Brainchild BTC-2500 User Manual
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Brainchild BTC-2500 User Manual

Self-tune fuzzy/pid process /temperature controller
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User's Manual
User's Manual
BTC-2500
BTC-2500
Self-Tune Fuzzy / PID
Self-Tune Fuzzy / PID
Process / Temperature Controller
Process / Temperature Controller
UM25001H

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Summary of Contents for Brainchild BTC-2500

  • Page 1 User's Manual User's Manual BTC-2500 BTC-2500 Self-Tune Fuzzy / PID Self-Tune Fuzzy / PID Process / Temperature Controller Process / Temperature Controller UM25001H...
  • Page 2 Warning Symbol Warning Symbol The Symbol calls attention to an operating procedure, practice, or the like, which, if not correctly performed or 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.

  • Page 3: Table Of Contents

    CONTENTS Page No Page No Page No Page No Chapter 1 Overview Chapter 1 Overview 1-1 Features 1-1 Features 3-21 Manual Tuning 3-21 Manual Tuning 1-2 Ordering Code 1-2 Ordering Code 3-22 Signal Conditioner DC Power Supply 3-22 Signal Conditioner DC Power Supply 1-3 Programming Port and DIP Switch 1-3 Programming Port and DIP Switch 3-23 Manual Control...

  • Page 4: Chapter 1 Overview

    BTC-2500 is powered by 11-26 or 90 - 264 VDC / AC supply, incorporating a 2 amp. BTC-2500 is powered by 11-26 or 90 - 264 VDC / AC supply, incorporating a 2 amp.
  • Page 5 Digital communications RS-485, RS-232 or 4 - 20 mA retransmission are available as an Digital communications RS-485, RS-232 or 4 - 20 mA retransmission are available as an additional option. These options allow BTC-2500 to be integrated with supervisory control additional option. These options allow BTC-2500 to be integrated with supervisory control...
  • Page 6 PID control with properly tuned PID + Fuzzy control Temperature Set point Figure 1.2 Fuzzy PID Figure 1.2 Fuzzy PID Enhances Control Enhances Control Stability Stability Load Disturbance Warm Up Time UM25001C...

  • Page 7: Ordering Code

    1 2 Ordering Code 1 2 Ordering Code BTC-2500- Power Input Power Input 4: 90 - 264 VAC, 47-63 HZ 4: 90 - 264 VAC, 47-63 HZ 5: 11 - 26 VAC or VDC, 5: 11 - 26 VAC or VDC,...

  • Page 8: Programming Port And Dip Switch

    1 3 Programming Port and DIP Switch 1 3 Programming Port and DIP Switch Access Hole Front Rear Panel Terminal Figure 1.3 Access Hole Figure 1.3 Access Hole Overview Overview The programming port is used to connect to SNA12A for automatic programming, also can be connected to ATE system for automatic testing &...

  • Page 9: Keys And Displays

    1 4 Keys and Displays 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. 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 Table 1.2 Keypad Operation TOUCHKEYS...
  • Page 10 Each display stays for 1.25 seconds Each display stays for 1.25 seconds The left diagram shows program The left diagram shows program no. 0 ( for BTC-2500 ) with version no. 0 ( for BTC-2500 ) with version Program Version Program Version Program No.

  • Page 11: Menu Overview

    1 5 Menu Overview 1 5 Menu Overview V Value User User Menu Menu SV Value SEL1 SEL2 SEL3 SEL4 SEL5 FUNC Setup Setup for 3 COMM seconds Menu Menu ADDR TIME BAUD DATA A1DV Hand (Manual) Hand (Manual) for 3 seconds A2DV AOFN Control...

  • Page 12: System Modes

    1 6 System Modes 1 6 System Modes System Modes System Modes The controller performs close loop control under its normal control mode condition. 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, The controller will maintain its normal control mode when you are operating user menu, Sleep Mode : Sleep Mode :...

  • Page 13: Parameter Description

    1 7 Parameter Description 1 7 Parameter Description Table 1.4 Parameter Description Table 1.4 Parameter Description Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value 100.0 C Set point 1 High: S 1L...
  • Page 14 Table 1.4 Parameter Description ( continued 2/7 ) Table 1.4 Parameter Description ( continued 2/7 ) Display Display Parameter Parameter Basic Basic Parameter Parameter Default Default Contained Contained Range Format Format Description Description Function Function Notation Notation Value Value High: ADDR Low: 0.3 Kbits/s baud rate...
  • Page 15 Table 1.4 Parameter Description ( continued 3/7 ) Table 1.4 Parameter Description ( continued 3/7 ) Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Range Format Format Description Description Function Function Notation Notation Value N type thermocouple L type thermocouple PT 100 ohms DIN curve PT 100 ohms JIS curve...
  • Page 16 Table 1.4 Parameter Description ( continued 4/7 ) Table 1.4 Parameter Description ( continued 4/7 ) Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value 0 - 20 mA current module 0 - 1V voltage module Output 1 Signal Type O1TY...
  • Page 17 Table 1.4 Parameter Description ( continued 5/7 ) Table 1.4 Parameter Description ( continued 5/7 ) Display Display Parameter Parameter Basic Basic Parameter Parameter Default Default Contained Contained Range Format Format Description Description Function Function Notation Notation Value Value Alarm output O as unit fails Alarm 1 Failure Transfer A1FT...
  • Page 18 Table 1.4 Parameter Description ( continued 6/7 ) Table 1.4 Parameter Description ( continued 6/7 ) Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value Use minute ramp rate as set point Use hour ramp rate as set point S MD Set point Mode Selection...
  • Page 19 Table 1.4 Parameter Description ( continued 7/7 ) Table 1.4 Parameter Description ( continued 7/7 ) Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value Cold Junction Gain Low: -199.9 199.9...
  • Page 20 J_TC K_TC T_TC E_TC B_TC R_TC Input Type S_TC -120 C -200 C -250 C -100 C Range Low (-184 F) (-328 F) (-418 F) (-148 F) (32 F) (32 F) (32 F) 1000 C 1370 C 400 C 900 C 1820 C 1767.8 C 1767.8 C...

  • Page 21: Chapter 2 Installation

    Chapter 2 Installation Chapter 2 Installation Dangerous voltages capable of causing death are sometimes present Dangerous voltages capable of causing death are sometimes present in this instrument. Before installation or beginning any troubleshooting in this instrument. Before installation or beginning any troubleshooting procedures the power to all equipment must be switched off and isolated.

  • Page 22: Wiring Precautions

    2 3 Wiring Precautions 2 3 Wiring Precautions Before wiring, verify the label for correct model number and options. Switch Before wiring, verify the label for correct model number and options. Switch off the power while checking. off the power while checking. Care must be taken to ensure that maximum voltage rating specified on the Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded.

  • Page 23: Power Wiring

    2 4 Power Wiring 2 4 Power Wiring The controller is supplied to operate at 11-26 VAC / VDC or 90-264VAC.Check 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 that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller.

  • Page 24: Sensor Installation Guidelines

    2 5 Sensor Installation Guidelines 2 5 Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a control system. The Proper sensor installation can eliminate many problems in a control system. The probe should be placed so that it can detect any temperature change with probe should be placed so that it can detect any temperature change with minimal thermal lag.

  • Page 25: Thermocouple Input Wiring

    2 6 Thermocouple Input Wiring 2 6 Thermocouple Input Wiring Thermocouple input connections are shown in Figure 2.5. The correct type of Thermocouple input connections are shown in Figure 2.5. The correct type of thermocouple extension lead-wire or compensating cable must be used for the entire thermocouple extension lead-wire or compensating cable must be used for the entire distance between the controller and the thermocouple, ensuring that the correct distance between the controller and the thermocouple, ensuring that the correct...

  • Page 26: Rtd Input Wiring

    2 7 RTD Input Wiring 2 7 RTD Input Wiring RTD connection are shown in Figure 2.6, with the compensating lead connected to RTD connection are shown in Figure 2.6, with the compensating lead connected to terminal 9. For two-wire RTD inputs, terminals 9 and 10 should be linked. The terminal 9.
  • Page 27 1 2 3 4 5 Figure 2.8 Figure 2.8 Input 1 Linear Current Wiring Input 1 Linear Current Wiring 8 9 10 11 12 13 14 DIP Switch DIP Switch 0~20mA or 0~20mA or 4~20mA 4~20mA 1 2 3 4 5 Figure 2.9 Figure 2.9 Input 2 Linear Voltage Wiring...

  • Page 28: Ct / Heater Current Input Wiring

    2 9 CT / Heater Current Input Wiring 2 9 CT / Heater Current Input Wiring Heater 1 Heater 1 Heater 2 Heater 2 Heater 3 Heater 3 Contactor Heater Supply Heater Supply Current Transformer Current Transformer T94 1 Fuse Fuse Mains Mains...

  • Page 29: Event Input Wiring

    2 10 Event Input wiring 2 10 Event Input wiring 1 2 3 4 5 1 2 3 4 5 Figure 2.13 Figure 2.13 Event Input Wiring Event Input Wiring 8 9 10 11 12 13 14 8 9 10 11 12 13 14 Switch Input Switch Input...

  • Page 30: Output 1 Wiring

    2 11 Output 1 Wiring 2 11 Output 1 Wiring Max. 2A Max. 2A Resistive Resistive Load 120V/240V 120V/240V Mains Supply Mains Supply 1 2 3 4 5 8 9 10 11 12 13 14 Relay Output Direct Drive Relay Output Direct Drive Figure 2.14 Figure 2.14 Output 1 Wiring...
  • Page 31 0 - 20mA, 0 - 20mA, Load 4 - 20mA 4 - 20mA 1 2 3 4 5 8 9 10 11 12 13 14 Linear Current Linear Current Maximum Load 500 ohms Maximum Load 500 ohms 0 - 1V, 0 - 5V 0 - 1V, 0 - 5V Load 1 - 5V, 0 - 10V...

  • Page 32: Output 2 Wiring

    2 12 Output 2 Wiring 2 12 Output 2 Wiring Max. 2A Max. 2A Resistive Resistive Load 120V/240V 120V/240V Mains Supply Mains Supply 1 2 3 4 5 8 9 10 11 12 13 14 Figure 2.15 Figure 2.15 Relay Output Direct Drive Relay Output Direct Drive Output 2 Wiring Output 2 Wiring...
  • Page 33 0 - 20mA, 0 - 20mA, Load 4 - 20mA 4 - 20mA 1 2 3 4 5 8 9 10 11 12 13 14 Linear Current Linear Current Maximum Load 500 ohms Maximum Load 500 ohms 0 - 1V, 0 - 5V 0 - 1V, 0 - 5V Load 1 - 5V, 0 - 10V...

  • Page 34: Alarm 1 Wiring

    2 13 Alarm 1 Wiring 2 13 Alarm 1 Wiring 5V DC 5V DC Max. 2A Max. 2A Relay Relay Resistive Resistive Load 120V/240V 120V/240V Mains Supply Mains Supply 1 2 3 4 5 Figure 2.16 Figure 2.16 Alarm 1 Wiring Alarm 1 Wiring 8 9 10 11 12 13 14...

  • Page 35: Alarm 2 Wiring

    2 14 Alarm 2 Wiring 2 14 Alarm 2 Wiring Max. 2A Max. 2A Resistive Resistive Load 120V/240V 120V/240V Mains Supply Mains Supply 1 2 3 4 5 Figure 2.17 Figure 2.17 Relay Output Direct Drive Relay Output Direct Drive Alarm 2 Wiring Alarm 2 Wiring 8 9 10 11...

  • Page 36: Rs-485

    2 15 RS-485 2 15 RS-485 Figure 2.18 Figure 2.18 RS-485 Wiring RS-485 Wiring RS-485 to RS-232 RS-485 to RS-232 1 2 3 4 5 network adaptor network adaptor SNA10A or SNA10A or 8 9 10 11 12 13 14 SNA10B SNA10B RS-232...
  • Page 37 RS-232 port CC94-1 Note: If the BTC-2500 is configured for RS-232 communication, the input 2 If the BTC-2500 is configured for RS-232 communication, the input 2 and EI ( Event Input ) are disconnected internally. The unit can no longer and EI ( Event Input ) are disconnected internally.

  • Page 38: Analog Retransmission

    2 17 Analog Retransmission 2 17 Analog Retransmission 1 2 3 4 5 The total effective resistance of serial The total effective resistance of serial loads can't exceed 500 ohms. loads can't exceed 500 ohms. 8 9 10 11 12 13 14 Load Load Indicators...

  • Page 39: Programming Port

    2 18 Programming Port 2 18 Programming Port See Figure 1.3 in Section 1-3 to find the programming port location. See Figure 1.3 in Section 1-3 to find the programming port location. Programmer Programmer connector and connector and ATE connector ATE connector Programmer Programmer...

  • Page 40: Chapter 3 Programming The Basic Function

    Chapter 3 Programming the Basic Function Chapter 3 Programming the Basic Function If you don't need: If you don't need: This unit provides an useful parameter " FUNC " which can be used to select This unit provides an useful parameter " FUNC " which can be used to select the function complexity level before setup.

  • Page 41: Out1 & Out2 Types

    IN1L IN1L : Selects the low scale value for the Linear type input 1. IN1L : Selects the low scale value for the Linear type input 1. Hidden if : Hidden if : T/C or RTD type is selected for IN1. T/C or RTD type is selected for IN1.

  • Page 42: Rearrange User Menu

    " sorry " to you. The BTC-2500 has the flexibility for you to select those will say " sorry " to you. The BTC-2500 has the flexibility for you to select those...

  • Page 43: Heat Only Control

    . See section unsatisfactory, then use manual tuning to improve the control . See section tuning tuning 3-21 for manual tuning. BTC-2500 contains a 3-21 for manual tuning. BTC-2500 contains a very clever PID and Fuzzy very clever PID and Fuzzy...

  • Page 44: Cool Only Control

    3 6 Cool Only Control 3 6 Cool Only Control Setup Cool Control : Setup Cool Control : ON-OFF control, P ( PD ) control and PID control can be used for cool control. ON-OFF control, P ( PD ) control and PID control can be used for cool control. OUT1 = OUT1 = Set OUT1 to DIRT ( direct action ).

  • Page 45: Heat - Cool Control

    3 7 Heat-Cool Control 3 7 Heat-Cool Control The Heat-Cool Control can use one of The Heat-Cool Control can use one of combinations of control modes. Setup of parameters for each control combinations of control modes. Setup of parameters for each control mode are shown in the following table.
  • Page 46 CPB Programming : The cooling proportional band is measured by % of PB with range 1~255. Initially set 100% for 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.

  • Page 47: Dwell Timer

    3 8 Dwell Timer 3 8 Dwell Timer Alarm 1 or alarm 2 can be configured as dwell timer by selecting TIMR for Alarm 1 or alarm 2 can be configured as dwell timer by selecting TIMR for A1FN or A2FN, but not both, otherwise A1FN or A2FN, but not both, otherwise Er07 Er07...

  • Page 48: Process Alarms

    3 9 Process Alarms 3 9 Process Alarms There are at most two independent alarms available by adjusting OUT2. If There are at most two independent alarms available by adjusting OUT2. If =AL2 is selected for OUT2, then OUT2 will perform alarm 2 function. Now =AL2 is selected for OUT2, then OUT2 will perform alarm 2 function.
  • Page 49 ( 3-9 2'nd page ) ( 3-9 2'nd page ) A1SP = 200 A1SP = 200 A1HY = 10.0 A1HY = 10.0 A1MD = LTCH A1MD = LTCH A1FN = PV1.H A1FN = PV1.H Process proceeds Process proceeds Figure 3.6 Figure 3.6 Latching Process Alarm Latching Process Alarm...

  • Page 50: Deviation Alarms

    3 10 Deviation Alarm 3 10 Deviation Alarm OUT2 can be configured as alarm 2 by selecting=AL2. If OUT2 selects=AL2, OUT2 can be configured as alarm 2 by selecting=AL2. If OUT2 selects=AL2, Error Code Error Code then output 2 will perform alarm 2 function. Now A2FN can't be selected with then output 2 will perform alarm 2 function.

  • Page 51: Deviation Band Alarms

    3 11 Deviation Band Alarm 3 11 Deviation Band Alarm A deviation band alarm presets two reference levels relative to set point. Two A deviation band alarm presets two reference levels relative to set point. Two 2 Types of Deviation Band Alarms: 2 Types of Deviation Band Alarms: types of deviation band alarm can be configured for alarm 1 and alarm 2.

  • Page 52: Heater Break Alarm

    3 12 Heater Break Alarm 3 12 Heater Break Alarm Heater Break Alarm 1 Heater Break Alarm 1 A current transformer ( parts No. A current transformer ( parts No. CT94-1 CT94-1 ) should be installed to detect the ) should be installed to detect the Setup : IN2 = CT Setup : IN2 = CT heater current if a heater break alarm is required.

  • Page 53: Loop Break Alarm

    3 13 Loop Break Alarm 3 13 Loop Break Alarm A1FN selects LB if alarm 1 is required to act as a loop break alarm. Similarly, if A1FN selects LB if alarm 1 is required to act as a loop break alarm. Similarly, if Loop Break Alarm 1 Loop Break Alarm 1 Setup : A1FN = LB...

  • Page 54: Sensor Break Alarm

    3 14 Sensor Break Alarm 3 14 Sensor Break Alarm Alarm 1 or alarm 2 can be configured as sensor break alarm by selecting SENB Alarm 1 or alarm 2 can be configured as sensor break alarm by selecting SENB Sensor Break Alarm 1 Sensor Break Alarm 1 for A1FN or A2FN.

  • Page 55: Pv1 Shift

    3 16 PV1 Shift 3 16 PV1 Shift In certain applications it is desirable to shift the controller display value from 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 its actual value.

  • Page 56: Failure Transfer

    3 17 Failure Transfer 3 17 Failure Transfer Failure Mode Occurs as : Failure Mode Occurs as : The controller will enter The controller will enter failure mode failure mode as one of the following conditions occurs: as one of the following conditions occurs: 1.

  • Page 57: Bumpless Transfer

    3 18 Bumpless Transfer 3 18 Bumpless Transfer The bumpless transfer function is available for output 1 and output 2 ( provided The bumpless transfer function is available for output 1 and output 2 ( provided Bumpless Transfer Setup : Bumpless Transfer Setup : that OUT2 is configured as COOL ).
  • Page 58 3 19 Self 3 19 Self tuning tuning The Self-tuning which is designed by using an The Self-tuning which is designed by using an innovative algorithm innovative algorithm provides an provides an Self-tune Menu Self-tune Menu alternative option for tuning the controller. It is activated as soon as SELF is alternative option for tuning the controller.
  • Page 59 3 20 Auto 3 20 Auto tuning tuning The auto-tuning process is performed at set point. The auto-tuning process is performed at set point. The process will oscillate around the set point during tuning process. The process will oscillate around the set point during tuning process. Set a set point to a lower value if overshooting beyond the normal Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage.
  • Page 60 Auto-tuning Auto-tuning Auto-tuning Auto-tuning Begins Begins Complete Complete Waiting Waiting Warm-up Warm-up Cycle Cycle Learning Cycle Learning Cycle New PID Cycle New PID Cycle Cycle Cycle =2 Integral =2 Integral Time Time Figure 3.22 Figure 3.22 Set Point Set Point Auto-tuning Procedure Auto-tuning Procedure Pre-tune Stage...

  • Page 61: Manual Tuning

    3 21 Manual Tuning 3 21 Manual Tuning In certain applications ( very few ) using both self-tuning and auto-tuning to 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 tune a process may be inadequate for the control requirement, then you can try manual tuning.
  • Page 62 The PBu is called the The PBu is called the Ultimate P Band Ultimate P Band and the period of oscillation Tu is called and the period of oscillation Tu is called Ultimate Period Ultimate Period in the flow chart of Figure 3.23 . When this occurs, the in the flow chart of Figure 3.23 .
  • Page 63 I action I action TI too high TI too high Figure 3.25 (Continued ) Figure 3.25 (Continued ) Set point Set point Effects of PID Adjustment Effects of PID Adjustment Perfect TI too low TI too low Time D action D action TD too low TD too low...

  • Page 64: Signal Conditioner Dc Power Supply

    3 22 Signal Conditioner DC Power Supply 3 22 Signal Conditioner DC Power Supply Three types of isolated DC power supply are available to supply an external transmitter or Three types of isolated DC power supply are available to supply an external transmitter or sensor.

  • Page 65: Manual Control

    3 23 Manual Control 3 23 Manual Control The manual control may be used for the following The manual control may be used for the following purposes purposes ( 1 ) To test the process characteristics to obtain a step response as well as an ( 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.

  • Page 66: Display Mode

    3 24 Display Mode 3 24 Display Mode Operation Press Press several times until several times until ( Display ) appears on the display. ( Display ) appears on the display. Then press Then press to enter the display mode. You can select more parameters to to enter the display mode.

  • Page 67: Heater Current Monitoring

    3 25 Heater Current Monitoring 3 25 Heater Current Monitoring Accessory Installed: Accessory Installed: A current transformer, CT94-1, should be equipped to measure the heater A current transformer, CT94-1, should be equipped to measure the heater CT94-1 CT94-1 current. Select CT for IN2. The input 2 signal conditioner measures the heater current.

  • Page 68: Chapter 4 Programming The Full Function

    Chapter 4 Programming the Full Function Chapter 4 Programming the Full Function 4 1 Event Input 4 1 Event Input Refer to Section 2-10 for wiring an event input. Refer to Section 2-10 for wiring an event input. The Event input accepts a digital type signal. The Event input accepts a digital type signal.

  • Page 69: Second Set Point

    Because of limitation of pin number, pin 11 is used for both Event input and RS-232. If you want to change function of BTC-2500 from RS-232 to event RS-232. If you want to change function of BTC-2500 from RS-232 to event...

  • Page 70: Second Pid Set

    In certain applications the process characteristics is strongly related to its In certain applications the process characteristics is strongly related to its process value. The BTC-2500 provides two set of PID values. When the process value. The BTC-2500 provides two set of PID values. When the...

  • Page 71: Ramp & Dwell

    4 4 Ramp & Dwell 4 4 Ramp & Dwell Ramp The ramping function is performed during power up as well as any time the set The ramping function is performed during power up as well as any time the set SPMD Choose SPMD Choose point is changed.
  • Page 72 Once the timer output was energized it will remain unchanged until power Once the timer output was energized it will remain unchanged until power down or an event input programmed for resetting alarm is applied. down or an event input programmed for resetting alarm is applied. Error Code.

  • Page 73: Remote Set Point

    4 5 Remote Set Point Setup SPMD selecting PV1 or PV2 will enable the BTC-2500 to accept a remote set SPMD selecting PV1 or PV2 will enable the BTC-2500 to accept a remote set point signal. If PV1 is selected for SPMD, the remote set point signal is sent to point signal.

  • Page 74: Differential Control

    4 6 Differential Control 4 6 Differential Control In certain applications it is desirable to control a second process such that its In certain applications it is desirable to control a second process such that its Setup process value always deviates from the first process with a constant value. To process value always deviates from the first process with a constant value.

  • Page 75: Output Power Limits

    4 7 Output Power Limits 4 7 Output Power Limits In certain system the heater ( or cooler ) is over-designed such that the In certain system the heater ( or cooler ) is over-designed such that the Menu process is too heavily heated or cooled. To avoid an excessive overshoot process is too heavily heated or cooled.

  • Page 76: Data Communication

    STOP=Stop Bit Count STOP=Stop Bit Count NOTE: If the BTC-2500 is configured for RS-232 communication, the EI ( Event NOTE: If the BTC-2500 is configured for RS-232 communication, the EI ( Event Input ) and input 2 are disconnected internally. The unit can no longer perform Input ) and input 2 are disconnected internally.

  • Page 77: Analog Retransmission

    4 9 Analog Retransmission Setup Menu Setup Menu The Analog Retransmission is available for model number BTC-2500-XXXXXN The Analog Retransmission is available for model number BTC-2500-XXXXXN Where N 3,4 or 5. See Ordering Code in Where N 3,4 or 5. See Ordering Code in section 1-2.

  • Page 78: Digital Filter

    In certain application the process value is too unstable to be read. To improve this a programmable low pass filter incorporated in the BTC-2500 can be used. this a programmable low pass filter incorporated in the BTC-2500 can be used.

  • Page 79: Sleep Mode

    4 11 Sleep Mode 4 11 Sleep Mode Enter Enter Sleep Mode: Sleep Mode: Sleep Mode Features: Sleep Mode Features: FUNC selects FULL to provide full function. FUNC selects FULL to provide full function. Shut off display Shut off display SLEP selects YES to enable the sleep mode.

  • Page 80: Pump Control

    4 12 Pump Control 4 12 Pump Control Pump Control function is one of the unique features of BTC-2500. Using this Pump Control function is one of the unique features of BTC-2500. Using this PUMP: A Cost Effective PUMP: A Cost Effective function the pressure in a process can be controlled excellently.

  • Page 81: Remote Lockout

    Programming Guide: Programming Guide: 1. Perform auto-tuning to the system under such condition that the material 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 ( ie.

  • Page 82: Chapter 5 Applications

    ... etc. Taking the chemical plant, electrical plant, semiconductor plant ... etc. Taking the advantage of PUMP function, the BTC-2500 can be used for these advantage of PUMP function, the BTC-2500 can be used for these...
  • Page 83 Set the following parameters in the setup menu: Set the following parameters in the setup menu: FUNC=FULL FUNC=FULL COMM: optional COMM: optional IN1=4-20 IN1=4-20 IN1U=PU IN1U=PU DP1=2-DP DP1=2-DP IN1L=0 IN1L=0 IN1H=20.00 IN1H=20.00 IN2=NONE IN2=NONE OUT1=REVR OUT1=REVR O1TY=4-20 O1TY=4-20 O1FT=0 O1FT=0 OUT2=DCPS OUT2=DCPS A1FN: optional...

  • Page 84: Variable Period Full Wave Ssr ( Vpfw Ssr )

    5 2 Variable Period Full Wave SSR ( VPFW SSR ) 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 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 cross output with superior controllability compared to a conventional SSR with a fixed time base.
  • Page 85 Shorter Shorter The output 1 and output 2 of BTC-2500 can be connected to VPFW SSR The output 1 and output 2 of BTC-2500 can be connected to VPFW SSR directly provided that a pulsed voltage drive output ( BTC-2500-XX2XXX or directly provided that a pulsed voltage drive output ( BTC-2500-XX2XXX or BTC-2500-XXX2XX ) is ordered.

  • Page 86: Heat Only Control

    5 3 Heat Only Control 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-2500 equipped with dwell timer dwell timer used for this purpose. The system diagram is shown as follows : SP1=150.0...

  • Page 87: Cool Only Control

    5 4 Cool Only Control ON-OFF control ON-OFF control A BTC-2500 is used to control a refrigerator at temperature below 0 C. To A BTC-2500 is used to control a refrigerator at temperature below 0 C. To Direct Control Action...

  • Page 88: Heat - Cool Control

    5 5 Heat-Cool Control 5 5 Heat-Cool Control An injection mold required to be controlled at 120 C to ensure a consistent 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 quality for the parts.
  • Page 89 The PID Heat-Cool is used for the above example. The PID Heat-Cool is used for the above example. Key Menu Key Menu To achieve this set the following parameters in the Setup Menu: To achieve this set the following parameters in the Setup Menu: FUNC FUNC FUNC=BASC...

  • Page 90: Ramp & Dwell

    5 6 Ramp & Dwell 5 6 Ramp & Dwell Example 1: Temperature cycling Chamber Example 1: Temperature cycling Chamber A chamber is used to test the temperature cycling effect on the personal A chamber is used to test the temperature cycling effect on the personal computers.
  • Page 91 5 minutes 5 minutes BTC-2500 provides 4-20 mA signal to control the speed of the Inverter.SP .P2 BTC-2500 provides 4-20 mA signal to control the speed of the Inverter.SP .P2 being chosen for EIFN is for the purpose of accomplishing a dual PID control.

  • Page 92: Remote Set Point

    If you order a BTC-2500 with a retransmission unit for the master controller, If you order a BTC-2500 with a retransmission unit for the master controller,...

  • Page 93: Differential Control

    5 8 Differential Control 5 8 Differential Control In certain applications it is desirable to control a second process such that its 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. process value always deviates from the first process with a constant value.

  • Page 94: Dual Set Point / Pid

    5 9 Dual Set Point / PID 5 9 Dual Set Point / PID The BTC-2500 will switch between the two PID sets based on the process The BTC-2500 will switch between the two PID sets based on the process value, the set point or either of the event input.
  • Page 95 Example 2: Dual Set Point / PID Example 2: Dual Set Point / PID A heat treating furnace is required to harden the mold at a high temperature ( 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 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 ).
  • Page 96 5 production lines. Each production line is equipped making plant has 5 production lines. Each production line is equipped with 16 units of BTC-2500 to control the temperature for the with 16 units of BTC-2500 to control the temperature for the...
  • Page 97 485 for COMM, RTU for PROT and select an unequal address ( ADDR ) for each COMM COMM unit. Use the same values of BAUD, DATA, PARI and STOP for BTC-2500's, unit. Use the same values of BAUD, DATA, PARI and STOP for BTC-2500's, PROT PROT SNA10B and BC-Net.
  • Page 98 FUNC FUNC He uses a BTC-2500 to control the temperature of the solution under test. A He uses a BTC-2500 to control the temperature of the solution under test. A COMM...

  • Page 99: Retransmit

    5 12 Retransmit 5 12 Retransmit An air-conditioned room uses two units of BTC-2500 to control its temperature An air-conditioned room uses two units of BTC-2500 to control its temperature and humidity. The temperature and humidity are required to be recorded on a and humidity.

  • Page 100: Chapter 6 Calibration

    Chapter 6 Calibration Chapter 6 Calibration Do not proceed through this section unless there is a definite need to Do not proceed through this section unless there is a definite need to re-calibrate the controller. Otherwise, all previous calibration data will be re-calibrate the controller.
  • Page 101 RTD input RTD input and 10 according to the connection shown below: and 10 according to the connection shown below: 100 ohms BTC-2500 Figure 6.1 Figure 6.1 RTD Calibration RTD Calibration Press scroll key for at least 3 seconds . The display will blink a Press scroll key for at least 3 seconds .
  • Page 102 Note that a K type TC input TC input thermocouple must be used. thermocouple must be used. 5520A 5520A Calibrator Calibrator BTC-2500 Figure 6.2 Figure 6.2 K-TC Cold Junction Cold Junction Calibration Setup Calibration Setup Stay at least...
  • Page 103 The programming port ( See The programming port ( See Section 2-18 Section 2-18 ) of BTC-2500 can be used for ) of BTC-2500 can be used for automatic calibration. automatic calibration. The equipments required for automatic calibration are available upon request.

  • Page 104: Chapter 7 Error Codes & Troubleshooting

    Chapter 7 Error Codes & Troubleshooting Chapter 7 Error Codes & Troubleshooting This procedure requires access to the circuitry of a live power unit. Dangerous accidental contact with line voltage This procedure requires access to the circuitry of a live power unit. Dangerous accidental contact with line voltage is possible.
  • Page 105 Table 7.1 Error Codes and Corrective Actions Table 7.1 Error Codes and Corrective Actions Display Error Error Description Corrective Action Symbol Code Illegal setup values been used: V1 is used for both VMD Check and correct setup values of VMD and S MD. V and S MD.
  • Page 106 Table 7.2 Common Failure Causes and Corrective Actions Table 7.2 Common Failure Causes and Corrective Actions Symptom robable Causes Corrective Actions - Clean contact area on CB -Bad connection between CB & keypads 1) Keypad no function - Replace keypads - No power to instrument - Check power line connections 2) LED's will not light...

  • Page 107: Chapter 8 Specifications

    Chapter 8 Specifications Chapter 8 Specifications Power Input 2 Input 2 90 264 VAC, 47 63 Hz, 15VA, 7W maximum 90 264 VAC, 47 63 Hz, 15VA, 7W maximum Resolution : Resolution : 18 bits 18 bits 11 26 VAC / VDC, 11 26 VAC / VDC, SELV, Limited Energy SELV, Limited Energy...
  • Page 108 Linear Output Linear Output Resolution : Resolution : 15 bits 15 bits Resolution : Resolution : 15 bits 15 bits Accuracy : Accuracy : 0.05 % of span 0.05 % of span 0.0025 %/ C 0.0025 %/ C Output Regulation : Output Regulation : 0.01 % for full load change 0.01 % for full load change...
  • Page 109 Environmental & Physical Environmental & Physical Operating Temperature : Operating Temperature : -10 C to 50 C -10 C to 50 C Storage Temperature : Storage Temperature : -40 C to 60 C -40 C to 60 C Humidity : Humidity : 0 to 90 % RH ( non-condensing ) 0 to 90 % RH ( non-condensing )

  • Page 110: Chapter 9 Modbus Communications

    Chapter 9 Modbus Communications 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).
  • Page 111 9 2 Exception Responses 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.
  • Page 112 Range Scale Register arameter Data Default arameter Description Unit Address Notation Type High Value 100.0 C Set point 1 S 1L S 1H -19999 (212.0 F) 6553.5 TIME Dwell Time minute 100.0 C Alarm 1 Set point -19999 45536 (212.0 F) -200.0 C 200.0 C 10.0 C...
  • Page 113 Range Scale arameter Register Data Default arameter Description Unit Notation Address Type High Value High S 1L -19999 45536 -19999 45536 S 1 Low Scale Value (32.0 F) 1000.0 C -19999 45536 -19999 45536 S 1H S 1 High Scale Value (1832.0 F) *B15 *B15...
  • Page 114 Range Scale arameter Register Data Default arameter Description Unit Notation Address Type High Value Cold Junction Low Temperature CJTL -5.00 40.00 -19999 45536 Calibration Coefficient Cold Junction Gain Calibration -199.9 199.9 -19999 45536 Coefficient Reference Voltage 1 Calibration -199.9 199.9 -19999 45536 REF1...
  • Page 115 Range Scale arameter Register Data Default arameter Description Unit Notation Address Type High High Value Historical Maximum Value of V -19999 45536 -19999 45536 Historical Minimum Value of V -19999 45536 -19999 45536 Sense Voltage of Cold Junction CJCL 31.680 40.320 65535 Calibration Low...
  • Page 116 Notes: *B5, Display symbol and description for PROT *A: R/W Specifies a readable / writable data, R specifies a read only Display Parameter Symbol data. Description Value *A1: The communication setup data which can't be modified via Modbus protocol RTU mode communication.
  • Page 117 *B15, Display symbol and description for IN2 *B12, Display symbol and description for IN1 Display Display Parameter Parameter Description Description Symbol Symbol Value Value J_TC J type thermocouple NONE IN2 no function K_TC K type thermocouple Current transformer input T_TC T type thermocouple 0 - 1V 0 - 1V linear voltage input...
  • Page 118 *B18, Display symbol and description for O1TY & O2TY *B23, Display symbol and description for A1MD & A2MD Parameter Display Display Parameter Description Description Value Symbol Symbol Value RELY Relay output NORM Normal alarm action SSRD Solid state relay drive output LTCH Latching alarm action Solid state relay output...
  • Page 119 *B30, Display symbol and description for SPMD *B33, Description of ALM Value Display Parameter Description Symbol Value ALM LOW BYTE SP1.2 MIN.R Use minute ramp rate as set point HR.R Use hour ramp rate as set point =ALMK = 00 : No alarm Use IN1 process value as set point activated = 01 : Alarm 1...
  • Page 120 *B34, Error messages Display Display Error Error Error Description Error Description Corrective Action Corrective Action Symbol Symbol Code Code Check and correct Illegal setup values 1.Correct the used: V1 is used for setup values of VMD communication both VMD and S MD and S MD, V and SV software to meet the can't use the same...
  • Page 121 *B35, PROG code description 1.Check and correct Parameter Specified product the wiring and Memory comparison Value grounding problems error, different value BTC-2500 controller 0.XX to minimize the detected in the system noise. EE ROM and mapped BTC-9300 controller 1.XX 2.Return to factory for repair.
  • Page 122 *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.
  • Page 123 9 4 Communication Examples 9 4 Communication Examples Example 1: Preset 9 multiple registers Example 1: Preset 9 multiple registers Starting Addr. Starting Addr. Bytes No. of words No. of words SP1=100.0 TIME=0.0 A1SP=100.0 Addr. Func. A1DV=10.0 A2SP=100.0 A2DV=10.0 RAMP=0.0 OFST=25.0 REFC=2 CRC16 Example 2: Read PV, SV, MV1 and MV2.

  • Page 124: Menu Existence Conditions

    A 1 Menu Existence Coditions A 1 Menu Existence Coditions Menu Existence Conditions Table Menu Existence Conditions Table Parameter Parameter Menu Existence Conditions Existence Conditions Notation Notation Exists unconditionally Exists unconditionally TIME Exists if A1FN selects TIMR or A2FN selects TIMR Exists if A1FN selects TIMR or A2FN selects TIMR A1SP Exists if A1FN selects PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H or D12L...
  • Page 125 Menu Existence Conditions Table ( continued 2/3 ) Menu Existence Conditions Table ( continued 2/3 ) Parameter Parameter Menu Existence Conditions Existence Conditions Notation Notation FUNC Exists unconditionally Exists unconditionally Exists if FUNC selects FULL Exists if FUNC selects FULL COMM PROT ADDR...
  • Page 126 Menu Existence Conditions Table ( continued 3/3 ) Menu Existence Conditions Table ( continued 3/3 ) Parameter Parameter Menu Existence Conditions Existence Conditions Notation Notation A1FN Exists unconditionally Exists unconditionally Exists if A1FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, Exists if A1FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, A1MD D12H, D12L, LB or SENB...

  • Page 127: Factory Menu Description

    A 2 Factory Menu Description A 2 Factory Menu Description Parameter Parameter Display Display Default Default Parameter Description Parameter Description Range Notation Notation Format Format Value Value High: Low: EROR Current Error Code rogram Identification Code Contains rogram High: Low: 15.99 Number and Version Number Contains Lockout Status Code and Current System...
  • Page 128 Parameter Parameter Display Display Default Default Parameter Description Parameter Description Range Notation Notation Format Format Value Value Working Hour Value High: 65535 Hours HOUR Low: High: Fractional Hour Value Low: 0.9 Hour HRLO Historical Error Record 1 Low: FFFF High: ERR1 High: Low:...

  • Page 129: Glossary

    A 3 Glossary A 3 Glossary Abosolute zero: The lowest theoretical temperature. At Abosolute zero: The lowest theoretical temperature. At Automatic reset (Integral): The integral function of a Automatic reset (Integral): The integral function of a absolute zero, a body would have no molecular motion absolute zero, a body would have no molecular motion control that automatically compensates for the control that automatically compensates for the...
  • Page 130 CE: A mark that designates compliance with European CE: A mark that designates compliance with European Dead band: 1. For chart recorders: the minimum change Dead band: 1. For chart recorders: the minimum change Union (EU) requirements for products sold in Europe. Union (EU) requirements for products sold in Europe.
  • Page 131 Electromagnetic Compatibility (EMC): A system meets Electromagnetic Compatibility (EMC): A system meets fpm: Flow velocity in feet per minute. fpm: Flow velocity in feet per minute. three requirements: 1. It does not cause interference three requirements: 1. It does not cause interference fps: Flow velocity in feet per second.
  • Page 132 Hi-Pot test : To apply a high voltage to an electrical Hi-Pot test : To apply a high voltage to an electrical Kilo: The prefix for one thousand (K). Kilo: The prefix for one thousand (K). conductor to test the surrounding insulation. conductor to test the surrounding insulation.
  • Page 133 NEMA 4X: A front panel rating designating the control as NEMA 4X: A front panel rating designating the control as Proportional control mode: When process temperature Proportional control mode: When process temperature washdown capable and corrosion resistance. washdown capable and corrosion resistance. approaches set point and enters the proportional band, approaches set point and enters the proportional band, the output is switched on and off at the established...
  • Page 134 RFI: Radio frequency interference. RFI: Radio frequency interference. Surge current: A current of short duration occurring when Surge current: A current of short duration occurring when power is initially applied to capacitive or resistive loads, power is initially applied to capacitive or resistive loads, RS232 or RS485 output signal: A serial interface suitable RS232 or RS485 output signal: A serial interface suitable usually lasting no more than several cycles.
  • Page 135 TTL: Transistor-to-transistor logic. A form of solid state TTL: Transistor-to-transistor logic. A form of solid state logic which uses only transistors to form the logic logic which uses only transistors to form the logic gates. gates. UL: Underwriters Laboratories, Inc. An independent UL: Underwriters Laboratories, Inc.

  • Page 136: Index

    A 4 Index A 4 Index A1DV: 11, 13, 18, 47, 48, 50, 51, 53 A1DV: 11, 13, 18, 47, 48, 50, 51, 53 Auto-tuning: 11, 12, 43, 45, 46, 58 Auto-tuning: 11, 12, 43, 45, 46, 58 CT: 4, 20, 22, 28, 40, 52, 67, 102 CT: 4, 20, 22, 28, 40, 52, 67, 102 54, 110 54, 110...
  • Page 137 FILT: 11, 17, 40, 78, 80, 81, 83, 108 FILT: 11, 17, 40, 78, 80, 81, 83, 108 Linear current: 15, 26, 27, 31, 33, 41 Linear current: 15, 26, 27, 31, 33, 41 OUT2: 11, 16, 22, 41, 45, 48, 50, OUT2: 11, 16, 22, 41, 45, 48, 50, 51, 53, 54, 56, 57, 64, 65, 75, 51, 53, 54, 56, 57, 64, 65, 75,...
  • Page 138 PVHI: 9, 11, 19, 66 PVHI: 9, 11, 19, 66 Second PID: 40, 68, 69, 70, 94, 95 Second PID: 40, 68, 69, 70, 94, 95 SP2: 11, 13, 17, 18, 20, 40, 42, 48, SP2: 11, 13, 17, 18, 20, 40, 42, 48, 68, 69, 72, 74, 80, 81, 83, 90, 91, 68, 69, 72, 74, 80, 81, 83, 90, 91, PV1: 11, 13, 17, 19, 20, 40, 41, 45,...

  • Page 139: Memo

    A 5 Memo A 5 Memo Use the following Table as a master copy for your settings. Use the following Table as a master copy for your settings. Contained Contained Parameter Parameter Display Display Contained Contained Parameter Parameter Display Display Your setting Your setting Your setting...
  • Page 140 Contained Contained Parameter Parameter Display Display Contained Contained Parameter Parameter Display Display Your setting Your setting Your setting Your setting Notation Notation Format Format Notation Notation Format Format OUT2 O2TY CYC2 O2FT CJTL Calibra- tion A1FN Mode Menu A1MD REF1 A1FT A2FN MA1G...
  • Page 141 A 6 Warranty WARRANTY Brainchild Electronic Co. is pleased to offer suggestions on the use of its various products. However, Brainchild makes no 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.
  • Page 142 Electronic Co., Ltd. Electronic Co., Ltd. No.209, Chung Yang Rd., Nan Kang Dist., Taipei, Taiwan, R.O.C. No.209, Chung Yang Rd., Nan Kang Dist., Taipei, Taiwan, R.O.C. Tel: 886-2-27861299 Tel: 886-2-27861299 Fax: 886-2-27861395 Fax: 886-2-27861395 web site: http://www.brainchild.com.tw web site: http://www.brainchild.com.tw...

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