Sixth Sense AI-200 Operating Manual

User's ManualUser's Manual

DIN EN ISO 9001

Certificate: 01 100 98505

R

C21 / C91

Auto-Tune Fuzzy / PID

Auto-Tune Process

Process / Temperature Controller

Fuzzy / PID

/ Temperature Controller

R

UM0C911C

BRAINCHILD

Warning SymbolWarning 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.

Use the ManualUse the Manual

Installers

System Designer

Expert User

NOTE:

It is strongly recommended that a process should incorporate a

CONTROL like L91 which will shut down the equipment at

LIMIT

LIMIT CONTROL like L91 which will shut down the equipment at

preset process condition in order to preclude possible

a

a preset process condition in order to preclude possible

damage

damage to products or system.

Information in this user's manual is subject to change without notice.

This manual is applicable for the products with software version

23 and later version.

23

Copyright April 2003, The Brainchild Corporation, all rights reserved. No part of this publication may be reproduced, transmitted, transcribed or stored in a retrieval system, or translated into any language in any form by any means without the written permission of the Brainchild Corporation.

to products or system.

and later version.

a

Read Chapter 1, 2

Read All Chapters

Read Page 12

UM0C911C2

Contents

Chapter 1 OverviewChapter 1 Overview 1-1 General -------------------------5

1-2 Ordering Code ---------------8 1-3 Programming Port ------------9 1-4 Keys and Displays ---------10 1-5 Menu Overview -------------12 1-6 Parameter Descriptions ---13

Chapter 2 Installation

2-1 Unpaking ----------------------20 2-2 Mounting ----------------------20 2-3 Wiring precautions ----------22 2-4 Power Wiring -----------------25 2-5 Sensor Installation ----------

Guidlines----------------------25 2-6 Sensor Input Wiring --------26 2-7 Control Output Wiring -----26 2-8 Alarm Wiring -----------------30 2-9 Data Communication ------31

Chapter 3 Programming

Chapter 3 Programming 3-1 Lockout ------------------------33

3-2 Signal Input -------------------33 3-3 Control Outputs --------------34 3-4 Alarm ---------------------------39 3-5 Configure Display -----------40 3-6 Ramp ---------------------------41 3-7 Dwell Timer -------------------42 3-8 PV Shift ------------------------43 3-9 Digital Filter -------------------44 3-10 Failure Transfer -------------45 3-11 Auto-tuning ------------------46 3-12 Manual tuning --------------47 3-13 Manual Control -------------48 3-14 Data Communication -----50 3-15 PV Retransmission --------50

Page No

Chapter 4 Applications

4-1 Heat Only Control with --

Dwell Timer ------------------51 4-2 Cool Only Control -----------52 4-3 Heat-Cool Control -----------53

Chapter 5 Calibration --------55Chapter 5 Calibration

Chapter 6 Specifications ----60Chapter 6 Specifications

Chapter 7

Modbus Communications---66

Modbus

7-1 Functions Supported -------66 7-2 Exception Responses -----68 7-3 Parameter Table -------------69 7-4 Data Conversion ------------73 7-5 Communication Examples-73

Appendix A-1 Error Codes ------------------76

A-2 Warranty ----------------------77

Communications

Page No

UM0C911A 3

Figures & TablesFigures & Tables

Figure 1.1 Fuzzy Control Advantage ----------------------------------------------------------------6 Figure 1.2 Programming Port Overview ------------------------------------------------------------9 Figure 1.3 Front Panel Description -----------------------------------------------------------------11 Figure 1.4 Display of Initial Stage -------------------------------------------------------------------11 Figure 2.1 Mounting Dimensions -------------------------------------------------------------------21 Figure 2.2 Lead Termination for C91 -------------------------------------------------------------23 Figure 2.3 Lead Termination for C21---------------------------------------------------------------23 Figure 2.4 Rear Terminal Connection for C21--------------------------------------------------23 Figure 2.5 Rear Terminal Connection for C91----- --------------------------------------------24 Figure 2.7 Power Supply Connections ------------------------------------------------------------25 Figure 2.8 Sensor Input Wiring ----------------------------------------------------------------------26 Figure 2.9 Output 1 Relay or Triac (SSR) to Drive Load ---------------------------------------26 Figure 2.10 Output 1 Relay or Triac (SSR) to Drive Contactor -------------------------------27 Figure 2.11 Output 1 Pulsed Voltage to Drive SSR ---------------------------------------------27 Figure 2.12 Output 1 Linear Current ---------------------------------------------------------------28 Figure 2.13 Output 1 Linear Voltage ---------------------------------------------------------------28 Figure 2.14 Output 2 Relay or Triac (SSR) to Drive Load -------------------------------------28 Figure 2.15 Output 2 Relay or Triac (SSR) to Drive Contactor -------------------------------29 Figure 2.16 Output 2 Pulsed Voltage to Drive SSR ---------------------------------------------29 Figure 2.17 Output 2 Linear Current ---------------------------------------------------------------29 Figure 2.18 Output 2 Linear Voltage --------------------------------------------------------------30 Figure 2.19 Alarm Output to Drive Load ----------------------------------------------------------30 Figure 2.20 Alarm Output to Drive Contactor ----------------------------------------------------30 Figure 2.21 RS-485 Wiring ---------------------------------------------------------------------------31 Figure 2.22 RS-232 Wiring ---------------------------------------------------------------------------32 Figure 2.23 Configuration of RS-232 Cable ------------------------------------------------------32 Figure 3.1 Conversion Curve for Linear Type Process Value ---------------------------------34 Figure 3.2 Heat Only ON-OFF Control ------------------------------------------------------------35 Figure 3.3 Output 2 Deviation High Alarm --------------------------------------------------------38 Figure 3.4 Output 2 Process Low Alarm ----------------------------------------------------------38 Figure 3.5 RAMP Function ---------------------------------------------------------------------------41 Figure 3.6 Dwell Timer Function --------------------------------------------------------------------42 Figure 3.7 PV Shift Application ----------------------------------------------------------------------43 Figure 3.8 Filter Characteristics ---------------------------------------------------------------------44 Figure 3.9 Effects of PID Adjustment -------------------------------------------------------------49 Figure 4.1 Heat Control Example -------------------------------------------------------------------51 Figure 4.2 Cooling Control Example ---------------------------------------------------------------52 Figure 4.3 Heat-Cool Control Example ------------------------------------------------------------53 Figure 5.1 RTD Calibration ---------------------------------------------------------------------------57 Figure 5.2 Cold Junction Calibration Setup ------------------------------------------------------58

Table 1.1 Display Form of Characters -------------------------------------------------------------11 Table 3.1 Heat-Cool Control Setup Value ---------------------------------------------------------34 Table 3.2 PID Adjustment Guide --------------------------------------------------------------------48 Table A.1 Error Codes and Corrective Actions --------------------------------------------------66

Page No

UM0C911B4

Chapter 1 OverviewChapter 1 Overview

1-1 General1-1 General

The Fuzzy Logic plus PID microprocessor-based controller series, incorporate a bright, easy to read 4-digit LED display, indicating process value or set point value. The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time, with the minimum of overshoot during power-up or external load disturbance.

C21 is a 1/32 DIN size panel mount controller. C91 is a 1/16 DIN size panel mount controller. These units are powered by 11-26 or 90-250

VDC/VAC supply, incorporatinga2amp.controlrelayoutput as standard. The second output can be used as cooling control, an alarm or dwell timer. Both outputs can select triac, 5V logic output, linear current or linear voltage to drive external device. There are six types of alarm plus a dwell timer can be configured for the second output.The units are fully programmable for PT100 and thermocouple types J,K, T, E, B, R, S, N, L with no need to modify the unit. The input signal is digitized by using a 18-bit A to D converter. Its fast sampling rate allows the unit to control fast processes.

Digital communications RS-485 or RS-232 ( for C21, C91) are available as an additional option. These options allow the units to be integrated with supervisory control system and software.

A programming port is available for automatic configuration, calibration and testing without the need to access the keys on front panel.

By using proprietary Fuzzy modified PID technology, the control loop will minimize the overshoot and undershoot in a shortest time. The following diagram is a comparison of results with and without Fuzzy technology.

UM0C911B 5

Temperature

Set point

PID control with properly tuned PID + Fuzzy control

Figure 1.1

Fuzzy Control

Fuzzy

Advantage

Control

Warm Up

High AccuracyHigh Accuracy

Load Disturbance

Time

The series are 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

B

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, low cost, enhanced reliability and higher density.

Fast Sampling Rate

Fast Sampling Rate The sampling rate of the input A to D converter reaches 5 times/second.

The fast sampling rate allows this series to control fast processes.

Fuzzy ControlFuzzy 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 is 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.

Digital Communication

The units are equipped with RS-485 or RS-232 interface card to provide digital communication. By using the twisted pair wires there are at most 247 units can be connected together via RS-485 interface to a host computer.

UM0C911A6

Programming PortProgramming Port

A programming port is used to connect the unit to a hand-held programmer or a PC for quick configuration, also can be connected to an ATE system for automatic testing & calibration.

Auto-tune

The auto-tune 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, one of four lockout levels can be selected 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 if the sensor is normal.

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.

Digital FilterDigital 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 be read.

UM0C911A 7

1-2 Ordering Code1-2 Ordering Code

C21-

C91-

Power InputPower Input

4: 90 - 250 VAC,

50/60 HZ

50/60

5: 11 - 26 VAC or VDC

5:

11 - 26 VAC or VDC

9: Special Order

9:

Special Order

Signal InputSignal Input

1: Standard Input

Thermocouple: J, K, T, E, B,

Thermocouple:

RTD:

RTD: PT100 DIN, PT100 JIS

2:

0 - 60 mA

2: 0 - 60 mA

0 - 1V

3:

3: 0 - 1V

4:

0 - 5V

4: 0 - 5V

5:

1 - 5V

5: 1 - 5V

6:

4 - 20 mA

6: 4 - 20 mA

0 - 20 mA

7:

7: 0 - 20 mA

8:

0 - 10 V

8: 0 - 10 V

9:

Special Order

9: Special Order

Output 1Output 1

0: None

1:

Relay rated 2A/240VAC

1: Relay rated 2A/240VAC

Pulsed voltage to drive SSR,

2:

2: Pulsed voltage to drive SSR,

3:

Isolated 4 - 20mA / 0 - 20mA

3: Isolated 4 - 20mA / 0 - 20mA

4:

Isolated 1 - 5V / 0 - 5V

4: Isolated 1 - 5V / 0 - 5V

Isolated 0 - 10V

5:

5: Isolated 0 - 10V

6:

Triac output 1A / 240VAC,SSR

6: Triac output 1A / 240VAC,SSR

C:

C: Pulsed voltage to drive SSR,

Special order

9:

9: Special order

HZ

J, K, T, E, B,

R,

S, N, L

PT100 DIN, PT100 JIS

5V/30mA

Pulsed voltage to drive SSR,

14V/40mA

R, S, N, L

Display ColorDisplay Color

0: Red color

1: Green color

1:

Green color

Communications

0: None

1: RS-485 interface (for C21)

1:

RS-485 interface (for C21)

2: RS-232 interface (for C21)

2:

RS-232 interface (for C21) Retransmit 4-20 mA / 0-20

3: Retransmit 4-20 mA / 0-20

3:

4:

Retransmit 1-5V /0-5V

4: Retransmit 1-5V /0-5V

Retransmit 0-10V (for C21)

5:

5: Retransmit 0-10V (for C21)

9:

Special order

9: Special order

Output 2Output 2

0: None

1: Form A relay 2A/240VAC

1:

Form A relay 2A/240VAC

2: Pulsed voltage to

2:

Pulsed voltage to

SSR, 5V / 30mA

drive SSR, 5V / 30mA

drive

3:

Isolated 4 - 20mA / 0 - 20mA

3: Isolated 4 - 20mA / 0 - 20mA

4:

Isolated 1 - 5V / 0 - 5V

4: Isolated 1 - 5V / 0 - 5V

5:

Isolated 0 - 10V

5: Isolated 0 - 10V

Triac output, 1A / 240VAC, SSR

6:

6: Triac output, 1A / 240VAC, SSR

7:

Isolated 20V/25mA transducer

7: Isolated 20V/25mA transducer

power

supply

power supply

8:

Isolated 12V/40mA transducer

8: Isolated 12V/40mA transducer

supply

power

power supply

9:

Isolated 5V/80mA transducer

9: Isolated 5V/80mA transducer

power

supply

power supply

A:

RS-485 interface (for C91)

A: RS-485 interface (for C91)

Pulsed voltage to drive SSR,

C:

C: Pulsed voltage to drive SSR,

14V/40mA

B:

Special order

B: Special order

mA

(for C21)

mA (for C21)

(for

C21)

(for C21)

8

UM0C911C

Accessories

OM94-6 = Isolated 1A / 240VAC Triac Output Module ( SSR )

= 14V / 40 mA SSR Drive Module

OM94-7 = 14V / 40 mA SSR Drive Module

OM94-7

= Isolated 4 - 20 mA / 0 - 20 mA Analog Output Module

OM96-3

OM96-3 = Isolated 4 - 20 mA /0-20mAAnalog Output Module

= Isolated 1 - 5V / 0 - 5V Analog Output Module

OM96-4

OM96-4 = Isolated1-5V/0-5VAnalog Output Module

= Isolated 0 -10V Analog Output Module

OM96-5

OM96-5 = Isolated 0 -10V Analog Output Module

= Isolated RS-485 Interface Module for C21

CM94-1

CM94-1 = Isolated RS-485 Interface Module for C21

= Isolated RS-232 Interface Module for C21

CM94-2

CM94-2 = Isolated RS-232 Interface Module for C21

= Isolated 4 - 20 mA / 0 - 20 mA Retrans Module for C21

CM94-3

CM94-3 = Isolated 4 - 20 mA /0-20mARetrans Module for C21

= Isolated 1 - 5V / 0 - 5V Retrans Module for C21

CM94-4

CM94-4 = Isolated1-5V/0-5VRetrans Module for C21

= Isolated 0 -10V Retrans Module for C21

CM94-5

CM94-5 = Isolated 0 -10V Retrans Module for C21

= Isolated RS-485 Interface Module for C91

CM96-1

CM96-1 = Isolated RS-485 Interface Module for C91

= Isolated 20V/25mA DC Output Power Supply

DC94-1

DC94-1 = Isolated 20V/25mA DC Output Power Supply

= Isolated 12V/40mA DC Output Power Supply

DC94-2

DC94-2 = Isolated 12V/40mA DC Output Power Supply

= Isolated 5V/80mA DC Output Power Supply

DC94-3

DC94-3 = Isolated 5V/80mA DC Output Power Supply

= RS-232 Interface Cable ( 2M )

CC94-1

CC94-1 = RS-232 Interface Cable ( 2M )

= Programming port cable for C21

CC91-1

CC91-1 = Programming port cable for C21

= Programming port cable for C91

CC91-2

CC91-2 = Programming port cable for C91

Related ProductsRelated Products

SNA10A = Smart Network Adaptor for third party software, which

SNA10B = Smart Network Adaptor for BC-Net software, which

SNA12A = Smart Network Adaptor for programming port to RS-232

converts 255 channels of RS-485 or RS-422 to RS-232

converts

255 channels of RS-485 or RS-422 to RS-232

Network.

converts 255 channels of RS-485 or RS-422 to RS-232

converts

255 channels of RS-485 or RS-422 to RS-232

network.

interface

BC-Set = Configuration SoftwareBC-Set = Configuration Software

UM0C911C 8-1

1-3 Programming Port1-3 Programming Port

Front Panel

Access Hole

1

2

3

46

5

Rear Terminal

C21

control board

Programming Port

pin 1

Power board

Open the housing TopviewofC91

Figure 1.2 Programming Port OverviewFigure 1.2 Programming Port Overview

A special connector can be used to touch the programming port which is connected to a PC for automatic configuration, also can be connected to an ATE system for automatic calibration and testing.

The programming port is used for off-line automatic setup and testing procedures only. Don't attempt to make any connection to these pins when the unit is used for a normal control purpose.

9

UM0C911B

1- 4 Keys and Displays1- 4 Keys and Displays

KEYPADOPERATIONKEYPADOPERATION

SCROLL KEY :

This key is used to select a parameter to be viewed or adjusted.

KEY :

UP KEY :

UP

This key is used to increase the value of selected parameter.

KEY :

DOWN

DOWN KEY : This key is used to decrease the value of selected parameter.

R

press for C91 and C92, press for C21press for C91 and C92, press for C21

KEY :

RESET

RESET KEY : This key is used to:

1. Revert the display to display the process value or set point value (if DISP is set with SP1 for C21).

2. Reset the latching alarm, once the alarm condition is removed.

3. Stop the manual control mode , auto-tuning mode and calibration mode.

4. Clear the message of communication error and auto-tuning error.

5. Restart the dwell timer when the dwell timer has been time out.

6. Enter the manual control menu during failure mode occurs.

KEY :

ENTER

ENTER KEY :

Press for 5 seconds to:

1. Ener setup menu. The display shows .

2. Enter manual control mode during manual control mode or is selected.

3. Enter auto-tuning mode during auto-tuning mode AT(for C91) or (for C21) is selected.

4. Perform calibration to a selected parameter during the calibration procedure. Press for 4.2 seconds to select calibration mode.

Press for 5 seconds or longer .

UM0C911C

10

OP1

OP2

Deviation Indicator

Output 2 Indicator

C

F

Output 1 Indicator

Process Unit Indicator

O1

O2

Output 2

Indicator

Output 1

Output 1 Indicator

Indicator

SP2SP1

PV

MAN

AT

Auto-tuning Indicator Manual Mode Indicator

R

4 Buttons for ease of control setup and

C91

set point adjustment.

Figure 1.3 Front Panel DescriptionFigure 1.3 Front Panel Description

Table 1.1 Display Form of CharactersTable 1.1 Display Form of Characters

A

E

I

N

B

F

C

G H

c Dh

O

J

P

K

Q

L

R

M

W

: Confused Character: Confused Character

OP1

PV

OP2

C

SP2SP1

MAN

Display program code of the product for 2.5 seconds.

F

The left diagram shows program no. 34 for C91 with version 24. The program no. for C21 is 33.

AT

R

Figure 1.4

C91

Display of Initial Stage

Display

11

UM0C911C

3 Silicone Rubber Buttons

and set point adjustment.

and

S

X

T

Y

U

Z ?

V

=

of Initial Stage

C21

for ease of control setup

for

ease of control setup

set point adjustment.

C

1- 5 Menu Overview1- 5 Menu Overview

User menu *1User menu *1

PV

SP1

SP2

H

C

PV

INPT UNIT

DP PB

TD CYC1 ADDR

5sec.

Manual

5 sec.

Mode

Manual

5 sec.

Mode

Auto-tuning

5 sec.

Mode

Valu e

TI

Valu e

C91

PV

SP1

SP2

MAN

AT

User Menu *1User Menu *1

(DISP=PV) (DISP=SP1)

C21

SP1

PV

or

SP1

PV

or

SP2

5 sec.

H

5 sec.

C

5 sec.

A-T

INPT UNIT

DP

PB

TI

TD CYC1 ADDR

Valu e

Manual

Mode

Manual

Mode

Auto-tuning

Mode

Valu e

Setup menu*1Setup menu*1

LOCK

INPT UNIT

DP INLO INHI

SP1L SP1H

SHIF FILT DISP

PB

TI

TD

OUT1 O1TY O1FT O1HY CYC1 OFST RAMP

RR

OUT2 O2TY O2FT O2HY CYC2

CPB

DB

ALMD

COMM

ADDR BAUD DATA

PARI

STOP RELO REHI SEL1 SEL2 SEL3 SEL4 SEL5 SEL6 SEL7 SEL8

Calibration ModeCalibration Mode

6.2 sec.

Valu e

Press for 5 seconds to perform calibration.

Apply these modes will break the control loop and change some of the previous setting data. Make sure that if the system is allowable to apply these modes.

*1:

The flow chart shows a complete listing of all parameters. For actual application the number of available parameters depends on setup conditions, and should be less than that shown in the flow chart.

*2:

Release , press again for 2 seconds or longer (but not longer than 3 seconds), then release to enter the calibration menu.

Valu e

ADLO

ADHI RTDL RTDH CJLO

CJHI

*2

7.4 sec.

2 sec.

Valu e

UM0C911C

12

1-6 Parameter Descriptions1-6 Parameter Descriptions

Parameter Notation

LOCK

13

Parameter Description

Set point for output 1

SP1

Set point for output 2 when output 2 performs

SP2

alarm function or dwell timer

Select parameters to be locked

Input sensor selection

INPT

UM0C911A

Range

Low: SP1L High :SP1H

Low: -19999 High :45536

0 : No parameter

1 : Setup data are

2 : Setup data and

3 : All data are locked

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

is locked

locked

User data except Set point are locked

J type thermocouple

:

K type thermocouple

:

T type thermocouple

:

E type thermocouple

:

B type thermocouple

: :

R type thermocouple

S type thermocouple

:

N type thermocouple

:

L type thermocouple

: :

PT 100 ohms DIN curve

:

PT 100 ohms JIS curve

:

4 - 20 mA linear current input

:

0 - 20 mA linear current input

:

0 - 60 mV linear millivolt input

:

0 - 1V linear voltage input

:

0 - 5V linear voltage

input

:

1 - 5V linear voltage

input

:

0 - 10V linear voltage

input

Default Value

25.0 C (77.0 F)BB

10.0 C (18.0 F)BB

0

1

(0)

Parameter Notation

UNIT

DP

INLO

INHI

SP1L

SP1H

SHIF

FILT

Parameter Description

Input unit selection

Decimal point selection

Input low sale value

Input high scale value

Low limit of set point value

High limit of set point value

PV shift (offset) value

Filter damping time constant of PV

0

1

2

0

1

2

3

Low:

0

1

2

3

4

5

6

7

8

9

UM0C911A

-19999

INLO+50

-19999

SP1L

-200.0 C

(-360.0 F)LL

:

Range

Degree C unit

:

Degree F unit

:

Process unit

No decimal

:

point

1 decimal digit

:

2 decimal digits

:

3 decimal digits

:

High:

200.0 C

High:

( 360.0 F)LL

0 second time

constant

0.2 second time constant

0.5 second time

constant 1 second time

constant 2 seconds time

constant 5 seconds time

constant 10 seconds time

constant 20 seconds time

constant 30 seconds time

constant 60 seconds time

constant

45486

45536

Default Value

0

(1)

1

-17.8 C

L

(0F)

93.3 C

L

(200.0 F)

-17.8 C (0 F)

L

537.8 C

(1000 F)

L

0.0

2

14

L

Parameter Notation

DISP

OUT1

O1TY

O1FT

O1HY

CYC1

Parameter Description

Normal display selection

Proportional band value

PB

Integral time value

TI

Derivative time value

TD

Output 1 function

Output 1 signal type

Output 1 failure transfer mode

Output 1 ON-OFF control hysteresis

Output 1 cycle time

OFST Offset value for P control

Range

0

1

Low: 0

Low:

0

1

0

1

2

3

4

5

6

7

8

Select BPLS ( bumpless transfer ) or 0.0 ~ 100.0 % to continue output 1 control function as the unit fails, or select OFF (0) or ON (1) for ON-OFF control.

: Display process

value normally

: Display set point 1

value normally

High:

0

High:

0

Reverse (heating )

:

control action

:

Direct (cooling) control action

: Relay output

: Solid state relay

drive output

: Solid state relay

output

: 4-20 mA current

module

:

0 - 20 mA current

module

:

0 - 1V voltage module

:

0 - 5V voltage module

:

1 - 5V voltage module

:

0 - 10V voltage module

500.0 C

(900.0 F)LL

1000 sec

360.0 sec

(18.0 F)LL

Low: 0.1 High: 50.0 C(90.0 F)BB

Low: 0.1 High: 90.0 sec.

High: 100.0 %

Low: 0

Default Value

0

10.0 C

100

25.0

0

0.1 C

(0.2 F)LL

18.0

25.0

15

UM0C911A

Parameter Notation

RAMP

RR

OUT2

O2TY

O2FT

Parameter Description

Ramp function selection

Ramp rate

Output 2 function

Output 2 signal type

Output 2 failure transfer mode

Range

0 : No Ramp Function

1 : Use unit/minute as

2 : Use unit/hour as

Low: 0

0 : Output 2 No Function

1 : Dwell timer action

2 : Deviation High Alarm

3 : Deviation Low Alarm

4 : Deviation band out of

5 : Deviation band in

6 : Process High Alarm

7 : Process Low Alarm

8 : Cooling PID Function

0

1

2

3

4

5

6

7

8

Select BPLS ( bumpless transfer ) or 0.0 ~ 100.0 % to continue output 2 control function as the unit fails, or select ON (0) or OFF (1) for alarm and dwell timer function.

UM0C911A

Ramp Rate

500.0 C

High:

(900.0 F)LL

band Alarm

:

Relay output

:

Solid state relay drive output

:

Solid state relay output

:

4 - 20 mA current module

:

0 - 20 mA current module

0 - 1V voltage

:

module 0 - 5V voltage

:

module

:

1 - 5V voltage module

:

0 - 10V voltage module

Default Value

0

0.0

2

0

16

Parameter Notation

O2HY

CYC2

CPB

DB

ALMD

COMM

ADDR

BAUD

Parameter Description

Output 2 hysteresis value when output 2 performs alarm function

Output 2 cycle time

Cooling proportional band value

Heating-cooling dead band (negative value= overlap)

Alarm operation mode

Communication

function

Address assignment of digital communication

Baud rate of digital communication

Range

50.0 C

Low: 0.1

Low: 50

Low: -36.0

0

1

2 3

0 : No communication

1 : Modbus RTU mode

2

3

4

5

6

Low: 1 High: 255

0

1

2

3

4

5

6

High:

(90.0 F)LL

High: 90.0 sec.

High: 300 %

High: 36.0 %

: Normal alarm action

: Latching alarm action : Hold alarm action

: Latching & actionHold

protocol

:4-20mA retransmission

output

:0-20mA retransmission

output

:0-5V retransmission

output

:1-5V retransmission

output

:0-10V retransmission

output

:

2.4 Kbits/s baud rate

:

4.8 Kbits/s baud rate

:

9.6 Kbits/s baud rate

:

14.4 Kbits/s baud rate

:

19.2 Kbits/s baud rate

:

28.8 Kbits/s baud rate

:

38.4 Kbits/s baud rate

Default Value

0.1 C

(0.2 F)LL

18.0

100

0

1

2

17

UM0C911C

Parameter Notation

DATA

PARI

STOP

RELO

REHI

SEL1

Parameter Description

Data bit count of digital communication

Parity bit of digital communication

Stop bit count of digital communication

Retransmission low scale value

Retransmission high scale value

Select 1'st parameter for user menu

Range

0 : 7 data bits

1 : 8 data bits

0 : Even parity

1 : Odd parity

2 : No parity bit

0 : One stop bit

1 : Two stop bits

Low: -19999

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

High: 45536

:No parameter selected

:LOCK is put ahead

:INPT is put ahead

:UNIT is put ahead

:DP is put ahead

:SHIF is put ahead

:PB is put ahead

:TI is put ahead

:TD is put ahead

:O1HY is put ahead

:CYC1 is put ahead

:OFST is put ahead

:RR is put ahead

:O2HY is put ahead

:CYC2 is put ahead

:CPB is put ahead

:DB is put ahead

:ADDR is put ahead

Default Value

1

0

0.0 C

(32.0 F)LL

100.0 C

(212.0 F)LL

2

UM0C911C

18

Parameter Notation

SEL2

SEL3

SEL4

SEL5

SEL6

SEL7

SEL8

Parameter Description

Select 2'nd parameter for user menu

Select 3'rd parameter for user menu

Select 4'th parameter for user menu

Select 5'th parameter for user menu

Select 6'th parameter for user menu

Select 7'th parameter for user menu

Select 8'th parameter for user menu

Same as SEL1

Range

Default Value

3

4

6

7

8

10

17

19

UM0C911A

Chapter 2 InstallationChapter 2 Installation

Dangerous voltages capable of causing death are sometimes

present in this instrument. Before installation or beginning any

present

in this instrument. Before installation or beginning any

cleaning or troubleshooting procedures the power to all equipment

cleaning

or troubleshooting procedures the power to all equipment

must be switched off and isolated. Units suspected of being faulty

must

be switched off and isolated. Units suspected of being faulty

must be disconnected and removed to a properly equipped

must

be disconnected and removed to a properly equipped

workshop for testing and repair. Component replacement and

workshop

internal adjustments must be made by a qualified maintenance

internal

person only.

person

for testing and repair. Component replacement and

adjustments must be made by a qualified maintenance

only.

This instrument is protected throughout by -- .

To minimize the possibility of fire or shock hazards, do not expose

To

minimize the possibility of fire or shock hazards, do not expose

this instrument to rain or excessive moisture.

this

instrument to rain or excessive moisture.

Do not use this instrument in areas under hazardous

conditions such as excessive shock, vibration, dirt, moisture,

conditions

corrosive gases or oil. The ambient temperature of the areas should

corrosive

not exceed the maximum rating specified in Chapter 6.

not

Don't use harsh chemicals, volatile solvent such as thinner or strong

Don't

detergents to clean the instrument in order to avoid deformation or

detergents

discoloration.

such as excessive shock, vibration, dirt, moisture,

gases or oil. The ambient temperature of the areas should

exceed the maximum rating specified in Chapter 6.

Remove stains from this instrument using a soft, dry cloth.

use harsh chemicals, volatile solvent such as thinner or strong

to clean the instrument in order to avoid deformation or

Double InsulationThis instrument is protected throughout by -- .

Insulation

Double

2-1 Unpacking2-1 Unpacking

Upon receipt of the shipment remove the unit from the carton and

inspect the unit for shipping damage.

inspect

the unit for shipping damage.

If any damage due to transit , report and claim with the carrier.

If

any damage due to transit , report and claim with the carrier.

Write down the model number, serial number, and date code for

Write

down the model number, serial number, and date code for

future reference when corresponding with our service center. The

future

reference when corresponding with our service center. The

serial number (S/N) and date code (D/C) are labeled on the box and

serial

number (S/N) and date code (D/C) are labeled on the box and

the housing of control.

the

housing of control.

2-2 Mounting2-2 Mounting

Make panel cutout to dimension shown in Figure 2.1.Make panel cutout to dimension shown in Figure 2.1. Take the mounting clamp away and insert the controller into

Ta ke the mounting clamp away and insert the controller into

cutout. Install the mounting clamp back.

panel cutout. Install the mounting clamp back.

panel

UM0C911B

20

Figure 2.1 Mounting DimensionsFigure 2.1 Mounting Dimensions

+0.5

_

45

0

+0.3

22.2

_

0

Panel

98.0mm

86 mm

94 mm

12.5mm

45 mm

10.0mm

MOUNTING CLAMP

C21

SCREW

C91

21

UM0C911B

2 - 3 Wiring Precautions2 - 3 Wiring Precautions

Before wiring, verify the label for correct model number and

*

options. Switch off the power while checking.

options.

Switch off the power while checking.

Care must be taken to ensure that maximum voltage rating

must be taken to ensure that maximum voltage rating

Care

*

specified on the label are not exceeded.

specified

It is recommended that power of these units to be protected by

It

*

fuses or circuit breakers rated at the minimum value possible.

fuses

All units should be installed inside a suitably grounded metal

All

*

enclosure to prevent live parts being accessible from human

enclosure

hands and metal tools.

hands

All wiring must conform to appropriate standards of good practice

All

*

and local codes and regulations. Wiring must be suitable for

and

voltage, current, and temperature rating of the system.

voltage,

Beware not to over-tighten the terminal screws. The torque should

Beware

*

not exceed 1 N-m ( 8.9 Lb-in or 10.2 KgF-cm )

not exceed

Unused control terminals should not be used as jumper points as

Unused

*

they may be internally connected, causing damage to the unit.

they

Verify that the ratings of the output devices and the inputs as

Verify

*

specified in Chapter 6 are not exceeded.

specified

Except the thermocouple wiring, all wiring should use stranded

Except

*

copper conductor with maximum gauge 18 AWG.

copper

on the label are not exceeded.

is recommended that power of these units to be protected by

or circuit breakers rated at the minimum value possible.

units should be installed inside a suitably grounded metal

to prevent live parts being accessible from human

and metal tools.

wiring must conform to appropriate standards of good practice

local codes and regulations. Wiring must be suitable for

current, and temperature rating of the system.

not to over-tighten the terminal screws. The torque should

1 N-m ( 8.9 Lb-in or 10.2 KgF-cm )

control terminals should not be used as jumper points as

may be internally connected, causing damage to the unit.

that the ratings of the output devices and the inputs as

in Chapter 6 are not exceeded.

the thermocouple wiring, all wiring should use stranded

conductor with maximum gauge 18 AWG.

UM0C911B

22

3.2mm min.

2.0mm

0.08" max.

7.0mm max.

4.5 ~7.0 mm

0.18" ~0.27"

Figure 2.2

Termination for C91

Lead Termination for C91

Lead

Figure 2.3

Termination for C21

Lead Termination for C21

Lead

OP2

+

3

2

1

N

L

90-250 VAC

47-63 Hz,10VA

V+,mA+

PTA

8 9

RTD

A

CAT.II

23

2A/240 VAC 2A/240 VAC

__

V,mA

_

TC

TC+

PTB

10

_

+

B

_

+

V

I

Figure 2.4

Terminal Connection

Rear Terminal Connection

Rear

C21

for

for C21

UM0C911B

OP1

__

+

5

L

RE+ RE

TX1 TX2

TXD RXD

RS-232

6

12 13 14

RS-485 or

RETRANSMISSION

4

COM

11

50 C max. Air ambient Use copper conductors (except on T/C input )

7

TX2

1

OP2

RS-485

TX1

2

A

RTD

I

50 C max. air ambient

L

Use copper conductors ( except on T/C input )

Figure 2.5

Rear Terminal Connection

Rear

C91

for

for C91

3

B

+

4

V

B

5

Terminal Connection

+

PTA

TC+

TC

L

6

N

7

NC

8

NO

OP1

9

+

C

10

CAT.II

UM0C911B

24

2 - 4 Power Wiring2 - 4 Power Wiring

The controller is supplied to operate at 11-26 VAC / VDC or 90-250

VAC. Check that the installation voltage corresponds with the power

VAC.

Check that the installation voltage corresponds with the power

rating indicated on the product label before connecting power to

rating

indicated on the product label before connecting power to

the controller. Near the controller a fuse and a switch rated at

the

controller. Near the controller a fuse and a switch rated at

2A/250VAC should be equiped as shown in the following diagram.

2A/250VAC

which provides adequate protection against electric shock. The

which

enclosure must be connected to earth ground.

enclosure

Local requirements regarding electrical installation should be rigidly

Local

observed. Consideration should be given to prevent from

observed.

unauthorized person access to the power terminals.

unauthorized

should be equiped as shown in the following diagram.

C21

C91

L

1

N

2

This equipment is designed for installation in an enclosure

Fuse

6

2A/250VAC

7

Figure 2.7 Power Supply ConnectionsFigure 2.7 Power Supply Connections

~

90 250 VAC or

~

11 26 VAC / VDC

provides adequate protection against electric shock. The

must be connected to earth ground.

requirements regarding electrical installation should be rigidly

Consideration should be given to prevent from

person access to the power terminals.

2-5 Sensor Installation Guidelines2-5 Sensor Installation Guidelines

Proper sensor installation can eliminate many problems in a control

The probe should be placed so that it can detect any

system. The probe should be placed so that it can detect any

system. temperature

temperature change with minimal thermal lag. In a process that

requires

requires fairly constant heat output, the probe should be placed

closed

closed to the heater. In a process where the heat demand is variable,

the

the probe should be closed to the work area. Some experiments with

probe

probe location are often required to find this optimum position.

change with minimal thermal lag. In a process that

fairly constant heat output, the probe should be placed

to the heater. In a process where the heat demand is variable,

probe should be closed to the work area. Some experiments with

location are often required to find this optimum position.

a liquid process, addition of a stirrer will help to eliminate thermal

In

In a liquid process, addition of a stirrer will help to eliminate thermal

Since the thermocouple is basically a point measuring device,

lag.

lag. Since the thermocouple is basically a point measuring device,

more than one thermocouple in parallel can provide an

placing

placing more than one thermocouple in parallel can provide an

temperature readout and produce better results in most

average

average temperature readout and produce better results in most

air

heated processes.

air heated processes.

25

UM0C911B

Proper sensor type is also a very important factor to obtain precise

measurements. The sensor must have the correct temperature range

measurements. to

to meet the process requirements. In special processes the sensor

meet the process requirements. In special processes the sensor

might need to have different requirements such as leak-proof, anti-

might

need to have different requirements such as leak-proof, anti-

vibration, antiseptic, etc.

vibration,

Standard

Standard sensor limits of error are 4 degrees F ( 2 degrees C )

or

or 0.75% of sensed temperature (half that for special ) plus drift

0.75% of sensed temperature (half that for special ) plus drift

caused by improper protection or an over-temperature occurrence.

caused

This error is far greater than controller error and cannot be corrected

This

error is far greater than controller error and cannot be corrected

on the sensor except by proper selection and replacement.

on

the sensor except by proper selection and replacement.

The sensor must have the correct temperature range

antiseptic, etc.

sensor limits of error are 4 degrees F (2degrees C )

AA

by improper protection or an over-temperature occurrence.

2-6 Sensor Input Wiring2-6 Sensor Input Wiring

C21 C91

PTA

TC+, V+

PTB, mA+

mA+

PTB,

TC-, V-

mA-

PTB, mA-

PTB,

83 94

10 5

+

_

TC V mA RTD

Figure 2.8 Sensor Input WiringFigure 2.8 Sensor Input Wiring

2-7 Control Output Wiring2-7 Control Output Wiring

C21 C91

+

5610

_

Figure 2.9

Output 1 Relay or Triac (SSR) to Drive Load

Output

9

1 Relay or Tri ac (SSR) to Drive Load

UM0C911B 26

A

RTD

+

B

V

_

B

LOAD

120V/240VAC

Mains Supply

C21 C91

+

5

10

6

9

_

Three Phase

Delta

Heater

Load

Figure 2.10

Output 1 Relay or Triac (SSR) to Drive Contactor

Output

1 Relay or Tri ac (SSR) to Drive Contactor

Contactor

No Fuse

Breaker

120V /240V

Mains Supply

Mains

Supply

Three

Phase

Heater

Power

C21 C91

5 6

+

10

9

_

30mA /5V

30mA / 5V

Pulsed

Voltage

SSR

+

_

Internal CircuitInternal Circuit

5V

0V

Figure 2.11 Output 1 Pulsed Voltage to Drive SSRFigure 2.11 Output 1 Pulsed Voltage to Drive SSR

27

UM0C911B

33

Load

120V /240V

Supply

Mains Supply

Mains

+

C21 C91

5

10

6

9

0-20mA,

0 - 20mA,

- 20mA

4-20mA

4

+

Load

_

Figure 2.12 Output 1 Linear CurrentFigure 2.12 Output 1 Linear Current

Maximum Load

500 ohms

500

ohms

C21 C91

5

10

6

9

0-1V, 0-5V

0 - 1V, 0 - 5V

- 5V, 0 - 10V

1-5V,0-10V

1

+

Minimum Load

Load

10Kohms

10

_

Figure 2.13 Output 1 Linear VoltageFigure 2.13 Output 1 Linear Voltage

C21 C91

+

3 4

_

Figure 2.14

Output 2 Relay or Triac (SSR) to Drive Load

Output

2 Relay or Tri ac (SSR) to Drive Load

LOAD

2

1

UM0C911B 28

120V/240VAC

Mains Supply

K ohms

C21 C91

+

3

2

4

1

_

No Fuse

Three Phase

Delta

Heater

Load

Figure 2.15

Output 2 Relay or Triac (SSR) to Drive Contactor

Output

Load

2 Relay or Tri ac (SSR) to Drive Contactor

Contactor

No Fuse

Breaker

120V /240V

Mains Supply

Mains

Supply

Three

Phase

Heater

Power

C21 C91

+

_

3 4

+

2

1

_

30mA /5V

30mA / 5V

Pulsed

Voltage

SSR

+

_

Internal CircuitInternal Circuit

5V

0V

Figure 2.16 Output 2 Pulsed Voltage to Drive SSRFigure 2.16 Output 2 Pulsed Voltage to Drive SSR

C21 C91

+

3

2

0-20mA,

0 - 20mA,

- 20mA

4-20mA

4

_

4

1

Figure 2.17 Output 2 Linear CurrentFigure 2.17 Output 2 Linear Current

29

UM0C911B

33

Load

120V /240V

Mains Supply

Mains

+

Maximum Load

Load

500 ohms

500

_

Supply

ohms

C21 C91

3 4

Figure 2.18 Output 2 Linear VoltageFigure 2.18 Output 2 Linear Voltage

2-8 Alarm Wiring2-8 Alarm Wiring

Figure 2.19 Alarm Output to Drive LoadFigure 2.19 Alarm Output to Drive Load

C21 C91

3 4

Figure 2.20 Alarm Output to Drive ContactorFigure 2.20 Alarm Output to Drive Contactor

2 1

C21 C91

3

2

4

1

2 1

0-1V, 0-5V

0 - 1V, 0 - 5V

- 5V, 0 - 10V

1-5V,0-10V

1

LOAD

Three Phase

Delta

Heater

Load

+

Load

_

120V/240VAC

Mains Supply

Mains

Supply

Contactor

Relay Output to

Contactor

Drive Contactor

Drive

Minimum Load

10Kohms

10

K ohms

120V /240V

Supply

Mains Supply

Mains

Three

Phase

Heater

Power

No Fuse

Breaker

Power

UM0C911B 30

2-9 Data Communication2-9 Data Communication

C21 C91

TX1

TX2

C21 C91

TX1

TX2

TX1

12

2

TX2

13

1

Twisted-Pair WireTwisted-Pair Wire

12

2

13

1

TX1

TX2

RS-485 to RS-232

adaptor

network adaptor

network

SNA10A or

SNA10B

TX1

TX2

Max. 247 units can be linkedMax. 247 units can be linked

RS-232

PC

TX1

TX2

C21 C91

12 13

TX1

2

TX2

1

Terminator

ohms / 0.5W

220 ohms / 0.5W

220

Figure 2.21 RS-485 WiringFigure 2.21 RS-485 Wiring

31

UM0C911B

RS-232

C21

TXD

12

RXD

13

COM

11

Figure 2.22

RS-232 Wiring

RS-232

If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable

must be modified according to the following circuit diagram.

must

be modified according to the following circuit diagram.

C21

TX1 RD

TXD

12

TX2 TD

RXD

13

COM

11

Figure 2.23

Configuration of RS-232 Cable

9-pin

RS-232

port

CC94-1

Wiring

To DTE ( PC) RS-232 PortTo DTE ( PC ) RS-232 Port

GND

1

2

3

4

5

Female DB-9Female DB-9

PC

1 DCD

6

RD

2RD

2

TD

3

3TD

7

DTR

4

4DTR

8

GND

5

5 GND

DSR

6

6DSR

9

RTS

7

7RTS

CTS

8

8CTS

RI

9

9RI

UM0C911B 32

Chapter 3 ProgrammingChapter 3 Programming

Press for 5 seconds and release to enter setup menu. Press to select the desired parameter. The display indicates the parameter symbol. Press or to view or adjust the value of the selected parameter.

3-1 Lockout3-1 Lockout

There are four security levels can be selected by using LOCK parameter.

NONE

If is selected for LOCK, then no parameter is locked.

NONE

SET

If is selected for LOCK, then all setup data are locked.

SET

USER

If is selected for LOCK, then all setup data as well as user data

USER

section

(refer to ) except set point are locked to prevent from being changed.

ALL

If is selected for LOCK, then all parameters are locked to prevent

ALL

from being changed.

3-2 Signal Input3-2 Signal Input

INPT:

Selects the sensor type or signal type for signal input.

INPT:

Range:

UNIT:

Selects the process unit

UNIT:

Range:

DP:

Selects the resolution of process value.

DP:

Range:

INLO:

Selects the low scale value for the linear type input.

INLO:

INHI : Selects the high scale value for the linear type input.

INHI

:

How to use INLO and INHI :How to use INLO and INHI :

If4-20mAisselected for INPT,let SL specifies the input signal low ( ie. 4 mA ), SH specifies the input signal high ( ie. 20 mA ), S specifies the current input signal value, the conversion curve of the process value is shown as follows :

1-5

section 1-5

( thermocouple ) J_TC, K_TC, T_TC, E_TC, B_TC, R_TC

S_TC, N_TC, L_TC ( RTD ) PT.DN, PT.JS (linear ) 4-20, 0-20, 0-60, 0-1V, 0-5V, 1-5V, 0-10

C, F, PU( process unit ). If the unit is neither C nor F,

LL L L

then selects PU.

( for T/C and RTD ) NO.DP, 1-DP (for linear ) NO.DP, 1-DP, 2-DP, 3-DP

33

UM0C911C

process value

INHI

PV

INLO

SL SHS

input signal

Formula : PV = INLO + ( INHI INLO )Formula : PV = INLO + ( INHI INLO )

Example : A 4-20 mA current loop pressure transducer with range

0 - 15 kg/cm is connected to input, then perform the

0

- 15 kg/cm is connected to input, then perform the

following setup :

following

INPT=4-20 INLO=0.00

INPT = 4 - 20 INLO = 0.00

INHI = 15.00 DP = 2-DP

INHI

course, you may select other value for DP to alter the

Of

Of course, you may select other value for DP to alter the

resolution.

2

setup :

= 15.00 DP = 2-DP

Figure 3.1

Conversion Curve for

Conversion

Linear Type Process Value

Linear

Curve for

Ty pe Process Value

SSLS SL

SH SLSH SL

3-3 Control Outputs3-3 Control Outputs

There are 4 kinds of control modes can be configured as shown in Table 3.1

Table 3.1

Table 3.1 Heat-Cool Control Setup ValueTable 3.1 Heat-Cool Control Setup Value

Control Modes

Heat only

Cool only

Heat: PID Cool: ON-OFF

Heat: PID Cool: PID

: Don't care

:Adjust to met process

requirements

OUT1 OUT2 O1HY O2HY CPB

REVR

DIRT

REVR

DE.HI

COOL

:Required if ON-OFF control

is configured

UM0C911A 34

DB

Heat Only ON-OFF Control : Select REVR for OUT1, Set PB to 0,

is used to adjust dead band for ON-OFF control, The output 1

O1HY is used to adjust dead band for ON-OFF control, The output 1

O1HY hysteresis

hysteresis ( O1HY ) is enabled in case of PB=0.Theheat only

on-off

on-off control function is shown in the following diagram :

SP1 O1HY

( O1HY ) is enabled in case of PB = 0 . The heat only

control function is shown in the following diagram :

PV

SP1

Dead band = O1HY

OUT1 Action

ON

OFF

Figure 3.2 Heat Only

ON-OFF Control

ON-OFF

The ON-OFF control may introduce excessive process oscillation even

hysteresis is minimized to the smallest. If ON-OFF control is set ( ie.

if hysteresis is minimized to the smallest. If ON-OFF control is set ( ie.

if

= 0 ), TI, TD, CYC1, OFST, CYC2, CPB, DB will be hidden and have

PB

PB=0),TI,TD,CYC1,OFST, CYC2, CPB, DB will be hidden and have

function to the system. The auto-tuning mode and bumpless

no

no function to the system. The auto-tuning mode and bumpless

will be disabled too.

transfer

transfer will be disabled too.

Heat

only P ( or PD ) control :

Heat onlyP(orPD)control :

is used to adjust the control offset ( manual reset ).

OFST

OFST is used to adjust the control offset ( manual reset ).

hidden OFST

hidden OFST Function :

stabilized

stabilized ) if the process value is lower than the set point a definite

value,

value, say 5 C, while 20 C is used for PB, that is lower 25 %,

PB is not equal to 0. OFST is measured by

if

if PB is not equal to 0. OFST is measured by

with range 0 - 100.0 %. In the steady state ( ie. process has been

%

% with range 0 - 100.0 %. In the steady state ( ie. process has been

) if the process value is lower than the set point a definite

say 5C,while 20 C is used for PB, that is lower 25 %,

LL

35

Control

REVR for OUT1, set TI to 0,

Select

Select REVR for OUT1, set TI to 0,

Function :

UM0C911A

Time

O1HY

O1HY is

is

then increase OFST 25 %, and vice versa. After adjusting OFST value,

process value will be varied and eventually, coincide with set point.

the process value will be varied and eventually, coincide with set point.

the

the P control ( TI set to 0 ), the auto-tuning is disabled.

Using

Using the P control ( TI set to 0 ), the auto-tuning is disabled.

to section 3-12 " manual tuning " for the adjustment of PB and

Refer

Refer to section 3-12 " manual tuning " for the adjustment of PB and

Manual reset ( adjust OFST ) is not practical because the load may

TD.

TD. Manual reset ( adjust OFST ) is not practical because the load may

from time to time and often need to adjust OFST repeatedly.

change

change from time to time and often need to adjust OFST repeatedly.

PID control can avoid this situation.

The

The PID control can avoid this situation.

Heat only PID control :

be zero. Operate auto-tuning for the new process, or set PB, TI

not be zero. Operate auto-tuning for the new process, or set PB, TI

not

TD with historical values. See section 3-11 for auto-tuning

and

and TD with historical values. See section 3-11 for auto-tuning

operation.

operation. If the control result is still unsatisfactory, then use manual

tuning

tuning to improve the control . See section 3-12 for manual tuning. The

unit

unit contains a algorithm to achieve a

small

small overshoot and very quick response

tuned.

Coolonlycontrol:ON-OFFcontrol,P(PD)control andPID

Cool only control:ON-OFF control, P ( PD ) control and PID

control can be used for cool control. Set OUT1 to DIRT ( direct

control

action ). The other functions for control,

action

onlyP(PD) cool only PID

only

descriptions for heat only control except that the output variable

descriptions

( and action ) for the cool control is inverse to the heat control.

(

NOTE :

undershoot problems in the process. TheP(orPD)control will result

undershoot in

in a deviation process value from the set point. It is recommended to

use

use PID control for the Heat-Cool control to produce a stable and zero

offset

offset process value.

If the control result is still unsatisfactory, then use manual

to improve the control . See section 3-12 for manual tuning. The

contains a algorithm to achieve a

overshoot and very quick response

can be used for cool control. Set OUT1 to DIRT ( direct

). The other functions for control,

control and control are same as

control

P ( PD ) cool only PID

and action ) for the cool control is inverse to the heat control.

The

The ON-OFF control may result excessive overshoot and

ON-OFF control may result excessive overshoot and

problems in the process. The P ( or PD ) control will result

a deviation process value from the set point. It is recommended to

PID control for the Heat-Cool control to produce a stable and zero

process value.

Selecting

Selecting REVR for OUT1, PB and TI should

clever PID and Fuzzy very

very clever PID and Fuzzy very

very

REVR for OUT1, PB and TI should

the process if it is properly

to

to the process if it is properly

cool only ON-OFF cool

only ON-OFF cool

cool

and control are same as

for heat only control except that the output variable

Setup Required :

Other Setup Required :

Other

& O2TY are set in accordance with the types of OUT1 & OUT2

O1TY

O1TY & O2TY are set in accordance with the types of OUT1 & OUT2

installed.

installed. CYC1 & CYC2 are selected according to the output 1 type (

O1TY

O1TY ) & output 2 type ( O2TY ). Generally, selects 0.5 ~ 2 sec. for

CYC1,

CYC1, if SSRD or SSR is used for O1TY; 10 ~ 20 sec. if relay is used

for

for O1TY, and CYC1 is ignored if linear output is used. Similar condition

is

is applied for CYC2 selection.

CYC1 & CYC2 are selected according to the output 1 type (

) & output 2 type ( O2TY ). Generally, selects 0.5 ~ 2 sec. for

if SSRD or SSR is used for O1TY; 10 ~ 20 sec. if relay is used

O1TY, and CYC1 is ignored if linear output is used. Similar condition

applied for CYC2 selection.

CYC1, O2TY, CYC2, O1FT, O2FT

O1TY,

O1TY, CYC1, O2TY, CYC2, O1FT, O2FT

UM0C911A 36

You can use the program for the new process or directly

auto-tuning

set the appropriate values for PB, TI & TD according to the historical records for the repeated systems. If the control behavior is still inadequate, then use to improve the control. See

3-12

section

section 3-12

CPB Programming : The cooling proportional band is measured by %

CPB Programming :

for manual tuning.

tuning

manual tuning

manual

of PB with range 50~300. 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 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:

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 PB. 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.

Output 2 ON-OFF Control ( Alarm function ):

The output 2 can also be configured as alarm function. There are 6 kinds of alarm functions can be selected for output 2, these are: (deviation high alarm ), DE.LO DB.HI

(deviation low alarm ), (deviation band out of band alarm

DE.LO DB.HI

DB.LO PV.HI

), (deviation band in band alarm), (process high alarm )

DB.LO PV.HI

PV.LO Figure 3.3 Figure 3.4

and ( process low alarm ). Refer to and for

PV.LO Figure

DE.HI

3.3 Figure 3.4

the description of deviation alarm and process alarm with normal alarm mode ( NORM is set for ALMD ).

37

UM0C911A

SV+SP2

SV+SP2-O2HY

PV

OUT2=DE.HI

OUT2 Action

ON

OFF

Figure 3.3 Output 2 Deviation

Alarm

High Alarm

High

PV

SP2+O2HY

SP2

OUT2 Action

ON

OFF

Figure 3.4 Output 2 Process

Alarm

Low Alarm

Low

UM0C911A 38

Time

3-4 Alarm3-4 Alarm

The output 2 can be selected as alarm output. There are 6 types of alarm functions and one dwell timer can be selected, and four kinds of alarm modes ( ALMD ) are available for each alarm function.

process

A sets two absolute trigger levels. When the process is

higher

higher than SP2, a process high alarm occurs, and the alarm

is

is off as the process is lower than SP2-O2HY. When the process is

lower

lower than SP2, a process low alarm occurs and the alarm is

off

off as the process is higher than SP2+O2HY. A process alarm is

independent

independent of set point.

A alerts the user when the process deviates too far

from set point. When the process is higher than SV+SP2, a deviation

from high

high alarm occurs and the alarm is off as the process is lower

than

than SV+SP2-O2HY. When the process is lower than SV+SP2, a

deviation

deviation low alarm occurs and the alarm is off as the process

is

is higher than SV+SP2+O2HY. Trigger level of deviation alarm is

moving

moving with set point.

A presets two trigger levels relative to set point.

The two trigger levels are and for alarm. When the

The process

process is higher than ( SV+SP2 ) or lower than ( SV - SP2 ), a

deviation

deviation band high alarm occurs. When the process is within

the

the trigger levels, a deviation band low alarm occurs.

In the above descriptions denotes the current set point value for control which is different from SP1 as the ramp function is performed.

control

There are four types of alarm modes available for each alarm function,

these are: Normal alarm, Latching alarm, Holding alarm and Latching/

these Holding

Holding alarm. They are described as follows:

Normal Alarm : ALMD = NORM

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

Latching Alarm : ALMD = LTCH

Latching Alarm : ALMD = LTC H

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 alarm is reset when the RESET key is pressed, once the alarm condition is removed.

alarm

process alarm

than SP2, a process high alarm occurs, and the alarm

PV.HI )

(

( PV.HI )

off as the process is lower than SP2-O2HY. When the process is

than SP2, a process low alarm occurs and the alarm is

PV.LO )

(

(PV.LO)

as the process is higher than SP2+O2HY. A process alarm is

of set point.

deviation

deviation alarm

alarm

set point. When the process is higher than SV+SP2, a deviation

alarm occurs and the alarm is off as the process is lower

(DE.HI)

SV+SP2-O2HY. When the process is lower than SV+SP2, a

low alarm occurs and the alarm is off as the process

(DE.LO)

higher than SV+SP2+O2HY. Trigger level of deviation alarm is

with set point.

deviation

deviation band alarm

band alarm

two trigger levels are and for alarm. When the

SV+SP2 SV - SP2

SV+SP2 SV

- SP2

is higher than ( SV+SP2 ) or lower than ( SV - SP2 ), a

band high alarm occurs. When the process is within

trigger levels, a deviation band low alarm occurs.

DB.HI )

(

( DB.HI )

SV

SVIn the above descriptions denotes the current set point value for

(DB.LO)

which is different from SP1 as the ramp function is performed.

are: Normal alarm, Latching alarm, Holding alarm and Latching/

alarm. They are described as follows:

39

UM0C911A

Holding Alarm : ALMD = HOLD

A holding alarm prevents an alarm from power up. The alarm is enabled only when the process reaches the set point value. Afterwards , the alarm performs same function as normal alarm.

Latching / Holding Alarm : ALMD = LT.HO

A latching / holding alarm performs both holding and latching function. The latching alarm is reset when the RESET key is pressed, once the alarm condition is removed.

Alarm Failure Transfer failure mode

Alarm will go on if is set for and go off if is

O2FT

set for . The unit will enter failure mode when sensor break

O2FT

is activated as the unit enters .

ON O2FT OFF

occurs or if the A-D converter of the unit fails.

3-5 Configure Display3-5 Configure Display

C21 can be configured to display the process value by selecting PV for DISP or to display the set point value by selecting SP1 for DISP in the normal condition.

Examples:

If LOCK is set with NONE, OUT2 is set with DEHI, DISP is set with PV, set SEL1=SHIF, SEL2=ADDR. SEL3=PB, SEL4~SEL8=NONE, then the display scrolling for C21 becomes:

PV

If LOCK is set with NONE, OUT1 is set with REVR,nonzero value is set for PB and TI, OUT2 is set with COOL, DISP is set with SP1, set SEL1=INPT, SEL2=PB, SEL3=TI, SEL4~SEL8=NONE, then the display scrolling for C21 becomes:

SP1

UM0C911A

40

Example for C91:Example for C91:

Set OUT2=PVLO, LOCK=NONE, SEL1=INPT, SEL2=UNIT, SEL3=DP, SEL4~SEL8=NONE, then the display scrolling for C91 becomes

PV

SP1 SP2

ATMAN

PV

3-6 Ramp3 - 6 Ramp

The ramping function is performed during power up as well as any

the set point is changed. Choose MINR or HRR for RAMP, the

time the set point is changed. Choose MINR or HRR for RAMP, the

time

will perform the ramping function. The ramp rate is programmed

unit

unit will perform the ramping function. The ramp rate is programmed

adjusting RR. The ramping function is disabled as soon as the

by

by adjusting RR. The ramping function is disabled as soon as the

mode, the manual control mode, the auto-tuning mode or the

failure

failure mode, the manual control mode, the auto-tuning mode or the

calibration

calibration mode occurs.

Example without Dwell TimerExample without Dwell Timer

Select MINR for RAMP, selects C for UNIT, selects 1-DP for DP, Set

RR= 10.0. SV is set to 200 C initially, and changed to 100 C after 30

RR= minutes

minutes since power up. The starting temperature is 30 C. After

power

power up the process is running like the curve shown below:

Note: When the ramp function is used, the display will show the

current ramping value. However it will revert to show the set point

current value

value as soon as the up or down key is touched for adjustment. The

ramping

ramping value is initiated to process value either as power up or RR

and

and /or set point are changed. Setting RR to zero means no ramp

function

function at all.

41

mode occurs.

L

10.0. SV is set to 200 C initially, and changed to 100 C after 30 since power up. The starting temperature is 30 C. After

LL

L

up the process is running like the curve shown below:

PV

200C200

C

100C100

C

30C30

C

0

30 40

17

Figure 3.5 RAMP FunctionFigure 3.5 RAMP Function

Time

(minutes)

ramping value. However it will revert to show the set point

as soon as the up or down key is touched for adjustment. The

value is initiated to process value either as power up or RR

/or set point are changed. Setting RR to zero means no ramp

at all.

UM0C911B

3-7 Dwell Timer3-7 Dwell Timer

Output 2 can be configured as dwell timer by selecting TIMR for OUT2. As the dwell timer is configured, the parameter SP2 is used for dwell time adjustment. The dwell time is measured in minute ranging from 0.1 to 4553.6 minutes. Once the process reaches the set point the dwell timer starts to count down until zero ( time out ). The timer relay will remain unchanged until time out. The dwell timer operation is shown as following diagram.

After time out the dwell timer will be restarted by pressing the RESET key.

The timer stops to count during the manual control mode, failure mode, calibration period and auto-tuning period.

PV

SP

ALM

SP3

power off or touch RESET key

Time

ON

OFF

Time

Timer starts

Figure 3.6 Dwell Timer FunctionFigure 3.6 Dwell Timer Function

If output 2 is configured as dwell timer, ALMD will be hidden.If output 2 is configured as dwell timer, ALMD will be hidden.

UM0C911A 42

3-8 PVShift3 - 8 PV Shift

In certain applications it is desirable to shift the controller display

from its actual value. This can be easily accomplished by using

value from its actual value. This can be easily accomplished by using

value

PV shift function.

the

the PV shift function.

The SHIF function will .alter PV onlyThe SHIF function will .alter PV only

Here is an example. A process is equipped with a heater, a sensor

a subject to be warmed up. Due to the design and position of the

and a subject to be warmed up. Due to the design and position of the

and components

components in the system, the sensor could not be placed any closer

the part. Thermal gradient ( different temperature ) is common and

to

to the part. Thermal gradient ( different temperature ) is common and

necessary

necessary to an extent in any thermal system for heat to be

transferred

transferred from one point to another. If the difference between the

sensor

sensor and the subject is 35 C, and the desired temperature at the

subject

subject to be heated is 200 C, the controlling value or the

temperature

temperature at the sensor should be 235 C. You should input -35 C

to subtract 35 C from the actual process display. This in turn will

as

as to subtract 35 C from the actual process display. This in turn will

cause

cause the controller to energize the load and bring the process

display

display up to the set point value.

Subject

165 C

in the system, the sensor could not be placed any closer

to an extent in any thermal system for heat to be

from one point to another. If the difference between the

and the subject is 35 C, and the desired temperature at the

to be heated is 200 C, the controlling value or the

at the sensor should be 235 C. Yo u should input -35 C

L

LL

the controller to energize the load and bring the process

up to the set point value.

Sensor

Heat Transfer

200 C

C

Heater

Subject

165 C

Sensor

Heat Transfer

200 C

C

Heater

Subject

200 C

235 C

Sensor

Heat Transfer

C

Heater

35 C temperature difference isobserved SHIF= 0

43

Adjust SHIF SHIF= -35 C Supply more heat

Figure 3.7

PV Shift Application

Shift Application

PV

UM0C911A

Display is stable SHIF= -35 C PV=SV

3- 9 Digital Filter3- 9 Digital Filter

In certain application the process value is too unstable to be read. To improve this a programmable low pass filter incorporated in the controller can be used. This is a first order filter with time constant specified by parameter . The default value of FILT is 0.5 sec. before shipping. Adjust FILT to change the time constant from 0 to 60 seconds. 0 second represents no filter is applied to the input signal. The filter is characterized by the following diagram.

PV

FILT

1 sec1 sec

FILT=0

FILT=1

FILT=30

Note

The Filter is available only for PV, and is performed for the displayed

only. The controller is designed to use unfiltered signal for

value only. The controller is designed to use unfiltered signal for

value

even if Filter is applied. A lagged ( filtered ) signal, if used for

control

control even if Filter is applied. A lagged ( filtered ) signal, if used for

may produce an unstable process.

control,

control, may produce an unstable process.

1 sec1 sec

Figure 3.8

Characteristics

Filter Characteristics

Filter

UM0C911A 44

Time

3 -10 Failure Transfer3 -10 Failure Transfer

The controller will enter as one of the following conditions occurs:

SBER

1. occurs due to the input sensor break or input current below

SBER 1mA if 4-20 mA is selected or input voltage below 0.25V if 1-5 V is selected .

ADER

2. occurs due to the A-D converter of the controller fails.

ADER

failure mode

The output 1 and output 2 will perform the function as

failure transferfailure transfer

the controller enters failure mode.

Output 1 Failure Transfer, if activated, will perform :

Output 1 Failure Transfer

1. If output 1 is configured as proportional control ( PB=0 ), and BPLS is selected for O1FT, then output 1 will perform bumpless transfer. Thereafter the previous averaging value of MV1 will be used for controlling output 1.

2. If output 1 is configured as proportional control ( PB=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.

3. If output 1 is configured as ON-OFF control ( PB=0 ), then output 1 will transfer to off state if OFF is set for O1FT and transfer to on state if ON is set for O1FT.

Output 2 Failure Transfer, if activated, will perform :

1. If OUT2 is configured as COOL, and BPLS is selected for O2FT,

1.

If OUT2 is configured as COOL, and BPLS is selected for O2FT,

then output 2 will perform bumpless transfer. Thereafter the previous

then

output 2 will perform bumpless transfer. Thereafter the previous

averaging value of MV2 will be used for controlling output 2.

averaging

2. If OUT2 is configured as COOL, and a value of 0 to 100.0 % is set

2.

If OUT2 is configured as COOL, and a value of 0 to 100.0 % is set

for O2FT, then output 2 will perform failure transfer. Thereafter the

for

value of O2FT will be used for controlling output 2.

value

3. If OUT2 is configured as alarm function, and OFF is set for O2FT,

3.

If OUT2 is configured as alarm function, and OFF is set for O2FT,

then output 2 will transfer to off state, otherwise, output 2 will transfer

then

to on state if ON is set for O2FT.

to

45

value of MV2 will be used for controlling output 2.

O2FT, then output 2 will perform failure transfer. Thereafter the

of O2FT will be used for controlling output 2.

output 2 will transfer to off state, otherwise, output 2 will transfer

on state if ON is set for O2FT.

UM0C911A

3 -11 Auto-tuning3 -11 Auto-tuning

The auto-tuning process is performed at set point.

process will oscillate around the set point during tuning

The process will oscillate around the set point during tuning

The process.

process. Set a set point to a lower value if overshooting beyond

the

the normal process value is likely to cause damage.

The auto-tuning is applied in cases of :

Initial setup for a new process

Initial

*

The

The set point is changed substantially from the previous auto-

*

tuning

tuning value

The

The control result is unsatisfactory

*

1. The system has been installed normally.

2. Set the correct values for the setup menu of the unit.

3. Set the set point to a normal operating value or a lower value if

4. Press several times until appears on the

5. Press for at least 5 seconds. The AT indicator ( for C91 )

NOTE :NOTE :

The ramping function, if used, will be disabled once auto-tuning is proceeding.

The auto-tuning mode is disabled as soon as either failure mode

Set a set point to a lower value if overshooting beyond

normal process value is likely to cause damage.

setup for a new process

set point is changed substantially from the previous auto-

value

control result is unsatisfactory

Operation :Operation :

But don't use a zero value for PB and TI , otherwise, the auto-tuning program will be disabled. The LOCK parameter should be set at NONE.

overshooting beyond the normal process value is likely to cause damage.

display.( for C21) or AT indicator is lit (for C91).

or the display ( for C21 )will begin to flash and the auto-tuning procedure is beginning.

or manual control mode occurs.

UM0C911C 46

Procedures:

The auto-tuning can be applied either as the process is warming

up ( Cold Start ) or as the process has been in steady state ( Warm Start ).

After the auto-tuning procedures are completed, the AT indicator will cease to flash and the unit revert to PID control by using its new PID values. The PID values obtained are stored in the nonvolatile memory.

Auto-Tuning ErrorAuto-Tuning Error

If auto-tuning fails an ATER message will appear on the display in

cases of :

cases

of :

If PB exceeds 9000 ( 9000 PU, 900.0 F or 500.0 C ). or if TI exceeds 1000 seconds.

or

if TI exceeds 1000 seconds.

or if set point is changed during auto-tuning procedure.

or

if set point is changed during auto-tuning procedure.

LLIf PB exceeds 9000 ( 9000 PU, 900.0 F or 500.0 C ).

LL

Solutions toSolutions to

1. Try auto-tuning once again.

1. Tr y auto-tuning once again.

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

2.

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

3. Don't set zero value for PB and TI.

3.

Don't set zero value for PB and TI.

4. Use manual tuning instead of auto-tuning. ( See section 3-12 ).

4.

Use manual tuning instead of auto-tuning. ( See section 3-12 ).

5. Touch RESET key to reset message.

5.

Touch RESET key to reset message.

3 - 12 Manual Tuning3 - 12 Manual Tuning

In certain applications ( very few ) using auto-tuning to tune a process may be inadequate for the control requirement, then you can try manual tuning.

If the control performance by using auto- tuning is still unsatisfactory, the following rules can be applied for further adjustment of PID values :

47

UM0C911A

ADJUSTMENT SEQUENCEADJUSTMENT SEQUENCE

(1) Proportional Band ( PB )

(2) Integral Time ( TI )(2) Integral Time ( TI )

(3) Derivative Time ( TD )(3) Derivative Time ( TD )

SYMPTOM SOLUTION

Slow ResponseSlow Response

High overshoot or

Oscillations

Slow ResponseSlow Response

Instability or

Oscillations

Slow Response or

Oscillations

High OvershootHigh Overshoot

Decrease PBDecrease PB

Increase PBIncrease PB

Decrease TIDecrease TI

Increase TIIncrease TI

Decrease TDDecrease TD

Increase TDIncrease TD

Table 3.2 PID Adjustment GuideTable 3.2 PID Adjustment Guide

Figure 3.9 shows the effects of PID adjustment on process response.Figure 3.9 shows the effects of PID adjustment on process response.

3 -13 Manual Control3 -13 Manual Control

Operation:

To enable manual control the LOCK parameter should be set with

NONE, then press for several times then (Heating output)

then press for several times then (Heating output)

NONE,

or (Cooling output) will appear on the display.Press for 5

or seconds

seconds then the MAN indicator (for C91) or the display (for C21) will

begin

begin to flash. The controller now enters the manual control mode.

down

down key to adjust the percentage values for the heating or cooling

output.

The

The controller performs open loop control as long as it stays in manual

control

control mode.

Exit Manual ControlExit Manual Control

To press key the controller will revert to its normal display mode.To press key the controller will revert to its normal display mode.

(Cooling output) will appear on the display. Press for 5

then the MAN indicator (for C91) or the display (for C21) will

to flash. The controller now enters the manual control mode.

indicates

indicates output control variable for output 1, and

indicates

indicates control variable for output 2. Now you can use up-

output control variable for output 1, and control variable for output 2. Now you can use up-

key to adjust the percentage values for the heating or cooling

controller performs open loop control as long as it stays in manual

mode.

UM0C911C 48

PV

Set pointSet point

PV

Perfect

PB too high

PB too lowPB too low

P actionP action

Time

TI too highTI too high

Set pointSet point

49

TI too low

PV

TD too lowTD too low

Perfect

TD too high

Figure 3.9 Effects of PID AdjustmentFigure 3.9 Effects of PID Adjustment

UM0C911A

I actionI action

Perfect

Time

D actionD action

Time

3 -14 Data Communication3 -14 Data Communication

The controllers support mode of protocol for the data communication. Other protocols are not available for the series.

Two types of interface are available for Data Communication. These are

Tw o types of interface are available for Data Communication. These are

and interface. Since RS-485 uses a differential architecture to

and interface.

485 RS-232

and sense signal instead of a single ended architecture which is used

drive

drive and sense signal instead of a single ended architecture which is used

RS-232, RS-485 is less sensitive to the noise and suitable for a longer

for

for RS-232, RS-485 is less sensitive to the noise and suitable for a longer

communication. RS-485 can communicate without error over 1 km

distance

distance communication. RS-485 can communicate without error over 1 km

while RS-232 is not recommended for a distance over 20 meters.

distance

distance while RS-232 is not recommended for a distance over 20 meters.

Using a PC for data communication is the most economic way. The signal

transmitted and received through the PC communication Port ( generally

is transmitted and received through the PC communication Port ( generally

is

). Since a standard PC can't support RS-485 port, a network

RS-232

RS-232 ). Since a standard PC can't support RS-485 port, a network

( such as ) has to be used to convert RS-485 to

adaptor

adaptor(suchas )hastobeusedtoconvertRS-485to

for a PC if RS-485 is required for the data communication. But there

RS-232

RS-232 for a PC if RS-485 is required for the data communication. But there

no need to be sad. Many RS-485 units ( up to 247 units ) can be

is

is no need to be sad. Many RS-485 units ( up to 247 units ) can be

connected

connected to one RS-232 port, therefore a PC with 4 comm ports can

communicate

communicate with 988 units. It is quite economic.

Setup

Enters the setup menu.

Select RTU for COMM . Set individual address as for those units which are

Select

connected to the same port.

connected

Set the Baud Rate ( ), Data Bit ( ), Parity Bit ( ) and Stop

Set

Bit ( ) such that these values are accordant with PC setup conditions.

Bit

If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable

should be modified for proper operation of RS-232 communication

should according

according to Section 2-9.

to one RS-232 port, therefore a PC with 4 comm ports can

with 988 units. It is quite economic.

RTU for COMM . Set individual address as for those units which are

to the same port.

the Baud Rate (),Data Bit ( ), Parity Bit ()and Stop

STOP

()such that these values are accordant with PC setup conditions.

STOP

be modified for proper operation of RS-232 communication

to

RTU Modbus

Since RS-485 uses a differential architecture to

SNA10A SNA10B,

BAUD DATA PARI

RS-

3 -15 PV Retransmission3 -15 PV Retransmission

C21 can output (retransmit) process value via its retransmission terminals RE+ and RE- provided that the retransmission option is ordered. A correct signal type should be selected for COMM parameter to meet the retransmission option installed. RELO and REHI are adjusted to specify the low scale and high scale values of retransmission.

UM0C911A 50

Chapter 4 ApplicationsChapter 4 Applications

4 - 1 Heat Only Control with Dwell Timer4 - 1 Heat Only Control with Dwell Timer

An oven is designed to dry the products at 150 C for 30 minutes and then stay unpowered for another batch. A C91 equipped with

timer

is used for this purpose. The system diagram is shown as

timer follows :

Set

SP1=150.0

=30.0

SP2

SP2 =30.0

To achieve this function set the following parameters in the setup

menu.

4 5

OP1

OP2

C

F

C

SP2SP1

PV

INPT=K_TC UNIT= C DP=1_DP

OUT1=REVR O1TY=RELY CYC1=18.0

OUT1=REVR

O1FT=BPLS OUT2=TIMR O2FT=ON

O1FT=BPLS

MAN

12

10

OUT1

Timer ( ALM )

AT

R

C91

9

T/C

Heater

OFF

L

O1TY=RELY CYC1=18.0

OUT2=TIMR O2FT=ON

Auto-Tuning is performed at 150 C for a new oven.LAuto-Tuning is performed at 150 C for a new oven.L

Oven

B

Figure 4.1

Heat Control

Heat Example

Example

dwell

Control

Mains

Supply

ON

51

UM0C911A

4 - 2 Cool Only Control4 - 2 Cool Only Control

A C91 is used to control a refrigerator at temperature below 0 C. The temperature is lower than the ambient, a cooling action is required. Hence select DIRT for OUT1. Since output 1 is used to drive a magnetic contactor, O1TY selects RELY. A small temperature oscillation is tolerable, hence use ON-OFF control to reduce the overall cost. To achieve ON-OFF control, PB is set with zero and O1HY is set at 0.1 C.BB

Setup Summary:

INPT=PT.DN

L

UNIT= C

DP=1-DP

OUT1=DIRT

O1TY=RELY

User Menu:User Menu:

PB =0( C)

PB = 0 (C)

O1HY=0.1 ( C )LL

O1HY=0.1

(C)LL

Refrigerator

RTD

4

9

5

3

OP1

OP2

C

F

SP2SP1

PV

Figure 4.2

Cooling Control Example

Cooling

MAN

AT

R

C91

Control Example

Mains

Supply

10

UM0C911A 52

4 - 3 Heat-Cool Control4 - 3 Heat-Cool Control

An injection mold required to be controlled at 120 C to ensure a

consistent quality for the parts. An oil pipe is buried in the mold. Since

consistent plastics

plastics is injected at higher temperature ( e.g. 250 C ), the

circulation

circulation oil needs to be cooled as its temperature rises. Here is an

example:

quality for the parts. An oil pipe is buried in the mold. Since

is injected at higher temperature ( e.g. 250 C ), the

oil needs to be cooled as its temperature rises. Here is an

L

53

Plastics

Freezer

OP1

PV

4-20 mA

OUT2

OP2

1,2 9

SP2SP1

MAN

Injection Mold

Oil Tank

OUT1

C

F

AT

R

C91

120 C

Oil Pump

RTD

10

INPT

5 4 3

Figure 4.3

Heat-Cool Control Example

Heat-Cool

UM0C911A

Heater Supply

Control Example

The PID Heat-Cool is used for the above example. To achieve this set the following parameters in the Setup Menu:

INPT=PT.DN

UNIT= C

L

UNIT= C

L

DP= 1-DP

DP=

1-DP

OUT1=REVR

O1TY=RELY

CYC1=18.0 (sec.)

CYC1=18.0

O1FT=BPLS

OUT2=COOL

O2TY=4-20

O2FT=BPLS

(sec.)

Adjust SV at 120.0 C , CPB at 125(%)andDBat-4.0 (%).LAdjust SV at 120.0 C , CPB at 125 ( % ) and DB at -4.0 (%).L

Apply at 120 C for a new system to get an optimal PID

values.

Adjustment of CPB is related to the cooling media used. If water is

used

used as cooling media instead of oil, the CPB is set at 250 (%). If air is

used

used as cooling media instead of oil, the CPB is set at 100 (%).

Adjustment

Adjustment of DB is dependent on the system requirements. More

positive

positive value of DB will prevent unwanted cooling action, but will

increase

increase the temperature overshoot, while more negative value of DB

will

will achieve less temperature overshoot, but will increase unwanted

cooling

cooling action.

Section 3-11.

See Section 3-11.

See

as cooling media instead of oil, the CPB is set at 250 (%). If air is as cooling media instead of oil, the CPB is set at 100 (%).

of DB is dependent on the system requirements. More

value of DB will prevent unwanted cooling action, but will

the temperature overshoot, while more negative value of DB

achieve less temperature overshoot, but will increase unwanted

action.

LAuto-tuning

UM0C911A 54

Chapter 5 CalibrationChapter 5 Calibration

Do not proceed through this section unless there is a definite need to re-calibrate the controller. Otherwise, all previous calibration data will be lost. Do not attempt recalibration unless you have appropriate calibration equipment. If calibration data is

lost, you will need to return the controller to your supplier who may charge you a service fee to re-calibrate the controller.

Entering calibration mode will break the control loop. Make sure that if the system is allowable to apply calibration mode.

Equipments needed before calibration:

Equipments needed before calibration: (1) A high accuracy calibrator ( Fluke 5520A Calibrator

recommended ) with following functions: 0 - 100 mV millivolt source with 0.005 % accuracy 0 - 10 V voltage source with 0.005 % accuracy 0 - 20 mA current source with 0.005 % accuracy 0 - 300 ohm resistant source with 0.005 % accuracy

(2) A test chamber providing 25 C - 50 C temperature range (3) A switching network ( SWU16K, optional for automatic

calibration )

(4) A calibration fixture equipped with programming units ( optional

for automatic calibration )

(5) A PC installed with calibration software BC-Net and Smart

Network Adaptor SNA10B ( optional for automatic calibration )

The calibration procedures described in the following section are a step by step manual procedures.

manual procedures.

Since it needs 30 minutes to warm up an unit before calibration, calibrating the unit one by one is quite inefficient. An

calibration

calibration system

system

for small quantity as well as for unlimited quantity is

available upon request.

A

BB

automatic

55

UM0C911A

Manual Calibration ProceduresManual Calibration Procedures

Perform step 1 to enter calibration mode.

*

Set the Lock parameter to the unlocked condition ( LOCK=

Step 1.

NONE).

Press and hold the scroll key until appears on the display, then release the scroll key. Press the scroll key for 2 seconds then release,the display will show and the unit enters calibration mode .

Perform step 2 to calibrate Zero of A to D converter and

*

step 3 to calibrate gain of A to D converter.

Short the thermocouple inpt terminals , then press scroll key

Step 2.

for at least 5 seconds. The display will blink a moment and a new value is obtained. Otherwise, if the display didn't blink or if the obtained value is equal to -199.9 or 199.9, then the calibration fails.

Press scroll key until the display shows . Send a 60

Step 3.Step 3.

mV signal to the thermocouple input terminals in correct polarity . Press scroll key for at least 5 seconds . The display will blink a moment and a new value is obtained . Otherwise , if the display didn't blink or if the obtained value is equal to

-199.9 or 199.9, then the calibration fails.

Perform both steps 4 and 5 to calibrate RTD function ( if

*

required ) for input .

UM0C911C 56

Step 4.Step 4.

Press scroll key until the display shows . Send a 100 ohms signal to the RTD input terminals according to the connection shown below:

100 ohms

C21

8 9

10

C91

3 4 5

Figure 5.1 RTD CalibrationFigure 5.1 RTD Calibration

Press scroll key for at least 5 seconds . The display will blink a moment, otherwise the calibration fails.

Press scroll key and the display will show . Change

Step 5.Step 5.

the ohm's value to 300 ohms .Press scroll key for at least 5 seconds. The display will blink a moment and two values are obtained for RTDH and RTDL ( step 4 ). Otherwise, if the display didn't blink or if any value obtained for RTDH and RTDL is equal to -199.9 or 199.9 , then the calibration fails.

Perform step 6 to calibrate offset of cold junction compensation

*

, if required.

Step 6.

Setup the equipments according to the following diagram

for calibrating the cold junction compensation. Note that a K

type thermocouple must be used.

57

UM0C911C

5520A

Calibrator

K-TC

Figure 5.2

Junction Calibration Setup

Cold Junction Calibration Setup

Cold

The 5520A calibrator is configured as K type thermocouple output

with internal compensation. Send a 0.00 C signal to the unit under

internal compensation. Send a 0.00 C signal to the unit under

with

calibration.

The unit under calibration is powered in a still-air room with temperature 25 3 C. Stay at least 20 minutes for warming up. Perform step 1 stated above, then press scroll key until the display shows . Press up/down key to obtain

40.00. Press scroll key for at least 5 seconds. The display will blink a moment and a new value is obtained . Otherwise , if the display didn't blink or if the obtained value is equal to -5.00 or

40.00, then the calibration fails.

Perform step 7 to calibrate of compensation

*

if required.

Setup the equipments same as step 6. The unit under

Step 7.Step 7.

calibration is powered in a still-air room with temperature

3C.

AB

calibrator source is set at 0.00 C with internal compensation mode.

AB

Stay at least 20 minutes for warming up . The

C21

K+

K

Stay at least 20 minutes in still-

air room

room temperature 25 3 C

gain cold junctiongain cold junction

C91

9

4

10

5

room

temperature 25 3 CAL

L

B

AL

50

UM0C911C 58

Perform step 1 stated above , then press scroll key until the display shows . Press scroll key for at least 5 seconds. The display will blink a moment and a new value is obtained. Otherwise , if the display didn't blink or if the obtained value is equal to -199.9 or 199.9, then the calibration fails.

This setup is performed in a hence

it is recommended to use a computer to perform the

procedures.

Input modification recalibration linear

*

voltage linear current

or a input:

voltage linear

1. Remove R60(3.3K) and install two 1/4 W resistors RA and RB on the control board with the recommended values specified in the following table.

The low temperature coefficient resistors should be used for RA and RB.

and procedures for a

current

high temperature chamber,

Input Function

T/C, RTD, 0~60mV

0~1V

0~5V,1~5V

0~10V

0~20mA, 4~20mA

2. Perform and to calibrate the linear input zero.

3. Perform but send a span signal to the input terminals

*

Step 8.Step 8.

59

Step 1 Step 2

Step 3

Step

instead of 60mV. The span signal is 1V for 0~1V input, 5V for 0~5V or 1~5V input, 10V for 0~10V input and 20mA for 0~20mA or 4~20mA input.

Final stepFinal step

Set the LOCK value to your desired function.Set the LOCK value to your desired function.

3

RA RB

XX

61.9K

324K

649K

39W

UM0C911C

3.92K

3.01W

R60

3.3K

X

Chapter 6 SpecificationsChapter 6 Specifications

Power

90 250 VAC, 47 63 Hz, 10VA, 5W maximum

11 26 VAC / VDC, 10VA, 5W maximum

11

26 VAC / VDC, 10VA, 5W maximum

Input

Resolution :

Sampling Rate :

Sampling Maximum

Maximum Rating :

Temperature

Temperature Effect :

Sensor

Sensor Lead Resistance Effect :

T/C:

T/C: 0.2uV/ohm

3-wire

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

2-wire

2-wire RTD: 2.6 C/ohm of resistance sum of two leads Burn-out Current :Burn-out Current :

Common

Common Mode Rejection Ratio ( CMRR ): Normal Mode Rejection Ratio ( NMRR ): 55dBNormal Mode Rejection Ratio ( NMRR ): 55dB

Sensor Break Detection :Sensor Break Detection :

Sensor open for TC, RTD and mV inputs,

Sensor short for RTD input

Sensor

below 1 mA for 4-20 mA input,

below

below 0.25V for1-5Vinput,

below

unavailable for other inputs.

unavailable

Sensor Break Responding Time :Sensor Break Responding Time :

Within 4 seconds for TC, RTD and mV inputs,

0.1 second for 4-20 mA and1-5Vinputs.

0.1

18

bits

18 bits

Rate :

times / second

5

5 times / second

Rating :

Lead Resistance Effect :

0.2uV/ohm RTD: 2.6 C/ohm of resistance difference of two

RTD: 2.6 C/ohm of resistance sum of two leads

Mode Rejection Ratio ( CMRR ):

short for RTD input

1 mA for 4-20 mA input,

0.25V for 1 - 5 V input,

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

VDC minimum, 12 VDC maximum

-2

-2 VDC minimum, 12 VDC maximum

1 minute for mA input )

(

( 1 minute for mA input )

Effect :

1.5uV/ C

AB

1.5uV/ C for all inputs except

AB

A

3.0uV/ C

A

3.0uV/ C for mA inputB

L

leads

L

200

200 nA

for other inputs.

input

mA

mA input

nA

for all inputs except

for mA inputB

120dB

UM0C911B 60

Characteristics:

Type Range

-120 C 1000 C

J

-184 F 1832 F )

( -184 F 1832 F )

(

-200 C 1370 C

K

-328 F 2498 F )

( -328 F 2498 F )

(

-250 C 400 C

T

-418 F 752 F )

( -418 F 752 F )

(

-100 C 900 C

E

-148 F 1652 F )

( -148 F 1652 F )

(

0 C 1800 C

B

32 F 3272 F )BB

( 32 F 3272 F )BB

(

0 C 1767.8 C

R

32 F 3214 F )BB

( 32 F 3214 F )BB

(

0 C 1767.8 C

S

32 F 3214 F )BB

( 32 F 3214 F )BB

(

-250 C 1300 C

N

-418 F 2372 F )

( -418 F 2372 F )

(

-200 C 900 C

L

-328 F 1652 F )

( -328 F 1652 F )

(

PT100

-210 C 700 C

DIN )

( DIN )

(

-346 F 1292 F )

( -346 F 1292 F )

(

PT100

-200 C 600 C

JIS )

(

( JIS )

-328 F 1112 F )

( -328 F 1112 F )

(

-8mV 70mV-8mV 70mV

mV

V

-3mA 27mA-3mA 27mA

-1.3V 11.5V-1.3V 11.5V

mA

Accuracy

25 C

@25 C

@

AL2CAL2C

( 200 C

C )

1800 C )

1800

AL2CAL2C

AL0.4 CAL0.4 C

A0.05 %A0.05 %

Input

Impedance

2.2 M2.2 M

1.3 K1.3 K

2.2 M2.2 M

70.5

650 K650 K

61

UM0C911A

Output 1 / Output 2Output 1 / Output 2

Relay Rating :

Pulsed Voltage :

Pulsed

Linear Output CharacteristicsLinear Output Characteristics

Type

4~20 mA4~20 mA 3.6~4 mA3.6~4 mA 20~21 mA20~21 mA

0~20 mA0~20 mA 0mA0 mA

0~5V0 ~ 5 V

1~5V1 ~ 5 V

0~10V0 ~ 10 V

Linear OutputLinear Output

Resolution :Resolution :

Output Regulation :

Output Settling Time :

Output

Isolation Breakdown Voltage :

Isolation

Temperature Effect :

Temperature

Triac ( SSR ) OutputTriac ( SSR ) Output

Rating :

Inrush Current :

Inrush

Min. Load Current :

Min.

Load Current :

Max. Off-state Leakage :

Max.

Off-state Leakage :

Max. On-state Voltage :

Max.

On-state Voltage :

Insulation Resistance :

Insulation

Dielectric Strength :

Dielectric

2A/240

2A/240 VAC, life cycles 200,000 for

VAC, life cycles 200,000 for

resistive load

resistive

load

Source Voltage 5V,

Voltage :

Source

Voltage 5V,

current limiting resistance 66 .

current

limiting resistance 66 .

Zero

Tolerance

0V0 V

0.9~1V0.9 ~ 1 V

0V0 V

15 bits15 bits

0.02 % for full load change

% for full load change

0.02

0.1 sec. ( stable to 99.9 % )

Settling Time :

Breakdown Voltage :

Effect :

1A / 240 VAC

/ 240 VAC

1A

Current :

Resistance :

Strength :

0.1

sec. ( stable to 99.9 % )

1000 VAC

1000

0.01 % of SPAN / C

0.01

AL

% of SPAN /CAL

20A for 1 cycle

20A

for 1 cycle

50 mA rms

50

mA rms

3mArms

3

mA rms

1.5 V rms

1.5

V rms

1000 Mohms min. at 500 VDC

1000

Mohms min. at 500 VDC

2500 VAC for 1 minute

2500

VAC for 1 minute

Tolerance

20~21 mA20~21 mA

5 ~ 5.25 V5 ~ 5.25 V

10 ~10.5 V10 ~10.5 V

VAC

Span

Load

Capacity

500 max.W500 max.W

10 K min.W10 K min.W

UM0C911B

62

DC Voltage Supply Characteristics ( Installed at Output 2 )DC Voltage Supply Characteristics ( Installed at Output 2 )

Type

Tolerance

Max. Output Current

20 V20 V A1 VA1 V 25 mA25 mA

A0.6 VA0.6 V 40 mA40 mA

12 V12 V

5V5 V A0.25 VA0.25 V 80 mA80 mA

Output 2 Functions :

Output

2 Functions :

Alarm Mode :

Alarm

Mode :

Dwell Timer :

Dwell

Timer :

Dwell timer, Deviation High / Low Alarm,

Deviation Band High / Low Alarm,

Deviation

PV High / Low Alarm, PID cooling control

PV

Normal, Latching, Hold, Latching / Hold.

Normal,

0.1 - 4553.6 minutes

0.1

High / Low Alarm, PID cooling control

Latching, Hold, Latching / Hold.

- 4553.6 minutes

Ripple VoltageRipple Voltage

0.2 Vp-p0.2 Vp-p

0.1 Vp-p0.1 Vp-p

0.05 Vp-p0.05 Vp-p

Band High / Low Alarm,

Data CommunicationData Communication

Interface :

Protocol :

Protocol

Address :

Address

Baud Rate :

Baud

Data Bits :

Data

Parity Bit :

Parity

Stop Bit :

Stop

Communication Buffer :

Communication

RS-232 ( 1 unit ), RS-485 ( up to 247 units )

( 1 unit ), RS-485 ( up to 247 units )

RS-232

Modbus Protocol RTU mode

Modbus

:

Rate :

Bits :

Bit :

Protocol RTU mode

1 - 247

1

- 247

2.4 ~ 38.4 Kbits/sec

2.4

~ 38.4 Kbits/sec

7 or 8 bits

7

or 8 bits

None, Even or Odd

None,

Even or Odd

1 or 2 bits

1

or 2 bits

Buffer :

160 bytes

160

bytes

Analog RetransmissionAnalog Retransmission

Output

Output Signal : 4-20 mA, 0-20 mA, 0 - 5V,

Resolution : 15 bits

Resolution : 15 bits Accuracy

Accuracy :

Load

Load Resistance :

Output

Output Regulation :

4-20 mA, 0-20 mA, 0 - 5V,

Signal :

- 5V, 0 - 10V

1-5V,0-10V

1

AAL

% of span 0.0025 %/ C

:

0.05 % of span 0.0025 %/ C

AAL

0.05

Resistance :

- 500 ohms ( for current output )

0

0 - 500 ohms ( for current output )

K ohms minimum ( for voltage output )

10

10 K ohms minimum ( for voltage output )

Regulation :

% for full load change

0.01

0.01 % for full load change

Isolation BarrierIsolation Barrier

500 VAC500 VAC

63

UM0C911C

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

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

Breakdown Voltage :

Isolation Breakdown Voltage :

Linearity Error :

Integral

Integral Linearity Error :

Temperature

Temperature Effect :

Saturation

Saturation Low :

Saturation

Saturation High :

Linear

Linear Output Range :

Low : High :

Output Range :

AL

Effect :

AL

mA ( or 0V )

0

0mA(or0V)

22.2

22.2 mA ( or 5.55V, 11.1V min. )

User InterfaceUser Interface

Single 4-digit LED Display

Keypad :

Keypad

Programming Port :

Programming

Communication Port :

Communication

4 keys for C91, 3 keys for C21

4

:

keys for C91, 3 keys for C21

For automatic setup, calibration and testing

For

Port :

A

0.005

0.005 % of span

A

0.0025

0.0025 % of span/ C

mA ( or 5.55V, 11.1V min. )

0-22.2mA(0-20mA

0-22.2mA(0-20mA or 4-20mA)

0-5.55V

0-5.55V(0-5V,1-5V)

- 11.1 V ( 0 - 10V )

0

0-11.1V(0-10V)

automatic setup, calibration and testing

Connection to PC for supervisory control

Connection

VAC min.

1000 VAC min.

1000

% of span

% of span/ C

( 0 - 5V, 1 - 5V )

to PC for supervisory control

Control ModeControl Mode

Output 1 :

Output 2 :

Output

ON-OFF :

ON-OFF

PorPD:

P

PID :

PID

Cycle Time :

Cycle

Manual Control :

Manual

Auto-tuning :

Auto-tuning

Failure Mode :

Failure

Ramping Control :

Ramping

Reverse ( heating ) or direct ( cooling ) action

( heating ) or direct ( cooling ) action

Reverse

PID cooling control, cooling P band 50~300%

PID

2 :

cooling control, cooling P band 50~300%

of PB, dead band -36.0 ~ 36.0 % of PB

of

PB, dead band -36.0 ~ 36.0 % of PB

0.1 - 90.0 ( F ) hysteresis control ( P band = 0 )

0.1

:

0 - 100.0 % offset adjustment

0

or PD :

- 100.0 % offset adjustment

Fuzzy logic modified

Fuzzy

:

logic modified

Proportional band 0.1 ~ 900.0 F.

Proportional

Integral time 0 - 1000 seconds

Integral

Derivative time 0 - 360.0 seconds

Derivative

0.1 - 90.0 seconds

0.1

Time :

Control :

:

Mode :

sensor break or A-D converter damage

sensor

Control :

L

- 90.0 (F) hysteresis control ( P band = 0 )

L

band 0.1 ~ 900.0 F.

time 0 - 1000 seconds

time 0 - 360.0 seconds

- 90.0 seconds

Heat (MV1) and Cool (MV2)

Heat

(MV1) and Cool (MV2)

Cold start and warm start

Cold

start and warm start

Auto-transfer to manual mode while

Auto-transfer

break or A-D converter damage

0 - 900.0 F/minute or

0

- 900.0 F/minute or

0 - 900.0 F/hour ramp rate

0

- 900.0 F/hour ramp rate

L

to manual mode while

L

Digital FilterDigital Filter

Function :

Function : Time

Constant :

Time Constant :

order

First

First order

0,

0.2, 0.5, 1, 2, 5, 10, 20, 30, 60

0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60

seconds

programmable

seconds programmable

or 4-20mA)

UM0C911B 64

Environmental & PhysicalEnvironmental & Physical

Operating Temperature :

Storage Temperature :

Storage

Temperature :

Humidity :

Humidity

Altitude:

Pollution:

Insulation Resistance :

Insulation

Dielectric Strength :

Dielectric

Vibration Resistance :

Vibration

Shock Resistance :

Shock

Moldings :

Moldings

Dimensions :

Dimensions

C21-----50mm(W) X 26.5mm(H) X 110.5mm(D),

C21-----50mm(W)

C91-----48mm(W) X 48mm(H) X 94mm(D),

C91-----48mm(W)

Weight :

Weight

0 to 90 % RH ( non-condensing )

0

:

to 90 % RH ( non-condensing )

2000m maximum

2000m

Degree 2

Degree

Resistance :

Strength :

Resistance :

Flame retardant polycarbonate

Flame

:

98 mm depth behind panel

98

86 mm depth behind panel

86

C21----- 120 grams

C21-----

:

C91----- 140 grams

C91-----

-10 Cto50 C

BB

to 50 C

BB

-10 C

-40 Cto60 C

-40 C

to 60 C

BB

maximum

2

20 Mohms min. ( at 500 VDC )

20

Mohms min. ( at 500 VDC )

2000 VAC, 50/60 Hz for 1 minute

2000

VAC, 50/60 Hz for 1 minute

10 - 55 Hz, 10 m/s for 2 hours

10

- 55 Hz, 10 m/s for 2 hours

2

200 m/s ( 20 g )

200

m/s ( 20 g )

retardant polycarbonate

X 26.5mm(H) X 110.5mm(D),

mm depth behind panel

X 48mm(H) X 94mm(D),

mm depth behind panel

120 grams

140 grams

Approval StandardsApproval Standards

Safety : UL61010C-1

CSA C22.2 No.24-93

CSA

C22.2 No.24-93

EN61010-1 ( IEC1010-1 )

Protective Class :

EMC:

EN61010-1

IP65 front panel for C21.

IP65

IP30 front panel for C91.

IP30

IP20 for terminals and housing with protective

IP20

cover.

All indoor use.

All

indoor use.

EN61326

( IEC1010-1 )

front panel for C21. front panel for C91. for terminals and housing with protective

2

65

UM0C911C

Chapter 7 Modbus CommunicationsChapter 7 Modbus Communications

This chapter specifies the Modbus Communications protocol as RS-232 or RS-485 interface module is installed. Only RTU mode is supported. Data is transmitted as eight-bit binary bytes with 1 start bit, 1 stop bit and optional parity checking (None, Even or Odd). Baud rate may be set to 2400, 4800, 9600, 14400, 19200, 28800 and 38400.

7-1 Functions Supported7-1 Functions Supported

Only function 03, 06 and 16 are available for this series of controllers. The message formats for each function are described as follows:

Function 03: Read Holding RegistersFunction 03: Read Holding Registers

Query ( from master )

Query

Slave address (0-255) Function code (3) Starting address of register Hi (0) Starting address of register Lo (0-79,

No. of words Hi (0) No. of words Lo (1-79) CRC16 Hi CRC16 Lo

Function 06: Preset single RegisterFunction 06: Preset single Register

Query ( from master )Query

Slave address (0-255) Function code (6) Register address Hi (0) Register address Lo (0-79, 128-131) Data Hi Data Lo CRC16 Hi CRC16 Lo

128-131)

Response ( from slave )Response

Byte count Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo

CRC16 Hi CRC16 Lo

Response ( from slave )Response

UM0C911B

66

Function 16: Preset Multiple RegistersFunction 16: Preset Multiple Registers

Query ( from master )Query

Slave address (0-255) Function code (16) Starting address of register Hi (0) Starting address of register Lo (0-79,

128-131) No. of words Hi (0) No. of words Lo (1-79) Byte count (2-158) Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo

CRC16 Hi CRC16 Lo

Response ( from slave )Response

CRC16 Hi CRC16 Lo

67

UM0C911B

7-2 Exception Responses7-2 Exception Responses

If the controller receives a message which contains a corrupted character (parity check error, framing error etc.), or if the CRC16 check fails, the controller ignores the message. However, if the controller receives a syntactically correct message which contains an illegal value, it will send an exception response, consisting of five bytes as follows:

slave address +offset function code + exception code + CRC16 Hi + CRC16 Lo

Where the offset function code is obtained by adding the function code with 128 (ie. function 3 becomes H'83), and the exception code is equal to the value contained in the following table:

Exception Code

1

2

3

Name

Bad function code

Illegal data address

Illegal data value

UM0C911A

Cause

Function code is not supported by the controller

Register address out of range

Data value out of range or attempt to write a read-only or protected data

68

7-3 Parameter Table7-3 Parameter Table

Register

Parameter

Address

Notation

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

Set point 1

SP1

Set point 2

SP2

Set point 3

SP3

Lock code

LOCK

Input sensor selection

INPT

Measuring unit

UNIT

Decimal point position

DP

Low scale value for linear input

INLO

High scale value for linear input

INHI

Low limit of SP1

SP1L

High limit of SP1

SP1H

PV shift value

SHIF

Filter time constant

FILT

Display form ( for C21 )

DISP

P ( proportional ) band

PB

Integral time

TI

Derivative time

TD

Output 1 function

OUT1

Output 1 signal type

O1TY

Output 1 failure transfer

O1FT

Output 1 ON-OFF hysteresis

O1HY

Output 1 cycle time

CYC1

Offset value for P control

OFST

Ramp function

RAMP

Ramp rate

RR

Output 2 function

OUT2

Retransmission low scale value

RELO

Output 2 signal type

O2TY

Output 2 failure transfer

O2FT

Output 2 ON-OFF hysteresis

O2HY

Parameter

Scale Low

*4

*7

*6

0

*4

0

*5

0

0.0

0

-1999.9

*5

0.0

0

*5

0

*4 *4

0

-1999.9

*5

Scale High

*4

*7

*6

65535

*4

65535

*5

65535

6553.5

65535

4553.6

*5

6553.5

65535

*5

65535

4553.6

*5

Notes

R/W

69

UM0C911C

Register Address

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

Parameter Notation

CYC2

CPB

DB

ALFN

REHI *4 *4

ALMD

ALHY

ALFT

COMM

ADDR

BAUD

DATA

PARI

STOP

SEL1

SEL2

SEL3

SEL4

SEL5

SEL6

SEL7

SEL8

ADLO

ADHI

RTDL

RTDH

CJLO

CJHI

DATE

SRNO

HOUR

Parameter

Output 2 cycle time

Cooling P band

Heating-cooling dead band

Alarm function

Retransmission high scale value

Alarm opertion mode

Alarm hysteresis

Alarm failure transfer

Communication function

Address

Baud rate

Data bit count

Parity bit

Stop bit count

Selection 1

Selection 2

Selection 3

Selection 4

Selection 5

Selection 6

Selection 7

Selection 8

mV calibration low coefficient

mV calibration high coefficient

RTD calibration low coefficient

RTD calibration high coefficient

Cold junction calibration low coefficient

Cold junction calibration high coefficient

Date Code

Serial Number

Working hours of the controller

Scale Low

0.0

0

-1999.9

0

*5

0

-1999.9

-199.99

-1999.9

0

Scale High

6553.5

65535

4553.6

65535

*5

65535

4553.6

455.36

4553.6

65535

Notes

R/W

UM0C911C

70

Register Address

61

62

63

64, 128

65, 129

66

130

67

131

68

69

70

71,140

72

73

74

75

76

77

78

79

Parameter Notation

BPL1

BPL2

CJCL

PV

SV

MV1

MV2

TIMER

EROR

MODE

PROG

CMND

JOB1

JOB2

JOB3

CJCT

Parameter

Bumpless transfer of OP1

Bumpless transfer of OP2

Cold junction signal low

Process value

Current set point value

OP1 control output value

OP2 control output value

Remaining time of dwell timer

Error code *1

Operation mode & alarm status *2

Program code *3

Command code

Job code

Cold Junction Temperature

Reserved

Scale Low

0.00

0.000

*4

0.00

-1999.9

0

0.00

0

-199.99

0

Scale High

655.35

65.535

655.35

4553.6

65535

655.35

65535

455.36

65535

*1: The error code is show in the first column of Table A.1.

*2: Definition for the value of MODE register

H'000X = Normal mode H'010X = Calibration mode

H'0X00 = Alarm status is off

H'0x01 = Alarm status is on H'020X = Auto-tuning mode H'030X = Manual control mode H'040X = Failure mode

The alarm status is shown in

MV2 instead of MODE for

models C21 and C91.

*4

Notes

R

Read only, unless in manual control

R

R/W

R

71

UM0C911C

*3: The PROG Code is defined in the following table:

Model No.

PROG Code

BTC-9100 BTC-8100 BTC-4100 BTC-7100

6.XX

11.XX 12.XX

13.XX

C21

33.XX

C91

34.XX

Where XX denotes the software version number. For example: PROG=34.18 means that the controller is C91 with software version

18.

*4: The scale high/low values are defined in the following table for SP1,

INLO, INHI, SP1L, SP1H, SHIF, PV, SV, RELO and REHI:

Conditions

Scale low

Scale high

Non-linear

input

-1999.9 -19999 -1999.9 -199.99 -19.999

4553.6

Linear input

DP = 0

Linear input

DP = 1

Linear input

DP = 2

Linear input

DP = 3

45536 4553.6 455.36 45.536

*5: The scale high/low values are defined in the following table for PB,

O1HY, RR, O2HY and ALHY:

Conditions

Scale low

Scale high

Non-linear

input

6553.5

Linear input

DP = 0

Linear input

DP = 1

Linear input

DP = 2

Linear input

DP = 3

0.0 0 0.0 0.00 0.000

65535 6553.5 655.35 65.535

*6: The scale high/low values are defined in the following table for SP3:

Conditions

Scale low

Scale high

ALFN=1

(TIMR)

-1999.9

4553.6

Linear input

input

-1999.9 -19999 -1999.9 -199.99 -19.999

4553.6

Linear input

DP = 0

DP = 1

Linear input

DP = 2

Linear input

DP = 3

45536 4553.6 455.36 45.536

Non-linear

*7: The scale high/low values are defined in the following table for SP2:

For C21and C91

Non-linear

Conditions

Scale low

Scale high

OUT2=1

(TIMR)

-1999.9

4553.6

Linear input

input

-1999.9 -19999 -1999.9 -199.99 -19.999

4553.6

Linear input

DP = 0

DP = 1

Linear input

DP = 2

Linear input

DP = 3

45536 4553.6 455.36 45.536

UM0C911C

72

For BTC-9100, BTC-8100, BTC-7100 and BTC-4100

Conditions

Scale low

Scale high

Non-linear

input

-1999.9 -19999 -1999.9 -199.99 -19.999

4553.6

Linear input

DP = 0

45536 4553.6 455.36 45.536

Linear input

DP = 1

Linear input

DP = 2

Linear input

DP = 3

7-4 Data Conversion7-4 Data Conversion

The word data are regarded as unsigned ( positive ) data in the Modbus message. However, the actual value of the parameter may be negative value with decimal point. The high/low scale values for each parameter are used for the purpose of such conversion.

Let M = Value of Modbus message

A = Actual value of the parameter SL = Scale low value of the parameter SH = Scale high value of the parameter

The conversion formulas are as follows:

M=

A=

65535 SH-SL

SH-SL 65535

( A SL)

M+SL

7-5 Communication Examples :7-5 Communication Examples :

Example 1: Down load the default values via the programming portExample 1: Down load the default values via the programming port

The programming port can perform Modbus communications regardless of the incorrect setup values of address, baud, parity, stop bit etc. It is especially useful during the first time configuration for the controller. The host must be set with 9600 baud rate, 8 data bits, even parity and 1 stop bit.

The Modbus message frame with hexadecimal values is shown as follows:

73

UM0C911A

01 10 00 00 00 34

Addr. Func.

Starting Addr.

No. of words

68

Bytes

19

4F

4E

83

4E

SP1=25.0 SP2=10.0 SP3=10.0

00 00 00 01 00 00 00 01 4D 6D 51 C4

LOCK=0 INPT=1 UNIT=0 DP=1 INLO=-17.8 INHI=93.3

4D 6D 63 21 4E 1F 00 02 00 00 00 64

SP1L=-17.8 SP1H=537.8

SHIF=0.0

FILT=2 DISP=0 PB=10.0

00 64 00 FA 00 00 00 00 4E 1F 00 01

TI=100 TD=25.0 OUT1=0 O1TY=0 O1FT=0 O1HY=0.1

83

00 B4 00 FA 00 00 00 00 00 02 4E

CYC1=18.0 OFST=25.0 RAMP=0 RR=0.0 OUT2=2

RELO=0.0

00 00 4E 1F 00 01 00 B4 00 64 4E

O2TY=0 O2FT=0 O2HY=0.1 CYC2=18.0 CPB=100

DB=0

00 02 52 07 00 00 00 01 00 00 00 01

ALFN=2 ALMD=0 ALHY=0.1 ALFT=0

REHI=100.0

COMM=1

00 01 00 02 00 01 00 00 00 00 00 02

ADDR=1 DATA=1 PARI=0 STOP=0

00 03 00 04 00

SEL2=3 SEL4=6 SEL5=7 SEL6=8

00

SEL8=17

11

BAUD=2

SEL3=4

Hi Lo

CRC16

00 07 00 08 00

06

UM0C911C

SEL1=2

SEL7=10

1F

0A

74

Example 2: Read PV, SV, MV1 and MV2.Example 2: Read PV, SV, MV1 and MV2. Send the following message to the controller via the COMM port or

programming port:

03 00

H'40 H'80

00

04 Hi Lo

Addr. Func. Starting Addr. No. of words CRC16

Example 3: Perform Reset Function (same effect as pressing key)Example 3: Perform Reset Function (same effect as pressing key)

R

Query

06 00 H'48

H'68

H'25 Hi Lo

Addr. Func. Register Addr. Data Hi/Lo CRC16

Example 4: Enter Auto-tuning ModeExample 4: Enter Auto-tuning Mode

Query

06 00 H'48

H'68

H'28 Hi Lo

Addr. Func. Register Addr. Data Hi/Lo CRC16

Example 5: Enter Manual Control Mode

Query

06 00 H'48

H'68

H'27 Hi Lo

Addr. Func. Register Addr. Data Hi/Lo CRC16

Example 6: Read All Parameters

Query

03 00 00

00

H'50 Hi Lo

Addr. Func. Starting Addr. No. of words CRC16

Example 7: Modify the Calibration Coefficient

Preset the CMND register with 26669 before attempting to change the calibration coefficient.

06 00 H'48

H'68

H'2D Hi Lo

Addr. Func. Register Addr. Data Hi / Lo CRC16

75

UM0C911C

Table A.1 Error Codes and Corrective ActionsTable A.1 Error Codes and Corrective Actions

Display

Error Code

4

10

11

14

15

26

29

30

39

40

Symbol

Error Description

Illegal setup values been used: Before COOL is used for OUT2, DIRT ( cooling action ) has already been used for OUT1, or PID mode is not used for OUT1 ( that is PB =0,and/orTI=0)

Communication error: bad function code

Communication error: register address out of range

Communication error: attempt to write a read-only data or a protected data

Communication error: write a value which is out of range to a register

Fail to perform auto-tuning function

EEPROM can't be written correctly

Cold junction compensation for thermocouple malfunction

Input sensor break, or input current below 1 mA if 4-20 mA is selected, or input voltage below

0.25V if 1 - 5V is selected A to D converter or related

component(s) malfunction

Corrective Action

Check and correct setup values of OUT2, PB, TI 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 use OUT2 for cooling control.

Correct the communication software to meet the protocol requirements.

Don't issue an over-range

address to the slave.register

Don't write a read-only data or a protected data to the slave.

Don't write an over-range data to the slave register.

1.The PID values obtained after

auto-tuning procedure are out

of range. Retry auto-tuning.

2.Don't change set point value

during auto-tuning procedure.

3.Use manual tuning instead of

auto-tuning.

4. Don't set a zero value for PB.4. Don't set a zero value for PB.

5. Don't set a zero value for TI.5. Don't set a zero value for TI.

6. Touch RESET key6. Touch RESET key

Return to factory for repair.

Return to factory for repair.Return to factory for repair.

Replace input sensor.

Return to factory for repair.

UM0C911A

76

WARRANTY

Brainchild Electronic Co. is pleased to offer suggestions on the use of its various products. However, Brainchild makes no warranties or representations of any sort regarding the fitness for use, or the application of its products by the Purchaser. The selection, application or useof Brainchildproducts isthe Purchaser's responsibility. No claims will be allowed for any damages or losses, whether direct, indirect, incidental, special or consequential. Specifications are subject to change without notice. In addition,Brainchild reserves the right to make changes-without notification to Purchaser-to materials or processing that do not affect compliance with any applicable specification. Brainchild products are warranted tobe free from defects inmaterial and workmanship for two years afterdelivery tothe first purchaser for use. An extended period is available with extra cost upon request. Brainchild's sole responsibilityunder thiswarranty,at Brainchild'soption, islimited to replacement or repair, free of charge, or refund of purchase price within the warranty period specified. This warranty does not apply to damage resulting from transportation, alteration, misuseor abuse.

RETURNS

No products return can be accepted without a completed Return Material Authorization ( RMA ) form.

77

UM0C911A

BRAINCHILD Electronic Co., Ltd.BRAINCHILD Electronic Co., Ltd.

No.209, Chung Yang Rd., Nan Kang Dist.,

No.209, Chung Ya n g Rd., Nan Kang Dist.,

Ta iw a n, R.O.C. 115

Taipei, Taiwan, R.O.C. 115

Taipei,

886-2-27861299

Te l:

Tel: 886-2-27861299

886-2-27861395

Fax:

Fax: 886-2-27861395

site: http://www.brainchild.com.tw

web

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