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Brainchild PR Series User Manual

Process control card
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PR Series Process Control Card PC201 User Guide
UMPC201A
October 2016

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  • Page 1 PR Series Process Control Card PC201 User Guide UMPC201A October 2016...
  • Page 2 The documentation and the software included with this product are copyrighted 2016 By Brainchild Electronic Co. Ltd. All rights are reserved. Brainchild Electronic Co., Ltd. reserves the right to make improvements in the products described in this manual at any time without notice.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ----------------------------------------------------------------------------------------------------- 8 ----------------------------------------------------------------------------------------------------- 8 NTRODUCTION ----------------------------------------------------------------------------------------------------------- 8 EATURES ------------------------------------------------------------------------------------------ 9 ROCESS ONTROL 1.3.1 Flexible Configuration of Program ------------------------------------------------------------------ 11 Maximum Capacity of Program --------------------------------------------------------------------- 11 1.3.2 Event Input ----------------------------------------------------------------------------------------------- 11 1.3.3 Programmable Event Outputs ----------------------------------------------------------------------- 11 1.3.4 High Accuracy ------------------------------------------------------------------------------------------- 11 1.3.5...
  • Page 4 --------------------------------------------------------------------- 33 ROCESS ONTROL ONFIGURATION Process Control Card Configuration ---------------------------------------------------------------- 34 4.3.1 4.3.1.1 Controller --------------------------------------------------------------------------------------------------------- 35 4.3.1.1.1 Name ---------------------------------------------------------------------------------------------------------- 36 4.3.1.1.2 Parameter ---------------------------------------------------------------------------------------------------- 36 4.3.1.1.3 Channel ------------------------------------------------------------------------------------------------------- 72 4.3.1.1.4 Sample Configuration of Process Control Card ------------------------------------------------------ 76 4.3.1.1.4.1 Heat Only ON-OFF Control ------------------------------------------------------------------------- 76 4.3.1.1.4.2 Cool Only ON-OFF Control -------------------------------------------------------------------------- 78 4.3.1.1.4.3 Heat Cool Control ------------------------------------------------------------------------------------ 78 4.3.1.1.4.4 Heater Break Alarm ---------------------------------------------------------------------------------- 80...
  • Page 5 Table of Figures Figure 1-1.Fuzzy PID System Block Diagram ...................... 9 Figure 1-2.PID System Stability with and without Fuzzy ................... 10 Figure 2-1.Process Control Card Wiring Diagram ..................... 21 Figure 3-1.Configuration Layout ........................22 Figure 4-1.Home Screen ..........................23 Figure 4-2.Menu Screen ..........................24 Figure 4-3.Real Time Menu ..........................
  • Page 6 Figure 4-47.Latching/Holding Deviation Band Alarm ..................91 Figure 4-48.Ramp Function ..........................94 Figure 4-49.Dwell Timer ..........................95 Figure 4-50.Ramp Accompanied with Dwell Timer ..................96 Figure 4-51.Relationship Between PV1 & PV2 for Differential Control .............. 97 Figure 4-52.Power Limit Function ........................98 Figure 4-53.Filter Characteristics ........................
  • Page 7 Table of Tables Table 1-1. Input 1 Characteristics ........................15 Table 1-2. Input 2 Characteristics ........................16 Table 1-3. Output Characteristics ........................16 Table 1-4. SSR Output Characteristics ......................17 Table 2-1.Environmental Specification ......................19 Table 4-1.PID Parameter List .......................... 47 Table 4-2.Process Control Card Input Range ....................

  • Page 8: Introduction

    1 Introduction 1.1 Introduction Generally most of the furnace applications require Controller and Recorder separately to control and record the data. Some Furnaces application requires Ramp & Dwell controllers .The new generation Paperless Recorder provides PID Control, Ramp & Dwell Control and Recording in one device by using the new process control Card PC201 .

  • Page 9: Process Control Card

    100msec Sampling rate and log speed for Data Acquisition Real time and Historical Trends for PV and SV 1.3 Process Control Card The Process Control Card uses Fuzzy Logic plus PID microprocessor technology for its control. The Fuzzy Logic plus PID microprocessor based 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.

  • Page 10: Figure 1-2.Pid System Stability With And Without Fuzzy

    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.PID + Fuzzy Control has been proven to be an efficient method to improve the control stability as shown by the comparison of curves shown below.

  • Page 11: Flexible Configuration Of Program

    Flexible Configuration of Program 1.3.1 There are up to 32 segments can be defined for a profile. Each segment can be configured as a ramp or a dwell (soak) segment or defining a repeat number of cycles at arbitrary location within the profile and finally terminated by an end segment.

  • Page 12: Fuzzy Control

    Fuzzy Control 1.3.7 The function of Fuzzy control is to adjust PID parameters from time to time in order to make manipulation output value more flexible and adaptive to various processes. The results are to enable a process to reach a predetermined set point in the shortest time with the minimum of overshoot and undershoot during power-up or external load disturbance.

  • Page 13: Smart Mechanism

    1.5 Smart Mechanism The data is recorded in manufacturer special binary format. It is not possible to manipulate the data. This feature guarantees the security and reliability of the recorded data . 1.6 Process Control Card PC201 Ordering Code PC201- □ □ □...

  • Page 14: Specification

    1.7 Specification Input1 1.7.1 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;...

  • Page 15: Input2

    Type Range Accuracy @ 25°C Input Impedance 0°C to 1767.8°C( 32°F to 3214°F ) ±2°C 2.2 MΩ 0°C to 1767.8°C( 32°F to 3214°F ) ±2°C 2.2 MΩ -250°C to 1300°C( -418°F to 2372°F ) ±2°C 2.2 MΩ -200°C to 900°C( -328°F to 1652°F ) ±2°C 2.2 MΩ...

  • Page 16: Input3 (Event Input)

    Type Range Accuracy @ 25°C Input Impedance -3mA to 27mA ±0.05% 70.5Ω+(0.8V/Input Current) -1.3V to 11.5V ±0.05% 302KΩ Table 1-2. Input 2 Characteristics Input3 (Event Input) 1.7.3 Logic Low: -10V minimum, 0.8V maximum. Logic high: 2V minimum, 10V maximum External pull-down Resistance: 400 KΩ maximum External pull-up Resistance: 1.5 MΩ...

  • Page 17: Alarm 1/ Alarm 2

    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 MΩ minimum at 500 VDC Dielectric Strength: 2500 VAC for 1 minute Type Tolerance Maximum Output Current Ripple Voltage Isolation Barrier ±0.5 V...

  • Page 18: Digital Filter

    PID: Fuzzy logic modified Proportional band 0.1 ~ 900.0°F, Integral time: 0 - 1000 Seconds, Derivative time 0 - 360.0 seconds Cycle Time: 0.1 - 100.0 seconds Manual Control: Heat (MV1) and Cool (MV2) Auto-tuning: (MV2) 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...

  • Page 19: Installation And Wiring

    2 Installation and Wiring Some times Dangerous voltages capable of causing death are present in this instrument. Before doing installation or any troubleshooting procedures the power to the 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.

  • Page 20: Input Output Wiring Connection

    2.2 Input Output Wiring Connection Wiring Precautions 2.2.1 Sometimes Dangerous voltages capable of causing death are present in this instrument. Before doing installation or any troubleshooting procedures the power to the 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.

  • Page 21: Figure 2-1.Process Control Card Wiring Diagram

    Figure Figure 2-1.Process Control Card Wiring Diagram Note: The IO Mo The IO Modules should not be removed or Inserted to the device when the Power dules should not be removed or Inserted to the device when the Power is ON. This should be carried out in the Power OFF Condition only. is ON.

  • Page 22: Process Control Card Features

    3 Process Control Card Features This Chapter will explain the features of the Process Control Card. 3.1 Configuration The Process Control Card can be configured by using the tree type configuration layout of the Paperless Recorder easily. This is much useful for the user to configure all necessary configurations without missing any configuration.

  • Page 23: Process Control Card Functions

    4 Process Control Card Functions This Section will explain the functions of Process Control Card. The user can configure the device as per their requirement by using the user friendly configuration menu. The below is the home screen of paperless recorder. This screen will be displayed when the device powered on.

  • Page 24: Figure 4-2.Menu Screen

    Figure 4-2.Menu Screen Press Real time to access the real time trend display pages of the furnace controller. Press the Page no to view the respective display pages. Press Overview to view the digital display of all channels. Press C1 to view the PID Controller Module display. Figure 4-3.Real Time Menu Page 24 of 113...

  • Page 25: Figure 4-4.Overview Display

    Figure 4-4.Overview Display Figure 4-5.PID Controller Module Display Press Mode to access the menu for different display modes. The user can select the desired display mode to display as per their requirements like trend, Bar, Digit or Mix mode. Page 25 of 113...

  • Page 26: Figure 4-6.Display Modes

    Figure 4-6.Display Modes Press Alarm to view Real time Alarms and acknowledge using Ack key. Figure 4-7.Real Time Alarms Page 26 of 113...

  • Page 27: Figure 4-8.Historical Data Screen

    Press History to access the historical data of the individual pages and do the remarking. The user can write their own comments by using Handwriting function .This is explained in detail in the respective Chapter. Figure 4-8.Historical Data Screen Press Event to access the Historical Event and Reports from Internal and External memory.

  • Page 28: Figure 4-9.Event History

    Figure 4-9.Event History Press Key to Scroll Page Horizontally and Key to Scroll Page Vertically. Press Keys to page Up and Down. Press Key to switch between Reports and Events. In Report display press Mode to display the reports in Daily, Weekly, Monthly and List Modes.

  • Page 29: Figure 4-10.Report Screen

    Figure 4-10.Report Screen Press More to access more menus like dump, Clear, Operate, Config, Start/Pause, Shut down Menus. Figure 4-11.More Menu Page 29 of 113...

  • Page 30: Figure 4-12.Operate Menu

    Press Dump to Dump the data from Internal memory to External memory like SD Card or USB Disk. Press Clear to Clear all the data in Internal memory. Press Operate to Operate the desired job from the list. Figure 4-12.Operate Menu Press Config to access Tree type Configuration Lay out and perform configuration as per the desired application.

  • Page 31: Figure 4-13.Configuration Layout

    Figure 4-13.Configuration Layout Press Save to save the configuration to SD Card or USB Device. Press Load to load the configuration from SD Card or USB Disk. Press Default to load the default configuration from Internal memory. Press key to go to home page. Press Keys to move Up and Down to select the desired menu.

  • Page 32: Status Bar

    Figure 4-14.More Menu 4.2 Status Bar The Status bar will be shown on top of every page. This will show the status of the memory, Alarm, logging status with real time Date and Time of the System. Figure 4-15.Status Bar During Logging Figure 4-16.Status Bar During Logging Stopped Figure 4-17.Status Bar during Logging with Batch function Figure 4-18.Status Bar During Logging Stopped with Batch Function...

  • Page 33: Process Control Card Configuration

    4.3 Process Control Card Configuration This Section will explain the configuration for Process Control Card functions. Press (Menu) and then press More then press Config to Enter to Configuration Screen. A Tree type configuration will be displayed for the easy configuration. In addition to that Save Load, Default and Home Soft keys also available.

  • Page 34: Process Control Card Configuration

    Enter Key Up Key Down Key Home Key Various options are available to select the configuration Parameters. The user can move the cursor up and down using the soft key and press the Enter Soft key to Enter in to the highlighted parameter configuration The user can touch the desired parameter in the configuration tree and press Enter Soft key to Enter in to that parameter Configuration The user can double touch the desired parameter in the configuration tree to Enter...

  • Page 35: Controller

    Figure 4-20.Process Control Card Channel Configuration 4.3.1.1 Controller Press Controller and press Enter Key to Entering in to the Process Control Card controller configuration. Initially it displays C1 as the first controller configuration. Use the navigational keys to select the next Controller Channels .Use the key move to other Controller Channels.

  • Page 36: Name

    Figure 4-21.Process Control Card Channel Configuration 4.3.1.1.1 Name Enable the user to define the name for each channel with the maximum limit of 18 Characters. Select “Name”, then Press “Enter”, soft key, a keyboard with several keys appears. Press “Shift” to select special characters. Press “Caps” to select capital letters. Press soft key “OK” after entering a new channel name.

  • Page 37: Figure 4-22.Process Control Card Configuration Window

    Default allows the user to load the default configuration of the Process Control Card Parameters Figure 4-22.Process Control Card Configuration Window Figure 4-23.Process Control Card Configuration Window for Read only Parameter Page 37 of 113...
  • Page 38 The below table shows the list of parameters available in the Process Control Card for PID Control function. Parameter Default Unit Range Parameter Description Range High Notation Value 100.0° C Set point 1 SP1L SP1H (212.0°F) minut TIME Dwell Time 6553.5 100.0°...
  • Page 39 Parameter Default Unit Range Parameter Description Range High Notation Value Derivative Time 1 Value 360.0 25.0 Cooling Proportional % of Band Value Heating-Cooling Dead % of -36.0 36.0 Band 37.8°C Set point 2 (100.0°F Proportional Band 2 500.0°C 10.0°C Value (900.0°F) (18.0°F Integral Time 2 Value...
  • Page 40 Parameter Default Unit Range Parameter Description Range High Notation Value COMM Protocol PROT Selection Address Assignment of ADDR Digital COMM Baud Rate of Digital BAUD COMM Data Bit count of Digital DATA COMM Parity Bit of Digital PARI COMM Stop Bit Count of *B10 STOP Digital COMM...
  • Page 41 Parameter Default Unit Range Parameter Description Range High Notation Value IN2 Signal Type *B13 *B15 Selection IN2U IN2 Unit Selection *B13 *B13 IN2 Decimal Point *B14 *B14 Selection IN2L -19999 45536 IN2 Low Scale Value IN2H IN2 High Scale Value -19999 45536 1000...
  • Page 42 Parameter Default Unit Range Parameter Description Range High Notation Value Alarm 2 Operation A2MD *B23 *B23 Mode Alarm 2 Failure Transfer A2FT *B24 *B24 Mode Self Tune Function SELF *B25 *B25 Selection Sleep mode Function SLEP *B26 *B26 Selection PVMD PV Mode Selection *B27 *B27...
  • Page 43 Parameter Default Unit Range Parameter Description Range High Notation Value Voltage Input1 Gain -199.9 199.9 Calibration Coefficient Cold Junction Low Temperature Calibration CJTL -5.0°C 40.0°C °C Coefficient Cold Junction Gain -199.9 199.9 Calibration Coefficient Reference Voltage1 Calibration Coefficient for -199.9 199.9 REF1 RTD1...
  • Page 44 Parameter Default Unit Range Parameter Description Range High Notation Value Point 1 Indication Value IND1 -19999 45536 of Special Sensor Point 2 Signal Value of SIG2 -19999 45536 Special Sensor Point 2 Indication Value IND2 -19999 45536 of Special Sensor Point 3 Signal Value of SIG3 -19999...
  • Page 45 Parameter Default Unit Range Parameter Description Range High Notation Value Point 9 Signal Value of SIG9 -19999 45536 Special Sensor Point 9 Indication Value IND9 -19999 45536 of Special Sensor Signal Type of Special TYPE Sensor Manufacturing Date of 3719 DATE Product Serial Number of...
  • Page 46 Parameter Default Unit Range Parameter Description Range High Notation Value Current Process Value -19999 45536 Current set point Value -19999 45536 Current Output 1 Value 100.00 Current Output 2 Value 100.00 Contains Conditional Code of parameters Resolution *B33 *B33 EF7F and Current Alarm Status Current Deviation (PV- -12600...

  • Page 47: Table 4-1.Pid Parameter List

    Parameter Default Unit Range Parameter Description Range High Notation Value Cold Junction CJCT -40.0 ° C 90.0° C °C Compensation Temperature Current Process Rate -16383 16383 PV/min Value Maximum Process Rate PV/min PVRH -16383 16383 Value Minimum Process Rate PVRL -16383 16383 PV/min...

  • Page 48: Table 4-2.Process Control Card Input Range

    Input Type Range Low Rang High PT100_JS -210°C(-346°F) 600°C(1112°F) 0 Amps 90 Amps Linear (mA or Voltage) -19999 45536 Table 4-2.Process Control Card Input Range *B1: Range For A1SP & A2SP If A1FN= Range of A1SP same as range of PV1.H,PV1.L PV2.H,PV2.L P1.2 H,P1.2 L,D1.2 H ,D1.2 L IN1,IN2...

  • Page 49: Table 4-6.Mode Selection

    *B3: Display Symbol and Description of FUNC Parameter Value Display Symbol Description BASC Basic Function Mode FULL Full Function Mode Table 4-6.Mode Selection *B4: Display Symbol and Description For COMM Parameter Value Display Symbol Description NONE No Communication Function RS-485 Interface RS-232 Interface 4-20 4-20mA Analog Retransmission Output...

  • Page 50: Table 4-8.Communication Protocol

    Parameter Value Display Symbol Description DNET Devicenet Protocol PBUS Profibus Protocol FBUS Fieldbus Protocol ABUS Reserved BNET Reserved Table 4-8.Communication Protocol *B7: Display Symbol and Description For BAUD Parameter Value Display Symbol Description 0.3 Kbits/Second Baud Rate 0.6 Kbits/Second Baud Rate 1.2 Kbits/Second Baud Rate 2.4 Kbits/Second Baud Rate 4.8 Kbits/Second Baud Rate...

  • Page 51: Table 4-10.Communication Data Length

    *B8: Display Symbol and Description For DATA Parameter Value Display Symbol Description 7BIT 7 Data Bits 8BIT 8 Data Bits Table 4-10.Communication Data Length *B9: Display Symbol and Description For PARI Parameter Value Display Symbol Description EVEN Even Parity Odd Parity NONE No Parity Table 4-11.Communication Parity...

  • Page 52: Table 4-13 Function Of Aofn

    *B11: Display Symbol and Description For AOFN Parameter Value Display Symbol Description Retransmit IN1 Process Value Retransmit IN2 Process Value P1-2 Retransmit IN1-IN2 Difference Process Value P2-1 Retransmit IN2-IN1 Difference Process Value Retransmit Set Point Value Retransmit Output1 manipulation Value Retransmit Output2 manipulation Value Retransmit Deviation(PV-SV) Value Table 4-13 Function of AOFN...

  • Page 53: Table 4-14 Selection Of In1 Type

    Parameter Value Display Symbol Description PT.JS PT100 Ohms JIS Curve 4-20 4-20mA Linear Current Input 0-20 0-20mA Linear Current Input 0-1V 0-1V Linear Voltage Input 0-5V 0-5V Linear Voltage Input 1-5V 1-5V Linear Voltage Input 0-10 0-10V Linear Voltage Input SPEC Special defined sensor Curve Table 4-14 Selection of IN1 Type...

  • Page 54: Table 4-17.In2 Input

    *B15: Display Symbol and Description For IN2 Parameter Value Display Symbol Description NONE IN2 No Function Current Transformer Input 4-20 4-20mA Linear Current Input 0-20 0-20mA Linear Current Input 0-1V 0-1V Linear Voltage Input 0-5V 0-5V Linear Voltage Input 1-5V 1-5V Linear Voltage Input 0-10 0-10V Linear Voltage Input...

  • Page 55: Table 4-18.Eifn Function

    Parameter Value Display Symbol Description D.O1 Disable Output1 D.O2 Disable Output2 D.O1.2 Disable Output1 &Output 2 LOCK Lock All Parameters Table 4-18.EIFN Function *B17: Display Symbol and Description For OUT1 Parameter Value Display Symbol Description REVR Reverse(Heating)Control Action DIRT Direct(Cooling)Control Action Table 4-19.OUT1 Action *B18: Display Symbol and Description For O1TY &...

  • Page 56: Table 4-21.Out2 Function

    *B19: Failure transfer mode for output 1 and output 2, select BPLS ( bumpless transfer ) or 0.0 ~ 100.0 % to continue output 1 and output 2 control function as the unit fails , power starts or manual mode starts. *B20: Display Symbol and Description For OUT2 Parameter Value Display Symbol Description NONE...

  • Page 57: Table 4-23. Alarm1 & Alarm 2 Function

    Parameter Value Display Symbol Description DB.HI Deviation band out of band alarm DB.LO Deviation band in band alarm PV1.H IN1 process value high alarm PV1.L IN1 process value low alarm PV2.H IN2 process value high alarm PV2.L IN2 process value low alarm P1.2.H IN1 or IN2 process value high alarm P1.2.L...

  • Page 58: Table 4-25.Alarm1 & Alarm2 Failure Transfer Mode

    *B24: Display Symbol and Description For A1FT & A2 FT Parameter Value Display Symbol Description Alarm Output OFF as unit Fails Alarm Output ON as unit Fails Table 4-25.Alarm1 & Alarm2 Failure Transfer Mode *B25: Display Symbol and Description For SFLF Parameter Value Display Symbol Description NONE Auto tuning (Self Tune) Function disabled...

  • Page 59: Table 4-28.Pv Mode Selection

    Parameter Value Display Symbol Description P1-2 Use PV1-PV2 Difference as Process Value P2-1 Use PV2-PV1 Difference as Process Value Table 4-28.PV Mode Selection *B28: Display Symbol and Description For SP2F Parameter Value Display Symbol Description ACTU Setpoint2 (SP2)is an Actual Value DEVI Setpoint2 (SP2) is an Deviation Value Table 4-29.SP2 Set Point Format...

  • Page 60: Table 4-31 Set Point Mode Selection

    *B30: Display Symbol and Description For SPMD Parameter Value Display Symbol Description SP1.2 Use SP1 or SP2 (depends on EIFN) as set point MIN.R Use minute ramp rate as set point HR.R Use hour ramp rate as set point Use IN1 process value as set point Use IN2 process value as set point PUMP Selected for pump control...

  • Page 61: Table 4-32 Sel Selection

    Parameter Value Display Symbol Description Parameter TI1 put ahead Parameter TD1 put ahead C.PB Parameter CPB put ahead Parameter DB put ahead Parameter SP2 put ahead Parameter PB2 put ahead Parameter TI2 put ahead Parameter TD2 put ahead Table 4-32 SEL Selection *B32: Display Symbol and Description For FILE Parameter Value Display Symbol Description Perform Default Setting by using °C File...
  • Page 62 *B33: Description of Alarm Value Page 62 of 113...
  • Page 63 *B34: Error Messages Error Code Display Symbol Error Description Corrective Action Illegal setup values Check and correct setup used: PV1 is used for values of PVMD and Er 01 both PVMD and SPMD SPMD, PV and SV can't that is meaningless for use the same value for control.
  • Page 64 Error Code Display Symbol Error Description Corrective Action Check and correct setup Illegal setup values values of IN1U used: unequal IN1U and IN2U or unequal DP1 , IN2U, DP1, DP2, and DP2 while PVMD, SPMD, A1FN or A2FN. Same unit and P1-2 or P2-1 is used for Er 05 decimal point...
  • Page 65 Error Code Display Symbol Error Description Corrective Action Correct the communication software Er 10 to meet the protocol Communication error: requirements. bad function code Communication error: Don't issue an over- Er 11 register address out of range address of register range to the slave.
  • Page 66 Error Code Display Symbol Error Description Corrective Action 1. Correct the multi-chip Timing error: check-sum communication software error received during to meet the protocol Er 22 multi-chip requirement. communication 2. Return to factory for procedure repair. 1. Correct the multi-chip Timing error: wrong communication software function code received...
  • Page 67 Error Code Display Symbol Error Description Corrective Action 1.Check and correct the wiring and grounding Memory comparison problems to minimize error, different value CAPE the system noise. detected in the EEPROM and mapped 2.Return to factory for repair. EEPE EEPROM can't be Return to factory for written correctly repair.

  • Page 68: Table 4-34.Error Codes And Corrective Actions

    Error Code Display Symbol Error Description Corrective Action 1.Check if the input 1 sensor used is accordant with IN1 type selection. 2.Check the connection LLL1 polarity of input 1 sensor. Input 1 ( IN1 ) signal too 3.Replace input 1 sensor.

  • Page 69: Table 4-35 Prog Code

    *B35:PROG CODE Description Parameter Specified product Value 0.XX BTC-2500 controller 1.XX BTC-4300 controller 2.XX BTC-9500 controller 3.XX BTC-8300 controller 4.XX BTC-4300 controller & Process Control card of PR 5.XX BTC-7200 controller 6.XX BTC-9100 controller 7.XX SM-40A smart panel meter 8.XX Reserved 9.XX ST-30A smart transmitter...

  • Page 70: Table 4-36 Mode

    *B36: Display Symbol and Description of MODE Parameter Value Description Perform normal mode Enter calibration mode Enter auto-tuning mode Enter failure mode Enter manual mode Enter sleep mode Unlock condition SP1, SEL1 SEL5 are unlocked Lock all parameters except SP1 All parameters are locked Table 4-36 Mode The Parameters are preset with the default values specified in the table during production...

  • Page 71: Table 4-38.Unit Determination For A2Sp,A2Dv,A2Hy

    *E2: Unit determination for A2SP, A2DV and A2HY If A2FN= Range of A2SP same as range of DE.HI,DE.LO,DB.HI,DB.LO PV1.H,PV1.L PV2.H,PV.L P1.2.H,P1.2.L,D1.2.H,D1.2.L PV1,PV2 Table 4-38.Unit Determination for A2SP,A2DV,A2HY *E3: Unit determination for Ramp If SPMD= Unit MIN.R PV/Minute HR.R PV/Hour Table 4-39.RAMP Unit *E4: Unit determination for AOLO and AOHI If AOFN=...

  • Page 72: Channel

    4.3.1.1.3 Channel The Channel will allow the user to configure the logging parameters. Press Channel and then press Enter Soft key to access the Channel parameter of Process Control Card. Figure 4-24.Process Control Card Channel Configuration Name: Enable the user to define the name for each channel with the maximum limit of 18 Characters.
  • Page 73 Source: There are two options are available for source. They are as below The first channel will show PV and the second Channel will show SV in source. These two parameters can be logged in the recorder from the Process Control Card. By using the Key to switch between Channels.

  • Page 74: Figure 4-25.Log Speed

    Figure 4-25.Log Speed Modbus Scale: Scale for reading the Analog Input Values through Modbus Events Events are generally used to generate Alarms. The Events can also be used to process Digital Output, Timer, Counter, Totalizers and to generate report. There are maximum 5 Events can be added for Analog Inputs. Press Add to Add the Events.
  • Page 75 L: Low limit. Any the process is lower than low limit, the alarm or job is actuated. HH: High High limit, to set up another limit higher than high limit for double warning. LL: Low Low limit, to set up another limit lower than low limit for double warning. Dev+: Trigger an event on positive deviation of process value.

  • Page 76: Sample Configuration Of Process Control Card

    Hysteresis To avoid the event or alarm has been activated too often hysteresis value can be set for the alarm to change it in to normal state. Hysteresis value can be defined for the event trigger set point. Holding time: It refers to, suppose the set point is reached, but the user want to wait for some time to activate that action.

  • Page 77: Figure 4-28.Heat Only On-Off Control

    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. Figure 4-28.Heat Only ON-OFF Control The ON-OFF control may introduce excessive process oscillation even if Hysteresis is minimized to the smallest.

  • Page 78: Cool Only On-Off Control

    improve the control .This Process Control Card 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. 4.3.1.1.4.2 Cool Only ON-OFF Control ON-OFF control, P (PD) control and PID control can be used for cool control. Set OUT1 to DIRT (direct action).

  • Page 79: Table 4-41.Heat Cool Control Modes

    Table 4-41.Heat Cool Control Modes Note The ON-OFF control may result excessive overshoot and undershoot problems in the process. The P (or PD) control will result in a deviation process value from the set point. It is recommended to use PID control for the Heat-Cool control to produce a stable and zero offset process value.

  • Page 80: Heater Break Alarm

    Heat PID+Cool PID: set OUT1=REVR, OUT2=COOL, CPB=100, DB=-4.0, PB1=0, TI1=0, TD1=0, and set appropriate values for O1TY, CYC1, O2TY, and CYC2. 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.

  • Page 81: Loop Break Alarm

    4.3.1.1.4.5 Loop Break Alarm A1FN selects LB if alarm 1 is required to act as a loop break alarm. Similarly, if alarm 2 is required to act as a loop break alarm, then set OUT2 with=AL2 and A1FN with LB. TIME, A1SP, A1DV and A1HY are hidden if alarm 1 is configured as a loop break alarm.

  • Page 82: Failure Transfer

    4.3.1.1.4.7 Failure Transfer The controller will enter failure mode as one of the following conditions occurs. SB1E Error 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 PVMD or PV1 is selected for SPMD.

  • Page 83: Bumpless 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.Alarm 2 Failure Transfer is activated as the controller enters failure mode. 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.

  • Page 84: Pv1 Shift

    continues to control by using its previous value. If the load doesn't change, the process will remain stable. Thereafter, once the load changes, the process may run away. Therefore, the user 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.

  • Page 85: Sp1 Range

    Figure 4-33.PV1 SHIFT Application 4.3.1.1.4.10 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. 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.

  • Page 86: Process Alarms

    out. The timer relay will remain unchanged until time out. The dwell timer operation is shown as following diagram. Figure 4-35.Dwell Timer If alarm 1 is configured as dwell timer, A1SP, A1DV, A1HY and A1MD are hidden. Same case is for alarm 2. Example Set A1FN=TIMR or A2FN=TIMR but not both.

  • Page 87: Figure 4-36.Normal Process Alarm

    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: A1MD = LTCH If a latching alarm is selected, once the alarm output is energized, it will remain unchanged even if the alarm condition is cleared.

  • Page 88: Deviation Alarm

    Figure 4-38.Holding Process Alarm Figure 4-39.Latching / Holding Process Alarm Although the above descriptions are based on alarm 1, the same conditions can be applied to alarm 2. 4.3.1.1.4.13 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.

  • Page 89: Figure 4-40.Normal Deviation Alarm

    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.

  • Page 90: Deviation Band Alarm

    Figure 4-43.Latching/Holding Deviation Alarm 4.3.1.1.4.14 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).

  • Page 91: Event Input

    Figure 4-45.Latching Deviation Band Alarm Figure 4-46.Holding Deviation Band Alarm Figure 4-47.Latching/Holding Deviation Band Alarm 4.3.1.1.4.15 Event Input The Event input accepts a digital type signal. Three types of signals can be connected to event input. These are Relay or switch contacts Open collector pull low Page 91 of 113...
  • Page 92 TTL logic level One of ten available functions can be chosen by using (EIFN) contained in setup menu. NONE: Event input No function. If chosen, the event input function is disabled. The controller will use PB1, TI1 and TD1 for PID control and SP1 (or other values determined by SPMD) for the set point.

  • Page 93: Second Set Point

    When any of D.O1, D.O2 or D.O1.2 is selected for EIFN, the output 1 and/or output 2 will revert to their normal conditions as soon as the event input is released. LOCK: All parameters are locked to prevent from being changed. SP2F Function: Define format of SP2 value.

  • Page 94: Ramp & Dwell

    Application 1: Programmed by Set Point Choose SP.P2 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.

  • Page 95: Figure 4-49.Dwell Timer

    The timer is programmed by using TIME which is contained in Configuration menu. The Timer starts to count as soon as the process reaches its set point, and triggers an alarm as time out. Here is an example. Example without Dwell Timer 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°...

  • Page 96: Remote Set Point

    Figure 4-50.Ramp Accompanied with Dwell Timer 4.3.1.1.4.19 Remote Set Point SPMD selecting PV1 or PV2 will enable the Process Control Card 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.

  • Page 97: Differential Control

    IN2L, IN2H if available, are set according to the process signal SPMD= PV1 Note: If PV1 are chosen for both SPMD and PVMD, an Error Code will appear. If PV2 are chosen for both SPMD and PVMD, an Error Code will appear. The user should not use these cases, otherwise, the Process Control Card will not control properly.

  • Page 98: Output Power Limit

    4.3.1.1.4.21 Output Power Limit 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 the user can use the Power Limit function. Output 1 power limit PL1 is contained in Configuration. If output 2 is not used for cooling (that is COOL is not selected for OUT2), then PL2 is hidden.

  • Page 99: Auto-Tuning And Manual Tuning

    from 0 to 60 seconds. 0 second represents no filter is applied to the input signal. The filter is characterized by the following diagram. Figure 4-53.Filter Characteristics 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.

  • Page 100: Figure 4-54.Process Control Module Real Time

    Figure 4-54.Process Control Module Real time Figure 4-55.Auto-Tuning Page 100 of 113...

  • Page 101: Figure 4-56.Auto-Tuning In Progress

    Figure 4-56.Auto-Tuning In progress Figure 4-57.Manual Tuning In Progress Page 101 of 113...

  • Page 102: Ramp & Dwell(Profile)

    4.3.1.2 Ramp & Dwell(Profile) Press Profile and press Enter Key to Entering in to the Process Control Card Ramp & Dwell configuration. Initially it displays Profile1 for configuration. Use the navigational keys to Use the navigational keys to select the next Profile .Use the key move to other Profiles.

  • Page 103: Ramp & Dwell

    Name: Enable the user to define the name for each Profile with the maximum limit of 18 Characters. Select “Name”, then Press “Enter”, soft key, a keyboard with several keys appears. Press “Shift” to select special characters. Press “Caps” to select capital letters. Press soft key “OK”...

  • Page 104: Segments

    Go Back: Jump to a specified segment in the same profile End: Make this segment the end of the profile The below four kinds of combination are allowable for connecting segments. Ramp-Ramp Ramp-Dwell Dwell-Ramp Dwell-Dwell 4.3.1.2.2 Segments: The user can add or Insert or Remove the segments of the Profile in this section. Press Add and then press Enter Soft key to access the Segment Configuration window.

  • Page 105: Ramp Segment Parameters

    4.3.1.2.2.1 Ramp Segment Parameters: Figure 4-60.Ramp Segment Condition: The condition to be selected for Ramp Segment to follow to reach set point as Ramp and Set point or Ramp and Time. The Ramp and SetPoint willchange the set point to reach the Set point in that segment in the Ramp Rate specified.The Ramp and Time will change the Set point based on the ramp rate specified for the duration mentioned.
  • Page 106 the profile at its current state. The action of Holdback is the same as a deviation alarm. It can be enabled or disabled. Holdback has three parameters. Holdback wait time Holdback band Holdback type. If the error from the set point exceeds the set holdback band (Band), then if the holdback feature is enabled it will automatically freeze the profile at its current point.

  • Page 107: Figure 4-61.Hold Back On Dwell

    Figure 4-61.Hold Back on Dwell Figure 4-62.Hold Back on Positive Ramp Figure 4-63.Hold Back Negative Ramp Page 107 of 113...

  • Page 108: Dwell Segment Parameters

    4.3.1.2.2.2 Dwell Segment Parameters: Figure 4-64.Dwell Segment Duration: Duration of the segment for the Dwell can be set in Hour: Minute: Second. PID: The PID Values to be used for this Dwell is PID1 or PID2. 4.3.1.2.2.3 Go Back Segment Parameters: Figure 4-65.Go Back Segment This segment will jump to the specified in the segment mentioned on the Segment for the no of cycles mentioned in Cycle.

  • Page 109: Time To Target Segment Parameters

    4.3.1.2.2.5 Time to Target Segment Parameters: Figure 4-67.Time To Target Segment This is similar to ramp segment with automatic calculation of ramp rate by the Process Control Card with the reference of Set point and duration given by the user. Set Point: Set Point to be reached in this segment.

  • Page 110: Figure 4-69.Run Profile

    Figure 4-69.Run Profile Press Hold to holde the profile. Press Stop to stop the Profile. Figure 4-70.Profile Running The real time display page will show the Profile and Segment no along with the remaining time of that particular segment. Page 110 of 113...

  • Page 111: Display

    4.4 Display The Display menu allows the user to configure PV and SV in to display. Each Process Control Card have two parameters can be added to display page as per the user requirement. Refer Recorder user manual for the detailed explanation. Page 111 of 113...

  • Page 112: Application

    The temperature of the diferent zones are recorded to ensure the operation of different zones. Generally for this application one temperature controller and 6 channel recorder are required. By using PR Series Recorder with PID Control card it can be achieved with one device.

  • Page 113: Figure 5-2. Oven Control With Zone Temperature Recording System

    To achieve this function set the following parameters in the PID Control setup menu and configure the Recorder as per the recording requirements. 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 Figure 5-2. Oven Control with Zone Temperature Recording System Page 113 of 113...

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