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1. FUNC av Jc Sera HA m Hand Manual tor 3 seconds wc gt E Eele A 2 aero P 2 Mode c 5 89x JC 5 ce x Jc A ce co C gt ORA S DICIA ce C 5 ce zx NEUE dE Mode 3c Mr Pres Press for 3 seconds to enter Gc 5 9E the auto tuning mode gc DIES cz JC gt OA Jc 5 9x Jc 5 9x C 5 e X Display _ Mode ANNNANANANANNANANNNNNANANANANANNNANANNANANNANNANANNANAN UUUUUUUUUUuUuUuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuu 3 E9J 9 9 9 9
2. 0 1V 0 5V 1 5V 0 10V 0 20mA or 4 20mA UM83001B Figure 2 8 Input 1 Linear Current Wiring Figure 2 9 Input 2 Linear Voltage Wiring Figure 2 10 Input 2 Linear Current Wiring 27 2 9 CT Heater Current Input Wiring Heater 1 Heater 2 Heater 3 Contactor Heater Supply Current Transformer QT CT94 1 T 1 amp Fuse 10 9 Mains o o supply 2 amp DIN Rail CT Signal Input CDC Figure 2 11 CT Input Wiring for Single Phase Heater Contactor Three Phase Heater Power Fuse 1e 9 Mains o o Supply Current Transformer CT Signal Input a T uae Figure 2 12 CT Input Wiring for Three Phase Heater DIN Rail Make sure that the total current through CT94 1 not exceed 50A rms 28 UM83001B 2 10 Event Input wiring E ESSI e e is SS ag Open Collector Input Switch Input The event input 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 s
3. E oec eater ees ie e dedo Honpe eats SP1 COMM 5nn TIME ki AE PROT r roc A1SP A SP ADDR Addr A1DV A ig BAUD 5Hud A2SP Hg 5P DATA gH HEH A2DV Hegg PARI PHr RAMP AnP STOP oP OFST oF SE AOFN AaFn REFC EFL AOLO Holoa SHIF 5H F AOHI AGH PB1 Pb IN1 ini uad TH E FAR INTU on lu TD1 Ed DP1 dF I CPB Pb INIL n db DB db INIH n IH SP2 5PP IN2 ine PB2 Phe IN2U neu T2 E g DP2 gPg TD2 EL dg IN2L nek O1HY o IHY IN2H ngH A1HY A IHH OUT out A2HY HgHH O1TY jo EY PL1 PL i cvci SE PL2 PL O1FT o IFE Men FUNC FunE UM83001E 139 Contained in Setup Menu Parameter Notation OUT2 Display Format 0 c n nu Your setting O2TY DO n rr LC CYC2 O2FT r Lie rm rm Pat 0 Pu t A1FN zn A1MD A1FT Jl a I OQ a3 EUN r A2FN I J A2MD A2FT EIFN za Mo Mu Po a 314 rm Oo NN m I PVMD Ic OL FILT SELF TI pu rr SLEP Ln rF inm r n un a SPMD SP1L ar 41 a a m SP1H j 4 Z I SP2F L ulum uU O n mh SEL1 SEL2 LU un mira m m nu SEL3 un m gt Ly SEL4 SEL5 un m p lt lt un m F un
4. Pelei et Parameter Description sen E ENDE Default Scale aa iid m 120 121 PVHI 122 Historical Maximum Value of PV R W 19999 45536 P 19999 45536 PV PVLO 123 Historical Minimum Value of PV R W 19999 45536 19999 PV CJCL Sne otage o Cold Junction 65535 mV FILE Default File Selection 65535 PV Current Process Value PV SV Current set point Value PV MV1 Current Output 1 Value 96 MV2 Current Output 2 Value 96 Contains Conditional Code of ALM Parameters Resolution and Current Alarm Status DV Current Deviation PV SV Value 12600 PV PV1 IN1 Process Value 45536 ES PV2 IN2 Process Value 45536 E6 PB Current Proportional Band Value ODE PV TI Current Integral Time Value Sec TD Current Derivative Time Value Sec EROR Current Error Code Program Identification Code PROG Contains Program Number and Version Number MODE CUT T aa CMND Command Password JOB Job Password CJCT Tone Compensation 40 00 C C PVR PV min PVRH Maximum Process Rate Value PV min PVRL Minimum Process Rate Value PV min SPC Current Target Value of set point PV 150 151 152 153 154 155 156 157 UM83001E 115 Notes A R W Specifies a readable writable data R specifies a read only data A1 The communication setup data which can t be modified via communication However these data can be set by using key pad on front panel or via programming port B The rang
5. UM83001B 31 2 12 Output 2 Wiring Max 2A Resistive Ol I 4 2 12 gt ISI 13 C3 414 S94 5 15 FS 6 16 S 7 17 j 8 18 Ko 19 10 20 gt 36 16 EE E91 ES IS I9 4707 8 18 30mA 5V Pulsed Voltage sss 32 120V 240V Mains Supply Relay Output Direct Drive Figure 2 15 Output 2 Wiring gt 120V 240V Mains Supply Three Phase No Fuse Relay or Triac SSR Delta Contactor Breaker Output to Drive Heater Contactor Load Load o oe 120V 240V Mains Supply Internal Circuit 5V Pulsed Voltage to Drive SSR UM83001B Maximum Load 500 ohms 5 9 SSIs Ss 10 20 kes 0 1V 0 5V 1 5V 0 10V Minimum Load 10 K ohms E GIGS Max 1A 240V 120V 240V Mains Supply UM83001B Linear Current Linear Volt
6. 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 3 for BTC 8300 with version 39 Display Date Code and Serial number for 2 5 seconds The left diagram shows Year 2001 Month May 5 Date 22 st and Serial number 192 This means that the product is the 192 th unit produced on May 22 st 2001 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 UM83001B Figure 1 5 Display Sequence of Initial Message Program Code E E a a E a l l l l Program Version Program No Date Code CC Lg l Lle d Date 31 st Month December Year 2001 1 5 Menu Overview Pv vae JUser Sv vane Menu SEE Setup jMenu
7. 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 Wining 30 2 12 Output 2 Wiring 32 2 13 Alarm 1 Wiring 34 2 14 Alarm 2 Wiring 35 2 15 R8 485 more 36 2516 RS 282 sar sss saa 37 2 17 Analog Retransmission 38 2 18 Programming Port 39 Chapter 3 Programming the Basic Function SsI input 1 5 1 555653 5 5078734 steer so cess 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
8. 55 3 16 Failure Transfer 56 3 17 Bumpless Transfer 57 3 18 Self tuning 58 3 19 Auto tuning 59 3 20 Manual Tuning 61 UM83001E 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 Seis asses 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 79 412 PUMP Contrl saan seen eens eotaar ener 80 4 13 Remote Lockout 81 Chapter 5 Applications 5 1 Pump Pressure Control 82 5 2 Variable Period Full
9. Yes Does the process oscillate Yes No Flag 0 Yes 1 6PB1 gt PB1 No Yes 0 8PB1 PB1 Figure 3 23 Manual Tuning Procedure No Wait and Examine the Process steady state reached Yes Does the process oscillate Yes PB1 gt 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 Tl 1 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 UM83001B 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 State 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
10. Bridge Type Sensor A alle aeee eS Caution Don t use the DC power supply beyond its rating current to avoid damage Purchase a correct voltage to suit your external devices See ordering code in section 1 2 64 UM83001B 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 Ly until Hand Control appears on the display Press c 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 ce the lower display will show Z and __ alternately where indicates output 1 or heating control variable value MV1 and 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 The controller performs open loop control as long as it stays in manual
11. 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 CRC16 Hi CRC16 Lo Function 06 Preset single Register Query from master Response from slave Slave address 0 255 T Function code 6 Register address Hi 0 LS Register address Lo 0 79 128 131 S Data Hi Data Lo t CRC16 Hi CRC16 Lo T Function 16 Preset Multiple Registers Query from master Slave address 0 255 Response from slave a Function code 16 L Starting address of register Hi 0 IL Starting address of register Lo 0 79 128 131 4 No of words Hi 0 1 No of words Lo 1 79 Byte count 2 158 CRC16 Hi Data 1 Hi CRC16 Lo Data 1 Lo Data 2 Hi Data 2 Lo CRC16 Hi CRC16 Lo UM83001E 110 9 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 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 f
12. 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 78 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 65 108 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
13. Contained in Calibra tion Mode Menu Display Mode Menu Fido E Your setting ADO Hg ADG Ad via 15 CJTL C JEL CJG CJG REF1 EF SR1 bid MA1G SA iG vag gl MA2G AAC PVHI PH PVLO PULg MV1 H MV2 DV B Pvi PY Pv2 Pug PB Pb TI ti TD Ed CJCT C JEE PVR PYF PVRH PU H PVRL PY 140 UM83001E 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 repai
14. 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 decreases 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
15. Type Tolerance Current Voltage Barrier 0 2 Vp p 500 VAC 0 1 Vp p 500 VAC 0 05 Vp p 500 VAC 20V 0 5V 25 mA 12V 03V 40 mA 5V x0 15V 80 mA Alarm 1 Alarm 2 Alarm 1 Relay Form C Rating 2A 240VAC life cycles 200 000 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 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 UM83001B Resolution 15 bits Accuracy 0 05 of span 0 0025 C Load Resistance 0 500 ohms for current output 10 K ohms minimum for voltage output Output Regulation 0 01 for full load change Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC m
16. 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 R 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 UM83001E 129 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 boiling 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
17. KTIMR is selected for can only be properly both A1FN and A2FN used for single alarm output UM83001E Code Scl Error Description Corrective Action 1 Correct the communication software to meet the Communication error protocol requirements receive error due to 2 Add a terminating parity error framing resister to the multi 9 Eri error overrun error drop link RS 485 to receive buffer full error minimize the noise ae Sais a 3 Use twisted pair wire OL TERS IVE GISIUEDE for RS 485 interface connection to minimize the noise 4 Check the polarity of RS 485 interface connection Correct the C icati _ communication 10 Ee iB ae paid software to meet the ad function code protocol requirements Communication error Don t issue an over 1 Er 1 register address out of range address of range register to the slave Communication error Don t issue a non 12 E ig laccess a non existent existent parameter to parameter the slave Communication error Don t write a read only 14 E i4 attempt to write a read data or a protected only data data to the slave Communication error Don t write an over 15 E 16 write a value which is range data to the lout of range to a slave register register Computing error Software bug Return 17 r 11 legal unnormalized to factory for repair floating point data Computing error Software bug Return 18 E 4 Arithmetic result to factory
18. Parameter A2SP put ahead Parameter A2DV put ahead Parameter RAMP put ahead Parameter OFST put ahead Parameter REFC put ahead 0 Parameter SHIF put ahead Parameter PB1 put ahead Parameter TI1 put ahead Parameter TD1 put ahead Parameter CPB put ahead Parameter DB put ahead Parameter SP2 put ahead Parameter PB2 put ahead Parameter TI2 put ahead Parameter TD2 put ahead 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 S PN SS eS SES LS A to D Gain Calibration Coefficient Low 199 9 Voltage Input 1 Gain Calibration Coefficient Cold Junction Low Temperature Calibration Coefficient UM83001B Low 199 9 40 00 C Table 1 4 Parameter Description continued 7 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value Cold Junction Gain pun L ib Calibration Coefficient Low Tus High 199 9 EE Reference Voltage 1 Calibration Coefficient for RTD 1 High 199 9 Calibration Serial Resistance 1 Mode 4 Calibration Coefficient for Low 199 9 High 199 9 Menu RTD 1 af m
19. The calibration mode auto tuning mode and normal control mode are in the same priority level The sleep mode is in the highest priority 12 UM83001B Mode 1 7 Parameter Description Table 1 4 Parameter Description Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value 100 0 C 4 SP1 Set point 1 Low SP1L High SP4H 212 0 F 4 TIME ty AE Dwell Time Low 0 High 6553 5 minutes 0 0 vA A1SP A ISP Alarm 1 Set point See Table 1 5 1 6 ise D zagi 200 0 C 200 0 C 10 0 C 4 A1DV A ig Alarm 1 Deviation Value Low 360 0 F High 360 0 F 18 0 F 100 0 C vA A2SP AZSPE Alarm 2 Set point See Table 1 5 1 7 212 0 F m 200 0 C A 200 0 C 10 0 C 4 A2DV Heg Alarm 2 Deviation Value Low 360 0 F High 360 0 F 18 0 F 500 0 C RAMP AnF 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 p REFC PEPE Specific Function Low 0 High 60 2 n 200 0 C iN 200 0 C 4 SHIF SH F PV1 Shift offset Value Low 360 0 F High 350 0 F 0 0 qh 500 0 C 10 0 C 4 PB1 Ph Proportional Band 1 Value Low 0 High 900 0 F 18 0 F User vA TH L Integral Time 1 Value Low 0 High 1000 sec 100 Menu 4 TD1 Ed l Derivative Time 1 Value Low 0 High 360 0 sec 25 0 Y CPB EPG colina Pro
20. 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 78 74 77 98 105 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 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
21. 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 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 Pre tune Function Advantage enters Warm up cycle As the process reaches the set point value the Consistent tuning results can be unit enters waiting cycle The waiting cycle elapses a double integral obtained 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
22. 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 UM83001E OUT2 11 16 22 41 45 48 50 51 53 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 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 82 108 137 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 5
23. ATFN A1MD Adjust ATSB A1HY Trigger level A1SP x 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 X XC 205 205 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 OO xt 210 210 210 210 205 205 205 205 205 OFF 205 195 195 195 195 ON 195 195 Figure 3 7 Holding Process Alarm A1SP 200 A1HY 10 0 SP1 210 A1MD LT HO A1FN PV1 L Process proceeds xc X 210 210 210 210 205 205 205 205 205 205 195 195 195 195 oN 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 UM83001B 49 3 9 Deviation Alarm 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
24. Normal Deviation Alarm Figure 3 10 Latching Deviation Alarm Es Figure 3 11 Holding Deviation Alarm 88 X 100 Figure 3 12 Latching Holding 88 Deviation Alarm 3 10 Deviation Band Alarm A deviation band 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 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 No Examples A1FN DB HI A1MD NORM SP1 100 A1DV 5 Process Process proceeds M XX 105 100 95 AIFN D 105 105 100 100 95 ON 95 AIFN D 105 1m AIFN D 105 105 ja OFF Process proceeds B HI Process Process proceeds 105 Process Process proceeds 105 105 e 105 100 105 ON 105 OFF 105 n bs 100 B HI A1MD LT HO SP1 100 A1DV 5 X ON 105 OFF 100 95 95 B LO A1MD LT
25. 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 63 296 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 of the step change value Retransmit output Analog output scaled to the process or the set point value 133 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 temperature 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 t
26. Sleep M ode 3 Output 1 Heating or Cooling Relay SSR SSRD Volt mA 11 Digital filter 4 Output 2 Cooling Relay SSR SSRD Volt mA DC Power supply 12 Pump control 5 Alarm 1 Relay for Deviation Deviation Band Process Heater Break Loop 13 Remote lockout Break Sensor Break Latch Hold or Normal Alarm then you can use Basic Mode 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 xe Ly 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 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
27. The operation mode menu will appear on the display Repeat the operation several times until KAL 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 terminals19 and 20 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 24 Send a 60mv signal to terminals 19 and 20 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 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 19 and 20 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 valu
28. 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 UM83001E TTL Transistor to transistor logic A form of solid state logic which uses only transistors 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 380 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 betwe
29. 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 Hence Self tuning can be used for ramping set point control a
30. 5V is selected Replace input 1 sensor 39 A to D converter or related component s malfunction Return to factory for 40 repair B35 PROG code description Feramieter Specified product 0 XX BTC 2500 controller 1 XX BTC 9300 controller 2 XX L91 controller 3 XX BTC 8300 controller 4 XX BTC 4300 controller XX indicates the program version B36 Display symbol and description for MODE Parameter Value Description X 0 Perform normal mode X1 Enter calibration mode X2 Enter auto tuning mode X3 Enter failure mode X4 Enter manual mode X5 Enter sleep mode 0 X Unlock condition 1 X SP1 SEL1 SEL5 are unlocked Lock all parameters except SP1 3 X All parameters are locked 121 C The parameters are preset with the default values specified in the table during production D The scale values specifiy the transformation relation between the value of parameter and the value of register The parameter with a scale low value is stored in the register with a number zero The parameter with a scale high value is stored in the register with a number 65535 For example if a value R is read from the addressed register and LS scale low value HS scale high value then HS LS the value of the parameter LS Rx 65535 Similarly before writing the value of parameter to the addressed register the value W of the parameter must be transformed
31. 69 9 9 t9 9 9 9 9 9 9 9 9j 9 9 9 9 9 9 t9 9 9 9 9 9 9 t9 9 9 9 9j 9 9 9 t9 9 9 9 9 9 9 9 9 o D D AAAA YAA C9 0 9 DI DI DI DI BI BI 9 9 DI DI DI DI DI DI DI D DI DI BI DI DI DID DI BI DI DI DI DI DI DI DI DI DI D 3 9 9 900A BAABA 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 DOBA AA 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 cc 5 9x Jc DOA EXE Gc Display Go Home Sc 06 The menu will revert to Default PAIA PV SV display after keyboard erau T1 2 de is kept untouched for 5 4 Setting aE 2 S CHE 2 minutes except Display Mode 5 to IC 5E Mode Menu and Manual T 3 seconds ec 5 9 Mode Menu However the To execute the menu can revert to PV SV bind SEMI eic display at any time by pressing and ros L Calibration 2 Mode eu cc ADO 5 ea ADG 2 C 3 0 BK MESH CJTL acf eja ee SEL5 CREF 24 Jc SRI gt OA OKS MA1G amp 1 The flow chart shows a complete listing of all parameters C voG Ga For actual application the number of available parameters cc MA2G 95 depends on setup conditions and should be less oS than that shown in the flow chart See Appendix A 1 for the existence conditions of each parameter Ap
32. 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 UM83001E 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 73 74 80 83 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 TH 11 13 17 18 42 43 45 53 59 61 62 68 70 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 54 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
33. B3 Display symbol and description for FUNC Parameter Siep Description 0 BASC Basic Function Mode 1 FULL Full Function Mode B4 Display symbol and description for COMM Parameter Sire Description 0 NONE No communication function 1 485 RS 485 interface 2 232 RS 232 interface 3 4 20 4 20 mA analog retransmission output 4 0 20 0 20 mA analog retransmission output 5 0 1V 0 1V analog retransmission output 6 0 5V 0 5V analog retransmission output 7 1 5V 1 5V analog retransmission output 8 0 10V 0 10V analog retransmission output 116 B5 Display symbol and description for PROT ad ae Description 0 RTU Modbus protocol RTU mode B7 Display symbol and description for BAUD Parameter ridi Description 0 0 3 0 3 Kbits s baud rate 1 0 6 0 6 Kbits s baud rate 2 1 2 1 2 Kbits s baud rate 3 2 4 2 4 Kbits s baud rate 4 4 8 4 8 Kbits s baud rate 5 9 6 9 6 Kbits s baud rate 6 14 4 14 4 Kbits s baud rate 7 19 2 19 2 Kbits s baud rate 8 28 8 28 8 Kbits s baud rate 9 38 4 38 4 Kbits s baud rate B8 Display symbol and description for DATA Parameter Display um Value Symbol Description 0 7BIT 7 data bits 1 8BIT 8 data bits B9 Display symbol and description for PARI Parameter Display Value Symbol 0 EVEN 1 ODD 2 NONE Description Even parity Odd parity No parity bit B10 Display symbol
34. BTC 8300 will not control properly UM83001B SPMD PV2 PVMD PV1 or SPMD PV1 PVMD PV2 Error Message 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 mw PV1 PV2 PV PV1 PV2 or PV2 PV1 Set point 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 Error Code will appear 74 UM83001B Setup PVMD P1 2 or PVMD P2 1 SPMD SP1 2 Figure 4 4 Relation between PV1 and PV2 for a Differential Control Error Message come cru 1 4 7 Output Po
35. Hour Value Historical Error Record 1 High 65535 Hours High 0 9 Hour Err Historical Error Record 2 High FFFF ASCII Input Delimiter OUT1 Bumpless Transfer Value 100 00 hPl Z OUT2 Bumpless Transfer Value Low 0 High 100 00 E C JEL Sense Voltage of Cold Junction Calibration Low Low 31 680 High 40 320 mV 128 UM83001E 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 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
36. IN2 difference process value high alarm 6 10 10 seconds time constant 13 D1 2 L IN1 IN2 difference process value low alarm 7 20 20 seconds time constant 14 LB Loop break alarm 8 30 30 seconds time constant 15 SEN B Sensor break or A D fails 9 60 60 seconds time constant 118 UM83001E B30 Display symbol and description for SPMD B32 Display symbol and description for FILE eon E Description 0 SP1 2 Use SP1 or SP2 depends on EIFN as set point 1 MIN R Use minute ramp rate as set point 2 HR R Use hour ramp rate as set point 3 PV1 Use IN1 process value as set point 4 PV2 Use IN2 process value as set point 5 PUMP Selected for pump control B31 Display symbol and description for SEL1 SEL5 Parameter Sirna Description 0 NONE No parameter put ahead 1 TIME Parameter TIME put ahead 2 A1 SP Parameter A1SP put ahead 3 A1 DV Parameter A1DV put ahead 4 A2 SP Parameter A2SP put ahead 5 A2 DV Parameter A2DV put ahead 6 RAMP Parameter RAMP put ahead 7 OFST Parameter OFST put ahead 8 REFC Parameter REFC put ahead 9 SHIF Parameter SHIF put ahead 10 PB1 Parameter PB1 put ahead 11 TH Parameter TI1 put ahead 12 TD1 Parameter TD1 put ahead 13 C PB Parameter CPB put ahead 14 DB Parameter DB put ahead 15 SP2 Parameter SP2 put ahead 16 PB2 Parameter PB2 put ahead 17 TI2 Parameter TI2 put ahead 18 TD2 Parameter TD2 put ahead Paramet
37. If the process value doesn t increase or decrease while 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 UM83001B 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 Setup A1FN SENB The sensor break alarm is activated as soon as failure mode occurs Refer to A1MD NOR M LTCH Section 3 16 for failure mode conditions Note that A D failure also creates a Hidden TIME A1SP A1DV sensor break alarm TIME A1SP A1DV and A1HY are hidden if alarm 1 is A1HY configured as a sensor break alarm Similarly TIME A2SP A2DV and A2HY are hidden if alarm 2 is configured as a sensor break alarm Sensor Break Alarm 2 On
38. PB1 or PB2 1 Proportional Band P PB1 and or PB2 High overshoot Or increase PB1 or PB2 Oscillations Slow Response Decrease Tl1 or TI2 2 Integral Time 1 TH and or Tl2 Instability OF Increase TI1 or TI2 Table 3 2 PID Adjustment Guide Oscillations Slow Response or 3 Derivative Time D Oscillations Decrease TD1 or TD2 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 UM83001B action TI too high PV Set point Perfect TI too low Time D action PV TD too low Perfect Set point TD too high Time UM83001B 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 Set OUT2 DC Power Supply Two line Transmitter E 1 F3 E E 9 4 20mA aa Figure 3 26 DC Power Supply Applications Three line Transmitter or sensor
39. 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 signal 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 c v several times until Then press c 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 Pre
40. 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 UM83001E 131 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 between 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 ray 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 port
41. 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 8300 can be used for automatic calibration The equipments required for automatic calibration are available upon request UM83001B 103 Chapter 7 Error Codes amp Troubleshooting This procedure requires access to the circuitry of a live power unit Dangerous accidental contact with line voltage is possible Only qualified personnel are 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 N
42. 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 is 30 40 1000 j Figure 5 16 Dual Set Point PID Profile 200T7 dc Use SP1 PID1 2e Use SP2 PID2 Time Minutes UM83001B 95 5 10 RS 485 A tile making plant has 5 production lines Each production line is equipped with 16 units of BTC 8300 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 83800 XXXXXX1 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 w gr nc w dr oe w fro Figure 5 17 B888 BBBB RS 485 Applications B888 BBBB B888 GJ aan aa Control Room TX1 PC BC Net RS 232 Twisted pair wire max distance 1 Km 96 UM83001B Setup Enters the setup mode to configure each BTC 8300 Choose FULL for FUNC 485 for COMM RTU for PROT and select an unequal address ADDR for each unit Use the same
43. and description for STOP Parameter Display Value Symbol Description 0 1BIT One stop bit 1 2BIT Two stop bits B11 Display symbol and description for AOFN UM83001E Parametar EM Description 0 PV1 j Retransmit IN1 process value 1 PV2 Retransmit IN2 process value 2 P1 2 Retransmit IN1 IN2 difference process value 3 P2 1 Retransmit IN2 IN1 difference process value 4 SV Retransmit set point value 5 MV1 Retransmit output 1 manipulation value 6 MV2 Retransmit output 2 manipulation value 7 DV Retransmit deviation PV SV Value B12 Display symbol and description for IN1 B15 Display symbol and description for IN2 P t Displa uw Parameter Display T pU er Symbol Description Value Symbol Description 0 J TC Jtype thermocouple 0 NONE IN2 no function 1 K TC Ktype thermocouple 1 CT Current transformer input 2 T TC Ttype thermocouple 2 4 20 4 20 mA linear current input 3 E TC Etype thermocouple 3 0 20 0 20 mA linear current input 4 B TC B type thermocouple 4 0O 1V 0 1V linear voltage input 5 R TC R type thermocouple 5 0 5V 0 5V linear voltage input 6 S TC Stype thermocouple 6 1 5V 1 5V linear voltage input r N_TC N type thermocouple 7 0 10 0 10V linear voltage input 8 L TC Ltype thermocouple 9 PT DN PT 100 ohms
44. 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 cc LE L E E a s Panel Cutout p O dni Panel mm _ gt UM83001B 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 tis 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 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 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 amo
45. 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 proportional 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 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 i
46. 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 is 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 4 v keys the controller will revert to its previous operating mode may be a failure mode or normal control mode UM83001B Means MV1 38 4 for OUT1 or Heating Means MV2 7 63 for OUT2 or Cooling 65 3 23 Display Mode Operation Press c Ly several times until Display appears on the display Then press to enter the display mode You can select more parameters to view by pressing or pressing c 4 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 i shows the percentage value for output 1 and f__ 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 me
47. 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 requirements 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 UM83001B 2 6 Thermocouple Input Wiring Thermocouple input connections are shown in Figure 2 5 The correct type of thermocouple extension lead wire or co
48. 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 UM83001B 5 12 Retransmit An air conditioned room uses two units of BTC 8300 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 4096 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 AOHI 30 0 C AOLO 40 0 96 AOHI 60 0 96 IN1 PTDN IN1 0 1 V According to humidity sensor IN1U C INTU PU DP1 1 DP DP1 1 DP SP1 25 0 SP1 50 0 SP1L 20 0 250 SP1L 40 0 SP1H 30 0 C 250 SP1H 60 0 T Sag 8 4 4 x Figure 5 18 Retransmission Application Chart Recorder 20 30 C 2 40 5096 SP1L and SP1H are used to limit the adjustment range of set point UM83001B 99 Chapter 6 Calibration AN 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
49. fe z 0 2 second time constant Gs 0 5 second time constant 1 second time constant pa i Filter Damping Time I 2seconds time constant Constant of PV 2 5 5 seconds time constant ig 10 seconds time constant g 20 seconds time constant t 80 seconds time constant g 60 seconds time constant T Self Tuning Function Self tune function disabled T Selection Self tune function enabled Sleep mode Function on ant Sleep mode function disabled SLEP SLEP Selection 9 1 YE 5 Sleep mode function enabled UM83001B 17 Table 1 4 Parameter Description continued 6 7 Contained Basic Parameter Display Parameter Range in Function Notation Format Description Value 173 Use SP1 or SP2 depends on EIFN o GP ie as set point dia Set point Mode Selection Default 1 ni rir Use minute ramp rate as set point 2 Heo Use hour ramp rate as set point 3 py Use IN1 process value as set point 4 itg Use IN2 process value as set point 5 Punt Selected for pump control SP1 Low Scale Value 0 C Low 19999 High 45536 32 0 F SP1 High Scale Value 1000 0 C Low 19999 High 45536 1832 0 F Format of set point 2 Value Select 1 st Parameter Select 2 nd Parameter 0 ACL Lj set point 2 SP2 is an actual value 0 LI Set point 2 SP2 is a deviation i d E value No parameter put ahead Parameter TIME put ahead Parameter A1SP put ahead Parameter A1DV put ahead
50. 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 Subject Subject Heater Heater Heat Heat Subject hal Heat Transfer Transfer Transfer 165 C 165 C 200 C 200 C 200 C 35 C temperature Adjust SHIF difference is observed SHIF 35 C SHIF 0 Supply more heat Figure 3 20 PV1 Shift Application UM83001B 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 1 5 V is selected if PV1 P1 2 or P2 1 is selected for PVM
51. 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 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 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 AiDV 10 A1HY 4 Process proceeds xc x xc 112 112 ON 112 112 I 112 108 108 108 108 108 100 100 100 100 100 A1HY DE LO A1MD HOLD SP1 100 A1DV 10 A1HY 4 Process proceeds 100 100 bs iva E 100 92 92 92 OFF 88 88 88 ON A1HY DE LO A1ND LT HO SP1 100 A1DV 10 A1HY 4 Process proceeds Xy Xy S S E bo D 100 100 100 92 92 92 88 ON 88 88 50 UM83001B 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 1 2A2HY Figure 3 9
52. 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 8300 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 UM83001B Setup ON OFF OUT PB1 0 Adjust SP1 O1HY TIME if enabled Figure 3 2 Heat Only ON OFF Control Setup P OUT TH 20 CYC1 if RELAY SSRD or SSR is selected for O1TY Adjust SP1 OFST TIME if enabled PB1 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 Td Auto tuning Used for new process during initial tuning Self tuning Used for a process any time Manual Tuning May be u
53. obtained and automatically stored in the nonvolatile memory After the auto tuning procedures are completed the process display will 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 UM83001B 59 Auto tuning Auto tuning Begins Complete Warm up Waiting Oycle Cycle Learning Cycle New PID Cycle Ei Fe 2 Integral Time Figure 3 22 Auto tuning Procedure Set Point Pre tune Stage Post tune Stage lt o ON OFF Control PID Control PID Control ails Time Cold Start Auto tuning Auto tuning Begins Complete Pre4tune Stage PV Waiting Cycle Learning Cycle New PID Cycle E 2 Integral Time Set Point Pre tune Stage Post tune Stage M 4 m PID Control ON OFF Control PID Control Warm Start i If the auto tuning begins near the s
54. 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 48mm W X 96mm H X 80mm D 65 mm depth behind panel Weight 220 grams Approval Standards Safety UL873 11 th edition 1994 CSA C22 2 No 24 93 EN61010 1 IEC1010 1 Protective Class IP 20 housing and terminals with protective covers EMC EN61326 UM83001B 109 Chapter 9 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 with 1 start bit 1 stop bit and optional parity checking None Even or Odd Baud rate may be set to 300 600 1200 2400 4800 9600 14400 19200 28800 and 38400 9 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 follows Function 03 Read Holding Registers Query from master Slave address 0 255 Response from slave ao Function code 3
55. 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 Range For T C and RTD NO DP 1 DP For Linear NO DP 1 DP 2 DP 3 DP Default 1 DP 40 UM83001B IN1L Selects the low scale value for the Linear type input 1 IN1L Hidden if T C or RTD type is selected for IN1 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 E 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 IN1U PU IN1H 15 0 DP1 1 DP Of course you may select other value for DP1 to alter the resolution 3 2 OUT1 amp OUT 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 IN1L INTH IN1L SS
56. values Refer sections 3 19 and 4 3 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 orr ON Q OQ l tt es R2 12 189 l 3 13 19 K a lle K 5 151 6 16 Figure 5 10 li A Bread Baking Oven Ei Es 9 SI to 20 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 PV DE e SPMD MINR Figure 5 11 B 180 c gt Time 40 0 minutes Temperature Profile 180 C RAMP 30 0 C min of Baking Oven 30 C min t Restart a new batch 5 45 Cooling Time down minutes 30 C UM83001B 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 8300 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
57. 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 96 accuracy 0 10 V voltage source with 3 0 005 accuracy 0 20 mA current source with x 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 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 UM83001B 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
58. 00 is fully programmable for PT100 thermocouple types J K T E B R S N L 0 20mA 4 20mA and voltage signal input with no need to modify the unit The input signals are digitized by using a 18 bit A to D converter Its fast sampling rate allows the BTC 8300 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 UM83001B Unique Valuable Digital communications RS 485 RS 232 or 4 20 mA retransmission are available as an additional option These options allow BTC 8300 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 8300 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 P12A a hand held programmer to program theunitvia 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 and or load disturbance circum
59. 1 0 TI1 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 ATFN or A2FN OFST been enabled in case of TlI1 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 disabled 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
60. 2 PROT RTU ADDR Address BAUD Baud Rate DATA Data Bit Count PAR Parity Bit STOP Stop Bit Count RS 232 Terminals A TXI 4 TX2 0 COM 76 UM83001B 4 9 Analog Retransmission The Analog Retransmission is available for model number BTC 8300 XXXXXXN 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 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 LM ormula AOS SL AOV AOLO aa 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 e
61. 3001B Set the following parameters in the setup menu FUNC FULL COMM optional IN1 4 20 IN1U PU DP1 2 DP INi1L 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 spe SP2 0 50 PL12100 Also refer to Section 4 12 for more details UM83001B 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 P Figure 5 2 Block Diagram of 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 Control Input j L IL qx 3e U 3 4 Power Input AAA AAA AAA AAA Figure 5 3 VPFW SSR l l i vs Conventional SSR I I dg I I I I N UA Power Output aft 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 rela
62. 6 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 26 138 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 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
63. 8 Range Determination for SP2 Exception If any of ATSP A2SP or SP2 is configured with respect to CT input its adjustment range is unlimited 20 UM83001B 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 AN 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 the 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
64. A2MD Alarm 2 Operation Mode A2FT Alarm 2 Failure Transfer Mode SELF Self Tune Function Selection 0 SLEP Sleep mode Function Selection PVMD PV Mode Selection 0 SP2F Format of Set point 2 Value FILT Filter Damping Time Constant of PV 0 SPMD Set point Mode Selection 0 5 SEL1 Select 1 st Parameter 0 SEL2 Select 2 nd Parameter SEL3 Select 3 rd Parameter 0 8 SEL4 Select 4 th Parameter 0 SEL5 Select 5 th Parameter DRIF Warm up Drift Calibration Factor 45536 C ADO A to D Zero Calibration Coefficient 45536 ADG 78 A to D Gain Calibration Coefficient R W 199 9 199 9 19999 VIG CM con R W 199 9 199 9 19999 45536 UM83001E 113 B C E Parameter Register Parameter Description Default Uiit Notation Address Value ni Cold Junction Low Temperature CJTL 8n Calibration Coefficient m c Cold Junction Gain Calibration CJG 81 Coefficient _ Reference Voltage 1 Calibration REF 82 Coefficient for RTD 1 E Serial Resistance 1 Calibration SRI 93 Coefficient for RTD 1 RW 199 9 199 9 19999 mA Input 1 Gain Calibration MA1G Coefficient zi REF2 Reference Voltage 2 Calibration Coefficient for RTD 2 SR2 Serial Resistance 2 Calibration Coefficient for RTD 2 Voltage Input 2 Gain Calibration V2G Coefficient mA Input 2 Gain Calibration MA2G Coeffi
65. Adjust A2SP Trigger levels A2SP 1 2 A2HY Limitations 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 xc disi X Alarm longer to detect heater current reliably 20 30 20 30 20 30 Figure 3 17 1 id ie p n 20 Heater Break Alarm 0 50 0 50 0 50 52 UM83001B 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
66. C 212 0 F 0 Table 1 4 Parameter Description continued 3 7 UM83001B 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 0 20 mA linear current input 0 1V linear Voltage input 0 5V linear Voltage input 1 5V linear Voltage input 0 10V linear Voltage input Special defined sensor curve Degree C unit IN1 Unit Selection Degree F unit gt Process unit No decimal point 1 0 1 decimal digit IN1 Decimal Point Selection 1 e dP 2 decimal digits 3 dP 3 decimal digits IN1 Low Scale Value Low 19999 High 45536 0 IN1 High Scale Value Low 19999 High 45536 1000 0 nant N2 no function 1 Lt Current transformer input 2 4 eu 4 20 mA linear current input B ei 0 20 mA linear current input IN2 Signal Type Selection g iv 0 1V linear voltage input 1 B 5 u 0 5V linear voltage input 1 5 1 5V linear voltage input 7 HH iG 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 ue Reverse heating control action Output 1 Function 0 1 gi r t Direct cooling control action 0 EL Y Relay output 1 5 5 7 pj Solid state relay drive output 2 amp 45 Soli
67. CH SP1 100 AIDV 5 105 100 A1MD HOLD SP1 100 AIDV 5 X ON 105 105 100 100 95 95 UM83001B A1SP and A1HY are hidden 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 Figure 3 13 Normal Deviation Band Alarm X 105 100 Figure 3 14 95 Latching Deviation Band Alarm x ps Figure 3 15 Holding Deviation Band Alarm X 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 A1MD NORM For more detailed descriptions about heater current monitoring please see ATHY 0 1 Section 3 24 Adjust A1SP Trigger levels A1SP 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 ATSP 13 0A A1HY 0 1 A2HY 0 1 A1FN PV2 L ATMD NORM then
68. D 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 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 will perform bumpless transfer Thereafter the previous avera
69. DIN curve B16 Display symbol and description for EIFN 10 PT JS PT 100 ohms JIS curve i Ferameter Sieny Description 11 4 20 4 20 mA linear current input 0 NONE Event input no function 12 0 20 0 20 mA linear current input 1 SP2 SP2 activated to replace SP1 13 O 1V 0 1V linear Voltage input 2 PID2 PB2 TI2 TD2 activated to replace PB1 TI1 TD1 14 0 5V 0 SV linear Voltage input 3 spp2 SP2 PB2 TI2 TD2 activated to replace SP1 PB1 TI1 TD1 15 1 5V 1 5V linear Voltage input RS A1 Reset alarm 1 output 16 0 10 0 10V linear Voltage input 5 RS A2 Reset alarm 2 output 17 SPEC Special defined EO PSSST GNS 6 R A1 2 Reset alarm 1 amp alarm 2 7 D O1 Disable Output 1 B13 Display symbol and description for INTU amp IN2U 8 D O2 Disable Output 2 Parameter edi Description 9 D O1 2 Disable Output 1 amp Output 2 0 C Degree C unit 10 LOCK Lock all parameters 1 F Degree F unit 2 PU Process unit B17 Display symbol and description for OUT1 Parameter Display Description B14 Display symbol and description for DP1 amp DP2 Value Symbol 0 REVR Reverse heating control action Parameter Display fur Value Symbol Description 1 DIRT Direct cooling control action 0 NO DP No decimal point 1 1 DP 1 decimal digit 2 2 DP 2 decimal digits 3 3 DP 3 decimal digits UM83001E 117 B18 Display symbol and description for O1TY amp O2TY B23 Dis
70. 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 130 UM83001E 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 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 O
71. FT Exists if A2FN is not NONE EIFN A1MD A2MD PVMD Exists if FUNC selects FULL Setup FILT SELF Exists unconditionally SLEP Exists if FUNC selects FULL SPMD SP1L Menu Exists unconditionally SP1H SP2F Exists if EIFN selects SP2 or SPP2 or if SPMD selects PUMP Exists unconditionally 126 UM83001E A 2 Factory Menu Description Parameter Display Default Notation Format Parameter Description Range Value Current Error Code Program Identification Code Contains Program Number and Version Number Contains Lockout Status Code and Current System Mode Command Password f Job Password i d m Warm up Drift Calibration Factor i A to D Zero Calibration Coefficient i p A to D Gain Calibration Coefficient i 3 Voltage Input 1 Gain Calibration Coefficient Cold Junction Low Temperature Calibration Coefficient Cold Junction Gain Calibration Coefficient B Reference Voltage 1 Calibration Coefficient for RTD 1 i Serial Resistance 1 Calibration Coefficient for RTD 1 i mA Input 1 Gain Calibration Coefficient i Voltage Input 2 Gain Calibration Coefficient E mA Input 2 Gain Calibration Coefficient Point 1 Signal Value of Special Sensor Point 1 Indication Value of Special Sensor Point 2 Signal Value of Special Sensor Low 19999 High 45536 Point 2 Indication Val
72. In Basic Parameter Function Notation Display Format Parameter Description Default Value 14 Hddr Address Assignment of Digital COMM Baud Rate of Digital COMM Data Bit count of Digital COMM 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 9 6 Kbits s baud rate 14 4 Kbits s baud rate 19 2 Kbits s baud rate 28 8 Kbits s baud rate 38 4 Kbits s baud rate 7 data bits 8 data bits Parity Bit of Digital COMM Even parity Odd parity No parity bit Stop Bit Count of Digital COMM Analog Output Function Analog Output Low Scale Value Low 19999 One stop bit Two stop bits Analog Output High Scale Value Low 19999 Retransmit IN1 process value Retransmit IN2 process value Retransmit IN1 IN2 difference process value Retransmit IN2 IN1 difference process value Retransmit set point value Retransmit output 1 manipulation value Retransmit output 2 manipulation value Retransmit deviation PV SV Value High 45536 High 45536 IN1 Sensor Type Selection UM83001B 0 1 I I I U re ne P3 P3 0 08 038 08 09 uy OF th re oes L I m o J type thermocouple K type thermocouple T type thermocouple E type thermocouple B type thermocouple R type thermocouple S type thermocouple 0 C 32 0 F 100 0
73. K Ohms UM83001B 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 P12A 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 UM83001B 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 STOP AOFN AOLO AOHI IN2 IN2U DP2 IN2L IN2H EIFN PVMD 5 Remote set point FILT SLEP SPMD and SP2F 6 Complex process value ban 7 Output power limit Basic Mode capabilities 8 Digital communication 1 Input 1 Thermocouple RTD Volt mA ecl 2 Input 2 CT for heater break detection ds abbia ius
74. P 11 13 18 20 45 48 50 51 52 58 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 40 136 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 Contactor 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 43 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 UM83001E
75. 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 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 Examples Heat PID Cool ON OFF Set OUT1 REVR A1FN or A2FN PV1 H A1FN or A2MD NORM A1HY or A2HY 0 1 PB1 O0 TI 1 50 TD1 0 and set appropriate values for O1TY and CYC1 Heat PID Cool PID set OUT1 REVR OUT2 COOL CPB 100 DB 4 0 PB1 0 Tl1 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 tunin
76. PMD 3 rx D3 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 of control Illegal setup values been used Before COOL is used for OUT2 DIRT cooling action has already been used for OUT1 or PID mode is not used for OUT1 that is PB1 or PB2 0 and TH or TI2 0 or PV2 is used for SV Check and correct setup values of OUT2 PB1 PB2 TI1 TI2 and OUT1 IF OUT2 is required for cooling control the control should use PID mode PB z 0 TI 0 and OUT1 should use reverse mode heating action otherwise don t use OUT2 for cooling control Illegal setup values been used unequal IN1U and IN2U or unequal DP1 and DP2 while P1 2 or P2 1 is used for PVMD or PV1 or PV2 is used for SPMD or P1 2 H P1 2 L D1 2 H or D1 2 L are used for A1FN or A2FN Check and correct setup values of IN1U IN2U DP1 DP2 PVMD SPMD A1FN or A2FN Same unit and decimal point should be used if both PV1 and PV2 are used for PV SV alarm 1 or alarm 2 Illegal setup values been used OUT2 select AL2 but A2FN select NONE Check and correct setup values of OUT2 and A2FN OUT2 will not perform alarm function if A2FN select NONE Illegal setup values been used Dwell timer TIMR is selected for both A1FN and A2FN Communication error bad function code Check and correct setup values of A1FN and A2FN Dwell timer can only be prope
77. RD Pulsed voltage output to drive SSR O1TY SSH Isolated zero switching solid state relay 4 20 4 20mA linear current output 0 20 0 20mA linear current output 0 1V 0 1 V linear voltage output O2TY 0 5V 0 5V linear voltage output 1 5V 1 5V linear voltage output 0 10V 0 10V 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 UM83001B 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 8300 has 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 Selects the most significant parameter for view and change SEL2 Selects the 2 nd significant parameter for view and change SEL3 Selects the 3 rd significant parameter for view and change SEL4 Selects the 4 th significant parameter for view and change SEL5 Selects the 5 th significant parameter
78. 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 Softface 1 3 Programming Port and DIP Switch Input 1 Select PER Rear Terminal Le lee dle Lll le Access Hole amp calibration TC RTD mV The programming port is used to connect to SNA12A for automatic programming also can be connected to ATE system for automatic testing Front Panel Figure 1 3 Access Hole Overview DIP Switch oFF B oN 0 1V 0 5V 1 5V 0 10V 0 20 mA 4 20 mA All parameters are Unlocked Only SP1 SEL1 SEL5 are unlocked Table 1 1 DIP Switch Configuration Lockout Only SP1 is unlocked All Parameters are locked Factory Default Setting B 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 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 r
79. T 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 gt e Power interrupted EL 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 the controller continues to control by using its previous val
80. 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 I Alarm 2 ON Alarm 2 OFF 72 UM83001B 4 5 Remote Set Point SPMD selecting PV1 or PV2 will enable the BTC 8300 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 INTU 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 an ti Error Code will appear If PV2 are chosen for both SPMD and PVMD an E 22 Error Code will appear You should not use these cases otherwise the
81. 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 TI2 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 Refer to Section 5 9 for more details 70 UM83001B Apply Signal To Event inp
82. User s Manual BTC 8300 Self Tune Fuzzy PID Process Temperature Controller BrainChild UM83001E 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 UM83001B CONTENTS Page No Chapter 1 Overview 1 1 Features 4 1 2 Ordering Code 7 1 3 Programming Port and DIP Switch 8 1 4 Keys and Displays 9 1 5 Menu Overvigw 7 11 1 6 System MOORS enee 12 1 7 Parameter Description 13 Chapter 2 Installation 2 1 Unpacking 21 2 2 Mounting 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
83. Wave SSR VPFW SSR 84 5 3 Heat Only Control 86 5 4 Cool Only Control 87 5 5 Heat Cool Control 88 5 6 Ramp amp Dwell 90 Ser Remote Set Point ec ecce episc 92 5 8 Differential Control 93 5 9 Dual Set Point PIB eeo eee eee 94 5 10 RS 485 777ta 96 bet AG aad e etae sniaciieiesde pues 98 5 12 R transmit 2 ease 99 Chapter 6 Calibration 100 Chapter 7 Error Codes amp Troubleshooting 104 Chapter 8 Specifications 107 Chapter 9 Modbus Communications 110 Appendix A 1 Menu Existence Conditions 124 A 2 Factory Menu Description 127 A 3 Glossary 129 A 4 Index D EE 136 A 5 Memo 139 A 6 Warranty 141 Chapter 1 Overview 1 1 Features xx High accuracy 18 bit input A D High accuracy 15 bit output D A k 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 Sleep mode function Soft start ramp and dwell timer Progr
84. Y 4 20 PVMD P1 2 SPMD SP1 2 From Controller Output Water Tank 1 Level Sensor 1 5 12 M Height Figure 5 13 Outlet Differential Control Example SV 1 00 PV 1 00 PV1 5 12 4 20 mA Valve Control Output Water Tank 2 PV2 4 12 OUTI Level Sensor 2 gt PV DF n c H dg d mn Inn 4 12 M Height dus a xn AE 4 GJ Outlet IBIc src ssoo 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 UM83001B 93 5 9 Dual Set Point PID The BTC 8300 will switch 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 Adj
85. a Input 1 Gain Calibration Low 199 9 High 199 9 Voltage Input 2 Gain TS Y Calibration Coefficient Low 199 9 High 199 9 y mA Input 2 Gain Calibration Low 199 9 High 199 9 Jf Historical Maximum Value of Low 19999 High 45536 7 Bene Minimum Value of Low 19999 High 45536 4 Current Output 1 Value High 100 00 96 A MV2 _ _ _ Current Output 2 Value Low 0 High 100 00 96 A DV dv ent Deviation PV SV Low 12600 High 12600 4 PV1 PY IN1 Process Value Low 19999 High 45536 Display Mode m PV2 PY IN2 Process Value Low 19999 High 45536 Menu Current Proportional Band iah 900 0 C EN Y Pb Value pun m High 909 9 F S Current Integral Time Value Low 0 High 4000 sec wo Ed elu Derivative Time Low 0 High 1440 sec E Y pucr Ege en ioe Compensation ow pad High 90 00 C 4 P Current Process Rate Value Low 16383 High 16383 4 P rH Maximum Process Rate Value Low 16383 High 16383 z 4 Minimum Process Rate Value Low 16383 High 16383 m UM83001B 19 3 P m H 418 C148 Fa 32 F Teel emel ame AS es Input Type N TC L TC PT DN PT JS EIER p EE Table 1 5 Input IN1 or IN2 Range If ATFN PV1 H PV1 L PV2 H PV2 L DISH DUE Table 1 6 Range Determination for ATSP same as range of If A2FN PV1 H PV1 L PV2 H pv2 L B12H Plot Table 1 7 Range Determination for A2SP Range of A2SP Range of SP2 same as range of Table 1
86. according to the following formula HS LS Note that the value stored in the register is always positive value E The unit PV means that the unit of parameter is the same as the unit of PV process value The unit of PV is determined by PVMD IN1 IN2 IN1U and IN2U E1 Unit determination for A1SP A1DV and A1HY DE HI DE LO PV1 H PV2 H P1 2 H P1 2 L DB HI DB LO PV1 L PV2 L D1 2 H D1 2 L If A1FN Unit same E2 Unit determination for A2SP A2DV and A2HY DE HI DE LO PV1 H PV2 H P1 2 H P1 2 L If A2FN DB HI DB LO PV1 L PV2 L D1 2 H D1 2 L Unit same E3 Unit determination for RAMP Unit PV Minute PV Hour E4 Unit determination for AOLO and AOHI If AOFN Same unit as unit of E5 Unit is the same as unit of PV1 IN1 E6 Unit is the same as unit of PV2 IN2 122 UM83001E 9 4 Communication Examples Example 1 Preset 9 multiple registers Por s w ow e e s s e e e s o es s2 or e s o v o F o0 o io Example 2 Read PV SV MV1 and MV2 Send the following message to the controller via the COMM port or programming port pee o wo o oe Mi to Example 3 Perform Reset Function same effect as pressing 4 v key Query 0 o Hee Hes H25 Hi Lo Register Adar Data Hi Lo CRC16 Example 4 Enter Auto tuning Mode Query IEEE TENES CENT Register Addr Data Hi Lo CRC16 Example 5 Enter Manual Control Mode Qu
87. age Triac SSR Output Direct Drive 33 2 13 Alarm 1 Wiring Max 2A Resistive 120V 240V Mains Supply Relay Output Direct Drive 414 5 15 3 Figure 2 16 6 16 E Alarm 1 Wiring 717 ele alale gt 120V 240V a Mains Supply RET I E Three Phase No Fuse Delta Contactor Breaker Heater Load E02 Relay Output to Drive Contactor E imi C3 34 UM83001B 2 14 Alarm 2 Wiring Max 2A Resistive 120V 240V o Mains Supply Relay Output Direct Drive Figure 2 17 Alarm 2 Wiring e e e E 120V 240V Mains Supply Phase Heater 0 0 9 Power Three Phase No Fuse Delta Contactor Breaker Heater aos Relay Output to Drive Contactor UM83001B 35 2 15 RS 485 Figure 2 18 RS 485 Wiring RS 232 lt gt PC SNA10A or RS 485 to RS 232 network adaptor SNA10B TX1 TX2 Max 247 units can be linked TXI Oooo 220 ohms 0 5W Terminator TX2 E ev z e Je 5 L OD Jm Z SS SS SiS SiS Sis Se de doy reo or
88. ammable inputs thermocouple RTD mA VDC Analog input for remote set point and CT Event input for changing function amp set point Programmable digital filter Hardware lockout remote lockout protection Loop break alarm Heater break alarm Sensor break alarm 4 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 x EMC CE EN61326 BTC 8300 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 8 DIN case measuring 48 mm x 96 mm with 65 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 itis easy to configure menu to suit the specific application BTC 8300 is powered by 11 26 VAC VDC or 90 264 V AC supply incorporating dual 2 amp control relays output and dual 2 amp alarm relays output as standard Alternative output options include SSR drive triac 4 20 mA and O 10 volts BTC 83
89. and mV inputs 0 1 second for 4 20 mA and 1 5 V inputs Characteristics Accuracy Input 25 C Impedance 120 C 1000 C o e4 F ma Fy e Bee 200 C 1370 C 328 F 2498 F 250 C 400 C 418 F 752 F 100 C 900 C 148 F 1652 F 0 C 1820 C 32 F 3308 F 2 C 2 2MQ 2 C 2 2 MQ 2 C 2 2MQ 2 C 200C 22M9 1820 C 0 C 1767 8 C 5 6 32 F 3214 F 0 C 1767 8 C 32 F 3214 F 250 C 1300 C 418 F 2372 F 300 C 900C 328 F 1652 F 2 C 22MO 210 C 700 C 346 F 1292 F 200 C 600 C 328 F 1112 F mv 8mV 7omv 0 05 22M2 2 2 MQ 2 C 2 2 MQ 2 C 2 2 MQ 0 4 C 1 3KQ 0 4 C 1 3KQ mA 3mA 27mA 0 05 70 50 V 1 3V 11 5V 0 05 302KQ UM83001E 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 bci 25 C Impedance 2 CT94 1 0 50 0A of Reading 302 KQ 0 2A 0 8V input current mA 3
90. 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 9 4 x SA SA 4 CJ 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 IN2 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 and IN2H should be set with values higher than the set point range used 92 UM83001B 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 IN1L INTH According to Sensor 1 signal INTU PU DP1 2 DP IN2 IN2L IN2H According to Sensor 2 signal IN2U PU DP2 2 DP OUT1 REVR O1T
91. bout 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 value 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 2 and 8 function then connect a switch to terminals 13 and 14 see Section 2 10 and Set LOCK for EIFN If remote lockout is configured all
92. ch 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 can 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
93. cient d O2L Output 2 Low Calibration Coefficient O2H Output 2 High Calibration Coefficient Point 1 Signal Value of Special PET Sensor Point 1 Indication Value of Special IND1 Sensor PV Point 2 Signal Value of Special as Sensor Point 2 Indication Value of Special IND2 Sensor PV Point 3 Signal Value of Special 2G Sensor IND3 ge Eoint3 Indication Value of Special Rw 19999 45536 19999 PV Point 4 Signal Value of Special Bet Sensor Point 4 Indication Value of Special IND4 Sensor PV Point 5 Signal Value of Special B Sensor Point 5 Indication Value of Special IND5 Sensor PV Point 6 Signal Value of Special SIG6 Sensor Point 6 Indication Value of Special IND6 Sensor PV Point 7 Signal Value of Special SiG Sensor Point 7 Indication Value of Special IND7 Sensor PV SIG8 105 LONE 8 Signal Value of Special R W 19999 45536 19999 Point 8 Indication Value of Special IND8 Sensor PV Point 9 Signal Value of Special alae Sensor Point 9 Indication Value of Special IND9 Sensor PV TYPE Signal Type of Special Sensor DATE Manufacturing Date of Product NO Serial Number of Product HOUR Working Hour Value Hour HRLO Fractional Hour Value 0 1Hour ERR1 Historical Error Record 1 ERR2 Historical Error Record 2 DELI ASCII Input Delimiter BPL1 OUT1 Bumpless Transfer Value BPL2 118 OUT2 Bumpless Transfer Value R 0 100 00 0 96 119 UM83001E 114
94. d 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 8300 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 icon SPMD PUMP SP2F DEVI and program the following parameters in the user menu REFC Reference constant SP2 A negative value 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 8300 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 P
95. d state relay output Output 1 Signal Type 3 UY gil 4 20 mA current module 0 15 Table 1 4 Parameter Description continued 4 7 Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value Setup Menu 16 Output 1 Signal Type 0 20 mA current module 0 1V voltage module 0 5V voltage module 0 1 5V voltage module 8 0 10V voltage module Output 1 Cycle Time Low j High 100 0 sec 18 0 Output 1 Failure Transfer Mode Select BPLS bumpless transfer or 0 0 100 0 96 to continue output 1 control function as the unit BPLS fails power starts or manual mode starts Output 2 no function s 0 Output 2 Function PID cooling control r or DC power supply module urs installed Output 2 Signal Type Same as O1TY 0 Output 2 Cycle Time Low 0 1 High 100 0 sec 18 0 Output 2 Failure Transfer Mode Alarm 1 Function Select BPLS bumpless transfer or 0 0 100 0 96 to continue output 2 control function as the unit BPLS fails power starts or manual mode starts 0 none No alarm function 1 Ei mi Dwell timer action 2 dEH Deviation high alarm 3 JEL C Deviation low alarm 4 doh Deviation band out of band alarm 5 dhL m Deviation band in band alarm 6 pu iH IN1 process value high alarm 7 py iL IN1 process value low alarm 2 8 PuUgH IN2 process value high alarm 9 pugi IN2 process value low alar
96. degree of a pure metal resistance device between 0 and 100 C Usually designated by the Greek letter alpha 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 10 8 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 reset 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
97. dn 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 Step 8 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 Step 9 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 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 calibrating the cold junction compensation Note that a K type ON thermocouple must be used B A A A TC input 5520A Calibrator BTC 8300 K TC Figure 6 2 Lel Cold Junction Stay at least 20 minutes in still Calibration Setup air room room temperature 25 3 C The 5520A calibrator is configured as K type the
98. 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 energy 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
99. e 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 oa n Outi Out2 Almi Alm2 4 Ev IBIcl src s30o 88 UM83001B 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 PTDN ud IN1U C TM 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 SPI CPB Adjust SP1 at 120 0 C CPB at 125 96 and DB at 4 0 96 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 96 If air is used as cooling media instead of oil the CPB is set at 100 96 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 UM83001B 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 eve
100. e 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 c F J Send a 100 ohms signal to terminals 18 19 and 20 according to the connection shown below 100 ohms BTC 8300 Press scroll key for at least 3 seconds The display will blink a moment otherwise the calibration fails UM83001B DIP Switch Position f aif T C input DIP Switch Position ELI 0 10V input DIP Switch Position L f RTD input 12 3 4 Figure 6 1 RTD Calibration 101 Step 6 Press scroll key and the display will show _5 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 REF1 last step Otherwise if the display didn t blink or if any value obtained for SR1 and REF1 is equalto 199 9 or 199 9 then the calibration fails Perform step 7 to calibrate mA function if required for input 1 Step 7 Change the DIP switch for mA input Press scroll key until the display DIP Switch Position shows Send a 20 mA signal to terminals 19 and 20 in ON correct polarity Press scroll key for at least 3 seconds The display i a mA input 1 2 3 4 will blink a moment and a new value is obtained Otherwise if the display di
101. e of 4 kinds of alarm modes can be selected for sensor break alarm These Setup OUT2 AL2 are Normal alarm Latching alarm Holding alarm and Latching Holding alarm A2FN SENB However the Holding alarm and Latching Holding alarm are not recommended A2MD NOR M LTCH to be chosen for sensor break alarm since sensor break alarm will not perform Hidden TIME A2SP A2DV holding function even if it is set with holding or latching holding mode See A2HY 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 SP1L 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 se Figure 3 19 SP1 Range IN1L or sensor range low 54 UM83001B 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 example A process is equipped with a
102. e of some parameters are dependent on the input types The range of IN1 and IN2 for various input type is shown in the following table Input IN1 or IN2 Range Table Input Type J TC KTC TTC ETC BTC R TC S TC 120 C 200 C 250 C 100 C orc oc OC Range Low Ctg4 F 328 F 418 F 148 F 32 F 32 F 32 F Ranae High 1000 C 1370 C 400 C 900 C 1820 C 1767 8 C 1767 8 C ge TON 1832 F 2498 F 752 F 1652 F 3308 F 3214 F 3214 F Input Type N TC L TC PT DN 250 C 200 C 210 C PT JS CT 200 C Linear V mA or Sect Range Low 418 F 328 F 346 F 328 F 0 Amp 19999 ah 1300 C 900 C 700 C 600 C Range High 5379 F 1652 F 1292 F 1112 F 90 Amp 45536 B1 Range of A1SP P1 2 H P1 2 L If A1FN PV1 H PV1 L PV2 H PV2 L Di 2H DIAL Range of A1SP sme as range of IN1 IN2 IN1 IN2 Range of A2SP PLZH PLZL IFA2EN PV1 H PVILL PVzHPV2L B2 DIST Rangs db IN1 IN2 IN1 IN2 same as range of Exception If ATSP or A2SP is configured with respect to CT input its adjustment range is unlimited B2 Range of SP2 If PVMD PV1 pv2 P1 2 P2 1 Range of SP2 same as range of INT IN2 IN1 IN2 Exception If SP2 is configured with respect to CT input its adjustment range is unlimited
103. ective Actions Symptom Probable Causes Corrective Actions 1 LED s will not light 2 Some segmenis of the display or LED lamps not lit or lit erroneously No power to instrument Power supply defective LED display or LED lamp defective Related LED driver defective Check power line connections Replace power supply board Replace LED display or LED lamp Replace the related transistor or IC chip 3 Display Unstable 4 Considerable error in temperature indication Analog portion or A D converter defective Thermocouple RTD or sensor defective Intermittent connection of sensor wiring Wrong sensor or thermocouple type wrong input mode selected Analog portion of A D converter defective Replace related components or board Check thermocouple RTD or sensor Check sensor wiring connections Check sensor or thermocouple type and if proper input mode was selected Replace related components or board 5 Display goes in reverse direction counts down scale as process warms 6 No heat or output Reversed input wiring of sensor No heater power output incorrect output device used Output device defective Open fuse outside of the instrument Check and correct Check output wiring and output device Replace output device Replace output fuse 7 Heat or output stays on but indicator reads normal Output device shorted or power service sho
104. ectricity 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 would 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 UM83001E 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 whi
105. en 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 UM83001E 135 A 4 Index A1DV 11 13 18 47 48 50 51 53 54 110 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 58 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 A2S
106. epresent those parameters which are selected by using SEL1 SEL2 SEL5 parameters contained in Setup menu Parameters been selected are then allocated at the beginning of the user menu UM83001D 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 Enter Key for at least 3 seconds TOUCHKEYS FUNCTION DESCRIPTION 4 Ub Ke Press and release quickly to increase the value of parameter Lane d Press and hold to accelerate increment speed v Down Ke Press and release quickly to decrease the value of parameter y Press and hold to accelerate decrement speed Scroll Key Select the parameter in a direct sequence Allow access to more parameters on user menu also used to Enter manual Press 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 J 4 Reverse Scroll Key Select the parameter in a reverse sequence during menu scrolling Press v Mode Key Select the operation Mode in sequence Pres a v Reset Key Sleep Key Factory Key Press a v for at least 3 seconds Press 4 v Reset the front panel display to a normal display m
107. er Display Value Symbol Description 0 0 Perform default setting by using C FILE 1 1 Perform default setting by using F FILE B33 Description of ALM Value ALM LOW BYTE 765 43 2 1 0 sBit t ALMK 00 No alarm activated 01 Alarm 1 activated 10 Alarm 2 activated 11 Alarm 1 amp Alarm 2 activated A1FNK If ATFN 8 9 then A1FNK 0 Otherwise A1FNK 1 A2FNK If A2FN 8 9 then A2FNK 0 Otherwise A2FNK 1 AOFNK If AOFN 0 2 3 then AOFNK 00 If AOFN 1 then AOFNK 01 If AOFN 4 7 then AOFNK 10 If AOFN 5 6 then AOFNK 11 BPVMDK If BPVMD 1 then BPVMDK 0 Otherwise BPVMDK 1 ALM HIGH BYTE MSB 15 14 13 12 8 Bit 11 T Eam DP1 DP2K DP2 BIN1K If BIN1 11 then BIN1K 00 If 11 BIN1 17 then BIN1K 01 Otherwise BIN1K 10 BIN2K If BIN2 2 8 18 then BIN2K 00 If BIN2 1 then BIN2K 01 If BIN2 19 21 22 23 then BIN2K 10 Otherwise BIN2K 11 119 B34 Error messages 120 und E Error Description Corrective Action Illegal setup values Check and correct used PV1 is used for setup values of PVMD 1 Er both PVMD and SPMD and SPMD PV and SV that is meaningless for can t use the same control value for normal control Illegal setup values Same as error code 1 used PV2 is used for 2 Eriig both PVMD and SPMD that is meaningless for control Illegal
108. ery 05 0 wee Hes H2r Hi Lo Register Addr Data Hi Lo CRC16 Example 6 Read All Parameters Query Je o o opaa e Sarin Aaah ELSE Example 7 Modify the Calibration Coefficient Preset the CMND register with 26665 before attemping to change the caliration coefficient NEEJXEXLELZLZCNES UM83001E 123 A 1 Menu Existence Coditions Menu Existence Conditions Table Menu Parameter Existence Conditions Notation Exists unconditionally TIME Exists if A1FN selects TIMR or A2FN selects TIMR A1SP Exists if ATFN selects PV1H PV1L PV2H PV2L P12H P12L D12H or D12L A1DV Exists if A1FN 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 RAMP Exists if SPMD selects MINR or HRR Exists if T11 is used for control depends on Event input and EIFN selection but Tl1 0 and OFST PB1 40 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 User Menu Li ete if 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 PB27 0 TI2 TD2 O1HY If PID2 or SPP2 is selected for EIFN then O1HY exists if PB1 0 o
109. et point warm start the unit passes 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 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 UM83001B 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 Wait and Examine the Process steady state reached Yes Does the process oscillate Yes 1 Flag 0 Flag 2PB1 PB1 0 5PB1 PBI the Process Wait and Examine l Is steady state reached
110. ff 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 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 fpm Flow velocity in feet per minute fps Flow velocity in feet per second Freezing point The temperature at which the substance goes fr
111. for repair overflow or underflow Computing error Don t use an equal 19 E 4 divi value for AOLO and i divided by zero y AOHI 2 E an Computing error Software bug Return Illegal BCD data entry to factory for repair Timing error Ato D A to D converter I conversion data error doesn t work properly 21 Er i dueto overrun Return to factory for repair Timing error 1 Correct the multi chip check sum error communication 22 E received during software to meet the multi chip protocol requirement communication 2 Return to factory for procedure repair Timing error wrong 1 Correct the multi chip function code received communication 23 7 during multi chip software to meet the communication procedure protocol requirement 2 Return to factory for repair N o za ce rm Fail to perform auto tuning function 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 procedure 3 Don t change Event input state during auto tuning procedure 4 Use manual tuning instead of auto tuning 27 Incorrect calibration procedure or tolerance of analog component too big to meet specified accuracy Memory comparison error different value 1 Pay more attention to the calibration procedures 2 Return to factory for repair 1 Check and correct the wiring and grounding p
112. for view and change Range NONE TIME A1 SP A1 DV A2 SP A2 DV RAMP OFST REFC SHIFR 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 TM 20 SEL1 selects TIME SEL2 selects A2 DV SEL3 selects OFST SEL4 selects PB1 SEL5 selects NONE Now the upper display scrolling becomes 42 UM83001B un i rm Sal c m im N un m r nu un FA 2 r r RN C m m A un m r lt ep m u Cc un m r 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 diagram PV A SP1 01HY 2 SP1 7 om band O1HY SP1 O1HY 2 gt OUT1 Action Time A OFF 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 PB
113. g NO c m OR DO MD LS e I1 FTF FT I9 E93 I9 IT amp f S omo mee eg e Nn c s d rcocoolSc UM83001B 36 2 16 RS 232 Bll ls PG Ri a 3 18 Su i B e TX2 Figure 2 19 K 6 16 R RS 232 Wiring K 747 E 9 pin RS 232 port OC eae alee mi CC94 1 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 To DTE PC RS 232 Port 1 DCD BTC 8300 2RD 3 TD Figure 2 21 4 DTR Configuration of RS 232 5 GND Cable 6 DSR 7 RTS 8CTS 9RI Female DB 9 UM83001B 37 2 17 Analog Retransmission 38 see ld uil Retransmit Current iud SISE is Retransmit Voltage 7 Indicators 0 20mA PLC s 4 20mA E Load Recorders Data loggers AVI Inverters etc Load Load The total effective resistance of serial loads can t exceed 500 ohms Figure 2 22 Analog Retransmission Wiring Indicators Load PLC s Recorders Data loggers Inverters etc The total effective resistance of parallel loads should be greater than 10
114. g UM83001B 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 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 UM83001B 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
115. ging value of MV2 will be used for controlling output 2 2 If OUT2 selects COOL and a value of 0 to 100 0 96 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 UM83001B 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 occurs as 1 Failure mode is activated Failure Transfer Setup 1 O1FT 2 O2FT 3 ATFT 4 A2F
116. ignal is pulled down Also refer to Section 4 1 for event input function UM83001B Figure 2 13 Event Input Wiring 29 2 11 Output 1 Wiring Max 2A Resistive Load 120V 240V Mains Supply Figure 2 14 Output 1 Wiring Relay Output Direct Drive 120V 240V Mains Supply i 9 0 _ oo o Three ia 64 o o o p PEN eater E O 0 0 0 9_ power eri Three Phase No Fuse Relay or Triac SSR Delta Contactor Breaker Output to Drive ial Heater Contactor Load SSR Loadi 9 150y py Mains Supply o Internal Circuit l 5V l l a l l 30mA 5V P 31 Pulsed Voltage to Drive SSR Pulsed l 33 l Voltage i TEE eee A oV is L l E 30 UM83001B Maximum Load 500 ohms Linear Current 0 1V 0 5V 1 5V 0 10V Minimum Load 10 K ohms Linear Voltage Max 1A 240V Load 120V 240V Mains Supply Triac SSR Output Direct Drive
117. in Integral Linearity Error 0 005 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 20mA 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 heating 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 96 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
118. ion 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 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 132 UM83001E Kilo The prefix for one thousand K Kilo
119. is used for dwell time adjustment 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 Timer starts If alarm 1 is configured as dwell timer ATSB 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 ATFN TIMR or A2MD if A2FN TIMR is ignored in this case UM83001B Error Code Figure 3 4 Dwell Timer Function 47 3 8 Process Alarms 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 determi
120. ither 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 valueis 100 4mA will be exported and if the difference value is 100 20mA will be exported Make the following Setup for BTC 8300 INTUZPU DP1 NODP IN2U PU DP2 NODP FUNC FULL COMM 4 20 AOFN P1 2 AOLO 100 AOHI 100 UM83001B Setup Menu Funk FUNC Lann COMM A AOFN AOLO aH AOHI Terminals 3 AO 4 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 unstable to be read To improve Menu this a programmable low pass filter incorporated in the BTC 8300 can be F LE FILT used 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 0 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 2 J Figure 4 7 Filter Characteri
121. ly module installed 1 YES Sleep mode function enabled B27 Displ bol and d iption for PVMD B21 Display symbol and description for DISF pepe eyes pugno Parameter Display Description Vale IM 0 PV1 Use PV1 as process value Display PV Value 1 PV2 Use PV2 as process value 1 SV Display SV Value 2 P1 2 Use PV1 PV2 difference as process value 3 P2 1 Use PV2 PV1 difference as process value B22 Display symbol and description for ATFN amp A2FN Parameter Sispa Description B28 Display e Mla and description for SP2F 0 NONE No alarm function co Syd 1 TIMR Dwell timer action 0 ACTU set point 2 SP2 is an actual value 2 DE HI Deviation high alarm 1 DEVI set point 2 SP2 is a deviation value 3 DE LO Deviation low alarm 4 DB HI Deviation band out of band alarm B29 Display symbol and description for FILT 5 DB LO Deviation band in band alarm Parameter Bipy Description 6 PV1 H IN1 process value high alarm 0 0 0 second time constant 7 PV1 L IN1 process value low alarm 1 0 2 0 2 second time constant 8 PVZ H IN2 process value high alarm 2 0 5 0 5 second time constant 9 PV2 L IN2 process value low alarm 3 1 1 second time constant 10 P1 2H IN1 or IN2 process value high alarm 4 2 2 seconds time constant 11 P1 2 L IN1 or IN2 process value low alarm 5 5 5 seconds time constant 12 D1 2 H IN1
122. m f i 10 P IPH 3 INT or IN2 process value high 11 AL IN1 or IN2 process value low alarm 12 d N1 IN2 difference process value high alarm N1 IN2 difference process value low alarm Loop break alarm Sensor break or A D fails Normal alarm action Latching alarm action Alarm 1 Operation Mode 0 UM83001B Hold alarm action 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 F Al tput OFF it fail y Alarm 1 Failure Transfer RF Ru SR AIEE 1 Mode 1 on Alarm output ON as unit fails 4 Alarm 2 Function Same as A1FN 2 S Alarm 2 Operation Mode Same as A1MD 0 A Alarm 2 Failure Transfer Same as A1FT Mode 1 0 anm E Event input no function 1 5 Pg SP2 activated to replace SP1 PB2 TI2 TD2 activated to replace P de PB1 TI1 TD1 5 PPe SP2 PB2 TI2 TD2 activated to replace SP1 PB1 TI1 TD1 r 5H Reset alarm 1 output Event Input Function r SAZ Reset alarm 2 output 1 rA ie Reset alarm 1 amp alarm 2 clo f Disable Output 1 doc Disable Output 2 da le Disable Output 1 amp Output 2 L nc EB Lock All Parameters B L Use PV1 as process value Setup Menu P ug Use PV2 as process value PV Mode Selection Use PV1 PV2 difference as 9 process value Use PV2 PV1 difference as process value o z O second time constant
123. mA 27mA 0 05 70 50 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 Ko 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 24 240 VAC life cycles 200 000 for resistive load Pulsed Voltage Source Voltage 5V current limiting resistance 66 Q Linear Output Characteristics Zero Span Load Typa Tolerance Tolerance Capacity 4 20 mA 3 8 4 mA 20 21 mA 5000 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 5 V 10 KQ 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 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
124. 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 25bmA 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 UM83001E drive SSR 5V 30mA 4 20mA 0 20mA 4 Isolated 1 5V 0 5V drive SSR 14V 40mA 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 7 Isolated 20V 25mA DC Output Power Supply 8 Isolated 12V 40 mA DC Output Power Supply 9 Isolated 5V 80mA DC Output Power Supply C Pulsed voltage to drive SSR 14V 40mA A Special order Range set by front keyboard 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 Network SNA10B Smart Network Adaptor for BC Net
125. meters are locked to prevent from being changed See Section 4 13 for more details 68 UM83001B SP2F Function Define format of SP2 value If SP2F in the setup menu is selected with ACTU the event input function will use SP2 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 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 17 and pin 16 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 The pressure gauge is switched ON as it senses a higher pressure Connect the output contacts of the pres
126. mory 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 shows the percentage control value for the output 1 Z shows the percentage control value for the output 2 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 a v keys 66 UM83001B PVHI PVLO MV1 MV2 DV PV1 PV2 PB TI TD CJCT
127. mpensating 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 m ni m Ks o Figure 2 5 Thermocouple Input Wiring DIP Switch is R 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 red yellow T Constantan blue red brown blue Cu Ni blue blue brown blue Iron Fe t yellow white red t yellow J Constantan blue red blue black Cu Ni black black blue black ed brown t yellow t red yellow K Nue zee Dey em O dele Ni Al R Pt 13 Rh Pt Sey i ea red yellow S Pt 10 Rh Pt Bicis is i d green green white green B Pt 30 Rh Use iod ce Use Pt 6 Rh Copper Wire grey grey Copper Wire Colour of overall sheath UM83001B 25 2 7 RID Input Wiring RTD connection are shown in Figure 2 6 with the compensati
128. nce over 20 meters RS 232 Benefits Direct Connection to a PC Using a PC for data communication is the most economic way The signal is transmitted and received through the PC communication Port generally RS Order BTC 8300 XXXXXX1 232 Since a standard PC can t support RS 485 port a network adaptor for RS 485 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 Order BTC 8300 XXXXXX2 be sad Many RS 485 units up to 247 units can be connected to one RS for RS 232 232 port therefore a PC with 4 comm ports can communicate with 988 units It is quite economic Setup RS 485 Setup Enters the setup menu FUNC FULL Select FULL Full function for FUNC COMM 485 Select 485 for COMM if RS 485 is required or 232 if RS 232 is required Select PROT RTU RTU ie Modbus protocol RTU mode for PROT Set individual address as ADDR Address for those units which are connected to the same port BAUD Baud Rate Set the Baud Rate BAUD Data Bit DATA Parity Bit PARI and Stop Bit DATA Data Bit Count STOP such that these values are accordant with PC setup conditions PARI Parity Bit STOP Stop Bit Count 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 according RS 485 Terminals to Section 2 16 3 Dx Tx2 RS 232 Setup FUNC FULL COMM 23
129. ned 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 AiMD 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 AIMD LTCH Ifa 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 a vo vo X X 205 205 ON 205 205 205 195 195 195 195 orr 195 48 UM83001B 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
130. ng lead connected to terminal 19 For two wire RTD inputs terminals 19 and 20 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 Figure 2 6 uu RTD Input Wiring om a DIP Switch BinTD 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 11 212 3 Ble 4 ES 5 15 IE 6 16 717 8 18 Z 9 19 Fey 10 20 FED DIP Switch Figure 2 7 0 1V 0 5V Input 1 Linear Voltage Wiring 1 5V 0 10V Fed EO ERES 26 UM83001B DIP Switch t1 e 2 121 aH 3 13 414 5 15 ele 16 7 171 ed 8 18 9 19 10 20 0 20mA or 4 20mA
131. nt 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 Figure 5 8 Chamber p e 3 Freezer b ig AC Relay H Xl 1d 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 _ ee gelee T at E E E Cycle Timer SM RY TIME 60 0 minutes SP1 60 0 C SP2 10 0 C CPB 100 RAMP 14 0 C minute Le ia A rm UJ t oo eS e 90 UM83001B A Temperature Cycling Chamber 60 minutes 60 minutes D 60 C 60 C Figure 5 9 Temperature Profile 30 35 of Chamber 5 minutes pp 65 minutes minutes BTC 8300 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
132. o 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 Refer to Table 7 2 for some probable causes and actions 104 UM83001B Table 7 1 Error Codes and Corrective Actions ci cei Error Description Corrective Action 1 cAI Illegal setup values been used PV1 is used for both PVMD Check and correct setup values of PVMD and SPMD PV cu and SPMD It is meaningless for control and SV can t use the same value for normal control a er Ge Megelsaiun values been used a e used for both PYMD same as error codo 1 Illegal setup values been used P1 2 or P2 1 is used for Check and correct setup values of PVMD and S
133. o 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 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 134
134. ode also used to leave the specific Mode execution to end up the auto tune and manual control execution and to quit the sleep mode The controller enters the sleep mode if the sleep function SLEP is enabled select YES By entering correct security code to allow execution of engineering programs This function is used only at the factory to manage the diagnostic reports The user should never attempt to operate this function Process Unit Indicator Output 1 Indicator gt o n o o Outi Out2 Alm1 Alm2 Output 2 Indicator 9 4 Ev Alarm 1 Indicator Alarm 2 Indicator Bic BTC 8300 Figure 1 4 Front Panel Description Upper Display to display process value menu symbol and error code etc 3 Buttons for ease of control setup and set point adjustment How to display a 5 digit number For a number with decimal point the display will be shifted one digit right 199 99 will be displayed by 199 9 4553 6 will be displayed by 4553 Lower Display to display set point value parameter value or control output value etc For a number without decimal point the display will be divided into two alternating phases 19999 will be displayed by 45536 will be displayed by Table 1 3 Display Form of Characters y im 4 5535 9999 will be displayed by JIOo Q U Confused Character UM83001B 9 10
135. om 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 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 Ib 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
136. on Complexity Level COMM Communication Interface Type PROT COMM Protocol Selection ADDR Address Assignment of Digital COMM BAUD Baud Rate of Digital COMM DATA Data Bit count of Digital COMM PARI Parity Bit of Digital COMM STOP Stop Bit Count of Digital COMM AOFN Analog Output Function AOLO Analog Output Low Scale Value isa on E4 AOHI Analog Output High Scale Value ee E4 IN1 IN1 Sensor Type Selection O IN1U IN1 Unit Selection DP1 IN1 Decimal Point Selection INIL 38 IN1 Low Scale Value R W 19999 45536 0 19999 ES IN1H 39 IN1 High Scale Value R W 19999 45536 1000 19999 45536 ES UM83001E 112 biben e Parameter Description gt Defauit m SP1L 40 SP1 Low Scale Value rence PV SP1H 41 SP1 High Scale Value erT PV IN2 42 IN2 Signal Type Selection IN2U IN2 Unit Selection 0 2 DP2 IN2 Decimal Point Selection 0 IN2L IN2 Low Scale Value vee IN2H IN2 High Scale Value E6 EIFN Event Input Function OUT1 Output 1 Function O1TY Output 1 Signal Type CYC1 Output 1 Cycle Time i Sec O1FT Output 1 Failure Transfer Mode j OUT2 Output 2 Function 0 3 O2TY Output 2 Signal Type 0 CYC2 Output 2 Cycle Time Sec O2FT Output 2 Failure Transfer Mode 96 A1FN Alarm 1 Function A1MD Alarm 1 Operation Mode 0 A1FT Alarm 1 Failure Transfer Mode A2FN Alarm 2 Function 0 5
137. 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 UM83001B 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 8300 can be used for these applications to achieve an economical yet versatile solution Here is an example BTC 8300 4137XXX j Kg cm Eni DO Pressure CE Reservoir LJ Figure 5 1 Pressure Awater Supply System Sensor IBIc BTC 8300 OUT1 OUT2 4 20 N1 DC20V mA S Water Control Motor Pump 3h AC AC Inverter The water pressure is required to be controlled at 10 Kg cm to achieve this the following devices are used for this example t Water 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 8300 4137XXX Order a BTC 8300 with standard input 4 20 mA output 1 20V DC output 2 for sensor power 82 UM8
138. parison curves below UM83001B 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 UM83001B 1 2 Ordering Code BTC 8300 O O U O LI 3 4 25 Power Input 1 2 6 7 4 90 264 VAC 47 63 HZ 5 11 26 VAC or VDC SELV Limited Energy Alarm 1 Alarm2 Communications Signal Input 0 None 0 None 0 None 1 Form C Relay 1 Relay 1 RS 485 Tiranaan Inau 2A 240VAC 2A 240VAC 9 RS 232 eed al 9 Special order 9 Special order 3 Ret it 4 20mA Thermocouple J K T E B oP uM ELANET E 0 20mA pu 4 Ret it1 5V RTD PT100 DIN PT100 JIS SEO er a g i 51 2 TH P Output 1 Output 2 5 Retransmit 0 10V Q 10V 0 None 0 None 9 Special order 1 Rel 240VA Input 2 CT and Analog Input 1 Te ay cde VAM alay PA CT 0 50 Amp AC Current A Pulsed WOO TO Transformer 3 Analog Input 4 20 mA 0 20mA 0 1V 0 5V Isolated 1 5V 0 10V l Input 3 Event Input El a io on al 9 Special Order 1A 240VAC SSR C Pulsed voltage to Example BTC 8300 4111101 e 90 264 operating voltage e nput Standard Input e Output 1 Relay e Output 2 Relay Alarm 1 Form C Relay RS 485 Communication Interface 9 Special order Accessories CT94 1 0 50 Amp AC Current Transformer OM95 3 Isolated 4 20 mA 0 20
139. play symbol and description for A1MD amp A2MD Value Syrhb l ERREUR lus Symbol Description o RELY Relay output 0 NORM Normal alarm action 1 SSRD Solid state relay drive output 1 LTCH Latching alarm action 2 SSR Solid state relay output 2 HOLD Hold alarm action 3 4 20 4 20 mA current module 3 LT HO Latching amp Hold action 4 0 20 0 20mA current module 5 0 1V O 1V voltage module B24 Display symbol and description for ATFT amp A2FT 6 0 5V 0 5V voltage module i rud Syinbel Description 7 1 5V 1 5V voltage module 0 OFF Alarm output OFF as unit fails 8 0 10 0 10V voltage module 1 ON Alarm output ON as unit fails i 1 1 B19 Failure transfer mode for output 1 and output 2 select BPLS B25 Display symbol and deseriptiori for SELF bumpless transfer or 0 0 100 0 to continue output 1 and Parameter Display Description output 2 control function as the unit fails power starts or Value Symbol P manual mode starts 0 NONE Self tune function disabled 1 YES Self tune function enabled B20 Display symbol and description for OUT2 Parameter Displa v as B26 Display symbol and description for SLEP Value Symbol Description pay sy P Parameter Display 0 NONE Output 2 no function Value Symbol Description 1 COOL PID cooling control 0 NONE Sleep mode function disabled 3 DCPS DC power supp
140. ply these modes will 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 UM83001B 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 DG Figure 1 6 System Mode Priority Failure Mode Low Request Request Request Calibration Auto tuning Normal Mode Mode Control
141. portional Band ow 1 High 25596 100 Heating Cooling Dead Band mm Y DB db Negative Value Overlap Low 36 0 High 36 0 0 SP2 GPE Set point 2 See Table 1 5 1 8 1008 A s 500 0 C 0 PB2 Phe Proportional Band 2 Value Low 0 High 900 0 F dso P TI2 E g Integral Time 2 Value Low 0 High 1000 sec 100 TD2 LE dg Derivative Time 2 Value Low 0 High 360 0 sec 25 0 Output 1 ON OFF Control f na 55 6 C A O1HY B IHY Hysteresis Low 0 1 High 100 0 F 0 1 4 AiHY A IH Hysteresis Control of Alarm 1 Low 0 1 High ied T 0 1 4 A2HY AZHY Hysteresis Control of Alarm 2 Low 0 1 High ae T 0 1 PL1 PL Output 1 Power Limit Low 0 High 100 100 PL2 PL d Output 2 Power Limit Low 0 High 100 100 0 H I Basic Function Mode 4 FUNC F nL Function Complexity Level b 5 1 1 Ful L Full Function Mode 0 nant No communication function 1 WES RS 485 interface 2 e 3j e RS 232 interface 3 A1 4 20 mA analog retransmission 4 eu output Setup ro I us T Menu COMM Lonn Communication Interface 4 1 70 0 20 mA analog retransmission 1 Type d i output 5 g Ju 0 1V analog retransmission Output 6n 5 LI O 5V analog retransmission Output 7 l 5472 1 5V analog retransmission Output 8 M Ifl 0 10V analog retransmission d tet output PROT Prok COMM Protocol Selection or t Lj 7 Modbus protocol RTU mode 0 UM83001B 13 Table 1 4 Parameter Description continued 2 7 Contained
142. processor 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 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 Control 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 el
143. r 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 UM83001E 141 e e BrainChild Electronic Co Ltd 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 brainchild com tw
144. r 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 PV1L 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 PB1 O or PB2 O If PID2 or SPP2 is not selected for EIFN then PL1 exists if PB1 0 Exists if OUT2 selects COOL 124 UM83001E 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 UM83001E 125 Menu Existence Conditions Table continued 3 3 Menu Parameter Existence Conditions Notation A1FN 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 A2
145. rly used for single alarm output Correct the communication software to meet the protocol requirements 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 Communication error write a value which is out of range to a register Fail to perform auto tuning function Don t write a read only data or a protected data to the slave Don t write an over range data to the slave register 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 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 1 5V is selected Replace input 2 sensor Input 1 IN1 sensor break or input 1 current below 1 mA if 4 20 mA is selected or input 1 voltage below 0 25V if 1 5V is selected Replace input 1 sensor A to D converter or related component s malfunction UM83001B Return to factory for repair 105 Table 7 2 Common Failure Causes and Corr
146. rmocouple output with internal compensation Send a 0 00 C signal to the unit under calibration 102 UM83001B The unit under calibration is powered in a still air room with temperature 25 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 i 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 calibration is powered in a still air room with temperature 50 2c 3 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 if 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
147. roblems 28 detected in the to minimize the EEPROM and mapped system noise RAM 2 Return to factory for repair 29 EEPROM can t be Return to factory for written correctly repair Cold junction Return to factory for 32 compensation device s repair malfunction Hey switch Shorted 9 Return to factory for 33 related PCB circuit repair shorted 1 Check if the input 2 sensor used is accordant with IN2 type selection 34 Input 2 IN2 signal 2 Check the too low connection polarity of input 2 sensor 3 Replace input 2 sensor 1 Check if the input 2 sensor used is 35 Input 2 IN2 signal accordant with IN2 too high type selection 2 Replace input 2 sensor 1 Check if the input 1 sensor used is accordant with IN1 type selection 36 bra Input 1 IN1 signal 2 Check the too low connection polarity of input 1 sensor 3 Replace input 1 sensor 1 Check if the input 1 sensor used is coos Input 1 INT signal accordant with IN1 37 riri too high type selection 2 Replace input 1 sensor UM83001E Error Display Code Symbol Error Description Corrective Action 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 1 5V is selected Replace input 2 sensor 38 Input 1 IN1 sensor break or input 1 current below 1 mA if 4 20 mA is selected or input 1 voltage below 0 25V if 1
148. rogrammable 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 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 UM83001B 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 4 111 is about 1 second TD1 is a
149. rted Check and replace 8 Control abnormal or operation incorrect 9 Display blinks entered values change by themselves CPU or EEPROM non volatile memory defective Key switch defective Incorrect setup values Electromagnetic interference EMI or Radio Frequency interference RFI EEPROM defective Check and replace Read the setup procedure carefully Suppress arcing contacts in system to eliminate high voltage spike sources Separate sensor and controller wiring from dirty power lines ground heaters Replace EEPROM 106 UM83001B Chapter 8 Specifications Power 90 264 VAC 47 63 Hz 15VA 7W maximum 11 26 VAC VDC SELV Limited Energy 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 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
150. s 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 LE changed to 40 0 200 F l l H 28 PV l minutes l Alarm 1 ON Alarm 1 OFF l l l lt ___ 40 e l minutes l Time minutes UM83001B SPMD Choose nu nu Unit minute Or Hcc Unit hour Adjust Ha RAMP Figure 4 1 RAMP Function A1FN or A2FN Choose TIMER Adjust 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 otherwise an error code will produce t Error Code 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 Select HRR for SPMD IN1U selects PU DP1 select 2 DP Set RAMP 60 00 A2FN selects TIMR Set
151. s 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 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 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
152. s 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 UM83001B 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 Applicable Conditions 1 The system has been installed normally PB1 0 TI1 O0 if PB1 TH TD1 2 Use the default values for PID before tuning assigned The default values are PB1 PB2 18 0 F TI1 T12 100 sec TD1 TD2 25 0 sec Of course you can use other PB2 0 Tl2 0 if PB2 Tl2 TD2 reasonable values for PID before tuning according to your previous assigned experiences But don t use a zero value for PB1 and TI1 or PB2 and TI2 otherwise the auto tuning program will be disabled
153. sed 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 SP1401HY 2 SP1 om band O1HY SP1 O1HY 2 t gt OUT1 Action Time A M I1 LI LL Figure 3 3 Cool Only OFF ON OFF Control gt Time Refer to section 3 4 in which similar descriptions for heat only control can be applied to cool only control 44 UM83001B 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 Heat Cool A1FN A1MD A1HY Uses Uses OUT1 OUT2 O1HY OFST PB1 TH TDI CPB DB or jor Jor A2MD A2HY Control Modes NORM x NORM x NORM x NORM x NORM x X Don t care Ye Adjust to meet process Table 3 1 Heat Cool Control Setup requirements NOTE The ON OFF control may result excessive overshoot and undershoot problems in the process The P or
154. setup values Check and correct 3 Ei Z used P1 2 or P2 1is setup values of PVMD used for PVMD while jand SPMD PV1 or PV2 is used for Difference of PV1 and SPMD Dependent PV2 can t be used for values are used for PV PV while PV1 or PV2 and SV will produce is used for SV incorrect result of control Illegal setup values Check and correct 4 fi4 used COOL is used for setup values of OUT2 OUT2 but DIRT PB1 PB2 TI1 TI2 and cooling action is OUT1 IF OUT2 is already used for OUT1 required for cooling or PID mode is not control the control used for OUT1 that is should use PID mode PB1 or PB2 0 and PB 0 TI 0 and TH or TI2 0 OUT1 should use reverse mode heating action otherwise don t use OUT2 for cooling control Illegal setup values Check and correct used unequal IN1U setup values of IN1U and IN2U or unequal IN2U DP1 DP2 DP1 and DP2 while PVMD SPMD A1FN 5 z rg P1 2 or P2 1 is used for or A2FN Same unit M PVMD or PV1 or PV2 is and decimal point used for SPMD or should be used if both P1 2 H P1 2 L D1 2 H PV1 and PV2 are used or D1 2 L are used for for PV SV alarm1 or A1FN or A2FN alarm 2 Check and correct Illegal setup values setup values of OUT2 6 cme used OUT2 select and A2FN OUT will M AL2 but A2FN select not perform alarm NONE function if A2FN select NONE Check and correct Illegal setup values setup values of A1FN 3 p 54 used Dwell timer and A2FN Dwell timer
155. shown as follows Set SP1 150 0 TIME 30 0 Figure 5 5 Heat Control Example Timer ALM1 To achieve this function set the following parameters in the setup menu FUNC BASC Basic function IN1 K TC IN1U 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 UM83001B 5 4 Cool Only Control A BTC 8300 is used to control a refrigerator at temperature below 0 C To ON OFF control avoid the set point adjustment beyond the interesting range SP1Lis setat Direct Control Action 10 C and SP1H is set at 0 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 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 PB1 is set with zero and O1HY is set at 0 1 C Setup Summary FUNC BASC IN1 PT DN IN1U C DP1 1 DP OUT1 DIRT O1TY RELY SP1L 10 C SP1H 0 C Refrigerator User Menu PB1 0 C O1HY 0 1 C Mains Supply 50 Figure 5 6 Cooling Control Example UM83001B 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 th
156. ss 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 UM83001B 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 TOHminals used to switch the event input 7 Event input One of ten functions can be chosen by using EIFN contained in Event input setup menu NONE Event input no function If chosen the event input function is disabled The controller will use PB1 TI1 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 TI and TD2 will be used to replace 3 SPP PB1 TI1 and TD1 for control 4 RS A1 SPP2 If chosen
157. stance 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 MV PV PROCESS Fuzzy Rule Language information igi Fuzzy Inference n igi Digital D Fuzzifier dd I 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 4 Fuzzy Control has been proven to be an efficient method to improve the control stability as shown by the com
158. stics FILT 30 1 sec 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 UM83001B 4 11 Sleep Mode To Enter Sleep Mode FUNC selects FULL to provide full function SLEP selects YES to enable the sleep mode Press 4 v Jfor 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 La to leave the sleep mode 2 Disconnect the power lt 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 not required by your system the SLEP should select NONE to disable sleep mode against undesirable occurrence UM83001B 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 8300 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 spee
159. sure 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 UM83001B SP2F Format of SP2 Value ACTU SP2 is an actual value DEVI SP2 is a deviation value Apply Signal To 7 Event input Event input Setup EIFN choose SP2 or SPP2 Availability SPMD choose Loan aic 1 du Or n 7447 Or Hra Format of SP2 Value SP2F choose LE Actual Value or g E Deviation Value 69 4 3 Second PID Set In certain applications the process characteristics is strongly related to its process value The BTC 8300 provides two set of PID values When the process is changed to different set point the PID values can be switched to another set to achieve an optimum condition Auto tuning Second PID
160. the SP2 PB2 TI2 and TD2 will replace SP1 PB1 TI1 and 3 Reve TD1 for control 6 R AM 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 PB2 TI2 and TD2 9 D O12 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 para
161. ue 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 UM83001B 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 values in reverse direction When an optimal condition is obtained
162. ue of Special Sensor Low 19999 High 45536 Point 3 Signal Value of Special Sensor Low 19999 High 45536 Point 3 Indication Value of Special Sensor Low 19999 High 45536 Point 4 Signal Value of Special Sensor Low 19999 High 45536 Point 4 Indication Value of Special Sensor Low 19999 High 45536 Point 5 Signal Value of Special Sensor Low 19999 High 45536 Point 5 Indication Value of Special Sensor Low 19999 High 45536 Point 6 Signal Value of Special Sensor Low 19999 High 45536 Point 6 Indication Value of Special Sensor Low 19999 High 45536 Point 7 Signal Value of Special Sensor Low 19999 High 45536 Point 7 Indication Value of Special Sensor Low 19999 High 45536 Point 8 Signal Value of Special Sensor Low 19999 High 45536 E Point 8 Indication Value of Special Sensor Low 19999 High 45536 Point 9 Signal Value of Special Sensor Low 19999 High 45536 Point 9 Indication Value of Special Sensor Low 19999 High 45536 Signal Type of Special Sensor Low 0 High 3 Manufacturing Date of Product Low 0 High 3719 gt NO Oo Serial Number of Product Low 1 High 999 S These parameters are available only if IN1 selects SPEC UM83001E 127 Notation HOUR HRLO Parameter Display Format Hour HrLao Parameter Description Range Default Value Working Hour Value Fractional
163. unction 3 becomes H 83 and the exception code is equal to the value contained in the following table Exception Code Name Bad function code Function code is not supported by the controller 1 2 Illegal data address Register address out of range 3 Illegal data value Data value out of range or attempt to write a read only or protected data 9 3 Parameter Table UM83001E 111 Parameter Register Parameter Description B Default E Notation Address Value Unit SP1 Set point 1 2n h PV TIME Dwell Time 0 0 minute A1SP Alarm 1 Set point RD pa E1 A1DV Alarm 1 Deviation Value 360 3 aono 3b E1 A2SP Alarm 2 Set point B1 B1 E2 A2DV Alarm 2 Deviation Value E 3800 db E2 RAMP Ramp Rate 900 0 B E3 OFST Offset Value for P control 100 0 96 REFC ioe Constant for Specific 60 2 SHIF PV1 Shift offset Value 950 05 P ae00 F 00 PV1 PB1 Proportional Band 1 Value eras 8 sp PV TH Integral Time 1 Value 1000 100 Sec TD1 Derivative Time 1 Value Sec CPB Cooling Proportional Band Value of PB DB Heating Cooling Dead Band of PB SP2 Set point 2 PV PB2 Proportional Band 2 Value ts PV TI2 Integral Time 2 Value Sec TD2 Derivative Time 2 Value Sec O1HY Output 1 ON OFF Control Hysteresis PV A1HY Hysteresis Control of Alarm 1 E1 A2HY Hysteresis Control of Alarm 2 E2 PL1 Output 1 Power Limit 96 PL2 Output 2 Power Limit FUNC Functi
164. unt 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 7 0mm max 3 2mm dE c Figure 2 2 Lead Termination C 15 VA Figure 2 3 Rear Terminal Connection Diagram ALL RELAY CONTACTS RESISTIVE 2A 240VAC 22 UM83001B 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 0 90 264 VAC or o gt 11 26 VAC VDC Figure 2 4 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 UM83001B 23 2 5 Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a
165. ust 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 Figure 5 14 Dual PID Furnace Furnace Heater Heater Power Input Alarm 1 controls Event input a Process Value Use PID 1 rope E ANE EMEN WO E Figure 5 15 Dual PID Crossover PID Crossover Value Use PID 2 Time 94 UM83001B Example 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 3 Set the proper values for PB1 TI1 TD1 PB2 Tl2
166. ut 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 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 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 to count as soon as the process reaches its set point and triggers an alarm a
167. values of BAUD DATA PARI and STOP for BTC 8300 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 UM83001B 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 FUNC temperature He uses a BTC 8300 to control the temperature of the solution COMM under test A testing report containing the relation between the concentration and temperature is particularly interested PROT ADDR UC BAUD For a single unit application it is adequate to order a BTC 8300200000 2 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
168. watt 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 referred 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 109 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 Micro
169. wer 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 ce 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 10096 Figure 4 5 5096 Power Limit Function MV2 10096 80 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 UM83001B 4 8 Data Communication Two types of interface are available for Data Communication These are RS 485 Benefits RS 485 and RS 232 interface Since RS 485 uses a differential architecture to Long distance drive and sense signal instead of a single ended architecture which is used for Multi units 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 dista
170. y 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 UM83001B The advantages of VPFW SSR over conventional SSR are summarized as following table VPRWSSR Conventional SSR Proportional Timing Error 5008 E Pas Table 5 1 cycle time Function Comparison between Conventional SSR and VPFW SSR The output 1 and output 2 of BTC 8300 can be connected to VPFW SSR directly provided that a pulsed voltage drive output BTC 8300 XX2XXXX or BTC 8300 XXX2XXX is ordered Here is an example BTC 8300 XX22XXX PV D OUT1 REVR BBBB O1TY SSRD out ous At ama CYC1 1 0 sec Figure 5 4 4 v OUT2 COOL VPFW SSR Application Example O2TY SSRD CYC2 1 0 SEC 19 VPFW SSR AC Power Three phase VPFW SSR s are also available upon request UM83001B 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 8300 equipped with dwell timer is used for this purpose The system diagram is

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