Brainchild PR Series, PC201 User Manual

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Page 1

PR Series Process Control Card PC201 User Guide

UMPC201A

October 2016

Page 2

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.

Preface

Original equipment manufacturer reserves the right to change information available in this document without notice. Manufacturer is not liable for any damages incurred to equipment/personal during installation or use of equipment as explained in this document. User must acquire sufficient knowledge & skills prior to use the equipment in the application and follow all the local standards & regulations to meet safety requirements

The documentation and the software included with this product are copyrighted 2016 By Brainchild Electronic Co. Ltd. All rights are reserved. Brainchild Electronic Co., Ltd. reserves the right to make improvements in the products described in this manual at any time without notice.

No part of this manual may be reproduced/ copied/ translated or transmitted in any form or by any means without the prior written permission of Brainchild Electronic Co .,Ltd. The information we supply is believed to be accurate and reliable as of this printing. However, we assume no responsibility for its use.

Contact Information

Head Office & Factory

Brainchild Electronic Co. Ltd.

209 Chongyang Road, Nangang Dist.,

Taipei 11573,Taiwan

Tel: +886-2-2786-1299 Fax: +886-2-2786-1395

Website: www.brainchild.com.tw

Email: [email protected]; [email protected]

China Sales Office

Brainchild Electronic (Kunshan) Co. Ltd.

Room 405, Building #6, Huamin Gentlefolk Garden

No. 13, Qianjin Central Road, Kunshan City, Jiangsu 215300, China

Tel: +86-512-5511-6133 Fax: +86-512-5511-6113 Website: www.brainchild.com.cn

Email: [email protected] ;

[email protected]

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Page 3

TABLE OF CONTENTS

INTRODUCTION ---------------------------------------------------------------------- ------------------------------- 8

1.1 I

NTRODUCTION

1.2 F

1.3 P

1.4 E

1.5 S

1.6 P

1.7 S

EATURES

ROCESS CONTROL CARD

1.3.1 Flexible Configuration of Program ------------------------------------------------------------------ 11

1.3.2 Maximum Capacity of Program --------------------------------------------------------------------- 11

1.3.3 Event Input ----------------------------------------------------------------------------------------------- 11

1.3.4 Programmable Event Outputs ----------------------------------------------------------------------- 11

1.3.5 High Accuracy ------------------------------------------------------------------------------------------- 11

1.3.6 Fast Sampling Rate ------------------------------------------------------------------------------------- 11

1.3.7 Fuzzy Control -------------------------------------------------------------------------------------------- 12

1.3.8 Auto-tuning ---------------------------------------------------------------------------------------------- 12

1.3.9 Lockout Protection ------------------------------------------------------------------------------------- 12

1.3.10 Bumpless Transfer -------------------------------------------------------------------------------------- 12

1.3.11 Digital Filter --------------------------------------------------------------------------------------------- 12

1.3.12 Soft-start Ramp ----------------------------------------------------------------------------------------- 12

1.3.13 Pump Control -------------------------------------------------------------------------------------------- 12

XPANSION

1.4.1 PID Control Module ------------------------------------------------------------------------------------ 12

MART MECHANISM

ROCESS CONTROL CARD

PECIFICATION

1.7.1 Input1 ----------------------------------------------------------------------------------------------------- 14

1.7.2 Input2 ----------------------------------------------------------------------------------------------------- 15

1.7.3 Input3 (Event Input) ------------------------------------------------------------------------------------ 16

1.7.4 Output1/Output2 --------------------------------------------------------------------------------------- 16

1.7.5 Alarm 1/ Alarm 2 --------------------------------------------------------------------------------------- 17

1.7.6 Control Mode -------------------------------------------------------------------------------------------- 17

1.7.7 Digital Filter --------------------------------------------------------------------------------------------- 18

----------------------------------------------------------------------------------------------------- 8

----------------------------------------------------------------------------------------------------------- 8

------------------------------------------------------------------------------------------ 9

I/O M

ODULES FOR

--------------------------------------------------------------------------------------------- 13

---------------------------------------------------------------------------------------------------- 14

PID ----------------------------------------------------------------------------- 12

PC201 O

RDERING CODE

------------------------------------------------------------- 13

INSTALLATION AND WIRING----------------------------------------------------------------------------------- 19

2.1 U

2.2 I

3.1 C

3.2 C

3.3 R

3.4 ON F

4.1 M

4.2 S

NPACKING

NPUT OUTPUT WIRING CONNECTION

2.2.1 Wiring Precautions ------------------------------------------------------------------------------------- 20

2.2.2 PID Control Module ------------------------------------------------------------------------------------ 20

PROCESS CONTROL CARD FEATURES ----------------------------------------------------------------------- 22

ONFIGURATION

ONTROLLER

AMP & DWELL FUNCTION

PROCESS CONTROL CARD FUNCTIONS ---------------------------------------------------------------------- 23

ENUS

TATUS BAR

------------------------------------------------------------------------------------------------------- 19

--------------------------------------------------------------------------- 20

-------------------------------------------------------------------------------------------------- 22

------------------------------------------------------------------------------------------------------ 22

-------------------------------------------------------------------------------------- 22

IELD CALIBRATION

------------------------------------------------------------------------------------------------------------ 23

------------------------------------------------------------------------------------------------------- 32

------------------------------------------------------------------------------------------- 22

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4.3 P

4.4 D

ROCESS CONTROL CARD CONFIGURATION

4.3.1 Process Control Card Configuration ---------------------------------------------------------------- 34

4.3.1.1 Controller --------------------------------------------------------------------------------------------------------- 35

4.3.1.1.1 Name ---------------------------------------------------------------------------------------------------------- 36

4.3.1.1.2 Parameter ---------------------------------------------------------------------------------------------------- 36

4.3.1.1.3 Channel ------------------------------------------------------------------------------------------------------- 72

4.3.1.1.4 Sample Configuration of Process Control Card ------------------------------------------------------ 76

4.3.1.1.4.1 Heat Only ON-OFF Control ------------------------------------------------------------------------- 76

4.3.1.1.4.2 Cool Only ON-OFF Control -------------------------------------------------------------------------- 78

4.3.1.1.4.3 Heat Cool Control ------------------------------------------------------------------------------------ 78

4.3.1.1.4.4 Heater Break Alarm ---------------------------------------------------------------------------------- 80

4.3.1.1.4.5 Loop Break Alarm ------------------------------------------------------------------------------------ 81

4.3.1.1.4.6 Sensor Break Alarm ---------------------------------------------------------------------------------- 81

4.3.1.1.4.7 Failure Transfer --------------------------------------------------------------------------------------- 82

4.3.1.1.4.8 Bumpless Transfer ----------------------------------------------------------------------------------- 83

4.3.1.1.4.9 PV1 Shift ------------------------------------------------------------------------------------------------ 84

4.3.1.1.4.10 SP1 Range --------------------------------------------------------------------------------------------- 85

4.3.1.1.4.11 Dwell Timer ------------------------------------------------------------------------------------------ 85

4.3.1.1.4.12 Process Alarms -------------------------------------------------------------------------------------- 86

4.3.1.1.4.13 Deviation Alarm ------------------------------------------------------------------------------------- 88

4.3.1.1.4.14 Deviation Band Alarm ------------------------------------------------------------------------------ 90

4.3.1.1.4.15 Event Input ------------------------------------------------------------------------------------------- 91

4.3.1.1.4.16 Second Set Point ------------------------------------------------------------------------------------ 93

4.3.1.1.4.17 Second PID Set --------------------------------------------------------------------------------------- 93

4.3.1.1.4.18 Ramp & Dwell ---------------------------------------------------------------------------------------- 94

4.3.1.1.4.19 Remote Set Point ----------------------------------------------------------------------------------- 96

4.3.1.1.4.20 Differential Control --------------------------------------------------------------------------------- 97

4.3.1.1.4.21 Output Power Limit--------------------------------------------------------------------------------- 98

4.3.1.1.4.22 Digital Filter ------------------------------------------------------------------------------------------ 98

4.3.1.1.4.23 Auto-Tuning and Manual Tuning ---------------------------------------------------------------- 99

4.3.1.2 Ramp & Dwell(Profile) ----------------------------------------------------------------------------------------- 102

4.3.1.2.1 Ramp & Dwell: --------------------------------------------------------------------------------------------- 103

4.3.1.2.2 Segments: --------------------------------------------------------------------------------------------------- 104

4.3.1.2.2.1 Ramp Segment Parameters: ---------------------------------------------------------------------- 105

4.3.1.2.2.2 Dwell Segment Parameters: ---------------------------------------------------------------------- 108

4.3.1.2.2.3 Go Back Segment Parameters: ------------------------------------------------------------------- 108

4.3.1.2.2.4 End Segment Parameters: ------------------------------------------------------------------------- 108

4.3.1.2.2.5 Time to Target Segment Parameters: ----------------------------------------------------------- 109

4.3.1.2.3 Start/End Jobs ---------------------------------------------------------------------------------------------- 109

4.3.1.2.4 Start/Stop Profile(Ramp &Dwell) ---------------------------------------------------------------------- 109

ISPLAY

---------------------------------------------------------------------------------------------------------- 111

--------------------------------------------------------------------- 33

APPLICATION ----------------------------------------------------------------------------------------------------- 112

5.1 O

VEN CONTROL WITH ZONE TEMPERATURE RECORDING

------------------------------------------------------ 112

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Table of Figures

Figure 1-1.Fuzzy PID System Block Diagram ...................................................................................................... 9

Figure 1-2.PID System Stability with and without Fuzzy ................................................................................... 10

Figure 2-1.Process Control Card Wiring Diagram ............................................................................................. 21

Figure 3-1.Configuration Layout ..................................................................................................................... 22

Figure 4-1.Home Screen .................................................................................... ............................................. 23

Figure 4-2.Menu Screen ................................................................................................................................. 24

Figure 4-3.Real Time Menu ............................................................................................................................ 24

Figure 4-4.Overview Display .......................................................................................................................... 25

Figure 4-5.PID Controller Module Display ....................................................................................................... 25

Figure 4-6.Display Modes .............................................................................................................................. 26

Figure 4-7.Real Time Alarms .......................................................................................................................... 26

Figure 4-8.Historical Data Screen ................................................................................................................... 27

Figure 4-9.Event History ................................................................................................................................ 28

Figure 4-10.Report Screen ............................................................................................................................. 29

Figure 4-11.More Menu ................................................................................................................................. 29

Figure 4-12.Operate Menu ............................................................................................................................. 30

Figure 4-13.Configuration Layout ................................................................................................................... 31

Figure 4-14.More Menu ................................................................................................................................. 32

Figure 4-15.Status Bar During Logging ............................................................................................................ 32

Figure 4-16.Status Bar During Logging Stopped ............................................................................................... 32

Figure 4-17.Status Bar during Logging with Batch function ............................................................................. 32

Figure 4-18.Status Bar During Logging Stopped with Batch Function ................................................................ 32

Figure 4-19.Tree Type Configuration Layout ................................................................................................... 33

Figure 4-20.Process Control Card Channel Configuration ................................................................................. 35

Figure 4-21.Process Control Card Channel Configuration ................................................................................. 36

Figure 4-22.Process Control Card Configuration Window ................................................................................. 37

Figure 4-23.Process Control Card Configuration Window for Read only Parameter ........................................... 37

Figure 4-24.Process Control Card Channel Configuration ................................................................................. 72

Figure 4-25.Log Speed ................................................................................................................................... 74

Figure 4-26.Events with Job ........................................................................................................................... 74

Figure 4-27. Event Configuration Example ...................................................................................................... 76

Figure 4-28.Heat Only ON-OFF Control ........................................................................................................... 77

Figure 4-29.Cool Only ON-OFF Control ............................................................................................................ 78

Figure 4-30. Heater Break Alarm .................................................................................................................... 80

Figure 4-31.Without Bumpless Transfer .......................................................................................................... 83

Figure 4-32.With Bumpless Transfer ............................................................................................................... 84

Figure 4-33.PV1 SHIFT Application.................................................................................................................. 85

Figure 4-34.SP1 Range ................................................................................................................................... 85

Figure 4-35.Dwell Timer ................................................................................................................................. 86

Figure 4-36.Normal Process Alarm ................................................................................................................. 87

Figure 4-37.Latching Process Alarm ................................................................................................................ 87

Figure 4-38.Holding Process Alarm ................................................................................................................. 88

Figure 4-39.Latching / Holding Process Alarm ................................................................................................. 88

Figure 4-40.Normal Deviation Alarm .............................................................................................................. 89

Figure 4-41.Latching Deviation Alarm ............................................................................................................. 89

Figure 4-42.Holding Deviation Alarm .............................................................................................................. 89

Figure 4-43.Latching/Holding Deviation Alarm ................................................................................................ 90

Figure 4-44.Normal Deviation Band Alarm ...................................................................................................... 90

Figure 4-45.Latching Deviation Band Alarm .................................................................................................... 91

Figure 4-46.Holding Deviation Band Alarm ..................................................................................................... 91

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Figure 4-47.Latching/Holding Deviation Band Alarm ....................................................................................... 91

Figure 4-48.Ramp Function ............................................................................................................................ 94

Figure 4-49.Dwell Timer ................................................................................................................................. 95

Figure 4-50.Ramp Accompanied with Dwell Timer .......................................................................................... 96

Figure 4-51.Relationship Between PV1 & PV2 for Differential Control .............................................................. 97

Figure 4-52.Power Limit Function ................................................................................................................... 98

Figure 4-53.Filter Characteristics .................................................................................................................... 99

Figure 4-54.Process Control Module Real time .............................................................................................. 100

Figure 4-55.Auto-Tuning .............................................................................................................................. 100

Figure 4-56.Auto-Tuning In progress ............................................................................................................. 101

Figure 4-57.Manual Tuning In Progress ......................................................................................................... 101

Figure 4-58.Ramp & Dwell Configuration Window ........................................................................................ 102

Figure 4-59.Set Point Profile ........................................................................................................................ 103

Figure 4-60.Ramp Segment .......................................................................................................................... 105

Figure 4-61.Hold Back on Dwell .................................................................................................................... 107

Figure 4-62.Hold Back on Positive Ramp ....................................................................................................... 107

Figure 4-63.Hold Back Negative Ramp .......................................................................................................... 107

Figure 4-64.Dwell Segment ....................................................................................... ................................... 108

Figure 4-65.Go Back Segment....................................................................................................................... 108

Figure 4-66.End Segment ........................................................................................ ..................................... 108

Figure 4-67.Time To Target Segment ............................................................................................................ 109

Figure 4-68.Profile Start/End Job .................................................................................................................. 109

Figure 4-69.Run Profile ................................................................................................................................ 110

Figure 4-70.Profile Running.......................................................................................................................... 110

Figure 5-1.Oven Control with Zone Temperature Recording .......................................................................... 112

Figure 5-2. Oven Control with Zone Temperature Recording System .............................................................. 113

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Table of Tables

Table 1-1. Input 1 Characteristics ................................................................................................................... 15

Table 1-2. Input 2 Characteristics ................................................................................................................... 16

Table 1-3. Output Characteristics ................................................................................................................... 16

Table 1-4. SSR Output Characteristics ............................................................................................................. 17

Table 2-1.Environmental Specification ........................................................................................................... 19

Table 4-1.PID Parameter List .......................................................................................................................... 47

Table 4-2.Process Control Card Input Range ................................................................................................... 48

Table 4-3.Range of A1SP ................................................................................................................................ 48

Table 4-4.Range of A2SP ................................................................................................................................ 48

Table 4-5.Range Of SP2 .................................................................................................................................. 48

Table 4-6.Mode Selection .............................................................................................................................. 49

Table 4-7.Communication Mode .................................................................................................................... 49

Table 4-8.Communication Protocol ................................................................................................................ 50

Table 4-9.Communication Baud Rate ............................................................................................................. 50

Table 4-10.Communication Data Length ......................................................................................................... 51

Table 4-11.Communication Parity .................................................................................................................. 51

Table 4-12.Communication Stop Bit ............................................................................................................... 51

Table 4-13 Function of AOFN ......................................................................................................................... 52

Table 4-14 Selection of IN1 Type .................................................................................................................... 53

Table 4-15.Display Unit for IN1 & IN2 ............................................................................................................. 53

Table 4-16.Decimal Digit for DP1&DP2 ........................................................................................................... 53

Table 4-17.IN2 Input ...................................................................................................................................... 54

Table 4-18.EIFN Function ............................................................................................................................... 55

Table 4-19.OUT1 Action ................................................................................................................................. 55

Table 4-20.OUT1 & OUT2 Type ....................................................................................................................... 55

Table 4-21.OUT2 Function ............................................................................................................................. 56

Table 4-22.Display Function ........................................................................................................................... 56

Table 4-23. Alarm1 & Alarm 2 Function .......................................................................................................... 57

Table 4-24.Alarm1 & Alarm2 Operation Mode ................................................................................................ 57

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

Table 4-26.Auto Tuning ................................................................................................................................. 58

Table 4-27.Sleep Mode .................................................................................................................................. 58

Table 4-28.PV Mode Selection ....................................................................................................................... 59

Table 4-29.SP2 Set Point Format .................................................................................................................... 59

Table 4-30 Filter Damping Time Constant of PV .............................................................................................. 59

Table 4-31 Set Point Mode Selection .............................................................................................................. 60

Table 4-32 SEL Selection ................................................................................................................................ 61

Table 4-33 Default File Selection .................................................................................................................... 61

Table 4-34.Error Codes and Corrective Actions................................................................................................ 68

Table 4-35 PROG CODE .................................................................................................................................. 69

Table 4-36 Mode ........................................................................................................................................... 70

Table 4-37.Unit Determination for A1SP,A1DV,A1HY ...................................................................................... 70

Table 4-38.Unit Determination for A2SP,A2DV,A2HY ...................................................................................... 71

Table 4-39.RAMP Unit ................................................................................. .................................................. 71

Table 4-40 .Unit Determination of AOLO & AOHI ............................................................................................ 71

Table 4-41.Heat Cool Control Modes .............................................................................................................. 79

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1 Introduction

1.1 Introduction

Generally most of the furnace applications require Controller and Recorder separately to control and record the data. Some Furnaces application requires Ramp & Dwell controllers .The new generation Paperless Recorder provides PID Control, Ramp & Dwell Control and Recording in one device by using the new process control Card PC201 . This is a single loop controller for Furnace applications. This will reduce Cost ,Space ,Wiring required for using controller and Recorder separately.

1.2 Features

The Process Control Card has lot of unique Features on its hardware and Software. The unique Features are listed below.

 PID Controller, Ramp & Dwell Controller and Recorder 3 in one Device

 Plug and Play I/O Options

 18-bit Universal input A-D for PID Control

 15-bit output D-A

 Fuzzy + PID microprocessor-based control

 Fast input sampling rate 200msec for PID Control

 Two level of function complexity

 50 Profiles,1000 Segments in Total

 Differential control

 Auto-tuning and Self Tuning function

 Sleep mode function

 " Soft-start " Ramp and Dwell timer

 Universal inputs( Thermocouple, RTD, mA, VDC )

 Analog input for remote set point and CT

 Event input for changing function & set point

 Programmable digital filter

 Hardware lockout + remote lockout protection

 Loop break alarm

 Heater break alarm

 Sensor break alarm + Bumpless transfer

 Pump control

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 100msec Sampling rate and log speed for Data Acquisition

 Real time and Historical Trends for PV and SV

1.3 Process Control Card

The Process Control Card uses Fuzzy Logic plus PID microprocessor technology for its control. The Fuzzy Logic plus PID microprocessor based technology enables a process to reach a predetermined set point in the shortest time, with the minimum of overshoot during power-up or external load disturbance. The module can be easily plugging into the rear side IO slots of the paperless recorder. Various control and input parameters can be configured easily by using the touch screen menus and navigations.

This Process Control Card can be configured by using the Configuration Menu on the device or by using the PC Based Configuration Software.

Even though PID control has been used and proved to be an efficient controlling method by many industries for more than a decade, yet the PID is difficult to deal with some sophisticated systems such as second and higher order systems, long time-lag systems, during set point change and/or load disturbance circumstance etc. The PID principle is based on a mathematic modeling which is obtained by tuning the process. Unfortunately many systems are too complex to describe in numerical terms precisely. In addition to these, systems may be variable from time to time. In order to overcome the imperfection of PID control, the Fuzzy Technology is introduced.

What is the Fuzzy Control? It works like a good driver. Under different speeds and circumstances, he can control a car well with experiences he had before and does not require the knowledge of kinetic theory of motion. The Fuzzy Logic is a linguistic control which is different from the numerical PID control. It controls the system by experiences and does not need to simulate the system precisely as been controlled by PID.

Figure 1-1.Fuzzy PID System Block Diagram

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The function of Fuzzy Logic is to adjust PID parameters internally in order to make manipulation output value MV more flexible and adaptive to various processes.PID + Fuzzy Control has been proven to be an efficient method to improve the control stability as shown by the comparison of curves shown below.

Figure 1-2.PID System Stability with and without Fuzzy

The Fuzzy Rule works like the below.

 If temperature difference is large and temperature rate is large, then MV is large.

 If temperature difference is high and temperature rate is small, then MV is small.

By using proprietary Fuzzy modified PID technology the control loop will minimize the overshoot and undershoot in a shortest time.

This Process Control Card can be configured as a single set point controller (static mode) or a ramp and dwell profiling controller (profile mode). The profile mode feature allows the user to program up to 50 profiles with up to 32 free format Segments (ramp, dwell, jump or end) each. The total segments available for the product are 1000 segments.

The Process Control Card contains the following features.

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1.3.1

Flexible Configuration of Program

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

1.3.2

1.3.3

1.3.4

Maximum Capacity of Program

There are at most 50 Profiles can be defined and 1000 segments totally available for all profiles. Each Profile can contain maximum of 32 Segments and limited to 1000 Segments in Total.

Event Input

The Event input feature allows the user to select one of eight functions below.

 Enter Profile Run Mode

 Enter Profile Hold Mode

 Abort Profile Mode

 Enter Manual Mode

 Perform Failure Transfer

 Enter Off Mode

 Advance to the next segment

 Select second set of PID values

Programmable Event Outputs

1.3.5

1.3.6

Up to 3 Relays are configurable for event outputs and the state of each output can be defined for each segment and end of profile.

High Accuracy

This Process Control Card is manufactured with custom designed ASIC(Application Specific Integrated Circuit ) technology which contains a 18-bit A to D converter for high resolution measurement ( true 0.1 F resolution for thermocouple and PT100 ) and a 15-bit D to A converter for linear current or voltage control output. The ASIC technology provides improved operating performance with low cost and enhanced reliability and higher density.

Fast Sampling Rate

The sampling rate of the input A to D converter reaches 5 times/second (200msec). The fast sampling rate allows this Process Control Card to control fast processes.

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1.3.7

Fuzzy Control

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

1.3.8

1.3.9

1.3.10

1.3.11

1.3.12

Auto-tuning

The auto-tuning function allows the user to simplify initial setup for a new system. A clever algorithm is provided to obtain an optimal set of control parameters for the process, and it can be applied either as the process is warming up ( cold start ) or as the process has been in steady state ( warm start ).

Lockout Protection

According to actual security requirement, a password is provided to prevent the unit from being changed abnormally.

Bumpless Transfer

Bumpless transfer allows the controller to continue to control by using its previous value as the sensor breaks. Hence, the process can be well controlled temporarily as like the sensor is normal.

Digital Filter

A first order low pass filter with a programmable time constant is used to improve the stability of process value. This is particularly useful in certain application where the process value is too unstable to read.

Soft-start Ramp

The ramping function is performed during power up as well as any time the set point is changed. It can be ramping up or ramping down. The process value will reach the set point with a predetermined constant rate.

1.3.13

Pump Control

In addition the fast sampling rate, this Process Control Card has superior noise rejection capability. So it can be used for pressure control of a Pump which is driven by Variable Frequency Drives.

1.4 Expansion I/O Modules for PID

The Paperless Recorder have the option to use PID function on it by using the Process Control Card in to it on the one of the 4 rear slots .

1.4.1

PID Control Module

This module is useful for single loop PID Control. This consists of Two Signal Inputs, one Event Input and control output and Alarm output as per the specification.

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1.5 Smart Mechanism

The data is recorded in manufacturer special binary format. It is not possible to manipulate the data. This feature guarantees the security and reliability of the recorded data .

1.6 Process Control Card PC201 Ordering Code

PC201- □ □ □

□

A B C D

A: Output 1

0: None

1: Relay 2A/240VAC

2: Pulse voltage to drive SSR, 5V/30mA

3: Isolated 4-20mA/0-20mA (OM95-3)

4: Isolated 1-5V/0-5V (OM95-4)

5: Isolated 0-10V (OM95-5)

6: Triac output 1A/240VAC,SSR

C: Pulse voltage to drive SSR, 14V/40mA (OM94-7)

B: Output 2

0: None

1: Relay 2A/240VAC

2: Pulse voltage to drive SSR, 5V/30mA

3: Isolated 4-20mA/0-20mA (OM95-3)

4: Isolated 1-5V/0-5V (OM95-4)

5: Isolated 0-10V (OM95-5)

6: Triac output 1A/240VAC,SSR

7: Isolated 20VDC/25mA power supply (DC94-1)

8: Isolated 12VDC/40mA power supply (DC94-2)

9: Isolated 5VDC/80mA power supply (DC94-3)

C: Pulse voltage to drive SSR, 14V/40mA (OM94-7)

C: Alarm 1

0: None

1: Form C relay 2A/240VAC

D: Alarm 2

0: None

1: Form A relay 2A/240VAC

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1.7 Specification

1.7.1

Input1

Resolution: 18 bits

Sampling Rate: 5 times / second

Maximum Rating: -2 VDC minimum, 12 VDC maximum (1 minute for mA input)

Temperature Effect: 1.5uV/°C for all inputs except mA input, ±3.0uV/°C for mA input

Sensor Lead Resistance Effect:

T/C: 0.2uV/ohm;

3-wire RTD: 2.6°C/ohm of resistance difference of two leads;

2-wire RTD: 2.6° C/ohm of resistance sum of two leads

Burn-out Current: 200nA

Common Mode Rejection Ratio (CMRR): 120dB

Normal Mode Rejection Ratio (NMRR): 55dB

Sensor Break Detection:

Sensor Open for TC, RTD and mV inputs

Sensor short for RTD input

Below 1 mA for 4-20 mA input,

Below 0.25V for 1 - 5 V input,

Unavailable for other inputs.

Sensor Break Responding Time:

Within 4 seconds for TC, RTD and mV inputs,

0.1 second for 4-20 mA and 1 - 5 V inputs.

Characteristics:

Type Range Accuracy @ 25°C Input Impedance

J -120°C to 1000°C ( -184°F to 1832°F )

K -200C to 1370 C ( -328°F to 2498°F ) ±2°C 2.2 MΩ

T -250°C to 400°C ( -418°F to 752°F ) ±2°C 2.2 MΩ

E -100°C to 900°C( -148°F to 1652°F ) ±2°C 2.2 MΩ

B 0°C to 1800°C( 32°F to 3272°F ) ±2°C( 200°C to 1800° C )

±2°C 2.2 MΩ

2.2 MΩ

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Type Range Accuracy @ 25°C Input Impedance

R 0°C to 1767.8°C( 32°F to 3214°F ) ±2°C 2.2 MΩ

S 0°C to 1767.8°C( 32°F to 3214°F ) ±2°C 2.2 MΩ

N -250°C to 1300°C( -418°F to 2372°F ) ±2°C 2.2 MΩ

L -200°C to 900°C( -328°F to 1652°F ) ±2°C 2.2 MΩ

PT100(DIN) -210°C to 700°C ( -346°F to 1292°F ) ±0.4°C 1.3KΩ

PT100(JIS) -200°C to 600°C( -328°F to 1112°F ) ±0.4°C 1.3Ω

mV -8mV to 70mV ±0.05% 2.2 MΩ

mA -3mA to 27mA ±0.05% 70.5Ω

V -1.3V to 11.5V ±0.05% 302KΩ

Table 1-1. Input 1 Characteristics

1.7.2

Input2

Resolution: 18 bits

Sampling Rate: 5 times / second

Maximum Rating: -2 VDC minimum, 12 VDC maximum (1 minute for mA input)

Temperature Effect: 1.5uV/°C for all inputs except mA input, ±3.0uV/°C for mA input

Common Mode Rejection Ratio (CMRR): 120dB

Normal Mode Rejection Ratio (NMRR): 55dB

Sensor Break Detection:

Below 1 mA for 4-20 mA input,

Below 0.25V for 1 - 5 V input,

Unavailable for other inputs.

Sensor Break Responding Time: 0.5 Seconds

Characteristics:

Type Range Accuracy @ 25°C Input Impedance

CT94-1 0.0 to 50.0 A ±2% of Reading ±0.2A

302KΩ

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Type Range Accuracy @ 25°C Input Impedance

1.7.3

1.7.4

mA -3mA to 27mA

V -1.3V to 11.5V

±0.05% 70.5Ω+(0.8V/Input Current)

±0.05% 302KΩ

Table 1-2. Input 2 Characteristics

Input3 (Event Input)

Logic Low: -10V minimum, 0.8V maximum.

Logic high: 2V minimum, 10V maximum

External pull-down Resistance: 400 KΩ maximum

External pull-up Resistance: 1.5 MΩ minimum

Functions: Select second set point and/or PID, Reset alarm 1 and/or alarm 2,

Disable output 1 and/or output 2, Remote lockout.

Output1/Output2

Relay Rating: 2A/240 VAC, life cycles 200,000 for Resistive load

Pulsed Voltage:

Source Voltage 5V, current limiting resistance 66Ω

Linear Output Characteristics:

Type Zero Tolerance Span Tolerance Load Capacity

4 to 20mA

0 to 20mA

3.8-4 mA 20-21 mA 500 Ω max

0 mA 20-21 mA 500 Ω max

0 to 5V 0 V 5 -5.25 V 10KΩ min

1 to 5V 0.95 to 1V 5 -5.25 V 10KΩ min

0 to 10V 0 V 10 - 10.5 V 10KΩ min

Table 1-3. Output Characteristics

Linear Output

Resolution: 15 bits

Output Regulation: 0.01 % for full load change

Output Settling Time: 0.1 sec. (stable to 99.9 %)

Isolation Breakdown Voltage: 1000 VAC

Page 16 of 113

Page 17

Temperature Effect: ±0.0025 % of SPAN /°C

Triac (SSR) Output

Rating: 1A / 240 VAC

Inrush Current: 20A for 1 cycle

Min. Load Current: 50 mA RMS

Max. Off-state Leakage: 3 mA RMS

Max. On-state Voltage: 1.5 V RMS

Insulation Resistance: 1000 MΩ minimum at 500 VDC

Dielectric Strength: 2500 VAC for 1 minute

Type Tolerance Maximum Output Current Ripple Voltage Isolation Barrier

20V ±0.5 V 25 mA 0.2 Vp-p 500 VAC

12V ±0.3 V 40 mA 0.1 Vp-p 500 VAC

5V ±0.15 V 80 mA 0.05 Vp-p 500 VAC

Table 1-4. SSR Output Characteristics

1.7.5

1.7.6

Alarm 1/ Alarm 2

Alarm 1 Relay: Form A or Form B, Max. Rating 2A/240VAC, life cycles 100,000 for

resistive load.

Alarm 2 Relay: Form A, Max. Rating 2A/240VAC, life cycles 200,000 for resistive load.

Alarm Mode: Normal, Latching, Hold, Latching / Hold.

Dwell Timer: 0 - 6553.5 minutes

Alarm Functions: Dwell timer, Deviation High / Low Alarm, Deviation Band High / Low

Alarm, PV1 High / Low Alarm, PV2 High / Low Alarm, PV1 or PV2 High / Low Alarm, PV1-PV2 High / Low Alarm, Loop Break Alarm, Sensor Break Alarm.

Control Mode

Output 1: Reverse (heating) or direct (cooling) action

Output 2: PID cooling control, cooling P band 1~255% of PB

ON-OFF: 0.1 - 100.0(F) hysteresis control (P band = 0)

P or PD: 0 - 100.0 % offset adjustment

Page 17 of 113

Page 18

PID: Fuzzy logic modified Proportional band 0.1 ~ 900.0°F, Integral time: 0 - 1000

Seconds, Derivative time 0 - 360.0 seconds

Cycle Time: 0.1 - 100.0 seconds

Manual Control: Heat (MV1) and Cool (MV2)

Auto-tuning: (MV2) Cold start and warm start

Self-tuning: Select None and YES

Failure Mode: Auto-transfer to manual mode while sensor break or A-D converter damage

Sleep Mode: Enable or Disable

Ramping Control: 0 - 900.0°F/minute or 0 - 900.0°F/hour ramp rate

Power Limit: 0 - 100 % output 1 and output 2

Pump / Pressure Control: Sophisticated functions provided

Remote Set Point: Programmable range for voltage or current input

Differential Control: Control PV1-PV2 at set point

1.7.7

Digital Filter

Function: First Order

Time Constant: 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60 seconds programmable

Page 18 of 113

Page 19

2 Installation and Wiring

Some times Dangerous voltages capable of causing death are present in this instrument. Before doing installation or any troubleshooting procedures the power to the equipment must be switched off and isolated. Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair. Component replacement and internal adjustments must be made by a qualified maintenance person only.

To minimize the possibility of fire or shock hazards, do not expose this instrument to rain or

excessive moisture

Do not use this instrument in areas under hazardous conditions such as excessive shock, vibration, dirt, moisture, corrosive gases or oil. The ambient temperature of the areas should not exceed the maximum rating specified in the specification

2.1 Unpacking

Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage. If any damage found then contact local representative immediately. Note the model number, serial number for future reference when corresponding with our service center. The serial number (S/N) is labeled on the box and the housing of Paperless Recorder

Remove stains from this equipment using a soft, dry cloth. Do not use harsh chemicals, volatile solvents such as thinner or strong detergents to clean the equipment in order to avoid deformation.

The Paperless Recorder is designed for indoor use and not in any hazardous area. It should be kept away from shock, vibration, and electromagnetic fields such as variable frequency drives, motors and transformers. It is intended to operate under the following environmental conditions.

Environmental Parameter Specification

Operating Temperature 0°C to 50 °C

Humidity 20% to 90% RH(Non-condensing)

Altitude 2000 M Maximum

Table 2-1.Environmental Specification

Page 19 of 113

Page 20

2.2 Input Output Wiring Connection

2.2.1

2.2.2

Wiring Precautions

Sometimes Dangerous voltages capable of causing death are present in this instrument. Before doing installation or any troubleshooting procedures the power to the equipment must be switched off and isolated. Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair. Component replacement and internal adjustments must be made by a qualified maintenance person only.

 Utmost Care must be taken to ensure that the maximum voltage rating specified on

the label is not exceeded.

 It is recommended to use an external fuse or an external switch rated at 2A/250

VAC for panel mount type wiring.

 The tightening torque on the Screw terminals should not exceed 0.4 N-m (3.6 Lb-in

or 4.0 Kg F-cm).

 Except Thermocouple Wiring, all other wires used to be Standard Copper

Conductor With maximum Gauge of 18AWG

 Grounding must be connected prior to turning on the Equipment with minimum of

1.6mm diameter conductor for protective grounding.

PID Control Module

This is a single loop PID Control Module which consists of Universal Input.

The Modules needs to be inserted to the rear slots or removed from the rear slots at

the Power OFF condition. Failure to do so may cause damage to the module or device or both. The Device will automatically detect the Module at Power ON, once it is inserted in to the rear

slots.

The Module output can be configured by using the configuration Menu. The configuration Menu can be reached by pressing Menu and then pressing More and then pressing Config key. It will display a tree type configuration layout for easy user configuration. By using Up/Down Key and Enter Key, PID Controller and Profile configuration window can be reached. In this window the user can configure the Controller parameters and profiles of PID Control Module. The user can select the desired output type and other parameters for analog output in this window.

Page 20 of 113

Page 21

Figure

The IO Mo

is ON. This should be carried out in the Power OFF Condition only.

For removing the IO Modules,

screws, after that press the lock on

to remove it. Failing to do so will damage the IO Card. Please follow

user manual

The Maximum Torque for the metal screw is 3Kg

Torque for the plastic

Calibration should be carried out by a qualified Engineer with qualified equipments

Thermocouple inputs requires 1 hour initial warm up time during initial setup.

dules should not be removed or Inserted to the device when the Power

First remove the metal screws then

the top and bottom of the Card and

cm (2.6in

Note:

2-1.Process Control Card Wiring Diagram



plastic

for more information.



screw is 0.8Kgf-cm (.7in-lb).



only.



remove the

pull

the Recorder

-lb) and the Maximum

Page 21 of 113

Page 22

3 Process Control Card Features

This Chapter will explain the features of the Process Control Card.

3.1 Configuration

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

3.2 Controller

The PID Module includes PID Controller function in the Paperless recorder and log the data .The PID Control module is used to control the process.

3.3 Ramp & Dwell Function

The PID Control Module includes Ramp & Dwell function. It is useful to control the process with varying set point time to time. There are 50 different Profiles can be configured with 32 Segments/Profile with the limit of 1000 Segments totally.

3.4 On Field Calibration

The Device allows the user to do on field calibration for the device. No need to send the device to factory for Calibration

Figure 3-1.Configuration Layout

Page 22 of 113

Page 23

4 Process Control Card Functions

This Section will explain the functions of Process Control Card. The user can configure the device as per their requirement by using the user friendly configuration menu.

The below is the home screen of paperless recorder. This screen will be displayed when the device powered on.

4.1 Menus

Press Soft key to access the menu in the furnace controller. The below menu screen will show the available menus.

Figure 4-1.Home Screen

Page 23 of 113

Page 24

Figure 4-2.Menu Screen

Press Real time to access the real time trend display pages of the furnace controller. Press the Page no to view the respective display pages. Press Overview to view the digital display of all channels. Press C1 to view the PID Controller Module display.

Figure 4-3.Real Time Menu

Page 24 of 113

Page 25

Figure 4-4.Overview Display

Figure 4-5.PID Controller Module Display

Press Mode to access the menu for different display modes. The user can select the desired display mode to display as per their requirements like trend, Bar, Digit or Mix mode.

Page 25 of 113

Page 26

Figure 4-6.Display Modes

Press Alarm to view Real time Alarms and acknowledge using Ack key.

Figure 4-7.Real Time Alarms

Page 26 of 113

Page 27

Press History to access the historical data of the individual pages and do the remarking. The user can write their own comments by using Handwriting function .This is explained in detail in the respective Chapter.

Figure 4-8.Historical Data Screen

Press Event to access the Historical Event and Reports from Internal and External memory. Press Storage to toggle between internal memory and External Memory like SD Card or USB Disk.

Page 27 of 113

Page 28

Figure 4-9.Event History

Press Key to Scroll Page Horizontally and Key to Scroll Page Vertically.

Press Keys to page Up and Down. Press Key to switch between Reports and Events.

In Report display press Mode to display the reports in Daily, Weekly, Monthly and List Modes.

Page 28 of 113

Page 29

Figure 4-10.Report Screen

Press More to access more menus like dump, Clear, Operate, Config, Start/Pause, Shut down Menus.

Figure 4-11.More Menu

Page 29 of 113

Page 30

Press Dump to Dump the data from Internal memory to External memory like SD Card or USB Disk.

Press Clear to Clear all the data in Internal memory.

Press Operate to Operate the desired job from the list.

Figure 4-12.Operate Menu

Press Config to access Tree type Configuration Lay out and perform configuration as per the desired application.

Page 30 of 113

Page 31

Figure 4-13.Configuration Layout

Press Save to save the configuration to SD Card or USB Device. Press Load to load the configuration from SD Card or USB Disk.

Press Default to load the default configuration from Internal memory.

Press key to go to home page.

Press Keys to move Up and Down to select the desired menu.

Press Key to Enter to the Selected Menu.

Press Start/Stop to Start and Stop logging. The status will be shown in the Status bar on the top of the screen.

Press Shut down to Stop and Shut down the Furnace controller.

Page 31 of 113

Page 32

4.2 Status Bar

The Status bar will be shown on top of every page. This will show the status of the memory, Alarm, logging status with real time Date and Time of the System.

Figure 4-14.More Menu

Figure 4-15.Status Bar During Logging

Figure 4-16.Status Bar During Logging Stopped

Figure 4-17.Status Bar during Logging with Batch function

Figure 4-18.Status Bar During Logging Stopped with Batch Function

Page 32 of 113

Page 33

4.3 Process Control Card Configuration

This Section will explain the configuration for Process Control Card functions. Press

(Menu) and then press More then press Config to Enter to Configuration Screen. A Tree type configuration will be displayed for the easy configuration. In addition to that Save Load, Default and Home Soft keys also available.

Figure 4-19.Tree Type Configuration Layout

Soft Keys

The below Soft Keys are available for the user to configure.

Page 33 of 113

Page 34

Enter Key

Up Key

Down Key

Home Key

Various options are available to select the configuration Parameters.

 The user can move the cursor up and down using the soft key and press the Enter

Soft key to Enter in to the highlighted parameter configuration

 The user can touch the desired parameter in the configuration tree and press Enter

Soft key to Enter in to that parameter Configuration

 The user can double touch the desired parameter in the configuration tree to Enter

in to that parameter configuration

Press Save to save the configuration to SD Card or USB Device. Press Load to load the configuration from SD Card or USB Disk. Press Default to load the default configuration from Internal memory.

4.3.1

Press key to return to home page.

The following section will explain the detailed explanation of configuration of the device.

Process Control Card Configuration

This section will explain the configuration of Process Control Process Control Card Channels. The Process Control Card configuration will have two sections for configuration as below

 Controller

 Profile

Page 34 of 113

Page 35

4.3.1.1 Controller

Press Controller and press Enter Key to Entering in to the Process Control Card controller configuration. Initially it displays C1 as the first controller configuration. Use the

navigational keys to select the next Controller Channels .Use the key move to

other Controller Channels. Use key to move between the different controller Configuration Parameters.

After completing the configuration press Back button and then press to return to main display and save the configuration automatically.

Figure 4-20.Process Control Card Channel Configuration

Page 35 of 113

Page 36

4.3.1.1.1 Name

Enable the user to define the name for each channel with the maximum limit of 18 Characters.

Select “Name”, then Press “Enter”, soft key, a keyboard with several keys appears. Press “Shift” to select special characters. Press “Caps” to select capital letters. Press soft key “OK” after entering a new channel name.

4.3.1.1.2 Parameter

This will allow the user to configure the PID Control function on the Process Control Card. Press Parameter and then press Enter Soft key to access the parameter configuration table. In the Configuration table the user can edit the parameters of the Process Control Card as per their requirement by selecting the desired parameter using the UP DOWN key and then press the Enter Soft Key. The Enter Soft key will be disabled for the restricted parameters.

Figure 4-21.Process Control Card Channel Configuration

Page 36 of 113

Page 37

Default allows the user to load the default configuration of the Process Control Card Parameters

Figure 4-22.Process Control Card Configuration Window

Figure 4-23.Process Control Card Configuration Window for Read only Parameter

Page 37 of 113

Page 38

The below table shows the list of parameters available in the Process Control Card for PID

Control function.

Parameter

Parameter Description

Notation

SP1 Set point 1 SP1L

TIME Dwell Time

A1SP Alarm 1 Set point

A1DV

Alarm 1 Deviation

Value

A2SP Alarm 2 Set point

A2DV

Alarm 2 Deviation

Value

Range

Low*B

*B1

-200.0°

(-360.0

*B1

-200.0°

(-360.0

°F)

Range High*B

SP1H

6553.5

*B1

200.0°

(360.0

°F)

*B1

200.0°

(360.0

°F)

Default

Value*C

100.0° C

(212.0°F)

0.0

100.0° C

(212.0° F)

10.0°

(18.0

°F)

100.0°

(212.0

°F)

10.0°

(18.0

°F)

Unit*E

minut

*E1

*E2

RAMP

Ramp

OFST

REFC

Offset Value for P

Reference Constant for

Specific Function

Rate

control

SHIF PV1 Shift (offset) Value

PB1

TI1

Integral Time 1 Value

Proportional Band 1

Value

-200.0°

(-360.0

°F)

500.0°

(900.0

100.0

200.0°

(360.0

500.0°

(900.0

1000

°F)

0.0

25.0

0.0

PV1

10.0°

(18.0

°F)

100

Sec

*E3

Page 38 of 113

Page 39

Parameter

Notation

TD1

Derivative Time 1 Value

Parameter Description

Range

Low*B

Range High*B

360.0

Default

Value*C

25.0

Sec

Unit*E

CPB

Cooling Proportional

Band Value

Heating-Cooling

Band

SP2 Set point 2

PB2

TI2

Integral Time 2 Value

TD2

Derivative Time 2 Value

O1HY

A1HY

Proportional Band 2

Value

Output 1 ON-OFF

Control

Hysteresis

Hysteresis Control of

Alarm 1

Dead

-36.0

*B2

0.1

255

36.0

*B2

500.0°

(900.0

°F)

1000

360.0

55.6°

(100.0

°F

100

37.8°

(100.0

10.0°

(18.0

100

25.0

0.1

°F

Sec

10.0°

(18.0

°F)

0.1

% of

*E1

A2HY

Hysteresis Control of

Alarm 2

PL1 Output 1 Power Limit

PL2 Output 2 Power Limit

FUNC

COMM

Function Complexity

Level

Communication

Interface Type

0.1

*B3

*B4

(18.0

100

*B3

*B4

°F)

0.1

100

10.0°

*E2

Page 39 of 113

Page 40

Parameter

Notation

Parameter Description

Range

Low*B

Range High*B

Default

Value*C

Unit*E

PROT

ADDR

BAUD

DATA

PARI

STOP

AOFN

Analog Output Function

COMM Protocol

Selection

Address Assignment

Digital COMM

Baud Rate of Digital

COMM

Data Bit count of Digital

COMM

Parity Bit of Digital

COMM

Stop Bit Count of

Digital

COMM

*B5

*B7

*B8

*B9

*B10

*B11

*B5

255

*B7

*B8

*B9

*B11

IN1

IN1U

IN1 Unit Selection

DP1

IN1 Sensor Type

Selection

IN1 Decimal Point

Selection

IN1L IN1 Low Scale Value

IN1H

IN1 High Scale Value

SP1L

SP1H

SP1 Low Scale Value

SP1 High Scale

Value

*B12

*B13

*B14

-19999

-19999 45536

-19999

*B12

*B13

*B14

45536

(0)

(1)

1000

0.0°

(32.0

°F)

1000.0°

(1832.0

°F)

*E5

Page 40 of 113

Page 41

Parameter

Notation

Parameter Description

Range

Low*B

Range High*B

Default

Value*C

Unit*E

IN2

IN2U

IN2 Unit

DP2

IN2L

IN2H

IN2 High Scale

EIFN

OUT1

O1TY

CYC1

Output 1 Cycle

O1FT

IN2 Signal Type

IN2 Decimal Point

IN2 Low Scale

Event Input

Output 1

Output 1 Signal

Output 1 Failure

Transfer

Selection

Function

Mode

Value

Type

Time

*B13

*B14

-19999

*B16

*B17

*B18

0.1

*B18

*B15

*B13

*B14

45536

*B16

*B17

*B18

100.0

*B18

1000

18.0

-0.1

*E6

Sec

OUT2

O2TY

CYC2

O2FT

A1FN

A1MD

A1FT

A2FN

Alarm 2

Output 2

Output 2 Signal

Output 2 Cycle

Function

Type

Time

Output 2 Failure

Transfer

Alarm 1

Mode

Function

Alarm 1 Operation

Mode

Alarm 1 Failure Transfer

Mode

Function

0.1

-0.1

*B18

*B19

100.0

*B22

*B23

*B24

*B22

*B18

100.0

*B22

*B23

*B24

*B22

*B19

18.0

-0.1

Sec

Page 41 of 113

Page 42

Parameter

Notation

Parameter Description

Range

Low*B

Range High*B

Default

Value*C

Unit*E

A2MD

A2FT

SELF

SLEP

PVMD

PV Mode

SP2F

FILT

SPMD

SEL1

Select 1'st

Alarm 2 Operation

Mode

Alarm 2 Failure Transfer

Mode

Self Tune Function

Selection

Sleep mode Function

Selection

Format of Set point 2

Value

Filter Damping Time

Constant of PV

Set point Mode

Selection

Parameter

*B23

*B24

*B25

*B26

*B27

*B28

*B29

*B30

*B31

*B23

*B24

*B25

*B26

*B27

*B28

*B29

*B30

*B31

SEL2

SEL3

SEL4

Select 4'th

SEL5

Select 5'th

DRIF

AD0

ADG

Select 2'nd

Select 3'rd

Parameter

Warm-up Drift

Calibration Factor

A to D Zero

Calibration

Coefficient

A to D Gain

Calibration

Coefficient

*B31

-360

-199.9

-5.0°C

*B31

5.0°C

360

199.9

°C

Page 42 of 113

Page 43

Parameter

Notation

Parameter Description

Range

Low*B

Range High*B

Default

Value*C

Unit*E

V1G

CJTL

CJG

REF1

SR1

MA1G

REF2

Voltage Input1 Gain

Calibration Coefficient

Cold Junction Low

Temperature Calibration

Coefficient

Cold Junction Gain

Calibration Coefficient

Reference Voltage1 Calibration Coefficient for RTD1

Serial Resistance 1 Calibration Coefficient for RTD1

mA input 1 Gain Calibration Coefficient

Reference Voltage2 Calibration Coefficient for RTD2

-199.9

-5.0°C

-199.9

199.9

40.0°C

199.9

°C

SR2

V2G

MA2G

O2L

O2H

SIG1

Serial Resistance 2 Calibration Coefficient for RTD2

Voltage input 2 Gain Calibration Coefficient

mA input 2 Gain Calibration Coefficient

Output 2 Low Calibration

Coefficient

Output 2 High

Calibration

Point 1 Signal Value of

Special Sensor

Coefficient

-199.9

-19999

199.9

360.0

900.0

45536

Page 43 of 113

Page 44

Parameter

Notation

Parameter Description

Range

Low*B

Range High*B

Default

Value*C

Unit*E

IND1

SIG2

IND2

SIG3

IND3

SIG4

IND4

SIG5

Point 1 Indication Value

of Special Sensor

Point 2 Signal Value of

Special Sensor

Point 2 Indication Value

of Special Sensor

Point 3 Signal Value of

Special Sensor

Point 3 Indication Value

of Special Sensor

Point 4 Signal Value of

Special Sensor

Point 4 Indication Value

of Special Sensor

Point 5 Signal Value of

Special Sensor

-19999

45536

IND5

SIG6

IND6

SIG7

IND7

SIG8

IND8

Point 5 Indication Value

of Special Sensor

Point 6 Signal Value of

Special Sensor

Point 6 Indication Value

of Special Sensor

Point 7 Signal Value of

Special Sensor

Point 7 Indication Value

of Special Sensor

Point 8 Signal Value of

Special Sensor

Point 8 Indication Value

of Special Sensor

-19999

45536

Page 44 of 113

Page 45

Parameter

Notation

Parameter Description

Range

Low*B

Range High*B

Default

Value*C

Unit*E

SIG9

IND9

TYPE

DATE

HOUR

HRLO

Fractional Hour

ERR1

ERR2

Point 9 Signal Value of

Point 9 Indication Value

of Special Sensor

Signal Type of Special

Manufacturing

Working Hour

Historical

Special Sensor

Sensor

Date of

Product

Serial Number of

Product

Value

Error

Record

Historical

Error

Record 2

-19999

45536

3719

999

65535

0.9

FFFF

Hour

0.1Hour

DELI

BPL1

BPL2

PVHI

PVLO

CJCL

FILE

ASCII Input

OUT1 Bumpless

Transfer

OUT2 Bumpless

Transfer

Historical Maximum

Value of PV

Historical Minimum

Value of PV

Sense Voltage of Cold

Junction Calibration Low

Default File

Delimiter

Value

Selection

0000

-19999

31.680

*B32

007F

100.00

45536

40.320

*B32

000A

Page 45 of 113

Page 46

Parameter

Notation

Parameter Description

Range

Low*B

Range High*B

Default

Value*C

Unit*E

Current Process

MV1

MV2

Current set point

Current Output 1

Current Output 2

Contains Conditional Code

ALM

of parameters Resolution and Current Alarm Status

PV1

IN1 Process

PV2

Current Deviation (PV-

SV)Value

IN2 Process

Current

Band

Current Integral Time

Value

Proportional

Value

-19999

-12600

-19999

*B33

45536

100.00

EF7F

12600

45536

500.0°

(900.0

°F)

4000

*B33

*E5

*E6

Sec

EROR

PROG

MODE

CMND

JOB

Current

Time

Current Error

Program

Identification

Contains Program

Number

Contains Lockout

Status code and

Current system mode

Command

Job

Derivative Value

Code

and

Version

Password

Code

*B34

*B35

*B36

1440

15.99

3.5

65535

*B34

*B35

Sec

Page 46 of 113

Page 47

Parameter

Notation

Parameter Description

Range

Low*B

Range High*B

Default

Value*C

Unit*E

Cold Junction

-40.0

CJCT

Compensation

° C

90.0° C

Temperature

PVR

PVRH

PVRL

SPC

Current Process Rate

Value

Maximum Process Rate

Value

Minimum Process Rate

Value

Current Target Value of

set

point

-16383

-19999

16383

45536

PV/min

Table 4-1.PID Parameter List

*B: The ranges of some parameters are dependent on the input types. The range of IN1 and IN2 for

various input type is shown in the following table:

Input Type Range Low Rang High

°C

J_T/C -120°C(-184°F) 1000°C(1832°F)

K_T/C -200°C(-328°F) 1370°C(2498°F)

T_T/C -250°C(-418°F) 400°C(752°F)

E_T/C -100°C(-148°F) 900°C(1652°F)

B_T/C 0°C(32°F) 1820°C(3308°F)

R_T/C 0°C(32°F) 1767.8°C(3214°F)

S_T/C 0°C(32°F) 1767.8°C(3214°F)

N_T/C -250°C(-418°F) 1300°C(2372°F)

L_T/C -200°C(-328°F) 900°C(1652°F)

PT100_DN -210°C(-346°F) 700°C(1292°F)

Page 47 of 113

Page 48

Input Type Range Low Rang High

PT100_JS -210°C(-346°F) 600°C(1112°F)

CT 0 Amps 90 Amps

Linear (mA or Voltage) -19999 45536

Table 4-2.Process Control Card Input Range

*B1: Range For A1SP & A2SP

If A1FN= Range of A1SP same as range of

PV1.H,PV1.L IN1

PV2.H,PV2.L IN2

P1.2 H,P1.2 L,D1.2 H ,D1.2 L IN1,IN2

If A2FN= Range of A2SP same as range of

PV1.H,PV1.L IN1

PV2.H,PV2.L IN2

P1.2 H,P1.2 L,D1.2 H ,D1.2 L IN1,IN2

*B2: Range For SP2

If PVMD= Range of SP2 same as range of

PV1 IN1

PV2 IN2

Table 4-3.Range of A1SP

Table 4-4.Range of A2SP

P1-2,P2-1 IN1,IN2

Table 4-5.Range Of SP2

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*B3: Display Symbol and Description of FUNC

Parameter Value Display Symbol Description

0 BASC Basic Function Mode

1 FULL Full Function Mode

Table 4-6.Mode Selection

*B4: Display Symbol and Description For COMM

Parameter Value Display Symbol Description

0 NONE No Communication Function

1 485 RS-485 Interface

2 232 RS-232 Interface

3 4-20 4-20mA Analog Retransmission Output

4 0-20 0-20mA Analog Retransmission Output

5 0-1V 0-1V Analog Retransmission Output

6 0-5V 0-5V Analog Retransmission Output

7 1-5V 1-5V Analog Retransmission Output

8 0-10V 0-10V Analog Retransmission Output

Table 4-7.Communication Mode

*B5: Display Symbol and Description For PROT

Parameter Value Display Symbol Description

0 RTU Modbus RTU Mode

1 ASCI Modbus ASCII Mode

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Parameter Value Display Symbol Description

2 DNET Devicenet Protocol

3 PBUS Profibus Protocol

4 FBUS Fieldbus Protocol

5 ABUS Reserved

6 BNET Reserved

Table 4-8.Communication Protocol

*B7: Display Symbol and Description For BAUD

Parameter Value Display Symbol Description

0 0.3 0.3 Kbits/Second Baud Rate

1 0.6 0.6 Kbits/Second Baud Rate

2 1.2 1.2 Kbits/Second Baud Rate

3 2.4 2.4 Kbits/Second Baud Rate

4 4.8 4.8 Kbits/Second Baud Rate

5 9.6 9.6 Kbits/Second Baud Rate

6 14.4 14.4 Kbits/Second Baud Rate

7 19.2 19.2 Kbits/Second Baud Rate

8 28.8 28.8 Kbits/Second Baud Rate

9 38.4 38.4 Kbits/Second Baud Rate

Table 4-9.Communication Baud Rate

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*B8: Display Symbol and Description For DATA

Parameter Value Display Symbol Description

0 7BIT 7 Data Bits

1 8BIT 8 Data Bits

Table 4-10.Communication Data Length

*B9: Display Symbol and Description For PARI

Parameter Value Display Symbol Description

0 EVEN Even Parity

1 ODD Odd Parity

2 NONE No Parity

Table 4-11.Communication Parity

*B10: Display Symbol and Description For STOP

Parameter Value Display Symbol Description

0 1 BIT One Stop Bit

1 2 BIT Two Stop Bits

Table 4-12.Communication Stop Bit

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*B11: Display Symbol and Description For AOFN

Parameter Value Display Symbol Description

0 PV1 Retransmit IN1 Process Value

1 PV2 Retransmit IN2 Process Value

2 P1-2 Retransmit IN1-IN2 Difference Process Value

3 P2-1 Retransmit IN2-IN1 Difference Process Value

4 SV Retransmit Set Point Value

5 MV1 Retransmit Output1 manipulation Value

6 MV2 Retransmit Output2 manipulation Value

7 DV Retransmit Deviation(PV-SV) Value

Table 4-13 Function of AOFN

*B12: Display Symbol and Description For IN1

Parameter Value Display Symbol Description

0 J_TC J Type Thermocouple

1 K_TC K Type Thermocouple

2 T_TC T Type Thermocouple

3 E_TC T Type Thermocouple

4 B_TC B Type Thermocouple

5 R_TC R Type Thermocouple

6 S_TC S Type Thermocouple

7 N_TC N Type Thermocouple

8 L_TC L Type Thermocouple

9 PT.DN PT 100 Ohms DIN Curve

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Parameter Value Display Symbol Description

10 PT.JS PT100 Ohms JIS Curve

11 4-20 4-20mA Linear Current Input

12 0-20 0-20mA Linear Current Input

13 0-1V 0-1V Linear Voltage Input

14 0-5V 0-5V Linear Voltage Input

15 1-5V 1-5V Linear Voltage Input

16 0-10 0-10V Linear Voltage Input

17 SPEC Special defined sensor Curve

Table 4-14 Selection of IN1 Type

*B13: Display Symbol and Description For IN1U & IN2U

Parameter Value Display Symbol Description

0 °C Degree Celsius Unit

1 °F Degree Fahrenheit Unit

2 PU Process Unit

Table 4-15.Display Unit for IN1 & IN2

*B14: Display Symbol and Description For DP1 &DP2

Parameter Value Display Symbol Description

0 NO-DP No Decimal Digit

1 1-DP One Decimal Digit

2 2-DP Two Decimal Digits

3 3-DP Three Decimal Digits

Table 4-16.Decimal Digit for DP1&DP2

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*B15: Display Symbol and Description For IN2

Parameter Value Display Symbol Description

0 NONE IN2 No Function

1 CT Current Transformer Input

2 4-20 4-20mA Linear Current Input

3 0-20 0-20mA Linear Current Input

4 0-1V 0-1V Linear Voltage Input

5 0-5V 0-5V Linear Voltage Input

6 1-5V 1-5V Linear Voltage Input

7 0-10 0-10V Linear Voltage Input

Table 4-17.IN2 Input

*B16: Display Symbol and Description For EIFN

Parameter Value Display Symbol Description

0 NONE Event Input No Function

1 SP2 SP2 Activated to replace SP1

2 PID2 PB2,TI2,TD2 Activated to replace PB1,TI1,TD1

3 SP.P2 SP2,PB2,TI2,TD2 Activated to replace SP1,PB1,TI1,TD1

4 RS.A1 Reset Alarm 1 Output

5 RS.A2 Reset Alarm2 Output

6 R.A1.2 Reset Alarm1 & Alarm2 Output

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Parameter Value Display Symbol Description

7 D.O1 Disable Output1

8 D.O2 Disable Output2

9 D.O1.2 Disable Output1 &Output 2

10 LOCK Lock All Parameters

Table 4-18.EIFN Function

*B17: Display Symbol and Description For OUT1

Parameter Value Display Symbol Description

0 REVR Reverse(Heating)Control Action

1 DIRT Direct(Cooling)Control Action

Table 4-19.OUT1 Action

*B18: Display Symbol and Description For O1TY & O2TY

Parameter Value Display Symbol Description

0 RELY Relay Output

1 SSRD Solid State Relay Drive Output

2 SSR Solid State Relay Output

3 4-20 4-20mA Current Module

4 0-20 0-20mA Current Module

5 0-1V 0-1V Voltage Module

6 0-5V 0-5V Voltage Module

7 1-5V 1-5V Voltage Module

8 0-10 0-10V Voltage Module

Table 4-20.OUT1 & OUT2 Type

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*B19: Failure transfer mode for output 1 and output 2, select BPLS ( bumpless transfer ) or

0.0 ~ 100.0 % to continue output 1 and output 2 control function as the unit fails , power starts or manual mode starts.

*B20: Display Symbol and Description For OUT2

Parameter Value Display Symbol Description

0 NONE Output 2 no function

1 COOL PID cooling control

3 DCPS DC power supply module installed

Table 4-21.OUT2 Function

*B21: Display Symbol and Description For DISF

Parameter Value Display Symbol Description

0 PV Display PV Value

1 SV Display SV Value

Table 4-22.Display Function

*B22: Display Symbol and Description For A1FN & A2FN

Parameter Value Display Symbol Description

0 NONE No alarm function

1 TIMR Dwell timer action

2 DE.HI Deviation high alarm

3 DE.LO Deviation low alarm

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Parameter Value Display Symbol Description

4 DB.HI Deviation band out of band alarm

5 DB.LO Deviation band in band alarm

6 PV1.H IN1 process value high alarm

7 PV1.L IN1 process value low alarm

8 PV2.H IN2 process value high alarm

9 PV2.L IN2 process value low alarm

10 P1.2.H IN1 or IN2 process value high alarm

11 P1.2.L IN1 or IN2 process value low alarm

12 D1.2.H IN1 IN2 difference process value high alarm

13 D1.2.L IN1 IN2 difference process value low alarm

14 LB Loop break alarm

15 SEN.B Sensor break or A-D fails

Table 4-23. Alarm1 & Alarm 2 Function

*B23: Display Symbol and Description For A1MD & A2MD

Parameter Value Display Symbol Description

0 NORM Normal alarm action

1 LTCH Latching alarm action

2 HOLD Hold alarm action

3 LT.HO Latching & Hold action

Table 4-24.Alarm1 & Alarm2 Operation Mode

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*B24: Display Symbol and Description For A1FT & A2 FT

Parameter Value Display Symbol Description

0 OFF Alarm Output OFF as unit Fails

1 ON Alarm Output ON as unit Fails

Table 4-25.Alarm1 & Alarm2 Failure Transfer Mode

*B25: Display Symbol and Description For SFLF

Parameter Value Display Symbol Description

0 NONE Auto tuning (Self Tune) Function disabled

1 YES Auto tuning (Self Tune) Function Enabled

Table 4-26.Auto Tuning

*B26: Display Symbol and Description For SLEP

Parameter Value Display Symbol Description

0 NONE Sleep Mode Function disabled

1 YES Sleep Mode Function Enabled

Table 4-27.Sleep Mode

*B27: Display Symbol and Description For PVMD

Parameter Value Display Symbol Description

0 PV1 Use PV1 as Process Value

1 PV2 Use PV2 as Process Value

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Parameter Value Display Symbol Description

2 P1-2 Use PV1-PV2 Difference as Process Value

3 P2-1 Use PV2-PV1 Difference as Process Value

Table 4-28.PV Mode Selection

*B28: Display Symbol and Description For SP2F

Parameter Value Display Symbol Description

0 ACTU Setpoint2 (SP2)is an Actual Value

1 DEVI Setpoint2 (SP2) is an Deviation Value

Table 4-29.SP2 Set Point Format

*B29: Display Symbol and Description For FILT

Parameter Value Display Symbol Description

0 0 0 second time constant

1 0.2 0.2 second time constant

2 0.5 0.5 second time constant

3 1 1 second time constant

4 2 2 seconds time constant

5 5 5 seconds time constant

6 10 10 seconds time constant

7 20 20 seconds time constant

8 30 30 seconds time constant

9 60 60 seconds time constant

Table 4-30 Filter Damping Time Constant of PV

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*B30: Display Symbol and Description For SPMD

Parameter Value Display Symbol Description

0 SP1.2 Use SP1 or SP2 (depends on EIFN) as set point

1 MIN.R Use minute ramp rate as set point

2 HR.R Use hour ramp rate as set point

3 PV1 Use IN1 process value as set point

4 PV2 Use IN2 process value as set point

5 PUMP Selected for pump control

Table 4-31 Set Point Mode Selection

*B31: Display Symbol and Description For SEL1-SEL5

Parameter Value Display Symbol Description

0 NONE No parameter put ahead

1 TIME Parameter TIME put ahead

2 A1.SP Parameter A1SP put ahead

3 A1.DV Parameter A1DV put ahead

4 A2.SP Parameter A2SP put ahead

5 A2.DV Parameter A2DV put ahead

6 RAMP Parameter RAMP put ahead

7 OFST Parameter OFST put ahead

8 REFC Parameter REFC put ahead

9 SHIF Parameter SHIF put ahead

10 PB1 Parameter PB1 put ahead

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Parameter Value Display Symbol Description

11 TI1 Parameter TI1 put ahead

12 TD1 Parameter TD1 put ahead

13 C.PB Parameter CPB put ahead

14 DB Parameter DB put ahead

15 SP2 Parameter SP2 put ahead

16 PB2 Parameter PB2 put ahead

17 TI2 Parameter TI2 put ahead

18 TD2 Parameter TD2 put ahead

Table 4-32 SEL Selection

*B32: Display Symbol and Description For FILE

Parameter Value Display Symbol Description

0 0 Perform Default Setting by using °C File

1 1 Perform Default Setting by using °F File

Table 4-33 Default File Selection

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*B33: Description of Alarm Value

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*B34: Error Messages

Error Code Display Symbol Error Description Corrective Action

Er 01

Illegal setup values

used: PV1 is used for

both PVMD and SPMD

that is meaningless for

control.

Er 02

Illegal setup values

used: PV2 is used for

both PVMD and SPMD

Check and correct setup

values of PVMD and

SPMD, PV and SV can't

use the same value for

normal control

Same as error code1

that is meaningless for

control

Illegal setup values used: P1-2 or P2-1 is used for PVMD while

Er 03

PV1 or PV2 is used for

SPMD. Dependent

values are used for PV

and SV will produce

incorrect result of

control

Check and correct setup

values of PVMD and

SPMD.

Difference of PV1 and

PV2 can't be used for

PV while PV1 or PV2

is used for SV

Check and correct setup

values of OUT2, PB1,

PB2, TI1, TI2 and OUT1.

IF OUT2 is required for

cooling control, the

control should use PID

mode

( PB = 0, TI = 0 ) and

OUT1 should use

reverse mode (heating

action), otherwise, don't

Illegal setup values

used: COOL is used for

Er 04

OUT2, but DIRT (cooling

action) is already used

for OUT1 or PID mode is

not

used for OUT1 (that is

PB1 or PB2 =0, and

TI1 or TI2 =0)

use OUT2 for cooling

control

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Error Code Display Symbol Error Description Corrective Action

Illegal setup values

Er 05

used: unequal IN1U and

IN2U or unequal DP1

and DP2 while

P1-2 or P2-1 is used for

PVMD or, PV1 or PV2 is

used for SPMD or,

P1.2.H, P1.2.L, D1.2.H

or D1.2.L is used for

A1FN or A2FN.

Er 06

Illegal setup values

used: OUT2 select

=AL2 but A2FN select

Check and correct setup

values of IN1U

, IN2U, DP1, DP2,

PVMD, SPMD, A1FN or

A2FN. Same unit and

decimal point

should be used if both

PV1 and PV2 are used

for PV, SV, alarm1 or

alarm 2.

Check and correct setup

values of OUT2 and

A2FN. OUT2 will not

perform alarm function if

A2FN select NONE.

NONE

Er 07

Illegal setup values

used: Dwell timer (TIMR)

is selected for both

A1FN and A2FN.

Check and correct setup

values of A1FN and

A2FN. Dwell timer can

only be properly used for

single alarm output.

9 Er 09

Communication error:

receive error due to parity error, framing error, overrun error,

receive buffer full error,

frame check-sum error

or receive disturbed

1.Correct the communication software to meet the protocol requirements

2. Add a terminating resister to the multi- drop link (RS-485) to minimize the noise.

3. Use twisted pair wire for RS-485 interface connection to minimize the noise.

4. Check the polarity of RS-485 interface connection.

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Error Code Display Symbol Error Description Corrective Action

10 Er 10

11 Er 11

12 Er 12

14 Er 14

15 Er 15

Communication error:

bad function code

Communication error:

range

Communication error:

access a non-existent

parameter

Communication error:

attempt to write a read

only data

Communication error:

write a value which is out

of range to a register

Correct the

communication software

to meet the protocol

requirements.

Don't issue an over-

range address of register

to the slave.

Don't issue a non-

existent parameter to

the slave.

Don't write a read only

data or a protected data

to the slave.

Don't write an over-

range data to the slave

17 Er 17

18 Er 18

19 Er 19

20 Er 20

21 Er 21

Computing error: Illegal

(abnormal) floating point

data

Computing error:

Arithmetic result

overflow or underflow

Computing error:

divided by zero

Computing error: Illegal

BCD data entry

Timing error: A toD

conversion data error

due to overrun

Software bug. Return to

factory for repair.

Software bug. Return to

factory for repair.

Don't use an equal value

for AOLO and AOHI.

Software bug. Return to

factory for repair.

A to D converter doesn't work properly. Return to

factory for repair.

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Error Code Display Symbol Error Description Corrective Action

22 Er 22

23 Er 23

26 AtEr

Timing error: check-sum

error received during

multi-chip

communication

procedure

Timing error: wrong

function code received

during multi-chip

communication

procedure

Fail to perform

auto-tuning function

1. Correct the multi-chip communication software to meet the protocol requirement.

2. Return to factory for repair.

1. Correct the multi-chip communication software to meet the protocol requirement.

2.Return to factory for

Repair.

1.The PID values obtained after autotuning procedure are out of range.Retry autotuning.

2.Don't change set point value during auto-tuning procedure.

3 .Don’t change Event input state during autotuning procedure.

4.Use manual tuning

instead of auto-tuning.

27 CAER

Incorrect calibration

procedure or tolerance

of analog component too

big to meet specified

accuracy

1.Pay more attention to the calibration procedures.

2.Return to factory for repair.

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Error Code Display Symbol Error Description Corrective Action

sensor used is accordant

28 CAPE

29 EEPE

32 CJER

33 YYER

34 LLL2

Memory comparison

error, different value

detected in the

EEPROM and mapped

RAM

EEPROM can't be

written correctly

Cold junction

compensation device(s)

malfunction

Key switch shorted or

related PCB circuit

shorted

Input 2 ( IN2 ) signal too

low

1.Check and correct the wiring and grounding problems to minimize the system noise.

2.Return to factory for repair.

Return to factory for

repair.

Return to factory for

repair.

Return to factory for

repair.

1.Check if the input 2 sensor used is accordan with IN2 type selection.

2.Check the connection polarity of input 2 sensor.

3.Replace input 2 sensor.

35 HHH2

Input 2 ( IN2 ) signal too

high

1.Check if the input 2

with IN2 type selection.

2.Replace input 2 sensor.

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Error Code Display Symbol Error Description Corrective Action

sensor used is accordant

nsor used is accordant

1.Check if the input 1

36 LLL1

37 HHH1

38 SB2E

Input 1 ( IN1 ) signal too

low

Input 1 ( IN1 ) signal too

high

Input 2 ( IN2 ) sensor

break, or input 2 current

below 1 mA if

4-20 mA is selected, or

input2 voltage below

0.25V if 1 - 5V is selected

with IN1 type selection.

2.Check the connection polarity of input 1 sensor.

3.Replace input 1 sensor.

1.Check if the input 1 se with IN1 type selection.

2.Replace input 1

sensor.

Replace input 2 sensor.

39 SB1E

40 ADER

Table 4-34.Error Codes and Corrective Actions

Input 1 ( IN1 ) sensor

break, or input 1 current

below 1 mA if

4-20 mA is selected, or

input1 voltage below

0.25V if 1 - 5V is selected

A to D converter or

related component(s)

malfunction

Replace input 1 sensor.

Return to factory for

repair.

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*B35:PROG CODE Description

Parameter

Value

0.XX BTC-2500 controller

1.XX BTC-4300 controller

2.XX BTC-9500 controller

3.XX BTC-8300 controller

4.XX BTC-4300 controller & Process Control card of PR

5.XX BTC-7200 controller

6.XX BTC-9100 controller

7.XX SM-40A smart panel meter

8.XX Reserved

9.XX ST-30A smart transmitter

Specified product

10.XX Reserved

11.XX Reserved

12.XX Reserved

13.XX Reserved

14.XX ST-20A smart transmitter ( software setup)

15.XX ST-20A smart transmitter ( DIP switches setup )

Table 4-35 PROG CODE

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*B36: Display Symbol and Description of MODE

Parameter Value Description

X.0 Perform normal mode

X.1 Enter calibration mode

X.2 Enter auto-tuning mode

X.3 Enter failure mode

X.4 Enter manual mode

X.5 Enter sleep mode

0.X Unlock condition

1.X SP1, SEL1 SEL5 are unlocked

2.X Lock all parameters except SP1

3.X All parameters are locked

Table 4-36 Mode

*C: The Parameters are preset with the default values specified in the table during production

*E: The unit PV means that the unit of parameter is the same as the unit of PV (process value ).The unit

of PV is determined by PVMD , IN1, IN2, IN1U, and IN2U.

*E1: Unit determination for A1SP, A1DV and A1HY

If A1FN= Range of A1SP same as range of

DE.HI,DE.LO,DB.HI,DB.LO PV

PV1.H,PV1.L PV1

PV2.H,PV.L PV2

P1.2.H,P1.2.L,D1.2.H,D1.2.L PV1,PV2

Table 4-37.Unit Determination for A1SP,A1DV,A1HY

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*E2: Unit determination for A2SP, A2DV and A2HY

If A2FN= Range of A2SP same as range of

DE.HI,DE.LO,DB.HI,DB.LO PV

PV1.H,PV1.L PV1

PV2.H,PV.L PV2

P1.2.H,P1.2.L,D1.2.H,D1.2.L PV1,PV2

Table 4-38.Unit Determination for A2SP,A2DV,A2HY

*E3: Unit determination for Ramp

If SPMD= Unit

MIN.R PV/Minute

HR.R PV/Hour

Table 4-39.RAMP Unit

*E4: Unit determination for AOLO and AOHI

If AOFN= Same Unit as Unit of

PV1 PV1

PV2 PV2

P1-2,P2-1 PV1,PV2

SV PV

MV1,MV2 %

Table 4-40 .Unit Determination of AOLO & AOHI

*E5: Unit is the same as unit of PV1 ( IN1 )

*E6: Unit is the same as unit of PV2 ( IN2 )

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4.3.1.1.3 Channel

The Channel will allow the user to configure the logging parameters. Press Channel and

then press Enter Soft key to access the Channel parameter of Process Control Card.

Figure 4-24.Process Control Card Channel Configuration

Name:

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

Desc:

The description about a specific channel on the display.

Type:

Option available to enable or disable the channel from logging.

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Source:

There are two options are available for source. They are as below

 PV

 SV

The first channel will show PV and the second Channel will show SV in source. These two parameters can be logged in the recorder from the Process Control Card.

 By using the Key to switch between Channels.

Log:

This is to set the desired logging parameter settings

Data Type:

2 byte

2 byte range: -3276.8 to +3276.7

Trigger:

Two options are available

 Disable: Select disable while the recording of a specific channel is not required.

 Enable: Select Enable while the recording of a specific channel is required.

Method:

This is the method of logging measured data. Select Method and Press “Enter”,

soft key to have the selection of different log methods. Then choose the required Log method. The available log methods are as below.

 Instant: logging the last measured data at the sampling interval

 Average: logging the averaged measured data at the sampling interval

 Minimum: logging the minimum measured data at the sampling interval

 Maximum: logging the maximum measured data at the sampling interval

Speed:

It is the logging speed (recording speed) of measured data. Select Log Speed and

then choose log speed to one of the below.

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Figure 4-25.Log Speed

Modbus Scale:

Scale for reading the Analog Input Values through Modbus

Events

Events are generally used to generate Alarms. The Events can also be used to process Digital Output, Timer, Counter, Totalizers and to generate report.

There are maximum 5 Events can be added for Analog Inputs.

Press Add to Add the Events. Press Remove to Remove the Events.

Figure 4-26.Events with Job

Type:

There are different types are available to select for Job of Event or Alarm. The available

types are H, L, HH, LL, Dev+, Dev-, and Error

H: High limit. When the process is over high limit, the alarm or job is actuated.

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L: Low limit. Any the process is lower than low limit, the alarm or job is actuated.

HH: High High limit, to set up another limit higher than high limit for double warning.

LL: Low Low limit, to set up another limit lower than low limit for double warning.

Dev+: Trigger an event on positive deviation of process value. The job or alarm is activated when

process value is deviated more than the set point in positive direction. (Set point +Previous sampled Process Value)

Example:

Set point =10

At 10.00.01 Hrs Tag1=40

At 10.00.02 Hrs Tag1 = 51

Then, job or alarm is activated

Dev-: Trigger an event on negative deviation of process value. The job or alarm is activated when process value is deviated less than the set point in negative direction. (Previous sampled Process Value-Set point)

Example:

Set point =10

At 10.00.01 Hrs, Tag1=40

At 10.00.02 Hrs, Tag1 = 29

Then, job or alarm is activated.

Error: On Channel error, an alarm or job is activated

Set point: To set up the process value for actuating Job1 and /or Job2 Alarm Log Alarm: Record alarms Log Alarm (Auto Ack): Record alarms and acknowledge automatically Log Event: Record events Job1, Job2:

When an event occurs, the task to be performed is called the job. A typical example is to trigger an alarm buzzer in the event of a high temperature. Each Channel can accept five different types of events (or alarms) and each event can create two jobs. Please note that a job under Event is different from a job created by pressing the Operate key. The former is actuated by an event, and the latter is actuated by manual control, no event necessary.

Note: Please refer to the section “Jobs”in Recorder user manual for full details about various jobs available

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Hysteresis

To avoid the event or alarm has been activated too often hysteresis value can be set for the alarm to change it in to normal state. Hysteresis value can be defined for the event trigger set point.

Holding time:

It refers to, suppose the set point is reached, but the user want to wait for some time to activate that action. This time is holding time. In process sometimes SP is reached but it will go down immediately, that might due to process instability. To encounter this issue the user have given an holding time, to see that PV stays at above that SP more than the holding time and then activate action for that event.

Example1

If the temperature is increased to more than 100 °C, log alarm and switch on digital

output1. When the temperature is decreased to less than 50 °C, log the alarm and switch off the digital output1. Setting of events for the analog input in the channel configuration is as follows.

Figure 4-27. Event Configuration Example

4.3.1.1.4 Sample Configuration of Process Control Card

4.3.1.1.4.1 Heat Only ON-OFF Control

Select REVR for OUT1, Set PB1 to 0, SP1 is used to adjust set point value, O1HY is used

to adjust dead band for ON-OFF control, TIME is used to adjust the dwell timer (enabled by

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selecting TIMR for A1FN or A2FN). The output 1 hysteresis (O1HY) is enabled in case of PB1 = 0. The heat only on-off control function is shown in the following diagram.

Figure 4-28.Heat Only ON-OFF Control

The ON-OFF control may introduce excessive process oscillation even if Hysteresis is minimized to the smallest. If ON-OFF control is set (i.e. PB1 = 0), TI1, TD1, CYC1, OFST, CPB and PL1 will be hidden and have no function to the system. The manual mode, auto-tuning, selftuning and bumpless transfer will be disabled too.

Select REVR for OUT1, set TI1 to 0, SP1 is used to adjust set point value, TIME is used to adjust the dwell timer (enabled by selecting TIMR for A1FN or A2FN). OFST been enabled in case of TI1 = 0 is used to adjust the control offset ( manual reset ). Adjust CYC1 according to

The output 1 type ( O1TY ).Generally, CYC1= 0.5 ~ 2 sec for SSRD and SSR, CYC1=10 ~ 20 sec

for relay output .CYC1 is ignored if linear output is selected for O1TY. If PB1 is not equal to 0.

OFST is measured by % with range 0 - 100.0 %. In the steady state ( i.e. process has been stabilized ) if the process value is lower than the set point a definite value, say 5 C, while 20 C is used for PB1, that is lower 25 %, then increase OFST 25 %, and vice versa. After adjusting OFST value, the process value will be varied and eventually, coincide with set point.

Using the P control ( TI1 set to 0 ), the auto-tuning and self-tuning are disabled. Manual reset ( adjust OFST ) is not practical because the load may change from time to time and often need to adjust OFST repeatedly. The PID control can avoid this situation. Selecting REVR for OUT1, SP1 is used to adjust set point value.

TIME is used to adjust the dwell timer ( enabled by selecting TIMR for A1FN or A2FN ). PB1 and TI1 should not be zero. Adjust CYC1 according to the output 1 type ( O1TY ). Generally, CYC1 = 0.5 ~ 2 sec for SSRD and SSR, CYC1 = 10 ~ 20 sec for relay output. CYC1 is ignored if linear output is selected for O1TY.

In most cases the self-tuning can be used to substitute the auto-tuning. See If self-tuning is not used ( select NONE for SELF ), then use auto-tuning for the new process, or set PB1, TI1 and TD1 with historical values. If the control result is still unsatisfactory, then use manual tuning to

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improve the control .This Process Control Card contains a very clever PID and Fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is properly tuned.

4.3.1.1.4.2 Cool Only ON-OFF Control

ON-OFF control, P (PD) control and PID control can be used for cool control. Set OUT1 to DIRT (direct action). The other functions for cool only ON-OFF control, cool only P(PD) control and cool only PID control are same as Heat only ON-OFF Control except that the output variable

(and action ) for the cool control is inverse to the heat control, such as the following diagram

shows:

4.3.1.1.4.3 Heat Cool Control

The Heat-Cool Control can use one of 6 combinations of control modes. Setups of

Parameters for each control mode are shown in the following table.

Figure 4-29.Cool Only ON-OFF Control

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Table 4-41.Heat Cool Control Modes

Note

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

Other Setup Required

O1TY, CYC1, O2TY, CYC2, A2SP, A2DV,O1TY & O2TY are set in accordance with the types of OUT1 & OUT2 installed. CYC1 & CYC2 are selected according to the output 1 type ( O1TY ) & output 2 type ( O2TY ).Generally, selects 0.5 ~ 2 sec. for CYC1, if SSRD or SSR is used for O1TY; 10 ~ 20 sec. if relay is used for O1TY, and CYC1 is ignored if linear output is used. Similar condition is applied for CYC2 selection.

Examples

 Heat PID+Cool ON-OFF: Set OUT1= REVR, A1FN or A2FN= PV1.H, A1FN or

A2MD=NORM, A1HY or A2HY=0.1, PB1=0, TI1=0, TD1=0, and set appropriate values for O1TY and CYC1.

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 Heat PID+Cool PID: set OUT1=REVR, OUT2=COOL, CPB=100, DB=-4.0, PB1=0,

TI1=0, TD1=0, and set appropriate values for O1TY, CYC1, O2TY, and CYC2.

CPB Programming

The cooling proportional band is measured by % of PB with range 1~255. Initially set 100% for CPB and examine the cooling effect. If cooling action should be enhanced then decrease CPB .If cooling action is too strong then increase CPB. The value of CPB is related to PB and its value remains unchanged throughout the self-tuning and auto-tuning procedures.

Adjustment of CPB is related to the cooling media used. For air is used as cooling media, adjust CPB at 100(%). For oil is used as cooling media, adjust CPB at 125(%). For water is used as cooling media, adjust CPB at 250(%)

DB Programming

Adjustment of DB is dependent on the system requirements. If more positive value of DB (greater dead band) is used, an unwanted cooling action can be avoided but an excessive overshoot over the set point will occur. If more negative value of DB (greater overlap) is used, an excessive overshoot over the set point can be minimized but an unwanted cooling action will occur. It is adjustable in the range -36.0% to 36.0 % of PB1 (or PB2 if PB2 is selected). A negative DB value shows an overlap area over which both outputs are active. A positive DB value shows a dead band area over which neither output is active

4.3.1.1.4.4 Heater Break Alarm

A current transformer CT94-1 should be installed to detect the heater current if a heater break alarm is required. The CT signal is sent to input 2, and the PV2 will indicate the heater current in 0.1 Amp. Resolution. The range of current transformer is 0 to 50.0 Amps.

Example

A furnace uses two 2KW heaters connected in parallel to warm up the process. The line voltage is 220V and the rating current for each heater is 9.09A. If we want to detect any one heater break, set A1SP=13.0A, A1HY=0.1 A1FN=PV2.L, A1MD=NORM, then

Figure 4-30. Heater Break Alarm

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4.3.1.1.4.5 Loop Break Alarm

A1FN selects LB if alarm 1 is required to act as a loop break alarm. Similarly, if alarm 2 is

required to act as a loop break alarm, then set OUT2 with=AL2 and A1FN with LB.

TIME, A1SP, A1DV and A1HY are hidden if alarm 1 is configured as a loop break alarm.

Similarly, TIME, A2SP, A2DV and A2HY are hidden if alarm 2 is configured as a loop break alarm.

One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2. These are: Normal alarm, latching alarm, Holding alarm and Latching/Holding alarm. However, the Holding mode and latching/Holding mode are not recommended to be chosen for loop break alarm since loop break alarm will not perform holding function even if it is set with holding or latching/holding mode.

Loop Break Conditions are detected during a time interval of 2TI1 (double of integral time, but 120 seconds maximum). Hence the loop break alarm doesn't respond quickly as it occurs. If the process value doesn't increase (or decrease) while the control variable MV1 has reached to its maximum (or minimum) value within the detecting time interval, a loop break alarm (if configured) will be actuated.

Loop Break Alarm (if configured) occurs when any following condition happens

 Input sensor is disconnected (or broken).

 Input sensor is shorted.

 Input sensor is defective.

 Input sensor is installed outside (isolated from) the process.

 Controller fails (A-D converter damaged).

 Heater ( or generally, chiller, valve, pump, motor etc. ) breaks or fails or uninstalled

 Switching device (used to drive heater) is open or shorted.

4.3.1.1.4.6 Sensor Break Alarm

Alarm 1 or alarm 2 can be configured as sensor break alarm by selecting SENB for A1FN or A2FN.The sensor break alarm is activated as soon as failure mode occurs. Note that A-D failure also creates a sensor break alarm. TIME, A1SP, A1DV, and A1HY are hidden if alarm 1 is configured as a sensor break alarm. Similarly, TIME, A2SP, A2DV and A2HY are hidden if alarm 2 is configured as a sensor break alarm.

One of 4 kinds of alarm modes can be selected for sensor break alarm. These are: Normal alarm, latching alarm, Holding alarm and Latching/Holding alarm. However, the Holding alarm and Latching/Holding alarm are not recommended to be chosen for sensor break alarm since sensor break alarm will not perform holding function even if it is set with holding or latching/holding mode.

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4.3.1.1.4.7 Failure Transfer

The controller will enter failure mode as one of the following conditions occurs.

 SB1E Error occurs ( due to the input 1 sensor break or input 1 current below

1mA,if 4-20 mA is selected or input 1 voltage below 0.25V if 1-5 V is selected ), if PV1, P1-2 or P2-1 is selected for PVMD or PV1 is selected for SPMD.

 SB2E Error occurs ( due to the input 2 sensor break or input 2 current below

1mA,if 4-20 mA is selected or input 2 voltage below 0.25V if 1-5 V is selected ), if PV2, P1-2 or P2-1 is selected for PVMD or PV2 is selected for SPMD.

 ADER Error occurs due to the A-D converter of the controller fails.

The output 1 and output 2 will perform the function as one of the following conditions occurs.

 During power starts (within 2.5 seconds).

 The controller enters the failure mode.

 The controller enters the manual mode.

 The controller enters the calibration mode.

Output 1 Failure Transfer, if activated, will perform

 If output 1 is configured as proportional control (PB1≠0), and BPLS selected for

O1FT, then output 1 will perform bumpless transfer. Thereafter the previous averaging value of MV1 will be used for controlling output 1.

 If output 1 is configured as proportional control (PB1 ≠ 0), and a value of 0 to

100.0 % is set for O1FT, then output 1 will perform failure transfer. Thereafter the value of O1FT will be used for controlling output 1.

 If output 1 is configured as ON-OFF control (PB1 = 0), then output 1 will be driven

OFF if O1FN selects REVR and be driven ON if O1FN selects DIRT.

 If output 1 is configured as ON-OFF control (PB1=0), then output 1 will be driven

OFF if O1FN selects REVR and be driven ON if O1FN selects DIRT.

Output 2 Failure Transfer, if activated, will perform

 If OUT2 selects COOL, and BPLS is selected for O1FT, then output 2 will perform

bumpless transfer. Thereafter the previous averaging value of MV2 will be used for controlling output 2.

 If OUT2 selects COOL, and a value of 0 to 100.0 % is set for O2FT, then output 2

will perform failure transfer. Thereafter the value of O1FT will be used for controlling output 2.

Alarm 1 Failure Transfer is activated as the controller enters failure mode. Thereafter the alarm 1 will transfer to the ON or OFF state preset by A1FT.

Exception: If Loop Break (LB) alarm or sensor Break (SENB) alarm is configured for A1FN, the alarm 1 will be switched to ON state independent of the setting of A1FT. If Dwell Timer (TIMR) is configured for A1FN, the alarm 1 will not perform failure transfer.

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Alarm 2 Failure Transfer is activated as the controller enters failure mode. Thereafter the alarm 2 will transfer to the ON or OFF state preset by A2FT.Alarm 2 Failure Transfer is activated as the controller enters failure mode.

Exception: If Loop Break (LB) alarm or sensor Break (SENB) alarm is configured for A2FN, the alarm 2 will be switched to ON state independent of the setting of A2FT. If Dwell Timer (TIMR) is configured for A2FN, the alarm 2 will not perform failure transfer.

4.3.1.1.4.8 Bumpless Transfer

The bumpless transfer function is available for output 1 and output 2 (provided that OUT2 is configured as COOL).

Bumpless Transfer is enabled by selecting BPLS for O1FT and/or O2FT and activated as one

of the following cases occurs.

 Power starts (within 2.5 seconds).

 The controller enters the failure mode.

 The controller enters the manual mode.

 The controller enters the calibration mode.

As the bumpless transfer is activated, the controller will transfer to open-loop control and uses the previous averaging value of MV1 and MV2 to continue control.

Without Bumpless Transfer

Since the hardware and software need time to be initialized, the control is abnormal as the power is recovered and results in a large disturbance to the process. During the sensor breaks, the process loses power.

Figure 4-31.Without Bumpless Transfer

Without Bumpless Transfer

After bumpless transfer is configured with the correct control variables applied, the

disturbance is small when the power is recovered. During the sensor breaks, the controller

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continues to control by using its previous value. If the load doesn't change, the process will remain stable. Thereafter, once the load changes, the process may run away. Therefore, the user should not rely on a bumpless transfer for a longer time. For fail safe reason, an additional alarm should be used to announce the operator when the system fails. For ,a Sensor Break Alarm, if configured, will switch to failure state and announces the operator to use manual control or take a proper security action when the system enters failure mode.

Figure 4-32.With Bumpless Transfer

Warning: After system fails, never depend on bumpless transfer for a long time; otherwise

it might cause a problem to the system to run away.

4.3.1.1.4.9 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 in card parameter. The value you adjust here, either positive or negative, will be added to the actual value. The SHIF function will alter PV1 only.

Here is an example. A process is equipped with a heater, a sensor and a subject to be warmed up. Due to the design and position of the components in the system, the sensor could not be placed any closer to the part. Thermal gradient (different temperature) is common and necessary to an extent in any thermal system for heat to be transferred from one point to another. If the difference between the sensor and the subject is 35 C, and the desired temperature at the subject to be heated is 200 C, the controlling value or the temperature at the sensor should be 235 C. You should input -35 C as to subtract 35 C from the actual process display. This in turn will cause the controller to energize the load and bring the process display up to the set point value

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4.3.1.1.4.10 SP1 Range

SP1L (SP1 low limit value) and SP1H (SP1 high limit value) in setup menu are used to confine the adjustment range of SP1.

Example: A freezer is working in its normal temperature range -10 C to -15 C. In order to avoid an abnormal set point, SP1L and SP1H are set with the following values:

SP1L = -15 C SP1H = -10 C

Now SP1 can only be adjusted within the range from -10 C to -15 C.

Figure 4-33.PV1 SHIFT Application

4.3.1.1.4.11 Dwell Timer

Alarm 1 or alarm 2 can be configured as dwell timer by selecting TIMR for A1FN or A2FN, but not both, otherwise Error will appear. As the dwell timer is configured, the parameter TIME is used for dwell time adjustment. The dwell time is measured in minute ranging from 0 to 6553.5 minutes. Once the process reaches the set point the dwell timer starts to count from zero until time

Figure 4-34.SP1 Range

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out. The timer relay will remain unchanged until time out. The dwell timer operation is shown as following diagram.

Figure 4-35.Dwell Timer

If alarm 1 is configured as dwell timer, A1SP, A1DV, A1HY and A1MD are hidden. Same case is for alarm 2.

Example

Set A1FN=TIMR or A2FN=TIMR but not both. Adjust TIME in minutes .A1MD (if A1FN=TIMR) or A2MD (if A2FN=TIMR) is ignored in this case.

4.3.1.1.4.12 Process Alarms

A process alarm sets an absolute trigger level (or temperature). When the process (could be PV1, PV 2 or PV1-PV2) exceeds that absolute trigger level an alarm occurs. A process alarm is independent from set point. Adjust A1FN (Alarm 1 function) in setup menu. One of 8 functions can be selected for process alarm. These are: PV1.H, PV1.L, PV2.H, PV2.L, P1.2.H,

P1.2.L, D1.2.H, D1.2.L.

When the PV1.H or PV1.L is selected the alarm examines the PV1 value. When the PV2.H or PV2.L is selected the alarm examines the PV2 value.

When the P1.2.H or P1.2.L is selected the alarm occurs if the PV1 or PV2 value exceed the trigger level. When the D1.2.H or D1.2.L is selected the alarm occurs if the PV1-PV2 (difference) value exceeds the trigger level. The trigger level is determined by A1SP (Alarm 1 set point) and A1HY (Alarm 1 hysteresis value) in configuration for alarm 1. The hysteresis value is introduced to avoid interference action of alarm in a noisy environment. Normally A1HY can be set with a minimum (0.1) value. A1DV and/or A2DV are hidden if alarm 1 and/or alarm 2 are set with process alarm.

Normal Alarm: A1MD = NORM

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When a normal alarm is selected, the alarm output is de-energized in the non-alarm condition and energized in an alarm condition.

Latching Alarm: A1MD = LTCH

If a latching alarm is selected, once the alarm output is energized, it will remain unchanged even if the alarm condition is cleared. The latching alarms are disabled when the power is shut off or if event input is applied with proper selection of EIFN.

Holding Alarm: A1MD = HOLD

A holding alarm prevents an alarm from power up. The alarm is enabled only when the process reaches the set point value ( may be SP1 or SP2 ). Afterwards, the alarm performs same function as normal alarm.

Latching / Holding Alarm: A1MD = LT .HO

A latching / holding alarm performs both holding and latching function.

Figure 4-36.Normal Process Alarm

Figure 4-37.Latching Process Alarm

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Figure 4-38.Holding Process Alarm

Although the above descriptions are based on alarm 1, the same conditions can be applied to alarm 2.

4.3.1.1.4.13 Deviation Alarm

A deviation alarm alerts the user when the process deviates too far from set point.

The user can enter a positive or negative deviation value (A1DV, A2DV) for alarm 1 and alarm

2. A hysteresis value (A1HY or A2HY) can be selected to avoid interference problem of alarm in a noisy environment. Normally, A1HY and A2HY can be set with a minimum (0.1) value.

Trigger levels of alarm are moving with set point.

Figure 4-39.Latching / Holding Process Alarm

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For alarm 1, Trigger levels=SP1+A1DV 1/2 A1HY.

For alarm 2, Trigger levels=SP1+A2DV 1/2 A2HY.

A1SP and/or A2SP are hidden if alarm 1 and/or alarm 2 are set with deviation alarm. One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2. These are Normal alarm, latching alarm, Holding alarm and Latching/Holding alarm.

Figure 4-40.Normal Deviation Alarm

Figure 4-41.Latching Deviation Alarm

Figure 4-42.Holding Deviation Alarm

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Figure 4-43.Latching/Holding Deviation Alarm

4.3.1.1.4.14 Deviation Band Alarm

A deviation band alarm presets two reference levels relative to set point. Two types of deviation band alarm can be configured for alarm 1 and alarm 2. These are deviation band high alarm (A1FN or A2FN select DB.HI) and deviation band low alarm (A1FN or A2FN select DB.LO). A1SP and A1HY are hidden if alarm 1 is selected with deviation band alarm. Similarly, A2SP and A2HY are hidden if alarm 2 is selected with deviation band alarm. Trigger levels of deviation band alarm are moving with set point. For alarm 1, trigger levels=SP1± A1DV. For alarm 2, trigger levels=SP1 ±A2DV.One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2. These are Normal alarm, latching alarm, Holding alarm and Latching/Holding alarm.

Figure 4-44.Normal Deviation Band Alarm

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Figure 4-45.Latching Deviation Band Alarm

Figure 4-46.Holding Deviation Band Alarm

4.3.1.1.4.15 Event Input

The Event input accepts a digital type signal. Three types of signals can be connected to event input. These are

 Relay or switch contacts

 Open collector pull low

Figure 4-47.Latching/Holding Deviation Band Alarm

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 TTL logic level



One of ten available functions can be chosen by using (EIFN) contained in setup menu.

 NONE: Event input No function. If chosen, the event input function is disabled. The

controller will use PB1, TI1 and TD1 for PID control and SP1 (or other values determined by SPMD) for the set point.

 SP2: If chosen, the SP2 will replace the role of SP1 for control. SP2: If chosen, the

SP2 will replace the role of SP1 for control.

 PID2: If chosen, the second PID set PB2, TI2 and TD2 will be used to replace PB1,

TI1 and TD1 for control.

 PID2: If chosen, the second PID set PB2, TI2 and TD2 will be used to replace PB1,

TI1 and TD1 for control.

 SP.P2: If chosen, the SP2, PB2, TI2 and TD2 will replace SP1, PB1, TI1 and TD1

for c



 NOTE: If the second PID set is chosen during Auto-tuning and/or Self-tuning

procedures, the new PID values will be stored in PB2, TI2 and TD2.



 RS.A1: Reset Alarm 1 as the event input is activated. However, if alarm 1 condition

is still existent, the alarm 1 will be retriggered again while the event input is released.

 RS.A2: Reset Alarm 2 as the event input is activated. However, if alarm 2

conditions are still existent, the alarm 2 will be retriggered again while the event input is released.

 R.A1.2: Reset both Alarm 1 and Alarm 2 as the event input is activated. However,

if the alarm 1 and/or alarm 2 are still existent, the alarm 1 and/or alarm 2 will be triggered again while the event input is released.

 The RS.A1, RS.A2 and R.A1.2 are particularly suitable to be used for a Latching

and/or Latching/Holding alarms.

 D.O1: Disable Output 1 as the event input is activated. The output 1 control

variable MV1 is cleared to zero.

 D.O2: Disable Output 2 as the event input is activated. The output 2 control

variables MV2 is cleared to zero.

 D.O1.2: Disable both Output 1 and Output 2 by clearing MV1 and MV2 values as

soon as the event input is activated.



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 When any of D.O1, D.O2 or D.O1.2 is selected for EIFN, the output 1 and/or output

2 will revert to their normal conditions as soon as the event input is released.



 LOCK: All parameters are locked to prevent from being changed.

 SP2F Function: Define format of SP2 value. If SP2F in the setup menu is selected

with ACTU, the event input function will use SP2 value for its second set point. If SP2F is selected with DEVI, the SP1 value will be added to SP2. The sum of SP1 and SP2 (SP1+SP2) will be used by the event input function for the second set point value. In certain applications it is desirable to move second set point value with respect to set point 1 value. The DEVI function for SP2 provides a convenient way in this case.



4.3.1.1.4.16 Second Set Point

In certain applications it is desirable to change the set point automatically without the need to adjust the set point. You can apply a signal to event input terminals. The signal applied to event input may come from a Timer, a PLC, and an Alarm Relay, a Manual switch or other devices. Select SP2 for EIFN which is contained in setup menu. This is available only with the case that SP1.2, MIN.R or HR.R is used for SPMD, where MIN.R and HR.R are used for the ramping function.

Application 1: A process is required to be heated at a higher temperature as soon as its pressure exceeds a certain limit. Set SPMD=SP1.2, EIFN=SP2 (or SP .P2 if the second PID is required for the higher temperature too).The pressure gauge is switched ON as it senses a higher pressure. Connect the output contacts of the pressure gauge to the event input. SP1 is set with a normal temperature and SP2 is set with a higher temperature. Choose ACTU for SP2F.

Application 2: An oven is required to be heated at 300°C from 8.00 AM to 6.00 PM After 6.00 PM it is desirable to be maintained at 80°C. Use a programmable 24 hours cycle timer for this purpose. The timer output is used to control event input. Set SPMD=SP1.2, and EIFN=SP2 (or SP .P2 if the second PID is required to be used for the second set point).SP1 is set with 300°C and SP2 is set with 80°C. Choose ACTU for SP2F. After 6.00 PM the timer output is closed. The event input function will select SP2 (=80°C) to control the process.

4.3.1.1.4.17 Second PID Set

In certain applications the process characteristics is strongly related to its process value. The Process Control Card provides two set of PID values. When the process is changed to different set point, the PID values can be switched to another set to achieve an optimum condition.

The optimal PID values for a process may vary with its process value and set point. Hence if a process is used for a wide range of set point, dual PID values are necessary to optimize the control performance. If the first PID set is selected (event input is not applied) during auto-tuning procedure, the PID values will be stored in PB1, TI1 and TD1. Similarly, if the second PID set is selected (event input is applied while PID2 or SP.P2 is selected for EIFN) during auto-tuning, the PID values will be stored in PB2, TI2 and TD2 as soon as auto-tuning is completed.

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Application 1: Programmed by Set Point

Choose SP.P2 for EIFN then both set point and PID values will be switched to another set simultaneously. The signal applied to event input may come from a Timer, a PLC, an Alarm Relay, a Manual Switch or other devices.

Application 2: Programmed by Process Value

If the process value exceeds a certain limit, 500°C for example, it is desirable to use another PID values to optimize the control performance. The user can use a process high alarm to detect the limit of the process value. Choose PV1H for A1FN, A1MD selects NORM, adjust A1SP to be equal to 500° C, and choose PID2 for EIFN. If the temperature is higher than 500°C, then alarm 1 is activated. The alarm 1 output is connected to event input; the PID values will change from PB1, TI1 and TD1 to PB2, TI2 and TD2.

4.3.1.1.4.18 Ramp & Dwell

Ramp

The ramping function is performed during power up as well as any time the set point is changed. Choose MINR or HRR for SPMD, the unit will perform the ramping function. The ramp rate is programmed by using RAMP which is available in user configuration of Process Control Card

Example without Dwell Timer

Select MINR for SPMD, IN1U selects °C, DP1 selects 1-DP, Set RAMP=10.0. SP1 is set to 200°C initially, and changed to 100°C after 30 minutes since power up. The starting temperature is 30° C. After power up the process is running like the curve shown below

Figure 4-48.Ramp Function

Note: When the ramp function is used, the lower display will show the current ramping value. However it will revert to show the set point value as soon as the up or down key is touched for adjustment. The ramping value is initiated to process value either power up or RAMP and /or set point are changed. Setting RAMP to zero means no ramp function at all.

Dwell

The Dwell timer can be used separately or accompanied with a Ramp. If A1FN selects TIMR,

the alarm 1 will act as a dwell timer. Similarly, alarm 2 will act as a dwell timer if A2FN selects TIMR.

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The timer is programmed by using TIME which is contained in Configuration menu. The Timer starts to count as soon as the process reaches its set point, and triggers an alarm as time out. Here is an example.

Example without Dwell Timer

Select TIMR for A1FN, IN1U selects F, DP1 selects NODP, Set TIME=30.0 SP1 is set to 400 F initially, and corrected to 200 F before the process reaches 200° F. As the process reaches set point (i.e. 200°F) the timer starts to count. The TIME value can still be corrected without disturbing the Timer before time out. The TIME is changed to 40.0 after 28 minutes since the process reached its set point. The behavior of process value and alarm 1 are shown below.

Once the timer output was energized it will remain unchanged until power down or an event input programmed for resetting alarm is applied.

Figure 4-49.Dwell Timer

Note: The TIMR can't be chosen for both A1FN and A2FN simultaneously; otherwise an error

code will produce.

Ramp &Dwell

A Ramp can be accompanied with a dwell timer to control the process. Here is an example.

Example Ramp & Dwell Timer

Select HRR for SPMD, IN1U selects PU, DP1 select 2-DP, Set RAMP=60.00 A2FN selects TIMR, Set TIME=20.0 as power is applied the process value starts from 0.00 and set SP1=30.00, SP2=40.00. The timer output is used to control event input.

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Figure 4-50.Ramp Accompanied with Dwell Timer

4.3.1.1.4.19 Remote Set Point

SPMD selecting PV1 or PV2 will enable the Process Control Card to accept a remote set

point signal. If PV1 is selected for SPMD, the remote set point signal is sent to Input 1, and Input 2 is used for process signal input. If PV2 is selected for SPMD, the remote set point signal is sent to Input 2, and Input 1 is used for process signal. To achieve this, set the following parameters in the Configuration menu.

Case 1: Use Input 2 to accept remote set point

FUNC=FULL

IN2, IN2U, DP2, IN2L, IN2H, are set according to remote signal.

PVMD=PV1

IN1, IN1U, DP1, are set according to the process signal

IN1L, IN1H if available, are set according to the process signal

SPMD= PV2

Case 2: Use Input 1 to accept remote set point

FUNC=FULL

IN1, IN1U, DP1, IN1L, IN1H, are set according to remote signal.

PVMD=PV2

IN2, IN2U, DP2, are set according to the process signal

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IN2L, IN2H if available, are set according to the process signal

SPMD= PV1

Note: If PV1 are chosen for both SPMD and PVMD, an Error Code will appear. If PV2 are

chosen for both SPMD and PVMD, an Error Code will appear. The user should not use these cases, otherwise, the Process Control Card will not control properly.

4.3.1.1.4.20 Differential Control

In certain applications it is desirable to control second process such that its process value

always deviates from the first process with a constant value. To achieve this, set the following parameter in the Setup menu.

FUNC=FULL

IN1, IN1L, IN1H are set according to input 1 signal

IN2, IN2L, IN2H are set according to input 2 signal

IN1U, DP1, IN2U, DP2, are set according to input 1 and input 2 signal

PVMD=P1-2 or P2-1

SPMD=SP1.2

The response of PV2 will be parallel to PV1 as shown in the following diagram

Figure 4-51.Relationship Between PV1 & PV2 for Differential Control

The PV display will indicate PV1-PV2 value if P1-2 is chosen for PVMD or PV2-PV1 value

if P2-1 is chosen for PVMD. If the user needs PV1 or PV2 to be displayed instead of PV, they can use the Display Mode to select PV1 or PV2 to be viewed

If PVMD selects P1-2 or P2-1, while SPMD selects PV1 or PV2, an Error Code will appear.

In this case the signals used for input 1 and input 2 should be the same unit and same decimal point, that is, IN1U=IN2U, DP1=DP2, otherwise Error Code will appear.

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4.3.1.1.4.21 Output Power Limit

In certain system the heater (or cooler) is over-designed such that the process is too heavily heated or cooled. To avoid an excessive overshoot and/or undershoot the user can use the Power Limit function. Output 1 power limit PL1 is contained in Configuration. If output 2 is not used for cooling (that is COOL is not selected for OUT2), then PL2 is hidden. If the controller is used for ON-OFF control, then both PL1 and PL2 are hidden

Example:

OUT2=COOL, PB1=10.0°C, CPB=50, PL1=50, PL2=80 the output 1 and output 2 will act as

following curves

NOTE:

The adjusting ranges of MV1 (H) and MV2 (C) for manual control and/or failure transfer are not

limited by PL1 and PL2.

4.3.1.1.4.22 Digital Filter

In certain application the process value is too unstable to be read. To improve this programmable low pass filter incorporated in this Process Control Card can be used. This is a first order filter with time constant specified by FILT parameter which is contained in setup menu. The default value of FILT is 0.5 sec. before shipping. Adjust FILT to change the time constant

Figure 4-52.Power Limit Function

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from 0 to 60 seconds. 0 second represents no filter is applied to the input signal. The filter is characterized by the following diagram.

Figure 4-53.Filter Characteristics

Note:

The Filter is available only for PV1, and is performed for the displayed value only. The

controller is designed to use unfiltered signal for control even if Filter is applied. A lagged (filtered) signal, if used for control, may produce an unstable process.

4.3.1.1.4.23 Auto-Tuning and Manual Tuning

The Auto-tuning and Manual tuning can be executed by pressing the mode button in the

Process control module realtime display page. Press and Press Real Time and Press C1 to access the Process Control module real time display page.

Press Mode and select Auto-tuning to perform auto tuning for the process.During Auto-

tuning process the PV display will blink continuously.

Press Mode and select Manual tuning to perform manual tuning for the process.In this the

user can control the process manually by adjusting the output value manually.

Press Back to exit auto tuning or manual tuning when it is in progress.

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Figure 4-54.Process Control Module Real time

Figure 4-55.Auto-Tuning

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