB 4 8 Kbits s baud rate 2 OB 9 6 Kbits s baud rate Baud rate of digital fi n BAUD communication 3 MM 14 4 Kbits s baud rate 2 4 190 19 2 Kbits s baud rate 5 CHE 28 8 Kbits s baud rate 6 JBM 38 4 Kbits s baud rate 7 4 DATA Data bit cou
29. S 485 Interface Module for BTC 8100 4100 7100 CM94 2 Isolated RS 232 Interface Module for BTC 8100 4100 CM94 3 Isolated 4 20 mA 10 20 mA Retrans Module for BTC 8100 4100 7100 CM94 4 Isolated 1 5V 0 5V Retrans Module for BTC 8100 BTC 4100 BTC 7100 CM94 5 Isolated 0 10V Retrans Module for BTC 8100 4100 7100 CM97 1 Isolated RS 485 Interface Module for BTC 9100 CM97 2 Isolated RS 232 Interface Module for BTC 9100 CM97 3 Isolated 4 20 mA 0 20mA Retrans Module for BTC 9100 CM97 4 Isolated 1 5V 0 5V Retrans Module for BTC 9100 CM97 5 Isolated 0 10V Retrans Module for BTC 9100 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 CC94 1 RS 232 Interface Cable 2M CC91 1 Programming Port Cable RK91 1 Rail Mount kit for BTC 9100 Related Products SNA10A Smart Network Adaptor for third party software which converts 255 channels of RS 485 or RS 422 to RS 232 etwork SNA12A Smart Network Adapter for programming port to RS 232 interface BC Set Configuration Software Communicator PC software to communicate 1024 tags Standard model without option BTC x100 4110000 UM91001E 8 1 1 3 Programming Port Front Panel Rear t Terminal Figure 1 2 Programming Port Overview Access Hole A special connector can be used to touch the programming por
30. User s Manual Coun DIN EN ISO 9001 Certificate 01 100 98505 NG CE BTC 4100 7100 8100 9100 Auto Tune Fuzzy PID Process Temperature Controller UM91001G BICI BRAINCHILD Warning Symbol AN 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 Installers Read Chapter 1 2 e System Designer Read All Chapters Expert User Read Page 12 NOTE Itis strongly recommended that a process should incorporate a LIMIT CONTROL like L91 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system Information in this users manual is subject to change without notice This manual is applicable for the products with software version 29 and later version Copyright February 2002 The Brainchild Corporation all rights reserved No part of this publication may be reproduced transmitted transcribed or stored in a retrieval system or translated into any language in any form by any means without the written permission of the Brainchild Corporation 2 UM91001F Contents Chapter 1 Overview 1 1 General 5 1 2 Ordering Code 8 1 3 Progr
31. amming Port 9 1 4 Keys and Displays 10 1 5 Menu Overview 12 1 6 Parameter Descriptions 13 Chapter 2 Installation 2 1 Unpaking 20 2 2 Mounting 20 2 3 Wiring precautions 22 2 4 Power Wiring 25 2 5 Sensor Installation Guidlines 2 6 Sensor Input Wiring 2 7 Control Output Wiring 26 2 8 Alarm Wiring 30 2 9 Data Communication 31 Chapter 3 Programming 3 1 Lockout 33 3 2 Signal Input 3 3 Control Outputs 3 4 Alarm 3 5 Configure User Menu 3 6 Ramp 7 Dwell Timer 8 PV Shift 9 Digital Filter 10 Failure Transfer 11 Auto tuning 1 1 1 1 2 Manual tuning 3 Manual Control 4 Data Communication 5 PV Retransmission Q9 LI CI CI Co CO CO CO CO Page No Chapter 4 Applications 4 1 Heat Only Control with Dwell Timer 4 2 Cool Only Control 4 3 Heat Cool Control 53 Chapter 5 Calibration 55 Chapter 6 Specifications 60 Chapter 7 Modbus Communications 66 7 1 Functions Supported 66 7 2 Exception Responses 7 3 Parameter Table 7 4 Data Conversion 73 7 5 Communication Examples 73 Appendix A 1 Error Codes 76 A 2 Warranty
32. board with the recommended values specified in the following table The low temperature coefficient resistors should be used for RA and RB Input Function RA T C RTD 0 60mV X 0 1V 61 9K 0 5V 1 5V 324K X 0 10V 649K X 0 20mA 4 20mA 390 3 010 X 2 Perform Step 1 and Step 2 to calibrate the linear input zero 3 Perform Step 3 but send a span signal to the input terminals instead of 60mV The span signal is 1V for 0 1V input 5V for 0 5V or 1 5V input 10V for 0 10V input and 20mA for 0 20mA or 4 20mA input Finalstep Step 8 Set the LOCK value to your desired function 59 UM91001D Chapter 6 Specifications Povver 90 250 VAC 47 63 Hz 12VA 5W maximum 11 26 VAC VDC SELV Limited Energy 12VA 5W maximum Input 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 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 Sensor short for RTD input below 1 mA for 4 20 mA input below 0 25V for 1 5 V input unavailabl
33. c calibration The calibration procedures described in the following 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 55 UM91001A Manual Calibration Procedures Perform step 1 to enter calibration mode Step 1 Set the Lock parameter to the unlocked condition LOCK NONE Press and hold the scroll key until appears on the display then release the scroll key Press the scroll key for 2 seconds then release the display will show Ad a land the unit enters calibration mode Perform step 2 to calibrate Zero of Ato D converter and step 3 to calibrate gain of A to D converter Step 2 Short the thermocouple inpt terminals then press scroll key for at least 5 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 Step 3 Press scroll key until the display shows Agh Send a 60 mV signal to the thermocouple input terminals in correct polarity Press scroll key for at least 5 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 calibrati
34. cessing 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 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 77 UM91001A BIG BRAINCHILD Electronic Co Ltd No 209 Chung Yang Rd Nan Kang Dist Taipei Taiwan R O C 115 Tel 886 2 27861299 Fax 886 2 27861395 web site http www brainchild com tw
35. d Refer to section 3 12 manual tuning for the adjustment of PB and TD Manual reset adjust OFST is not practical because the load may change from time to time and often need to adjust OFST repeatedly The PID control can avoid this situation Heat only PID control Selecting REVR for OUT1 PB and TI should not be zero Operate auto tuning for the new process or set PB TI and TD with historical values See section 3 11 for auto tuning operation If the control result is still unsatisfactory then use manual tuning to improve the control See section 3 12 for manual tuning The unit 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 Cool only control ON OFF control P PD control and PID control can be used for cool control Set OUT1 to DIRT direct action The other functions for cool only ON OFF control cool only P PD control and cool only PID control are same as descriptions for heat only control except that the output variable and action for the cool control is inverse to the heat control 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 CYC
36. e 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 UM91001B 60 Characteristics Accuracy Input Le Range 25 C Impedance 120 C 1000 C J as te 22 C 22140 200 C 1370 C K 3282 24og2F 2 C 22Ma 250 C 400 C T 270 22Ma 100 C 900 C E 148 F 1652 F 2 C 2 2 MQ 2 C 0 C 1800 C B S neon ies 2000 22140 82 F 9272 F Noe 0 C 1767 8 C R 3006 9214 2C 22149 0 C 1767 8 C 7 S 32 F 3214 F 2 C 2 2 MQ 250 C 1300 C N 418 F 2372 F 2 C 2 2 MQ 206 606 L 328 F 1652 p 2 C 22M9 PTI00 210 C 700 DIN 346 12920 04 C 13Ko PT100 200 C 600 C i JIS a2a F 11129F 04 13 Ko mV 8mV 70mV 005 221410 mA 3mA 27mA 00596 7050 v 1 3V 115V 0 05 6500 61 UM91001A Output 1 Output 2 Relay Rating 24 240 VAC life cycles 200 000 for resistive load Pulsed Voltage Source Voltage 5V current limiting resistance 66 0 Linear Output Characteristics Type eau SS gay 4 20 mA 3 6 4 mA 20 21 mA 50092 max 500 max 10 KQ min 10 KQ min 0 10V OV 10 10 5 V 10 KO min Linear Output Resolution 15 bits Output Regulation 0 02 96 for full load change Output Settling Time 0 1 sec
37. egister register 1 The PID values obtained after auto tuning procedure are out of range Retry auto tuning 2 Don t change set point value 26 BE E Fail to perform auto tuning during auto tuning procedure meer function 3 Use manual tuning instead of auto tuning 4 Don t set a zero value for PB 5 Don t set a zero value for TI 6 Touch RESET key 29 EE FE EEPROM cant be written correctly Return to factory for repair 30 sz _ Cold junction compensation for i Ler thermocouple malfunction Return to factory for repair Input sensor break or input z _ current below 1 mA if 4 20 mA is i 39 55Er selected or input voltage below Replace input sensor 0 25V if 1 5V is selected 40 Ag r D Converter op related Return to factory for repair component s malfunction UM91001A 76 VVARRANTY 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 pro
38. ent below 1mA if 4 20 mA is selected or input voltage below 0 25V if 1 5 V is selected 2 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 the controller enters failure mode Output 1 Failure Transfer if activated will perform 1 If output 1 is configured as proportional control 9 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 PB 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 PB 0 then output 1 will transfer to off state if OFF is set for O1FT and transfer to on state if ON is set for O1FT Output 2 Failure Transfer if activated will perform 1 If OUT2 is configured as COOL and BPLS is selected for O2FT then output 2 will perform bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 2 If OUT2 is configured as COOL and a value of 0 to 100 0 is set for O2FT then output 2 will perform failure transfer Thereafter the value of O2FT will be used for controlling output 2 3 If OUT2 is configured as alarm function and OFF is set fo
39. g 8r Deviation High Alarm Deviation Low Alarm Process Low Alarm Cooling PID Function Deviation High Alarm with Hold Function Deviation Low Alarm with Hold Function Process High Alarm with Hold Function Process Low Alarm with Hold Function Cool 9 dHHo 10dL Ho 1PHHo 12P1 Ho O2TY Output 2 signal type Relay output 0 ELY 155rg 2 55r 3 q ec aY Ag 5 N 6 eu 7 GU 80 Solid state relay drive output Solid state relay output 4 20 mA current module 0 20 mA current module 0 1V voltage module 3 0 5V voltage module a ES 1 5V voltage module i0 0 10V voltage module O2FT Output 2 failure transfer mode Select BPLS bumpless transfer or 0 0 100 0 to continue output 2 control function as the unit fails or select ON 0 or OFF 1 for alarm function O2HY Output 2 hysteresis value when output 2 performs alarm function 50 0 C Low 0 1 90 0 F High 0 1 C 0 2 F CYC2 Output 2 cycle time Low 0 1 High 90 0 sec 18 0 CPB Cooling proportional band value Lovv 50 High 300 96 100 UM91001B 16 Parameter Notation Parameter Description Range Default Value DB Heating cooling dead band negative value overlap Lovv 36 0 High 36 0 96 ALFN Alarm function for alarm output 0 non t nr 2 JEH 3 dELo 4 dbHi 5 dhLo e
40. hoot or M Increase PB Oscillations Slow Response Decrease TI 2 Integral Time TI Instability or Oscillations Increase TI EY Slow Response 9r Decrease TD 3 Derivative Time TD Oscillations High Overshoot Increase TD Table 3 2 PID Adjustment Guide Figure 3 9 shovys the effects of PID adjustment on process response 3 13 Manual Control Operation To enable manual control the LOCK parameter should be set vvith NONE then press c2 for 6 2 seconds Hand Control will appear on the display Press for 5 seconds then the MAN indicator will begin to flash and the lower display will show H The controller now enters the manual control mode H indicates output control variable for output 1 and _ _ _ Jindicates control variable for output 2 Now you can use up down key to adjust the percentage values for the heating or cooling output The controller performs open loop control as long as it stays in manual control mode Exit Manual Control To press R key the controller will revert to its normal display mode UM91001D 48 PV PB too low Set poini P action PB too high Time TI too high PV Set point l action Perfect TI too low Time PV TD too low Set point D action TD too high Time Figure 3 9 Effects of PID Adjustment 49 UM91001A 3 14 Data Communication The controllers support RTU mode of Modbus protocol for the data communication
41. ion The alarm reverts to a normal alarm once the alarm condition is removed Alarm Failure Transfer is activated as the unit enters failure mode Alarm will go on if ON is set for ALFT and go off if OFF is set for ALFT The unit will enter failure mode when sensor break occurs or if the A D converter of the unit fails 3 5 Configure User Menu The conventional controllers are designed with a fixed parameters scrolling If you need a more friendly operation to suit your application the vender will say sorry to you The series have the flexibility for you to select those parameters which are most significant to you and put these parameters in the front of display sequence SEL1 SEL8 Selects the parameter for view and change in the user menu Range LOCK INPT UNIT DP SHIF PB TI TD O1HY CYC1 OFST RR O2HY CYC2 CPB DB ADDR ALHY When using the up 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 UM91001F 40 Example OUT selects DELO PB 100 0 SEL1 selects INPT SEL2 selects UNIT SEL3 selects PB SELA selects TI SEL5 SEL8 selects NONE Now the upper display scrolling becomes jap Saje EE 3 6 Ramp The ramping function is perfor
42. irements 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 UM91001A 54 Chapter 5 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 A 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 96 accuracy 0 10 V voltage source with 0 005 accuracy 0 20 mA current source with 0 005 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 SWU16K 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 automati
43. l Ramp function Ramp rate Output 2 function Retransmission low scale value Output 2 signal type Output 2 failure transfer 29 O2HY Output 2 ON OFF hysteresis 5 5 R W 69 UM91001D Register Address Parameter Notation Scale Scale Parameter Low High Notes 30 31 CYC2 CPB Output 2 cycle time 0 0 6553 5 32 DB Cooling P band 0 65535 Heating cooling dead band 1999 9 4553 6 33 LFN Alarm function 0 65535 34 EHI Retransmission high scale value 4 x4 Alarm opertion mode 0 65535 35 LMD 36 LHY Alarm hysteresis k s 5 37 LFT Alarm failure transfer 65535 38 OMM Communication function 65535 39 DDR 40 41 BAUD DA Address 65535 Baud rate 65535 42 43 Data bit count 65535 Parity bit 65535 44 45 Stop bit count 65535 Selection 1 65535 46 47 Selection 2 65535 Selection 3 65535 48 49 Selection 4 65535 Selection 5 65535 50 51 Selection 6 65535 Selection 7 65535 52 53 Selection 8 0 65535 mV calibration low coefficient 1999 9 4553 6 54 55 mV calibration high coefficient 1999 9 4553 6 RTD calibration low coefficient 1999 9 4553 6 56 57 RTD calibration high coefficient 1999 9 4553 6 Cold junction calibration low coefficient 199 99 455 36 58 59 Cold junction calibration high coefficient 1999 9
44. logic output linear current or linear voltage to drive external device There are six types o alarm plus a dwell timer can be configured for the third output The units are fully programmable for PT100 and thermocouple types J K T E B R S N L with no need to modify the unit The input signal is digitized by using a 18 bit A to D converter Its fast sampling rate allows the unit to control fast processes Digital communications RS 485 or RS 232 excluding BTC 7100 are available as an additional option These options allow the units to be integrated with supervisory control system and software A programming port is available for automatic configuration calibration and testing without the need to access the keys on front panel By using proprietary Fuzzy modified PID technology the control loop will minimize the overshoot and undershoot in a shortest time The following diagram is a comparison of results with and without Fuzzy technology UM91001B 5 PID control vvith properly tuned PID t Fuzzy control Temperature Set point Figure 1 1 Fuzzy Control Advantage Warm Up Load Disturbance Time High Accuracy The series are manufactured with custom designed ASIC Application Specific Integrated Circuit technology which contains a 18 bit A to D converter for high resolution measurement true 0 1 F resolution for thermocouple and PT100 and a 15 bit D to A converter for linear current or voltage cont
45. med during power up as well as any time the set point is changed Choose MINR or HRR for RAMP the unit will perform the ramping function The ramp rate is programmed by adjusting RR The ramping function is disabled as soon as the failure mode the manual control mode the auto tuning mode or the calibration mode occurs Example without Dwell Timer Select MINR for RAMP selects C for UNIT selects 1 DP for DP Set RR 10 0 SV 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 Figure 3 5 RAMP Function gt Time 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 as power up or RR and or set point are changed Setting RR to zero means no ramp function at all 41 UM91001A 3 7 Dyvell Timer Alarm output can be configured as dyvell timer by selecting TIMR for ALFN As the dwell timer is configured the parameter SP3 is used for dwell time adjustment The dwell time is measured in minute ranging from 0 1 to 4553 6 minutes Once the process reaches the set point the dwell timer starts to count down until zero time out The timer relay will remain unchanged until time out The dwell
46. n T C input Figure 2 5 Rear Terminal Connection for BTC 7100 5 PTA LA 6 RETRANSMISSION RE RE RS 232 TXD RXD COM RS 485 1X1 TX E car 90 250VAC 47 63 Hz 12VA 50 C max air ambient Use copper conductors except on T C input Figure 2 6 Rear Terminal Connection for BTC 9100 UM91001B 24 2 4 Power Wiring The controller is supplied to operate at 11 26 VAC VDC or 90 250 VAC Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller Near the controller a fuse and a switch rated at 2A 250VAC should be equiped as shown in the following diagram BTC 4100 BTC 7100 BTC 8100 BTC 9100 i 7 Fuse n ve oo gt 90 250 VAC or NE en pee Figure 2 7 Power Supply Connections 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 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 fairl
47. nd 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 UM91001B 20 Figure 2 1 Mounting Dimensions 92 mm Panel Cutout 21 92 mm Panel Cutout 45mm 68 mm i Panel Cutout 68 mm Panel Panel L 65 mm UM91001A BTC 4100 BTC 8100 BTC 7100 Panel le 45 mm gt Panel Cutout BTC 9100 Panel Mount 45 mm e 11 5mm f 104 8mm 7 5mm 1 62 0mm 48 0mm BTC 9100 L Rail Mount 11 5mm be 104 8mm 6 5mi 2 3 Wiring Precautions x 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 It is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible All units should be installed inside a suitably grounded metal enclosure to prevent live parts
48. ng action 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 36 096 to 36 0 of PB 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 Output 2 ON OFF Control Alarm function The output 2 can also be configured as alarm function There are 8 kinds of alarm functions can be selected for output 2 these are DE HI deviation high alarm DE LO deviation low alarm PV HI process high alarm PVLO process low alarm DHHO deviation high alarm with hold function DLHO deviation low alarm with hold function PHHO process high alarm with hold function and PLHO process low alarm with hold function The hold function includes both cases of power up and changing set point Refer to Figure 3 3 and Figure 3 4 for the description of deviation alarm and process alarm 37 UM91001B PV OUT2 DE HI SV SP2 SV SP2 O2HY OUT2 Action Time ON OFF Figure 3 3 Output 2 Deviation Time High Alarm PV i SP2 O2HY i i spat Ji NJI I I I I 1 aa E 387 fm OUT2 Action I I I Time Hop ON pu LE Time Figure 3 4 Output 2 Process Low Alarm UM91001A
49. nge thermocouple J TC K TC T TC E TC B TC R TC S TC N TC L TC RTD PT DN PT JS linear 4 20 0 20 0 60 0 1V 0 5V 1 5V 0 10 UNIT Selects the process unit Range C F PU process unit If the unit is neither C nor F then selects PU DP Selects the resolution of process value Range for T C and RTD NO DP 1 DP for linear NO DP 1 DP 2 DP 3 DP INLO Selects the low scale value for the linear type input INHI Selects the high scale value for the linear type input How to use INLO and INHI If 4 20 mA is selected for INPT 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 33 UM91001D process value Figure 3 1 Conversion Curve for Linear Type Process Value input signal Formula PV INLO INHI INLO SE Example 4 20 mA current loop pressure transducer with range 0 15 kg om is connected to input then perform the following setup INPT 4 20 INLO 0 00 INHI 15 00 DP 2 DP Of course you may select other value for DP to alter the resolution 3 3 Control Outputs There are 4 kinds of control modes can be configured as shown in Table 3 1 Table 3 1 Heat Cool Control Setup Value Control Modes eat only Cool only eat PID Cool ON OFF eat PID Cool PID X Dont care yx Required if
50. nt of digital 0 ib E 7 data bits 1 communication 1 Bb L 8 data bits 0 E UE n Even parity Parity bit of digital i i PARI communication 1 add Odd parity 0 2 non No parity bit 1 j srop Stop bit count of digital 0 ibi E One stop bit communication 1 eb E Two stop bits Retransmission low iah 0 0 C RELO scale value Low 19999 High 45536 32 0 F Retransmission high tah 100 0 C REHI scale value Low 19999 High 45536 212 0 F 0 7r No parameter selected 1 L oc LOCK is put ahead 2 nPE INPT is put ahead SEL 561601 1 st parameter for 3 Ur E UNIT is put ahead 5 user mend 4 dF DP is put ahead 5 SH F SHIF is put ahead 6 PG PB is put ahead 7 E Tlis put ahead UM91001D 18 rrameter Parameter Description Range 8 E g TD is put ahead 9p IHY O1HY is put ahead 10 4 CYC1 is put ahead 11 pF GE OFST is put ahead 12 r r RR is put ahead SEE EN das ZHY O2HY is put ahead 2 14 ML g CYC2 is put ahead 15 PE CPBis put ahead 16 ci b DB is put ahead 17 Hd dr ADDR is put ahead 18 AL HUY ALHY is put ahead SEL2 Select 2nd parameter Same as SELI 3 secs Select 3rd parameter Same as SELI 4 SEL4 Select th parameter same as SELI 6 sels Select 5th parameter same as SELI 7 sELe Select 6th parameter same as SELI 8 SEL7 Select 71h parameter Same as SELI t0 SEL8 Select 8 th parameter Same as SELI 17 for user menu
51. on fails Perform both steps 4 and 5 to calibrate RTD function if required for input UM91001D 56 Step 4 Press scroll key until the display shows Send a 100 ohms signal to the RTD input terminals according to the connection shown below BTC 4100 BTC 8100 BTC 7100 BTC 9100 18 12 4 10 ohms 19 13 5 20 14 6 Figure5 1 RTD Calibration Press scroll key for at least 5 seconds The display will blink a moment otherwise the calibration fails Step 5 Press scroll key and the display will show Change he ohm s value to 300 ohms Press scroll key for at least 5 seconds The display will blink a moment and two values are obtained for RTDH and RTDL step 4 Otherwise if the display didn t blink or if any value obtained for RTDH and RTDL is equalto 199 9 or 199 9 then the calibration fails x Perform step 6 to calibrate offset of cold junction compensation if required Step 6 Setup the equipments according to the following diagram for calibrating the cold junction compensation Note that a K type thermocouple must be used 57 UM91001D 5520A BTC 4100 Calibrator BTC 8100 BTC 7100 BTC 9100 ell ie 13 5 E RES 14 6 Stay at least 20 minutes in still air room room temperature 25 3 C Figure 5 2 Cold Junction Calibration Setup The 5520A calibrator is configured as K type thermocouple output with internal compensation Send a 0 0
52. ording to Section 2 9 3 15 PV Retransmission The controller can output retransmit process value via its retransmission terminals RE and RE provided that the retransmission option is ordered A correct signal type should be selected for COMM parameter to meet the retransmission option installed RELO and REHI are adjusted to specify the low scale and high scale values of retransmission UM91001A 50 Chapter 4 Applications 4 1 Heat Only Control with Dyvell Timer An oven is designed to dry the products at 150 C for 30 minutes and then stay unpowered for another batch A BTC 8100 equipped with dwell timer is used for this purpose The system diagram is shown as follows Set Figure 4 1 Heat Control Example Timer ALM To achieve this function set the following parameters in the setup menu INPT K TC UNIT C DP 1 DP OUT1 REVR O1TY RELY CYC1 18 0 O1FT BPLS ALFN TIMR ALFT ON Auto Tuning is performed at 150 C for a new oven 51 UM91001A 4 2 Cool Only Control A BTC 8100 is used to control a refrigerator at temperature below 0 C The temperature is lovver than the ambient a cooling action is required Hence select DIRT for OUT1 Since output 1 is used to drive a magnetic 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 PB is set with zero and O1HY is set at 0 1
53. ording to actual security requirement one of four lockout levels can be selected to prevent the unit from being changed abnormally Bumpless Transfer Bumpless transfer allows the controller to continue to control by using its previous value as the sensor breaks Hence the process can be well controlled temporarily as if the sensor is normal Soft start Ramp The ramping function is performed during power up as well as any time the set point is changed It can be ramping up or ramping down The process value will reach the set point with a predetermined constant rate Digital Filter A first order low pass filter with a programmable time constant is used to improve the stability of process value This is particularly useful in certain application where the process value is too unstable to be read SEL Function The units have the flexibility for user to select those parameters which are most significant to him and put these parameters in the front of display sequence There are at most 8 parameters can be selected to allow the user to build his own display sequence UM91001A 7 1 2 Ordering Code BTC 4100 1 1 L1 L1 L1 L1 L1 BTC 7100 BTC 8100 BTC 9100 Power Input 4 90 250 VAC 47 63 HZ 5 11 26 VAC or VDC SELV Limited Energy Signal Input 1 Standard Input Thermocouple J K T E B R S N L RTD PT100 DIN PT100 JIS 0 60 mV 0 1V 0 5V 1 5V 4 20 mA 0 20 mA 0 10V Special Order
54. r Heater Load Figure 2 15 Output 2 Relay or Triac SSR to Drive Contactor gri p 7100 BTC 9100 Loadj o 4120y 1240V ero o pad i _ o o Mains Supply Co EE a 30mA 5V _ Pulsed 1 Voltage 33 im 33 i M Ov N s ati E X Figure 2 16 Output 2 Pulsed Voltage to Drive SSR BTC 4100 BTC 8100 BTC 7100 BTC 9100 pa 5 6 110 20mA I La Maximum Load 6 7 421 4 20mA 500 ohms Figure 2 17 Output 2 Linear Current 29 UM91001A BI 8100 BTC 7100 BTC 9100 q 0 1V 0 5V Minimum Load H E 1 5V 0 10V 10K ohms Figure 2 18 Output 2 Linear Voltage 2 8 Alarm Wiring BTC 8100 BTC 7100 BTC 9100 Js 3 3 001 rvoe 4 1 Mains Supply 5 2 Figure 2 19 Alarm Output to Drive Load BTC 4100 BTC 8100 BTC 7100 BTC 9100 7 3 3 el 4 9 5 2 120V 240V o Mains Supply o o Three o Phase Heater o Power Three Phase No Fuse Delta Contactor Breaker Heater Load Relay Output to Drive Contactor Figure 2 20 Alarm Output to Drive Contactor UM91001A 30 2 9 Data Communication Her RS 485 to RS 232 BTC 9100 BTC 7100 network adaptor 3 Ho X SNA10A or SNA10B Twisted Pair Wire BTC 4100 TX2 pend 11 RS 232 BTC 8100 TX1 lc 4 P xis 00 Tio 0 e Max 247 units can be linked
55. r O2FT then output 2 will transfer to off state otherwise output 2 will transfer to on state if ON is set for O2FT Alarm Failure Transfer is activated as the controller enters failure mode Thereafter the alarm will transfer to the ON or OFF state which is determined by the set value of ALFT 45 UM91001A 3 11 Auto tuning The auto tuning process is performed at set point The process vvill 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 x Initial setup for a new process x The set point is changed substantially from the previous auto tuning value x The control result is unsatisfactory Operation 1 The system has been installed normally 2 Set the correct values for the setup menu of the unit But don t use a zero value for PB and TI otherwise the auto tuning program will be disabled The LOCK parameter should be set at NONE 3 Set the set point to a normal operating value or a lower value if overshooting beyond the normal process value is likely to cause damage 4 Press ej and hold until appears on the display 5 Press 9 for at least 5 seconds The AT indicator will begin to flash and the auto tuning procedure is beginning NOTE The ramping function if used will be disabled once auto tuning is proceeding The auto tuning mode is disabled as soon as
56. r voltage output Output Regulation 0 01 96 for full load change 63 UM91001D Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC min Integral Linearity Error 20 005 96 of span Temperature Effect 0 0025 96 of span C Saturation Low O mA or OV Saturation High 22 2 mA or 5 55V 11 1V min Linear Output Range 0 22 2mA 0 20mA or 4 20mA 0 5 55V 0 5V 1 5V 0 11 1V 0 10V User Interface Dual 4 digit LED Displays Keypad 4 keys Programming Port For automatic setup calibration and testing Communication Port Connection to PC for supervisory control Control Mode Output 1 Reverse heating or direct cooling action Output 2 PID cooling control cooling P band 50 300 of PB dead band 36 0 36 0 96 of PB ON OFF 0 1 90 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 0 3600 seconds Derivative time O 360 0 seconds Cycle Time 0 1 90 0 seconds Manual Control Heat MV1 and Cool MV2 Auto tuning Cold start and warrn start Failure Mode Auto transfer to manual mode while sensor break or A D converter damage Ramping Control 0 900 0 Fiminute or 0 900 0 F hour ramp rate Digital Filter Function First order Time Constant 0 0 2 0 5 1 2 5 10 20 30 60 seconds programmable UM91001E 64 Environmental 8 Physical
57. rol output The ASIC technology provides improved operating performance low cost enhanced reliability and higher density Fast Sampling Rate The sampling rate of the input A to D converter reaches 5 times second The fast sampling rate allows this series to control fast processes Fuzzy Control The function of Fuzzy control is to adjust PID parameters from time to time in order to make manipulation output value more flexible and adaptive to various processes The results is to enable a process to reach a predetermined set point in the shortest time with the minimum of overshoot and undershoot during power up or external load disturbance Digital Communication The units are equipped with RS 485 or RS 232 interface card to provide digital communication By using the twisted pair wires there are at most 247 units can be connected together via RS 485 interface to a host computer 6 UM91001A Programming Port A programming port is used to conneci the unit to a hand held programmer or a PC for quick configuration also can be connected to an ATE system for automatic testing 8 calibration Auto tune The auto tune function allows the user to simplify initial setup for a new system A clever algorithm is provided to obtain an optimal set of control parameters for the process and it can be applied either as the process is warming up cold start or as the process has been in steady state warm start Lockout Protection Acc
58. select auto tuning mode Press for 8 6 seconds to select calibration mode UM91001D 10 Alarm r Upper Display to display process value Indicator ndicator menu symbol and error code etc Output 2 Process Unit Indicator ndicator Y Y Output 1 OP1 OP2 ALM La ndicator CICE anual ri ri LI LI Lower Display ode LI LI LI LI to display set point value ndicator MAN 1 parameter value or Auto tuningj r AT 55565 control output value etc Bici 4 v R 4 Buttons for ease of control setup and BTC 9100 set point adjustment Figure 1 3 Front Panel Description Table 1 1 Display Form of Characters d V Confused Character OP1 OP2 ALM BIG BTC 9100 Display program code of the product for 2 5 seconds The left diagram shows program no 6 for BTC 9100 with version 24 The program no for BTC 7100 is 13 for BTC 8100 is 11 and for BTC 4100 is 12 Figure 1 4 Display of Initial Stage UM91001D 1 5 Menu Overview
59. t DP 1 z2 Conditions 7 4 Data Conversion The word data are regarded as unsigned positive data in the Modbus message However the actual value of the parameter may be negative value with decimal point The high low scale values for each parameter are used for the purpose of such conversion Let M Value of Modbus message A Actual value of the parameter SL Scale low value of the parameter SH Scale high value of the parameter The conversion formulas are as follows 65535 n i SH SL ASSI SH SL MISL 65535 s 7 5 Communication Examples Example 1 Down load the default values via the programming port The programming port can perform Modbus communications regardless of the incorrect setup values of address baud parity stop bit etc It is especially useful during the first time configuration for the controller The host must be set with 9600 baud rate 8 data bits even parity and 1 stop bit The Modbus message frame with hexadecimal values is shown as follows 73 UM91001A 10 00 00 o0 34 es 4F 19 e 83 4E 83 Starting Add r No of words SP1 25 0 SP2 10 0 SP3 10 0 oo oo o0 01 oo 00 00 01 aD eD 51 ca LOCK 0 INPT 1 UNIT 0 DP 1 INLO 17 8 INHI 93 3
60. t which is connected to a PC for automatic configuration also can be connected to an ATE system for automatic calibration and testing The programming port is used for off line automatic setup and testing procedures only Don t attempt to make any connection to these pins when the unit is used for a normal control purpose 9 UM91001A 1 4 Keys and Displays KEYPAD OPERATION SCROLL KEY This key is used to select a parameter to be viewed or adjusted UP KEY 4 This key is used to increase the value of selected parameter DOWN KEY v This key is used to decrease the value of selected parameter RESET KEY R This key is used to 1 Revert the display to display the process value 2 Reset the latching alarm once the alarm condition is removed 3 Stop the manual control mode auto tuning mode and calibration mode 4 Clear the message of communication error and auto tuning error 5 Restart the dwell timer when the dwell timer has been time out 6 Enter the manual control menu during failure mode occurs ENTER KEY Press for 5 seconds or longer Press for 5 seconds to 1 Ener setup menu The display shows 2 Enter manual control mode during manual control mode is selected 3 Enter auto tuning mode during auto tuning mode A E is selected 4 Perform calibration to a selected parameter during the calibration procedure Press for 6 2 seconds to select manual control mode Press for 7 4 seconds to
61. timer operation is shown as following diagram After time out the dwell timer will be restarted by pressing the RESET key The timer stops to count during the manual control mode failure mode calibration period and auto tuning period PV A sp ey y o Time I SP3 power off or i touch RESET key ON SS OFF T La 4 Time Timer starts Figure 3 6 Dyvell Timer Function If alarm is configured as dyvell timer ALHY and ALMD are hidden UM91001A 42 3 8 PV 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 PV shift function The SHIF function will alter PV only Here is an example 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 displa
62. y 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 25 UM91001B 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 requirements such as leak proof anti vibration antiseptic etc Standard sensor limits of error are 4 degrees F 2 degrees C or 0 7596 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 2 6 Sensor Input Wiring BTC 4100 BTC 8100 BTC 7100 BTC 9100 A PTA 18 12 4 4 RTD K to 3 5 SHO B TV 20 haj jekrvr le PTB mA TC V mA RID Figure 2 8 Sensor Input Wiring 2 7 Control Output Wiring BTC 4100 BTC 8100 BTC 7100 BTC 9100
63. y up to the set point value Subject Heater Subject Subject Heater Heater Y Heat Heat t Heat Transfer Transfer Transfer 165 C 165 C 200 C 200 C 200 C 235 C Sensor Sensor T Sensor C UU c00 35 C temperature Adjust SHIF Display is stable difference is observed SHIF 35 C SHIF 35 C SHIF 0 Supply more heat PV SV Figure 3 7 PV Shift Application 43 UM91001A 3 9 Digital Filter In certain application the process value is too unstable to be read To improve this a programmable low pass filter incorporated in the controller can be used This is a first order filter with time constant specified by FILT parameter The default value of FILT is 0 5 sec before shipping Adjust FILT to change the time constant from 0 to 60 seconds 0 second represents no filter is applied to the input signal The filter is characterized by the following diagram PV Vi A Figure 3 8 Filter Characteristics Note The Filter is available only for PV 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 UM91001A 44 3 10 Failure Transfer The controller will enter failure mode as one of the following conditions OCCUIS 1 SBER occurs due to the input sensor break or input curr

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