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Brainchild BTC-9300 User Manual

Self-tune fuzzy / pid process / temperature controller
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User's Manual
BTC-9300
Self-Tune Fuzzy / PID
Process / Temperature Controller
UM93001H

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  • Page 1 User's Manual BTC-9300 Self-Tune Fuzzy / PID Process / Temperature Controller UM93001H...

  • Page 2: Warning Symbol

    Warning Symbol 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.

  • Page 3: Table Of Contents

    CONTENTS Page No Page No Chapter 1 Overview 1-1 Features 3-21 Signal Conditioner DC Power Supply 1-2 Ordering Code 3-22 Manual Control 1-3 Programming Port and DIP Switch 3-23 Display Mode 1-4 Keys and Displays 3-24 Heater Current Monitoring 1-5 Menu Overview 3-25 Reload Default Values 1-6 System Modes Chapter 4 Programming the Full Function...

  • Page 4: Chapter 1 Overview

    SEL1 to SEL5 contained in the setup menu. This is particularly useful to OEM's as it is easy to configure menu to suit the specific application. BTC-9300 is powered by 11-26 VAC/VDC or 90 - 264 V AC supply, incorporating a 2 amp. control relay output and dual 2 amp. alarm relays output as standard whereby second alarm can be exceptionally configured into second output for cooling purpose or dwell timer.
  • Page 5 Digital communications RS-485, RS-232 or 4 - 20 mA retransmission are available as an additional option. These options allow BTC-9300 to be integrated with supervisory control system and software, or alternatively drive remote display, chart recorders or data- loggers. Three kinds of method can be used to program BTC-9300.
  • Page 6 PID control with properly tuned PID + Fuzzy control Temperature Set point Figure 1.2 Fuzzy PID Enhances Control Stability Load Disturbance Warm Up Time UM93001H...

  • Page 7: Ordering Code

    1 2 Ordering Code BTC-9300- Standard leave blank Power Input Special Order AA-ZZ 4:90-264VAC,47-63HZ 5:11-26VACorVDC, SELV, Limited Energy Communications 0:None 1:RS-485 Signal Input 2:RS-232 1:StandardInput 3:Retransmit4-20mA/0-20mA Input 1 - Universal Input 4:Retransmit1-5V/0-5V Thermocouple: J, K, T, E, B, 5:Retransmit0-10V R, S, N, L...

  • Page 8: Programming Port And Dip Switch

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

  • Page 9: Keys And Displays

    Output 1 output value etc. Indicator 3 Silicone Rubber Buttons BTC-9300 for ease of control setup and set point adjustment. 45536 will be displayed by: Figure 1.4 Front Panel Description Table 1.3 Display Form of Characters...

  • Page 10: Program Code

    2 seconds. BTC-9300 Program Code Display program code of the product for 2.5 seconds. The left diagram shows program no. 1 ( for BTC-9300 ) with version Program Version Program No. BTC-9300 Display Date Code and Serial number for 2.5 seconds.

  • Page 11: Menu Overview

    1 5 Menu Overview User PV Value Menu SV Value SEL1 SEL2 SEL3 SEL4 SEL5 for 3 Setup seconds Menu FUNC TIME COMM A1SP PROT A1DV ADDR A2SP BAUD A2DV Hand (Manual) DATA RAMP for 3 seconds PARI OFST Control STOP REFC Mode...

  • Page 12: System Modes

    1 6 System Modes 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 Sleep Mode : menu, setup menu or display mode, reloading default values or applying event input See Section 4-11.

  • Page 13: Parameter Description

    1 7 Parameter Description Table 1.4 Parameter Description Display Parameter Basic Parameter Default Contained Range Format Description Function Notation Value 100.0 LC Set point 1 SP1L High: SP1H Low: (212.0 LF) TIME High: 6553.5 minutes Dwell Time Low: 100.0 LC Alarm 1 Set point See Table 1.5, 1.6 A1SP...
  • Page 14 Table 1.4 Parameter Description ( continued 2/7 ) Display Parameter Contained Basic Parameter Default Range Format Description Function Notation Value Address Assignment of Digital High: ADDR Low: 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 Baud Rate of Digital COMM...
  • Page 15 Table 1.4 Parameter Description ( continued 3/7 ) Display Parameter Default Contained Basic Parameter Range Value Format Description Function Notation 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 )
  • Page 16 Table 1.4 Parameter Description ( continued 4/7 ) Display Parameter Contained Basic Parameter Default Range Format Description Function Notation Value 0 - 20 mA current module 0 - 1V voltage module 0 - 5V voltage module Output 1 Signal Type O1TY 1 - 5V voltage module 0 - 10V voltage module...
  • Page 17 Table 1.4 Parameter Description ( continued 5/7 ) Display Parameter Basic Parameter Default Contained Range Format Description Function Notation Value Alarm output OFF as unit fails Alarm 1 Failure Transfer A1FT Mode Alarm output ON as unit fails Alarm 2 Function A2FN Same as A1FN Same as A1MD...
  • Page 18 Table 1.4 Parameter Description ( continued 6/7 ) Display Parameter Contained Basic Parameter Default Range Format Description Function Notation Value Use SP1 or SP2 (depends on EIFN) as set point Use minute ramp rate as set point Use hour ramp rate as set point SPMD Set point Mode Selection Use IN1 process value as set point...
  • Page 19 Table 1.4 Parameter Description ( continued 7/7 ) Display Parameter Basic Parameter Default Contained Range Format Description Function Notation Value Cold Junction Gain Low: -199.9 199.9 High: Calibration Coefficient Reference Voltage 1 High: -199.9 199.9 REF1 Calibration Coefficient for Low: RTD 1 Calibration Serial Resistance 1...
  • Page 20 Input Type J_TC K_TC T_TC E_TC B_TC R_TC S_TC -120 LC -200 LC -250 LC -100 LC 0 LC 0 LC 0 LC Range Low (-184 LF) (-328 LF) (-418 LF) (-148 LF) (32 LF) (32 LF) (32 LF) 1000 LC 1370 LC 400 LC 900 LC...

  • Page 21: Chapter 2 Installation

    Chapter 2 Installation 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.

  • Page 22: Wiring Precautions

    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. It is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible.

  • Page 23: Power Wiring

    2 4 Power Wiring The controller is supplied to operate at 11-26 VAC / VDC or 90-264VAC.Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller. Fuse 264 VAC or 26 VAC / VDC Figure 2.4 Power Supply Connections...

  • Page 24: Sensor Installation Guidelines

    2 5 Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a control system. The probe should be placed so that it can detect any temperature change with minimal thermal lag. In a process that requires fairly constant heat output, the probe should be placed closed to the heater.

  • Page 25: Thermocouple Input Wiring

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

  • Page 26: Rtd Input Wiring

    2 7 RTD Input Wiring RTD connection are shown in Figure 2.6, with the compensating lead connected to terminal 12. For two-wire RTD inputs, terminals 12 and 13 should be linked. The three-wire RTD offers the capability of lead resistance compensation provided that the three leads should be of same gauge and equal length.
  • Page 27 Figure 2.8 Input 1 Linear Current Wiring DIP Switch 0~20mA or 4~20mA Figure 2.9 Input 2 Linear Voltage Wiring 0~1V, 0~5V 1~5V, 0~10V Figure 2.10 Input 2 Linear Current Wiring 0~20mA or 4~20mA UM93001H...

  • Page 28: Ct / Heater Current Input Wiring

    2 9 CT / Heater Current Input Wiring Heater 1 Heater 2 Heater 3 Contactor Heater Supply Current Transformer CT94 1 Fuse Mains supply DIN Rail Figure 2.11 CT Input Wiring for Single Phase Heater CT Signal Input Contactor Three Phase Heater Power Fuse Mains...

  • Page 29: Event Input Wiring

    2 10 Event Input wiring Figure 2.13 Event Input Wiring Switch Input Open Collector 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 signal ) is pulled down.

  • Page 30: Output 1 Wiring

    2 11 Output 1 Wiring Max. 2A Resistive Load 120V/240V Mains Supply Relay Output Direct Drive Figure 2.14 Output 1 Wiring 120V /240V Mains Supply Three Phase Heater Power Relay or Triac (SSR) No Fuse Three Phase Output to Drive Breaker Delta Contactor...
  • Page 31 0 - 20mA, Load 4 - 20mA Linear Current Maximum Load 500 ohms 0 - 1V, 0 - 5V Load 1 - 5V, 0 - 10V Minimum Load 10 K ohms Linear Voltage Max. 1A / 240V Load 120V /240V Mains Supply Triac Triac (SSR) Output...

  • Page 32: Output 2 Wiring

    2 12 Output 2 Wiring Max. 2A Resistive Load 120V/240V Mains Supply Figure 2.15 Relay Output Direct Drive Output 2 Wiring 120V /240V Mains Supply Three Phase Heater Power No Fuse Three Phase Relay or Triac (SSR) Breaker Delta Contactor Output to Drive Heater Contactor...
  • Page 33 0 - 20mA, Load 4 - 20mA Linear Current Maximum Load 500 ohms 0 - 1V, 0 - 5V Load 1 - 5V, 0 - 10V Minimum Load 10 K ohms Linear Voltage Max. 1A / 240V Load 120V /240V Mains Supply Triac Triac (SSR) Output...

  • Page 34: Alarm 1 Wiring

    2 13 Alarm 1 Wiring Max. 2A Resistive Load 120V/240V Mains Supply Figure 2.16 Relay Output Direct Drive Alarm 1 Wiring 120V /240V Mains Supply Three Phase Heater Power No Fuse Three Phase Breaker Delta Contactor Heater Load Relay Output to Drive Contactor Note: Both Form A and B contacts are available for alarm 1 relay.

  • Page 35: Alarm 2 Wiring

    2 14 Alarm 2 Wiring Max. 2A Resistive Load 120V/240V Mains Supply Relay Output Direct Drive Figure 2.17 Alarm 2 Wiring 120V /240V Mains Supply Three Phase Heater Power No Fuse Three Phase Breaker Delta Contactor Heater Load Relay Output to Drive Contactor UM93001H...

  • Page 36: Rs-485

    2 15 RS-485 Figure 2.18 RS-485 Wiring RS-485 to RS-232 network adaptor SNA10A or SNA10B RS-232 RS-485 Twisted-Pair Wire Max. 247 units can be linked Terminator 220 ohms / 0.5W UM93001H...
  • Page 37 RS-232 port CC94-1 Note: If the BTC-9300 is configured for RS-232 communication, the EI ( Event Input ) is disconnected internally. The unit can no longer perform event input function (EIFN). When you insert a RS-232 module (CM94-2) to the connectors on CPU board...

  • Page 38: Analog Retransmission

    2 17 Analog Retransmission The total effective resistance of serial loads can't exceed 500 ohms. Load Load Indicators PLC's Figure 2.22 Analog Recorders 0 - 20mA, Load Retransmission Wiring Data loggers 4 - 20mA Inverters etc. Retransmit Current The total effective resistance of parallel loads should be greater than 10K Ohms.

  • Page 39: Programming Port

    2 18 Programming Port See Figure 1.3 in Section 1-3 to find the programming port location. Programmer connector and ATE connector Programmer inserted here P10A Access hole I N P T 1 Figure 2.23 Programming on the bottom view Port Wiring Switch Unit SW6400 HP 34401A...

  • Page 40: Chapter 3 Programming The Basic Function

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

  • Page 41: Out1 & Out2 Types

    IN1L IN1L : Selects the low scale value for the Linear type input 1. Hidden if : T/C or RTD type is selected for IN1. IN1H : Selects the high scale value for the Linear type input 1. IN1H Hidden if : T/C or RTD type is selected for IN1.

  • Page 42: Rearrange User Menu

    " sorry " to you. The BTC-9300 has the flexibility for you to select those parameters which are most significant to you and put these parameters in the SEL2 front of display sequence.

  • Page 43: Heat Only Control

    Used for new process. during initial unsatisfactory, then use manual tuning to improve the control . See Section tuning 3-20 for manual tuning. BTC-9300 contains a very clever PID and Fuzzy Self-tuning: algorithm to achieve a very small overshoot and very quick response to the Used for a process any time.

  • Page 44: On/Off Control

    3 5 Cool Only Control Setup Cool Control : ON-OFF control, P ( PD ) control and PID control can be used for cool control. OUT1 = Set OUT1 to DIRT ( direct action ). The other functions for cool only ON-OFF control, cool only P ( PD ) control and...

  • Page 45: Heat - Cool Control

    3 6 Heat-Cool Control The Heat-Cool Control can use one of combinations of control modes. Setup of parameters for each control mode are shown in the following table. Setup Values Heat Cool Control Modes Uses Uses OUT1 OUT2 O1HY OFST PB1 TI1 TD1 CPB A2FN A2MD A2HY DE.HI Heat : ON-OFF...
  • Page 46 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 47: Dwell Timer

    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 Error Code configured, the parameter TIME is used for dwell time adjustment. The dwell time is measured in minute ranging from 0 to 6553.5 minutes.

  • Page 48: Process Alarms

    3 8 Process Alarms There are at most two independent alarms available by adjusting OUT2. If =AL2 is selected for OUT2, then OUT2 will perform alarm 2 function. Now Error Code A2FN can't be selected with NONE, otherwise Er06 will be displayed. A process alarm sets an absolute trigger level ( or temperature ).
  • Page 49 ( 3-8 2'nd page ) A1SP = 200 A1HY = 10.0 A1MD = LTCH A1FN = PV1.H Process proceeds Figure 3.6 Latching Process Alarm A1SP = 200 A1HY = 10.0 SP1 = 210 A1MD = HOLD A1FN = PV1.L Process proceeds Figure 3.7 Holding Process Alarm A1SP = 200...

  • Page 50: Deviation Alarms

    3 9 Deviation Alarm OUT2 can be configured as alarm 2 by selecting=AL2. If OUT2 selects=AL2, Error Code then output 2 will perform alarm 2 function. Now A2FN can't be selected with NONE, otherwise Er06 will appear. 2 Types of Deviation Alarms : A deviation alarm alerts the user when the process deviates too far from set DE.HI, DE.LO point.

  • Page 51: Deviation Band Alarms

    3 10 Deviation Band Alarm A deviation band alarm presets two reference levels relative to set point. Two 2 Types of Deviation Band Alarms: types of deviation band alarm can be configured for alarm 1 and alarm 2. These DB.HI, DB.LO are deviation band high alarm ( A1FN or A2FN select DB.HI ) and deviation Deviation Band Alarm 1 band low alarm ( A1FN or A2FN select DB.LO ).

  • Page 52: Heater Break Alarm

    3 11 Heater Break Alarm Heater Break Alarm 1 A current transformer ( parts No. CT94-1 ) should be installed to detect the Setup : IN2 = CT heater current if a heater break alarm is required. The CT signal is sent to A1FN = PV2.L input 2, and the PV2 will indicate the heater current in 0.1 Amp.

  • Page 53: Loop Break Alarm

    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 A1MD = NORM, LTCH A1FN with LB.

  • Page 54: Sensor Break Alarm 1

    3 13 Sensor Break Alarm Alarm 1 or alarm 2 can be configured as sensor break alarm by selecting SENB Sensor Break Alarm 1 for A1FN or A2FN. If alarm 2 is required for sensor break alarm, then Setup: A1FN=SENB OUT2 should be selected with =AL2.

  • Page 55: Pv1 Shift

    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.

  • Page 56: Failure Transfer

    3 16 Failure Transfer Failure Mode Occurs as : The controller will enter failure mode as one of the following conditions occurs: 1. SB1E SB1E occurs ( due to the input 1 sensor break or input 1 current below 1mA 2.

  • Page 57: Bumpless Transfer

    3 17 Bumpless Transfer The bumpless transfer function is available for output 1 and output 2 ( provided Bumpless Transfer Setup : that OUT2 is configured as COOL ). 1. O1FT = BPLS 2. O2FT = BPLS Bumpless Transfer is enabled by selecting BPLS for O1FT and/or O2FT and activated as one of the following cases occurs : Bumpless Transfer Occurs as : 1.

  • Page 58: Self-Tuning

    3 18 Self tuning The Self-tuning which is designed by using an innovative algorithm provides an Self-tune Menu 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.

  • Page 59: Operation

    3 19 Auto tuning 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...

  • Page 60: Cold Start

    Auto-tuning Auto-tuning Begins Complete Waiting Warm-up Cycle Learning Cycle New PID Cycle Cycle =2 Integral Time Figure 3.22 Set Point Auto-tuning Procedure Pre-tune Stage Post-tune Stage PID Control ON-OFF Control PID Control Time Cold Start Auto-tuning Auto-tuning Begins Complete Pre-tune Stage Waiting Cycle Learning Cycle...

  • Page 61: Manual Tuning

    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 Figure 3.23 to the flow chart shown in the following diagram.
  • Page 62 The PBu is called the Ultimate P Band and the period of oscillation Tu is called 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.
  • Page 63 I action TI too high Figure 3.25 (Continued ) Set point Effects of PID Adjustment Perfect TI too low Time D action TD too low Perfect Set point TD too high Time UM93001H...

  • Page 64: Signal Conditioner Dc Power Supply

    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.

  • Page 65: Manual Control

    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.

  • Page 66: Display Mode

    3 23 Display Mode Operation Press 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 in reverse sequence . The system mode of the controller and its operation will remain unchanged.

  • Page 67: Heater Current Monitoring

    3 24 Heater Current Monitoring Accessory Installed: A current transformer, CT94-1, should be equipped to measure the heater CT94-1 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 Setup unchanged during the heater is unpowered.

  • Page 68: Chapter 4 Programming The Full Function

    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 : relay Terminals: or switch contacts, open collector pull low and TTL logic level, can be used to switch the event input.

  • Page 69: Second Set Point

    1 value. Modification from RS-232 to Event input: Because of limitation of pin number, pin 14 is used for both Event input and RS-232. If you want to change function of BTC-9300 from RS-232 to event input, you must...

  • Page 70: Second Pid Set

    4 3 Second PID Set In certain applications the process characteristics is strongly related to its process value. The BTC-9300 provides two set of PID values. When the Apply Signal To process is changed to different set point, the PID values can be switched to another set to achieve an optimum condition.
  • Page 71 4 4 Ramp & Dwell Ramp The ramping function is performed during power up as well as any time the set SPMD Choose point is changed. Choose MINR or HRR for SPMD, the unit will perform the Unit / minute ramping function.

  • Page 72: Ramp & Dwell

    Once the timer output was energized it will remain unchanged until power down or an event input programmed for resetting alarm is applied. Error Code. Note: The TIMR can't be chosen for both A1FN and A2FN simultaneously, otherwise an error code will produce. Ramp &...

  • Page 73: Remote Set Point

    4 5 Remote Set Point Setup SPMD selecting PV1 or PV2 will enable the BTC-9300 to accept a remote set point signal. If PV1 is selected for SPMD, the remote set point signal is sent to FUNC=FULL Input 1, and Input 2 is used for process signal input. If PV2 is selected for...

  • Page 74: Differential Control

    4 6 Differential Control 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 PVMD=P1-2 achieve this, set the following parameter in the Setup menu. or PVMD=P2-1 FUNC=FULL SPMD=SP1.2...

  • Page 75: Output Power Limits

    4 7 Output Power Limits 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 and/or undershoot you can use the Power Limit function. Output 1 power limit PL1 is contained in User Menu.

  • Page 76: Data Communication

    STOP ) such that these values are accordant with PC setup conditions. PARI=Parity Bit STOP=Stop Bit Count NOTE: If the BTC-9300 is configured for RS-232 communication, the EI ( Event Input ) is disconnected internally. The unit can no longer perform event input RS-485 Terminals function ( EIFN ).

  • Page 77: Analog Retransmission

    1 and input 2 ( PV1 PV2 ). It is required that if the difference value is -100, 4mA will be exported, and if the difference value is 100, 20mA will be exported. Make the following Setup for BTC-9300: IN1U PU, DP1 NODP, IN2U PU, DP2 NODP, FUNC FULL, COMM 4- UM93001H...

  • Page 78: Digital Filter

    Menu In certain application the process value is too unstable to be read. To improve this a programmable low pass filter incorporated in the BTC-9300 FILT can be used. This is a first order filter with time constant specified by FILT parameter which is contained in setup menu.

  • Page 79: Sleep Mode

    4 11 Sleep Mode Sleep Mode Features: Enter Sleep Mode: FUNC selects FULL to provide full function. Shut off display Shut off outputs SLEP selects YES to enable the sleep mode. Green Power Press for 3 seconds, the unit will enter its sleep mode. Replace Power Switch (1) Shut off all display except a decimal point which is lit periodically.

  • Page 80: Pump Control

    4 12 Pump Control Pump Control function is one of the unique features of BTC-9300. Using this PUMP: A Cost Effective function the pressure in a process can be controlled excellently. The pressure yet Perfect Solution in a process is commonly generated by a pump driven by a variable speed motor.

  • Page 81: Programming Guide

    Programming Guide: 1. Perform auto-tuning to the system under such condition that the material ( ie. pressure ) is exhausted at typical rate. A typical value for PB1 is about 10 Kg/cm , TI1 is about 1 second, TD1 is about 0.2 second. 2.

  • Page 82: Chapter 5 Applications

    A regulated water supply system is widely used in residence, water plant, yet Perfect Solution chemical plant, electrical plant, semiconductor plant ... etc. Taking the advantage of PUMP function, the BTC-9300 can be used for these applications to achieve an economical versatile solution.
  • Page 83 Set the following parameters in the setup menu: FUNC=FULL COMM: optional IN1=4-20 IN1U=PU DP1=2-DP IN1L=0 IN1H=20.00 IN2=NONE OUT1=REVR O1TY=4-20 O1FT=0 OUT2=DCPS A1FN: optional EIFN=NONE PVMD=PV1 FILT=1 SELF=NONE SLEP=NONE SPMD=PUMP SP1L=5.00 SP1H=15.00 SP2F=DEVI Adjust the following parameters in the user menu: A1SP: optional Key menu: REFC= 3...

  • Page 84: 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 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: Input Output Figure 5.2...
  • Page 85 Stress on the Load Load ( Heater ) Life Longer Shorter The output 1 and output 2 of BTC-9300 can be connected to VPFW SSR directly provided that a pulsed voltage drive output ( BTC-9300-XX2XXX or Here is an example: BTC-9300-XX22XX...

  • Page 86: 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-9300 equipped with dwell timer SP1=150.0 TIME=30.0 Oven Figure 5.5 Heater Heat Control Example...

  • Page 87: Cool Only Control

    5 4 Cool Only Control ON-OFF control A BTC-9300 is used to control a refrigerator at temperature below 0 BC. To Direct Control Action avoid the set point adjustment beyond the interesting range, SP1L is set at -10 BC and SP1H is set at 0 BC. The temperature is lower than the ambient, a cooling action is required.

  • Page 88: Heat - Cool Control

    An oil pipe is buried in the mold. Since plastics is injected at higher temperature ( e.g. 250 C ), the circulation oil needs to be Injection Mold Plastics 120 C Figure 5.7 Heat-Cool Control Example Pump Oil Tank Freezer Heater Supply 4-20 mA OUT2 OUT1 BTC-9300 UM93001H...
  • Page 89 The PID Heat-Cool is used for the above example. Key Menu To achieve this set the following parameters in the Setup Menu: FUNC FUNC=BASC IN1=PT.DN IN1U IN1U= C DP1=1-DP OUT1 OUT1=REVR O1TY O1TY=RELY CYC1 CYC1=18.0 (sec ) O1FT O1FT=BPLS OUT2 O2TY OUT2=COOL O2FT...

  • Page 90: Ramp & Dwell

    The circuit diagram and its temperature profile are shown below: Figure 5.8 Chamber A Temperature Cycling Chamber Freezer Heater Inverter Mains AC Relay BTC-9300 TIME=60.0 (minutes ) SP1=60.0 C SP2=-10.0 C CPB=100 (%) Cycle Timer RAMP=14.0 ( C/minute ) UM93001H...
  • Page 91 65 minutes 5 minutes BTC-9300 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. You can perform auto-tuning twice at SP1 and SP2 for initial setup to the dual PID values.

  • Page 92: Remote Set Point

    If you order a BTC-9300 with a retransmission unit for the master controller, To Control To Control To Control...

  • Page 93: Differential Control

    OUT1 4.12 M Height Outlet BTC-9300 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 ).

  • Page 94: Dual Set Point / Pid

    5 9 Dual Set Point / PID The BTC-9300 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.
  • Page 95 Example 2: Dual Set Point / PID A heat treating furnace is required to harden the mold at a high temperature ( 1000 LC ) for 30 minutes, then the mold is cooled down with a programmable ramp ( 20 LC / minute ) toward a lower set point ( 200 LC ). ( 1 ) Set the following parameters in the Setup menu: FUNC= FULL A1FN= TIMR...

  • Page 96: Control Room

    A cost effective solution for the above application is to use 80 units of BTC-9300- XXXXX1 plus a...
  • Page 97 Setup Setup Menu FUNC Enters the setup mode to configure each BTC-9300. Choose FULL for FUNC, 485 for COMM, RTU for PROT and select an unequal address ( ADDR ) for COMM each unit. Use the same values of BAUD, DATA, PARI and STOP for BTC- PROT 9300's, SNA10B and BC-Net.
  • Page 98 Suppose a chemical experiment is performed in a laboratory. And an FUNC engineer desires to find out the relation between the chemical reaction and COMM temperature. He uses a BTC-9300 to control the temperature of the solution under test. A testing report containing the relation between the PROT ADDR...

  • Page 99: Retransmit

    5 12 Retransmit An air-conditioned room uses two units of BTC-9300 to control its temperature and humidity. The temperature and humidity are required to be recorded on a chart recorder. The interesting ranges for these two quantity are: 20 C to 30 C and 40% RH to 60% RH.

  • Page 100: Chapter 6 Calibration

    Chapter 6 Calibration Do not proceed through this section unless there is a definite need to re-calibrate the controller. Otherwise, all previous calibration data will be lost. Do not attempt recalibration unless you have appropriate calibration equipment. If calibration data is lost, you will need to return the controller to your supplier who may charge you a service fee to re-calibrate the controller.

  • Page 101: Dip Switch Position

    . Send a 100 ohms signal to terminals 11, 12 RTD input and 13 according to the connection shown below: 100 ohms BTC-9300 Figure 6.1 RTD Calibration Press scroll key for at least 3 seconds . The display will blink a moment, otherwise the calibration fails.
  • Page 102 Setup the equipments according to the following diagram for DIP Switch Position calibrating the cold junction compensation. Note that a K type TC input thermocouple must be used. 5520A Calibrator BTC-9300 Figure 6.2 K-TC Cold Junction Calibration Setup Stay at least minutes in still-...
  • Page 103 Step 12. Set the DIP switch to your desired position ( refer to Section 1-3 Automatic Calibration Procedures The programming port ( See Section 2-18 ) of BTC-9300 can be used for automatic calibration. The equipments required for automatic calibration are available upon request. UM93001H...

  • Page 104: Chapter 7 Error Codes & Troubleshooting

    Press both sides of the latch located on rear terminal block.Hold tightly and remove the Expand the rear edge of the housing by using a tool. Pull out the PCB from the housing. Figure 7.1 Dismantling the Controller BTC-9300 UM93001H...
  • Page 105 Table 7.1 Error Codes and Corrective Actions Display Error Error Description Corrective Action Symbol Code Illegal setup values been used: PV1 is used for both PVMD Check and correct setup values of PVMD and SPMD. PV and SPMD. It is meaningless for control. and SV can't use the same value for normal control Illegal setup values been used: PV2 is used for both PVMD Same as error code 1...
  • Page 106 Table 7.2 Common Failure Causes and Corrective Actions Symptom Probable Causes Corrective Actions - Clean contact area on PCB -Bad connection between PCB & keypads 1) Keypad no function - Replace keypads - No power to instrument - Check power line connections 2) LED's will not light - Power supply defective - Replace power supply board...

  • Page 107: Chapter 8 Specifications

    Chapter 8 Specifications Power Input 2 90 264 VAC, 47 63 Hz, 15VA, 7W maximum Resolution : 18 bits 11 26 VAC / VDC, SELV, Limited Energy Sampling Rate : 1.66 times / second 15VA, 7W maximum Maximum Rating : -2 VDC minimum, 12 VDC maximum Input 1 Temperature Effect :...
  • Page 108 Linear Output Resolution : 15 bits Resolution : 15 bits Accuracy : A0.05 % of span A0.0025 %/ LC Output Regulation : 0.01 % for full load change Load Resistance : Output Settling Time : 0.1 sec. ( stable to 99.9 % ) 0 - 500 ohms ( for current output ) Isolation Breakdown Voltage : 1000 VAC...

  • Page 109: Environmental And Physical

    Environmental & 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 :...

  • Page 110: 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 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 Parameter Data Default Parameter Description Unit Address Notation Type High High Value 100.0 C Set point 1 -19999 SP1L SP1H 45536 (212.0 F) TIME Dwell Time 6553.5 minute 65535 100.0 C Alarm 1 Set point -19999 A1SP 45536 (212.0 F) -200.0 C...
  • Page 113 Range Scale Parameter Register Data Default Parameter Description Unit Notation Address Type High High Value -19999 45536 -19999 45536 SP1L SP1 Low Scale Value (32.0 F) 1000.0 C SP1H -19999 45536 -19999 45536 SP1 High Scale Value (1832.0 F) *B15 *B15 IN2 Signal Type Selection 65535...
  • Page 114 Range Scale Parameter Register Data Default Parameter Description Unit Notation Address Type High High Value Cold Junction Low Temperature -5.00 40.00 -19999 45536 CJTL Calibration Coefficient Cold Junction Gain Calibration -199.9 199.9 -19999 45536 Coefficient Reference Voltage 1 Calibration -199.9 199.9 -19999 45536...
  • Page 115 Range Scale Parameter Register Data Default Parameter Description Unit Notation Address Type High High Value Historical Maximum Value of PV -19999 45536 -19999 45536 PVHI PVLO Historical Minimum Value of PV -19999 45536 -19999 45536 Sense Voltage of Cold Junction CJCL 31.680 40.320...
  • 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 Description Symbol data. 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 4 - 20 4 - 20 mA linear current 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 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 =ALMK = 00 : No alarm...
  • Page 120 *B34, Error messages Display Display Error Error Error Description Error Description Corrective Action Corrective Action Symbol Symbol Code Code Illegal setup values Check and correct 1.Correct the used: PV1 is used for setup values of PVMD communication both PVMD and SPMD and SPMD, PV and SV software to meet the that is meaningless for...
  • Page 121 0.XX BTC-2500 controller to minimize the detected in the system noise. EEPROM and mapped 1.XX BTC-9300 controller 2.Return to factory for repair. L91 controller 2.XX 3.XX BTC-8300 controller EEPROM can't be Return to factory for 4.XX...
  • 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 Example 1: Preset 9 multiple registers Starting Addr. Bytes 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. Send the following message to the controller via the COMM port or programming port: H'80 Starting Addr.

  • Page 124: Menu Existence Conditions

    A 1 Menu Existence Coditions Menu Existence Conditions Table Parameter Menu Existence Conditions Notation Exists unconditionally TIME Exists if A1FN selects TIMR or A2FN selects TIMR A1SP Exists if A1FN selects PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H or D12L A1DV Exists if A1FN selects DEHI, DELO, DBHI, or DBLO A2SP...
  • Page 125 Menu Existence Conditions Table ( continued 2/3 ) Parameter Menu Existence Conditions Notation FUNC Exists unconditionally COMM Exists if FUNC selects FULL PROT ADDR BAUD Exists if COMM selects 485 or 232 DATA PARI STOP AOFN Exists if COMM selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10 AOLO Exists if COMM selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10 and AOFN is not MV1 and MV2 AOHI...
  • Page 126 Menu Existence Conditions Table ( continued 3/3 ) Parameter Menu Existence Conditions Notation A1FN Exists unconditionally Exists if A1FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, A1MD D12H, D12L, LB or SENB A1FT Exists if A1FN is not NONE A2FN Exists unconditionally Exists if A2FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H, P12L,...

  • Page 127: Factory Menu Description

    A 2 Factory Menu Description Parameter Display Default Parameter Description Range Notation Format Value Low: High: EROR Current Error Code Program Identification Code Contains Program High: Low: 15.99 PROG Number and Version Number Contains Lockout Status Code and Current System High: Low: MODE...
  • Page 128 Parameter Display Default Parameter Description Range Notation Format Value Working Hour Value 65535 Hours HOUR High: Low: High: Fractional Hour Value Low: 0.9 Hour HRLO Historical Error Record 1 Low: FFFF High: ERR1 High: Low: FFFF ERR2 Historical Error Record 2 ASCII Input Delimiter DELI High:...

  • Page 129: Glossary

    A 3 Glossary Abosolute zero: The lowest theoretical temperature. At Automatic reset (Integral): The integral function of a absolute zero, a body would have no molecular motion control that automatically compensates for the of heat energy. Absolute zero is the zero point on the difference between the set point and the actual process Rankine and Kelvin scale.
  • Page 130 Dead band: 1. For chart recorders: the minimum change CE: A mark that designates compliance with European Union (EU) requirements for products sold in Europe. of input signal required to cause a deflection in the pen position. 2. For temperature controllers: the Celsius: (Centigrade) A temperature scale with 0 C temperature band where heat is turned off upon rising defined as the ice point and 100 C as the boiling point...
  • Page 131 Electromagnetic Compatibility (EMC): A system meets fpm: Flow velocity in feet per minute. three requirements: 1. It does not cause interference fps: Flow velocity in feet per second. with other systems, 2. It is not susceptible to emissions Freezing point: The temperature at which the substance from other systems and 3.
  • Page 132 Hi-Pot test : To apply a high voltage to an electrical Kilo: The prefix for one thousand (K). conductor to test the surrounding insulation. Kilowatt (kw): 1000 watts or 3412Btu per hour. Hysteresis: In ON/OFF control, the temperature change Lag: 1. A time delay between the output of a signal and necessary to change the output from full ON to full OFF.
  • Page 133 NEMA 4X: A front panel rating designating the control as Proportional control mode: When process temperature washdown capable and corrosion resistance. approaches set point and enters the proportional band, the output is switched on and off at the established NIST: National Institute of Standards and Technology, cycle time.
  • Page 134 RFI: Radio frequency interference. Surge current: A current of short duration occurring when power is initially applied to capacitive or resistive loads, RS232 or RS485 output signal: A serial interface suitable usually lasting no more than several cycles. for connection between a digital control and a personal Temperature gradient: The range of temperature variations computer, a host computer or printer.
  • Page 135 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).

  • Page 136: Index

    A 4 Index A1DV: 11, 13, 18, 47, 48, 50, 51, 53 Auto-tuning: 11, 12, 43, 45, 46, 58 CT: 4, 20, 22, 28, 40, 52, 67, 102 54, 110 59, 60, 61, 68, 70, 81, 86, 89, 91, 94, 97, 98, 105, 108 Current transformer: 7, 15, 28, 52, 67 A1FN: 11, 16, 17, 20, 42, 43, 47, 48, 49, 50, 51, 52, 53, 54, 56, 70, 71,...
  • Page 137 FILT: 11, 17, 40, 78, 80, 81, 83, 108 Linear current: 15, 26, 27, 31, 33, 41 OUT2: 11, 16, 22, 41, 45, 48, 50, 51, 53, 54, 56, 57, 64, 65, 75, Flow: 4, 11, 61, 62 Linear DC input wiring: 26 82, 83, 85, 88, 89, 90, 105 Freezer: 54, 88, 90 Linear output: 43, 45, 52, 67, 107, 108...
  • Page 138 PVHI: 9, 11, 19, 66 Second PID: 40, 68, 69, 70, 94, 95 SP2: 11, 13, 17, 18, 20, 40, 42, 48, 68, 69, 72, 74, 80, 81, 83, 90, 91, PV1: 11, 13, 17, 19, 20, 40, 41, 45, Second set point: 69, 107 48, 49, 55, 56, 66, 70, 73, 74, 77, 78, 80, 83, 92, 93, 94, 95, 99, 105,...

  • Page 139: Memo

    A 5 Memo Use the following Table as a master copy for your settings. Parameter Display Parameter Display Contained Contained Your setting Your setting Notation Format Notation Format COMM TIME PROT A1SP ADDR A1DV BAUD A2SP DATA A2DV PARI RAMP STOP OFST AOFN...
  • Page 140 Parameter Display Parameter Display Contained Contained Your setting Your setting Notation Format Notation Format OUT2 O2TY CYC2 O2FT CJTL Calibra- tion A1FN Mode Menu A1MD REF1 A1FT A2FN MA1G A2MD A2FT MA2G EIFN PVHI Setup PVMD PVLO Menu FILT SELF SLEP SPMD Display...

  • Page 141: 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.
  • Page 142 0,196 N-m (1,74 Lb-in ou 2 KgF-cm). La température minimale est de 60°C. Utilisez uniquement des conducteurs en cuivre. For any repair or maintenance needs, please contact us. 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...

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