DIN EN ISO 9001 Certificate: 01 100 98505

UM0C911A

BRAINCHILD

Warning Symbol
The Symbol calls attention to an operating procedure, practice, or the like, which, if not correctly performed or adhered to, could result in personal injury or damage to or destruction of part or all of the product and system. Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met.

Use the Manual

Installers System Designer Expert User NOTE: It is strongly recommended that a process should incorporate a LIMIT CONTROL like L91 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system. Information in this user's manual is subject to change without notice. Copyright a 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. Read Chapter 1, 2 Read All Chapters Read Page 12

UM0C911A

Contents
Page No Chapter 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 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 Chapter 6 Specifications ----60 Chapter 7 Communications Modbus Communications---66 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 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 --------55

UM0C911A

Figures & Tables

Page No

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 and C92--------------------------------------------------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 2.6 Rear Terminal Connection for C92----- --------------------------------------------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

UM0C911A

Chapter 1 Overview
1-1 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. C92 is DIN rail mount controller. These units are powered by 11-26 or 90-264 VDC/VAC supply, incorporating a 2 amp. control relay output 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.

UM0C911A

Temperature Set point

PID control with properly tuned PID + Fuzzy control

Figure 1.1 Fuzzy Control Advantage Warm Up High Accuracy 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 BF resolution for thermocouple and PT100 ) and a 15-bit D to A converter for linear current or voltage control output. The ASIC technology provides improved operating performance, low cost, enhanced reliability and higher density. 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 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.
6 UM0C911A

Load Disturbance

Time

Programming 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 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

1-2 Ordering Code

C21C91C92Power Input
4: 90 - 264 VAC, 50/60 HZ 5: 11 - 26 VAC or VDC 9: Special Order

Accessories
OM94-6 = Isolated 1A / 240VAC Triac Output Module ( SSR ) OM96-3 = Isolated 4 - 20 mA / 0 - 20 mA Analog Output Module OM96-4 = Isolated 1 - 5V / 0 - 5V Analog Output Module OM96-5 =Isolated 0 -10V Analog Output Module CM94-1 = Isolated RS-485 Interface Module for C21, C92. CM94-2 = Isolated RS-232 Interface Module for C21, C92 CM96-1 = Isolated RS-485 Interface Module for C91 DC94-1 = Isolated 20V/25mA DC Output Power Supply DC94-2 = Isolated 12V/40mA DC Output Power Supply DC94-3 = Isolated 5V/80mA DC Output Power Supply CC94-1 = RS-232 Interface Cable ( 2M )

Signal Input
1: Standard Input Thermocouple: J, K, T, E, B, R, S, N, L RTD: PT100 DIN, PT100 JIS 9: Special Order

Output 1
0: None 1: Relay rated 2A/240VAC 2: Pulsed voltage to drive SSR, 5V/30mA 3: Isolated 4 - 20mA / 0 - 20mA 4: Isolated 1 - 5V / 0 - 5V 5: Isolated 0 - 10V 6: Triac output 1A / 240VAC,SSR 9: Special order

Output 2
0: None 1: Form A relay 2A/240VAC 2: Pulsed voltage to drive SSR, 5V / 30mA 3: Isolated 4 - 20mA / 0 - 20mA 4: Isolated 1 - 5V / 0 - 5V 5: Isolated 0 - 10V 6: Triac output, 1A / 240VAC, SSR 7: Isolated 20V/25mA transducer power supply 8: Isolated 12V/40mA transducer power supply 9: Isolated 5V/80mA transducer power supply A: RS-485 interface (for C91) B: Special order

Related Products
SNA10A = Smart Network Adaptor for third party software, which converts 255 channels of RS-485 or RS-422 to RS-232 Network. SNA10B = Smart Network Adaptor for BC-Net software, which converts 255 channels of RS-485 or RS-422 to RS-232 network.

Communications
0: None 1: RS-485 interface (for C21, C92) 2: RS-232 interface (for C21, C92) 9: Special order

Display Color
0: Red color 1: Green color

UM0C911A

1-3 Programming Port

Front Panel

Access Hole

Rear Terminal

6 4 2

5 31

C21

pin 1 control board pin 1 Programming Port

Programming Port

C9 NT RO LLE R

CO

Power board Open the housing Top view of C91

BR A IN CH IL D

C92

Figure 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.

UM0C911A

1- 4 Keys and Displays

KEYPAD OPERATION SCROLL KEY : This key is used to select a parameter to be viewed or adjusted. UP KEY : This key is used to increase the value of selected parameter. DOWN KEY : This key is used to decrease the value of selected parameter. for C21 RESET KEY : press R for C91 and C92, press 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.

ENTER KEY : Press for 3 seconds or longer . Press for 3 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, C92) 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.

10

UM0C911A

Deviation Indicator Output 2 Indicator

OP1 OP2 C F

Output 1 Indicator Process Unit Indicator

O1 O2

Output 2 Indicator Output 1 Indicator

C21

PV

SP1 SP2 MAN

AT

R
C91

Auto-tuning Indicator Manual Mode Indicator 4 Buttons for ease of control setup and set point adjustment.

3 Silicone Rubber Buttons for ease of control setup and set point adjustment.

Figure 1.3

Front Panel Description

Table 1.1 Display Form of Characters

A B C c D

E F G H h

I J K L M

N O P Q R

S T U V W

X Y Z ? =

: Confused Character
OP1 OP2 C F

Display program code of the product for 2.5 seconds. The left diagram shows program no. 34 for C91 with version 16. The program no. for C21 is 33, and for C92 is 35.

PV

SP1 SP2 MAN

AT

R
C91

Figure 1.4 Display of Initial Stage

UM0C911A 11

1- 5 Menu Overview
User menu *1
PV SP1 SP2 MAN MAN AT

Setup menu*1 3 sec. 4.2 sec.

Calibration Mode 5.4 sec. 2 sec.

*2

PV
SP1 SP2 H C PV INPT UNIT DP PB TI TD CYC1 ADDR

3 sec. 3 sec. 3 sec.

Manual Mode Manual Mode Auto-tuning Mode

C91 C92

Value

Value

User Menu *1
(DISP=PV)
PV SP1 SP2

(DISP=SP1)

or or

SP1 PV

Value Value

H C

3 sec. 3 sec. 3 sec.

Manual Mode Manual Mode Auto-tuning Mode

C21

A-T

INPT UNIT DP PB TI TD CYC1 ADDR

Value

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 SEL1 SEL2 SEL3 SEL4 SEL5 SEL6 SEL7 SEL8

Value
ADLO ADHI RTDL RTDH CJLO CJHI

Value

Value

Press for 3 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 Value release to enter the calibration menu.

Value

12

UM0C911A

1-6 Parameter Descriptions

Parameter Notation Parameter Description Range Default Value
25.0 BC (77.0BF)

SP1 SP2

Set point for output 1 Set point for output 2 when output 2 performs alarm function or dwell timer

Low: SP1L Low: -19999

High :SP1H High :45536

10.0 BC (18.0BF)

0 1 LOCK Select parameters to be locked 2 3 0 1 2 3 4 5 6 7 8

: No parameter is locked : Setup data are locked : Setup data and User data except Set point are locked : All data 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 1 (0)

INPT

Input sensor selection

9 10 11 12 13 14 15 16 17

UM0C911A

13

Parameter Notation

Parameter Description
0

Range : Degree C unit : Degree F unit : Process unit

Default Value 0 (1)

UNIT

Input unit selection

1 2

0 1 2 3
INLO INHI SP1L SP1H

: No decimal point : 1 decimal digit 1 : 2 decimal digits : 3 decimal digits High: 45486
-17.8 LC ( 0 LF )

DP

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

Low: -19999 Low: INLO+50 Low: -19999 Low: SP1L

93.3 LC High: 45536 (200.0 LF)

High: 45536

-17.8 LC (0 LF)

537.8 LC High: 45536 (1000 LF)

SHIF

200.0 LC -200.0 LC Low: (-360.0 LF) High:( 360.0 LF)

0 1 2 3 4

0.0

: 0 second time
constant constant

: 0.2 second time : 0.5 second time

constant constant constant

: 1 second time : 2 seconds time : 5 seconds time : : : : 2

constant 10 seconds time constant 20 seconds time constant 30 seconds time constant 60 seconds time constant

FILT

Filter damping time constant of PV

5 6 7 8 9

14

UM0C911A

Parameter Notation

Parameter Description

Range

Default Value

0
DISP

Normal display selection 1

: Display process value normally

PB
TI TD

Proportional band value

Integral time value Derivative time value

Low: 0 Low: 0 Low: 0

0

0 : Display set point 1 value normally 10.0 LC High: 500.0 LC (900.0 LF) (18.0 LF) High: 1000 sec High: 360.0 sec : Reverse (heating )
control action control action

100 25.0

OUT1

Output 1 function
1

: Direct (cooling)

0 1 2 3
O1TY Output 1 signal type 4 5 6 7 8

: 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 module module

: 0 - 5V voltage : 1 - 5V voltage : 0 - 10V voltage

module

O1FT

Output 1 failure transfer mode

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.

O1HY CYC1
OFST

Output 1 ON-OFF control hysteresis Output 1 cycle time

Offset value for P control

Low: 0.1 High: 50.0 BC(90.0BF) Low: 0.1 High: 90.0 sec.
Low: 0 High: 100.0 %

0.1LC (0.2LF) 18.0

25.0

UM0C911A

15

Parameter Parameter Description Notation

Range

Default Value

0 RAMP Ramp function selection 1 2

RR Ramp rate Low: 0

: No Ramp Function : Use unit/minute as Ramp Rate : Use unit/hour as Ramp Rate
High: 500.0 LC (900.0 LF)

0.0

0 1 2 3 4 OUT2 Output 2 function 5 6 7 8

0 1 2 3

: Output 2 No Function : Dwell timer action : Deviation High Alarm : Deviation Low Alarm : Deviation band out of band Alarm : Deviation band in band Alarm : Process High Alarm : Process Low Alarm : Cooling PID Function 2

: Relay output : Solid state relay

drive output output

: Solid state relay : 4 - 20 mA current

module

O2TY

Output 2 signal type

4 5 6 7 8

: 0 - 20 mA current : : : :
module 0 - 1V voltage module 0 - 5V voltage module 1 - 5V voltage module 0 - 10V voltage module

O2FT

Output 2 failure transfer mode

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.

16

UM0C911A

Parameter Parameter Description Notation

Range

Default Value

O2HY CYC2 CPB DB

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)

Low: 0.1 Low: 0.1 Low: 50 Low: -36.0

0
1

High: 50.0 LC (90.0 LF) High: 90.0 sec. High: 300 % High: 36.0 %

0.1 LC (0.2 LF) 18.0 100 0

: Normal alarm
action

: Latching alarm

ALMD

Alarm operation mode

2 3

action : Hold alarm action

: Latching & Hold

action

COMM

Communication function Address assignment of digital communication

0 1

: No communication : Modbus RTU mode protocol High: 255 : 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 1

ADDR

Low: 1 0 1 2

BAUD

Baud rate of digital communication

3 4 5

6 UM0C911A

: 38.4 Kbits/s baud rate 17

Parameter Parameter Description Notation

Range

Default Value

DATA

Data bit count of digital 0 communication 1 0

: 7 data bits : 8 data bits : Even parity : Odd parity : No parity bit : One stop bit : Two stop bits
: 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

PARI

Parity bit of digital communication

1 2

STOP

Stop bit count of digital communication

0 1 0 1 2 3 4 5 6 7

SEL1

Select 1'st parameter for 8 user menu 9 10 11 12 13 14 15 16 17

18

UM0C911A

Parameter Parameter Description Notation

Range

Default Value

SEL2 SEL3 SEL4 SEL5 SEL6 SEL7 SEL8

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 Same as SEL1 Same as SEL1 Same as SEL1 Same as SEL1 Same as SEL1 Same as SEL1

3 4 6 7 8 10 17

UM0C911A

19

Chapter 2 Installation
Dangerous voltages capable of causing death are sometimes present in this instrument. Before installation or beginning any troubleshooting procedures the power to all equipment must be switched off and isolated. Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair. Component replacement and internal adjustments must be made by a qualified maintenance person only. To minimize the possibility of fire or shock hazards, do not expose this instrument to rain or excessive moisture. Do not use this instrument in areas under hazardous conditions such as excessive shock, vibration, dirt, moisture, corrosive gases or oil. The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 6.

2-1 Unpacking
Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage. If any damage due to transit , report and claim with the carrier. Write down the model number, serial number, and date code for future reference when corresponding with our service center. The serial number (S/N) and date code (D/C) are labeled on the box and the housing of control.

2-2 Mounting
Make panel cutout to dimension shown in Figure 2.1. Take the mounting clamp away and insert the controller into panel cutout. Install the mounting clamp back.

20

UM0C911A

Figure 2.1 Mounting Dimensions

MOUNTING CLAMP

_ 45 +0.5 0 +0.3 22.2 _ 0

C21
SCREW Panel 98.0mm 10.0mm

12.5mm

45 mm

45 mm

C91
Panel

86 mm 94 mm

44.8mm
CONTROLLER

126.9mm
C92

OP1 OP2

LC

LF

17.6

91.8mm

35.4

PV

SP1 SP2

MAN

AT

17.8

BRAINCHILD

C92
UM0C911A 21

2 - 3 Wiring Precautions
* Before wiring, verify the label for correct model number and options. Switch off the power while checking. * Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded. * It is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible. * All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools. * All wiring must conform to appropriate standards of good practice and local codes and regulations. Wiring must be suitable for voltage, current, and temperature rating of the system. * Beware not to over-tighten the terminal screws. * Unused control terminals should not be used as jumper points as they may be internally connected, causing damage to the unit. * Verify that the ratings of the output devices and the inputs as specified in Chapter 6 are not exceeded.

22

UM0C911A

3.2mm min. 7.0mm max.

Figure 2.2 Lead Termination for C91 and C92

2.0mm 0.08" max.

4.5 ~7.0 mm 0.18" ~0.27"

Figure 2.3 Lead Termination for C21

OP2

_
4

OP1

_
6 7

+
2
N 3

1
L

90-264 VAC 47-63 Hz,10VA

2A/240 VAC

2A/240 VAC
TX1 TXD 12 TX2 RXD 13

V+,mA+ V _,mA _ TC _ TC+ PTB PTA PTB 10 8 9

COM 11

14

_
B V I

+
RTD

RS-485 RS-232

Figure 2.4 Rear Terminal Connection for C21

CAT. I I

UM0C911A

23

TX2 OP2 TX1

A RTD + I V B B +

1 2 3 4 5

6 90-264VAC 47-63Hz 10VA 7 NC PTA 8 NO TC+ 9 OP1 TC 2A C 10 + CAT. I I

L
+

2A 240 VAC

240 VAC

Figure 2.5 Rear Terminal Connection for C91

RS-485 OP2 + RS-232 TX2 TX1 COM RXD TXD

9
NO

10
C + OP1

11 12 13 14 15

INPUT

POWER IN RA N L

IN

IN+

16 17 18 19 20
+ TC

V
B

+ V + mA B RTD A

90-264VAC 47-63Hz 10VA

CAT. I I

Figure 2.6 Rear Terminal Connection for C92

24

UM0C911A

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

C21 C91 C92 L N

1 2

6 7

20 19

Fuse

90 ~ 264 VAC or 11 ~ 26 VAC / VDC

Figure 2.7 Power Supply Connections

This equipment is designed for installation in an enclosure which provides adequate protection against electric shock. The enclosure must be connected to earth ground. Local requirements regarding electrical installation should be rigidly observed. Consideration should be given to prevent from unauthorized person access to the power terminals.

2-5 Sensor Installation Guidelines

Proper sensor installation can eliminate many problems in a control system. The probe should be placed so that it can detect any temperature change with minimal thermal lag. In a process that requires fairly constant heat output, the probe should be placed closed to the heater. In a process where the heat demand is variable, the probe should be closed to the work area. Some experiments with probe location are often required to find this optimum position. In a liquid process, addition of a stirrer will help to eliminate thermal lag. Since the thermocouple is basically a point measuring device, placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes.
UM0C911A 25

Proper sensor type is also a very important factor to obtain precise measurements. The sensor must have the correct temperature range to meet the process requirements. In special processes the sensor might need to have different requirements such as leak-proof, antivibration, antiseptic, etc. Standard sensor limits of error are A4 degrees F (A 2 degrees C ) or 0.75% of sensed temperature (half that for special ) plus drift caused by improper protection or an over-temperature occurrence. This error is far greater than controller error and cannot be corrected on the sensor except by proper selection and replacement.

2-6 Sensor Input Wiring

C21 C91 C92
PTA TC+, V+ PTB, mA+ TC-, VPTB, mA-

A RTD

8 9 10

3 4 5

18 17 16

B B

_
TC

Figure 2.8 Sensor Input Wiring

2-7 Control Output Wiring

C21

C91

C92

5 6

10 9

15 14

_V _

V mA RTD

LOAD

120V/240VAC Mains Supply

Figure 2.9 Output 1 Relay or Triac (SSR) to Drive Load

26

UM0C911A

C21 C91 C92

+
_

5 6

10 9

15 14

120V /240V Mains Supply

Three Phase Delta Heater Load

Contactor

No Fuse Breaker

Three Phase Heater Power

Figure 2.10 Output 1 Relay or Triac (SSR) to Drive Contactor

C21 C91 C92

+

SSR
Load

5 6

10 9

15 14

+
_

120V /240V Mains Supply

Internal Circuit 30mA / 5V Pulsed Voltage

5V 33 33 0V
+

Figure 2.11 Output 1 Pulsed Voltage to Drive SSR

UM0C911A

27

C21 C91 C92

+

5 6

10 9

15 14

0 - 20mA, 4 - 20mA

Load _

Maximum Load 500 ohms

Figure 2.12 Output 1 Linear Current

C21 C91 C92

+

5 6

10 9

15 14

0 - 1V, 0 - 5V 1 - 5V, 0 - 10V

Load _

Minimum Load 10 K ohms

Figure 2.13 Output 1 Linear Voltage

C21 C91 C92

+
_

3 4

2 1

7 6

LOAD

120V/240VAC Mains Supply

Figure 2.14 Output 2 Relay or Triac (SSR) to Drive Load

28

UM0C911A

C21 C91 C92

+
_

3 4

2 1

7 6

120V /240V Mains Supply

Figure 2.15 Output 2 Relay or Triac (SSR) to Drive Contactor

Three Phase Delta Heater Load

Contactor

No Fuse Breaker

Three Phase Heater Power

C21 C91 C92

+ +
_

SSR
Load

3 4

2 1

7 6

120V /240V Mains Supply

Internal Circuit 30mA / 5V Pulsed Voltage

5V 33 33 0V
+

Figure 2.16 Output 2 Pulsed Voltage to Drive SSR

C21 C91 C92

+ +
_

3 4

2 1

7 6

0 - 20mA, 4 - 20mA

Load _

Maximum Load 500 ohms

Figure 2.17 Output 2 Linear Current

UM0C911A 29

C21 C91 C92

3 4

2 1

7 6

0 - 1V, 0 - 5V 1 - 5V, 0 - 10V

Load _

Minimum Load 10 K ohms

Figure 2.18 Output 2 Linear Voltage

2-8 Alarm Wiring

C21 C91 C92

3 4

2 1

7 6

LOAD

120V/240VAC Mains Supply

Figure 2.19 Alarm Output to Drive Load

C21 C91 C92

3 4

2 1

7 6

120V /240V Mains Supply

Three Phase Heater Power Three Phase Contactor Delta Heater Load No Fuse Breaker

Relay Output to Drive Contactor

Figure 2.20 Alarm Output to Drive Contactor

30

UM0C911A

2-9 Data Communication

RS-485 to RS-232 network adaptor TX1 TX2 SNA10A or SNA10B RS-232 TX1 TX2

C21 C91 C92

TX1 TX2

12 13

2 1

10 9

Twisted-Pair Wire

PC

C21 C91 C92

TX1 TX2

12 13

2 1

10 9

TX1

TX2

Max. 247 units can be linked

C21 C91 C92

TX1 TX2

12 13

2 1

10 9

TX1 TX2 Terminator 220 ohms / 0.5W

Figure 2.21 RS-485 Wiring

UM0C911A

31

RS-232

C21 C92
TXD RXD COM

12 10 13 9 11 8

PC

9-pin RS-232 port

CC94-1 Figure 2.22 RS-232 Wiring

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.

To DTE ( PC ) RS-232 Port

1

C21 C92
TXD RXD COM

12 10 13 9 11 8

TX1 TX2 COM

RD TD GND

2 3 4 5

6 7 8 9

Female DB-9 Figure 2.23 Configuration of RS-232 Cable

1 DCD 2 RD 3 TD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI

32

UM0C911A

Chapter 3 Programming
Press for 3 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 Lockout
There are four security levels can be selected by using LOCK parameter. If NONE is selected for LOCK, then no parameter is locked. If SET is selected for LOCK, then all setup data are locked. If USER is selected for LOCK, then all setup data as well as user data (refer to section 1-5) except set point are locked to prevent from being changed. If ALL is selected for LOCK, then all parameters are locked to prevent from being changed.

3-2 Signal Input

INPT: Selects the sensor type or signal type for signal input. Range: ( 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 UNIT: Selects the process unit Range: LC, LF, PU( process unit ). If the unit is neither LC nor LF, then selects PU. DP: Selects the resolution of process value. Range: ( for T/C and RTD ) NO.DP , 1-DP (for linear ) NO.DP , 1-DP , 2-DP , 3-DP INLO: Selects the low scale value for the linear type input. INHI : Selects the high scale value for the linear type input.

How to use INLO and INHI :

If 4 - 20 mA is selected 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 :
UM0C911A 33

process value INHI PV INLO SL S SH input signal Figure 3.1 Conversion Curve for Linear Type Process Value

Formula : PV = INLO + ( INHI INLO )

S SL SH SL Example : A 4-20 mA current loop pressure transducer with range 2 0 - 15 kg/cm is connected to input, then perform the following setup :
INPT = 4 - 20 INLO = 0.00 INHI = 15.00 DP = 2-DP Of course, you may select other value for DP to alter the resolution.

3-3 Control Outputs

There are 4 kinds of control modes can be configured as shown in Table 3.1 Table 3.1 Heat-Cool Control Setup Value Control Modes Heat only Cool only Heat: PID Cool: ON-OFF Heat: PID Cool: PID OUT1 REVR DIRT REVR REVR DE.HI COOL :Required if ON-OFF control is configured
UM0C911A

OUT2

O1HY

O2HY

CPB

DB

34

: Don't care :Adjust to met process requirements

Heat Only ON-OFF Control : Select REVR for OUT1, Set PB to 0, O1HY is used to adjust dead band for ON-OFF control, The output 1 hysteresis ( O1HY ) is enabled in case of PB = 0 . The heat only on-off control function is shown in the following diagram : PV SP1 Dead band = O1HY SP1 O1HY Time

OUT1 Action

ON OFF Time

Figure 3.2 Heat Only ON-OFF Control

The ON-OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest. If ON-OFF control is set ( ie. PB = 0 ), TI, TD, CYC1, OFST, CYC2, CPB, DB will be hidden and have no function to the system. The auto-tuning mode and bumpless transfer will be disabled too. Heat only P ( or PD ) control : Select REVR for OUT1, set TI to 0, OFST is used to adjust the control offset ( manual reset ). O1HY is hidden if PB is not equal to 0. OFST Function : OFST is measured by % with range 0 - 100.0 %. In the steady state ( ie. process has been stabilized ) if the process value is lower than the set point a definite value, say 5 LC, while 20 LC is used for PB, that is lower 25 %,
UM0C911A 35

then increase OFST 25 %, and vice versa. After adjusting OFST value, the process value will be varied and eventually, coincide with set point. Using the P control ( TI set to 0 ), the auto-tuning is disabled. Refer to section 3-12 " manual tuning " for the adjustment of PB and TD. Manual reset ( adjust OFST ) is not practical because the load may change from time to time and often need to adjust OFST repeatedly. The PID control can avoid this situation. Heat only PID control : Selecting REVR for OUT1, PB and TI should not be zero. Operate auto-tuning for the new process, or set PB, TI and TD with historical values. See section 3-11 for auto-tuning operation. If the control result is still unsatisfactory, then use manual tuning to improve the control . See section 3-12 for manual tuning. The unit contains a very clever PID and Fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is properly tuned. Cool only control:ON-OFF control, P ( PD ) control and PID control can be used for cool control. Set OUT1 to DIRT ( direct action ). The other functions for cool only ON-OFF control, cool only P ( PD ) control and cool only PID control are same as descriptions for heat only control except that the output variable ( and action ) for the cool control is inverse to the heat control. NOTE : The ON-OFF control may result excessive overshoot and undershoot problems in the process. The P ( or PD ) control will result in a deviation process value from the set point. It is recommended to use PID control for the Heat-Cool control to produce a stable and zero offset process value. Other Setup Required : O1TY, CYC1, O2TY, CYC2, O1FT, O2FT O1TY & O2TY are set in accordance with the types of OUT1 & OUT2 installed. CYC1 & CYC2 are selected according to the output 1 type ( O1TY ) & output 2 type ( O2TY ). Generally, selects 0.5 ~ 2 sec. for CYC1, if SSRD or SSR is used for O1TY; 10 ~ 20 sec. if relay is used for O1TY, and CYC1 is ignored if linear output is used. Similar condition is applied for CYC2 selection.

36

UM0C911A

You can use the auto-tuning program for the new process or directly 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 manual tuning to improve the control. See section 3-12 for manual tuning. CPB Programming : The cooling proportional band is measured by % 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: 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: DE.HI (deviation high alarm ), DE.LO (deviation low alarm ), DB.HI (deviation band out of band alarm ), DB.LO (deviation band in band alarm), PV.HI (process high alarm ) and PV.LO ( process low alarm ). Refer to Figure 3.3 and Figure 3.4 for the description of deviation alarm and process alarm with normal alarm mode ( NORM is set for ALMD ).

UM0C911A

37

PV SV+SP2 SV+SP2-O2HY OUT2 Action ON OFF

OUT2=DE.HI

Time

Figure 3.3 Output 2 Deviation High Alarm

PV SP2+O2HY SP2 OUT2 Action ON OFF

Time

Time

Figure 3.4 Output 2 Process Low Alarm

38 UM0C911A

Time

3-4 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. A process alarm sets two absolute trigger levels. When the process is higher than SP2, a process high alarm ( PV.HI ) occurs, and the alarm is off as the process is lower than SP2-O2HY. When the process is lower than SP2, a process low alarm ( PV.LO ) occurs and the alarm is off as the process is higher than SP2+O2HY. A process alarm is independent of set point. A deviation alarm alerts the user when the process deviates too far from set point. When the process is higher than SV+SP2, a deviation high alarm (DE.HI) occurs and the alarm is off as the process is lower than SV+SP2-O2HY. When the process is lower than SV+SP2, a deviation low alarm (DE.LO) occurs and the alarm is off as the process is higher than SV+SP2+O2HY. Trigger level of deviation alarm is moving with set point. A deviation band alarm presets two trigger levels relative to set point. The two trigger levels are SV+SP2 and SV - SP2 for alarm. When the process is higher than ( SV+SP2 ) or lower than ( SV - SP2 ), a deviation band high alarm ( DB.HI ) occurs. When the process is within the trigger levels, a deviation band low alarm (DB.LO) occurs. In the above descriptions SV denotes the current set point value for control which is different from SP1 as the ramp function is performed. There are four types of alarm modes available for each alarm function, these are: Normal alarm, Latching alarm, Holding alarm and Latching/ 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 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. 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 is activated as the unit enters failure mode. Alarm will go on if ON is set for O2FT and go off if OFF is set for O2FT. The unit will enter failure mode when sensor break occurs or if the A-D converter of the unit fails.

3-5 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

40

UM0C911A

Example for C91/C92: Set OUT2=PVLO, LOCK=NONE, SEL1=INPT, SEL2=UNIT, SEL3=DP , SEL4~SEL8=NONE, then the display scrolling for C91 and C92 becomes
PV SP1 SP2 MAN AT

PV

SP1

SP2

PV

3 - 6 Ramp
The ramping function is performed during power up as well as any time the set point is changed. Choose MINR or HRR for RAMP , the unit will perform the ramping function. The ramp rate is programmed by adjusting RR. The ramping function is disabled as soon as the failure mode, the manual control mode, the auto-tuning mode or the calibration mode occurs. Example without Dwell Timer Select MINR for RAMP , selects LC for UNIT, selects 1-DP for DP , Set RR= 10.0. SV is set to 200 LC initially, and changed to 100 LC after 30 minutes since power up. The starting temperature is 30 LC. After power up the process is running like the curve shown below:
PV 200 C 100 C 30 C 0 17 30 40

Figure 3.5 RAMP Function

Time (minutes)

Note: When the ramp function is used, the display will show the current ramping value. However it will revert to show the set point value as soon as the up or down key is touched for adjustment. The ramping value is initiated to process value either as power up or RR and /or set point are changed. Setting RR to zero means no ramp function at all.
UM0C911A 41

3-7 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

Time SP3
power off or touch RESET key

ON OFF Time Timer starts

Figure 3.6 Dwell Timer Function

If output 2 is configured as dwell timer, ALMD will be hidden.
42 UM0C911A

3 - 8 PV Shift
In certain applications it is desirable to shift the controller display value from its actual value. This can be easily accomplished by using the PV shift function. The SHIF function will alter PV only. Here is an example. A process is equipped with a heater, a sensor and a subject to be warmed up. Due to the design and position of the components in the system, the sensor could not be placed any closer to the part. Thermal gradient ( different temperature ) is common and necessary to an extent in any thermal system for heat to be transferred from one point to another. If the difference between the sensor and the subject is 35 LC, and the desired temperature at the subject to be heated is 200 LC, the controlling value or the temperature at the sensor should be 235 LC. You should input -35 LC as to subtract 35 LC from the actual process display. This in turn will cause the controller to energize the load and bring the process display up to the set point value.
Subject Heat Transfer 165 C 200 C Sensor
C

Heater

Subject Heat Transfer 165 C 200 C Sensor

C

Heater

Subject Heat Transfer 200 C 235 C Sensor

C

Heater

35 C temperature difference is observed SHIF= 0

Adjust SHIF SHIF= -35 C Supply more heat

Display is stable SHIF= -35 C PV=SV

Figure 3.7 PV Shift Application

UM0C911A 43

3- 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 FILT 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=0 1 sec FILT=1

FILT=30

1 sec

Time
Figure 3.8 Filter Characteristics
Note The Filter is available only for PV, and is performed for the displayed value only. The controller is designed to use unfiltered signal for control even if Filter is applied. A lagged ( filtered ) signal, if used for control, may produce an unstable process.

44

UM0C911A

3 -10 Failure Transfer

The controller will enter failure mode as one of the following conditions occurs: 1. SBER occurs due to the input sensor break or input current below 1mA if 4-20 mA is selected or input voltage below 0.25V if 1-5 V is selected . 2. ADER occurs due to the A-D converter of the controller fails. The output 1 and output 2 will perform the failure transfer function as the controller enters failure mode. Output 1 Failure Transfer, Transfer if activated, will perform : 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, then output 2 will perform bumpless transfer. Thereafter the previous averaging value of MV2 will be used for controlling output 2. 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 value of O2FT will be used for controlling output 2. 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 to on state if ON is set for O2FT.

UM0C911A

45

3 -11 Auto-tuning
The auto-tuning process is performed at set point. The process will oscillate around the set point during tuning process. Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage. The auto-tuning is applied in cases of :

* Initial setup for a new process * The set point is changed substantially from the previous autotuning value

* The control result is unsatisfactory

Operation :
1. The system has been installed normally. 2. Set the correct values for the setup menu of the unit. 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. 3. Set the set point to a normal operating value or a lower value if overshooting beyond the normal process value is likely to cause damage. 4. Press several times until appears on the display.( for C21) or AT indicator is lit (for C91 and C92). 5. Press for at least 3 seconds. The AT indicator ( for C91 and C92 ) or the display ( for C21 )will begin to flash and the auto-tuning procedure is beginning.

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 or manual control mode occurs.
46 UM0C911A

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 Error If auto-tuning fails an ATER message will appear on the display in cases of : If PB exceeds 9000 ( 9000 PU, 900.0 LF or 500.0 LC ). or if TI exceeds 1000 seconds. or if set point is changed during auto-tuning procedure. Solutions to 1. Try auto-tuning once again. 2. Don't change set point value during auto-tuning procedure. 3. Don't set zero value for PB and TI. 4. Use manual tuning instead of auto-tuning. ( See section 3-12 ). 5. Touch RESET key to reset message.

3 - 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 :

UM0C911A

47

ADJUSTMENT SEQUENCE (1) Proportional Band ( PB )

SYMPTOM Slow Response High overshoot or Oscillations Slow Response

SOLUTION Decrease PB Increase PB Decrease TI Increase TI Decrease TD Increase TD

(2) Integral Time ( TI )

Instability or Oscillations Slow Response or Oscillations High Overshoot

(3) Derivative Time ( TD )

Table 3.2 PID Adjustment Guide Figure 3.9 shows the effects of PID adjustment on process response.

3 -13 Manual Control

Operation: To enable manual control the LOCK parameter should be set with NONE, then press (Heating output) for several times then or (Cooling output) will appear on the display. Press for 3 seconds then the MAN indicator (for C91 and C92) or the display (for C21) will begin to flash. The controller now enters the manual control indicates output control variable for output 1, and mode. indicates control variable for output 2. Now you can use updown key to adjust the percentage values for the heating or cooling output. The controller performs open loop control as long as it stays in manual control mode. Exit Manual Control To press R key the controller will revert to its normal display mode.
48 UM0C911A

PV Perfect Set point

PB too low

P action
PB too high

Time

TI too high PV

Set point Perfect TI too low

I action

Time

PV

TD too low Perfect

Set point

TD too high

D action

Time

Figure 3.9 Effects of PID Adjustment

UM0C911A 49

3 - 14 Data Communication
The controllers support RTU mode of Modbus protocol for the data communication. Other protocols are not available for the series.
Two types of interface are available for Data Communication. These are RS485 and RS-232 interface. Since RS-485 uses a differential architecture to drive and sense signal instead of a single ended architecture which is used for RS-232, RS-485 is less sensitive to the noise and suitable for a longer distance communication. RS-485 can communicate without error over 1 km 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 is transmitted and received through the PC communication Port ( generally RS-232 ). Since a standard PC can't support RS-485 port, a network adaptor ( such as SNA10A , SNA10B ) has to be used to convert RS-485 to RS-232 for a PC if RS-485 is required for the data communication. But there is no need to be sad. Many RS-485 units ( up to 247 units ) can be connected to one RS-232 port, therefore a PC with 4 comm ports can 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 connected to the same port. Set the Baud Rate ( BAUD ), Data Bit ( DATA ), Parity Bit ( PARI ) and Stop Bit ( STOP ) such that these values are accordant with PC setup conditions. 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 according to Section 2-9.

50

UM0C911A

Chapter 4 Applications
4 - 1 Heat Only Control with Dwell Timer
An oven is designed to dry the products at 150 BC for 30 minutes and then stay unpowered for another batch. A C91 equipped with dwell timer is used for this purpose. The system diagram is shown as follows : Set SP1=150.0 SP2 =30.0
4
OP1 OP2 C F

Oven

C
PV SP1 SP2 MAN AT

T/C

Heater

R
C91

Figure 4.1 Heat Control Example

10 9 Mains Supply ON

OUT1

Timer ( ALM )

OFF

To achieve this function set the following parameters in the setup menu. INPT=K_TC OUT1=REVR O1FT=BPLS UNIT= L C O1TY=RELY OUT2=TIMR DP=1_DP CYC1=18.0 O2FT=ON

Auto-Tuning is performed at 150 LC for a new oven.

UM0C911A 51

4 - 2 Cool Only Control

A C91 is used to control a refrigerator at temperature below 0 BC. 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 BC. Setup Summary: INPT=PT.DN UNIT= L C DP=1-DP OUT1=DIRT O1TY=RELY
Refrigerator

RTD

Mains Supply

User Menu: PB = 0 ( LC ) O1HY=0.1 ( LC )

4 3

9 10
C F

OP1 OP2

PV

SP1 SP2 MAN

AT

R
C91

Figure 4.2 Cooling Control Example

52

UM0C911A

4 - 3 Heat-Cool Control
An injection mold required to be controlled at 120 LC to ensure a consistent quality for the parts. An oil pipe is buried in the mold. Since plastics is injected at higher temperature ( e.g. 250 LC ), the circulation oil needs to be cooled as its temperature rises. Here is an example:

Plastics

Injection Mold 120 C

Oil Pump Oil Tank Freezer RTD

4-20 mA OUT2 1,2

OP1 OP2 C F

Heater Supply OUT1 9

10 5 4 3
INPT

PV

SP1 SP2 MAN

AT

R
C91

Figure 4.3 Heat-Cool Control Example

UM0C911A

53

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= LC DP= 1-DP OUT1=REVR O1TY=RELY CYC1=18.0 (sec.) O1FT=BPLS OUT2=COOL O2TY=4-20 O2FT=BPLS

Adjust SV at 120.0 LC , CPB at 125 ( % ) and DB at -4.0 (%). Apply Auto-tuning at 120 LC for a new system to get an optimal PID values. See Section 3-11.

Adjustment of CPB is related to the cooling media used. If water is used as cooling media instead of oil, the CPB is set at 250 (%). If air is used as cooling media instead of oil, the CPB is set at 100 (%). Adjustment of DB is dependent on the system requirements. More positive value of DB will prevent unwanted cooling action, but will increase the temperature overshoot, while more negative value of DB will achieve less temperature overshoot, but will increase unwanted cooling action.

54

UM0C911A

Chapter 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: (1) A high accuracy calibrator ( Fluke 5520A Calibrator recommended ) with following functions: 0 - 100 mV millivolt source with A0.005 % accuracy 0 - 10 V voltage source with A0.005 % accuracy 0 - 20 mA current source with A0.005 % accuracy 0 - 300 ohm resistant source with A0.005 % accuracy (2) A test chamber providing 25 BC - 50 BC 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.

Since it needs 30 minutes to warm up an unit before calibration, calibrating the unit one by one is quite inefficient. An automatic calibration system for small quantity as well as for unlimited quantity is available upon request.

UM0C911A

55

Manual Calibration Procedures

* Perform step 1 to enter calibration mode.

Step 1. Set the Lock parameter to the unlocked condition ( LOCK= 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.

Step 2. Short the thermocouple inpt terminals , then press scroll key for at least 3 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. Step 3. Press scroll key until the display shows . Send a 60 mV signal to the thermocouple input terminals in correct polarity . Press scroll key for at least 3 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 .

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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: C21 8 9 10 C91 3 4 5 C92 18 17 16

100 ohms

Figure 5.1 RTD Calibration

Press scroll key for at least 3 seconds . The display will blink a moment, otherwise the calibration fails.

Step 5. Press scroll key and the display will show . Change the ohm's value to 300 ohms .Press scroll key for at least 3 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.

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5520A Calibrator K-TC K+

C21
9 10

C91
4 5

C92
17 16

Figure 5.2 Cold Junction Calibration Setup

Stay at least 20 minutes in stillair room room temperature 25 A 3 LC

The 5520A calibrator is configured as K type thermocouple output with internal compensation. Send a 0.00 LC signal to the unit under calibration.
The unit under calibration is powered in a still-air room with temperature 25A3 BC. 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 3 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. step 7 to calibrate gain of cold junction compensation * Perform if required. Step 7. Setup the equipments same as step 6. The unit under calibration is powered in a still-air room with temperature 50 A3 BC. Stay at least 20 minutes for warming up . The calibrator source is set at 0.00 BC with internal compensation mode.

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Perform step 1 stated above , then press scroll key until the display shows . Press scroll key for at least 3 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 high temperature chamber, hence it is recommended to use a computer to perform the procedures.

Input modification and recalibration procedures for a linear * voltage or a linear current input: 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. Input Function T/C, RTD, 0~60mV 0~1V 0 ~ 5V, 1 ~ 5V 0 ~ 10 V 0~20mA, 4~20mA RA X 61.9K 324K 649K 39W RB X 3.92K 3.92K 3.92K 3.01W R60 3.3K X X X X

2. Perform Step 1 and Step 2 to calibrate the linear input zero. 3. Perform Step 3 but send a span signal to the input terminals 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 step

Step 8. Set the LOCK value to your desired function.

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Chapter 6 Specifications
Power
90 264 VAC, 47 63 Hz, 10VA, 5W maximum 11 26 VAC / VDC, 10VA, 5W maximum

Input
Resolution : 18 bits Sampling Rate : 5 times / second Maximum Rating : -2 VDC minimum, 12 VDC maximum ( 1 minute for mA input ) Temperature Effect : A1.5uV/ BC for all inputs except mA input A3.0uV/ BC for mA input Sensor Lead Resistance Effect : T/C: 0.2uV/ohm 3-wire RTD: 2.6 LC/ohm of resistance difference of two leads 2-wire RTD: 2.6 LC/ohm of resistance sum of two leads Burn-out Current : 200 nA Common Mode Rejection Ratio ( CMRR ): 120dB Normal Mode Rejection Ratio ( NMRR ): 55dB

Sensor Break Detection :

Sensor open for TC, RTD and mV inputs, Sensor short for RTD input below 1 mA for 4-20 mA input, below 0.25V for 1 - 5 V input, unavailable for other inputs.

Sensor Break Responding Time :

Within 4 seconds for TC, RTD and mV inputs, 0.1 second for 4-20 mA and 1 - 5 V inputs.

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Characteristics:
Type J K T E B Range

Accuracy @ 25 C
A2 LC A2 LC A2 LC A2 LC A2 LC ( 200 C 1800 C ) A2 LC A2 LC A2 LC A2 LC A0.4 LC A0.4 LC A0.05 % A0.05 % A0.05 %

Input Impedance

-120 C ( -184 F -200 C ( -328 F -250 C ( -418 F -100 C ( -148 F

1000 C 1832 F ) 1370 C 2498 F ) 400 C 752 F ) 900 C 1652 F )

2.2 M 2.2 M 2.2 M 2.2 M 2.2 M

0 C 1800 C ( 32 BF 3272 BF ) 0 C 1767.8 C ( 32 BF 3214 BF ) 0 C 1767.8 C ( 32 BF 3214 BF ) -250 C 1300 C ( -418 F 2372 F ) -200 C 900 C ( -328 F 1652 F ) -210 C 700 C ( -346 F 1292 F ) -200 C 600 C ( -328 F 1112 F ) -8mV 70mV -3mA 27mA -1.3V 11.5V

R S N L PT100 ( DIN ) PT100 ( JIS ) mV mA V

2.2 M 2.2 M 2.2 M 2.2 M 1.3 K 1.3 K 2.2 M 70.5 650 K

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Output 1 / Output 2
Relay Rating : 2A/240 VAC, life cycles 200,000 for resistive load Pulsed Voltage : Source Voltage 5V, current limiting resistance 66 . Linear Output Characteristics

Type 4-20 mA 0-20 mA 0~5V 1~5V 0 ~ 10 V

Zero Tolerance 3.8-4 mA 0 mA 0V 0.95 ~ 1 V 0V

Span Tolerance 20-21 mA 20-21 mA 5 ~ 5.25 V 5 ~ 5.25 V 10 ~10.5 V

Load Capacity 500W max. 500W max. 10 KW min. 10 KW min. 10 KW min.

Linear Output Resolution : 15 bits

Output Regulation : 0.02 % for full load change Output Settling Time : 0.1 sec. ( stable to 99.9 % ) Isolation Breakdown Voltage : 1000 VAC Temperature Effect : A0.01 % of SPAN / LC

Triac ( SSR ) Output

Rating : 1A / 240 VAC Inrush Current : 20A for 1 cycle Min. Load Current : 50 mA rms Max. Off-state Leakage : 3 mA rms Max. On-state Voltage : 1.5 V rms Insulation Resistance : 1000 Mohms min. at 500 VDC Dielectric Strength : 2500 VAC for 1 minute

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DC Voltage Supply Characteristics ( Installed at Output 2 ) Type Tolerance Max. Output Current 20 V 12 V 5V A0.5 V A0.3 V A0.15 V 25 mA 40 mA 80 mA Ripple Voltage 0.2 Vp-p 0.1 Vp-p Isolation Barrier 500 VAC 500 VAC

0.05 Vp-p 500 VAC

Output 2 Functions : Dwell timer, Deviation High / Low Alarm, Deviation Band High / Low Alarm, PV High / Low Alarm, PID cooling control Alarm Mode : Normal, Latching, Hold, Latching / Hold. Dwell Timer : 0.1 - 4553.6 minutes

Data Communication
Interface : RS-232 ( 1 unit ), RS-485 ( up to 247 units ) Protocol : Modbus Protocol RTU mode Address : 1 - 247 Baud Rate : 2.4 ~ 38.4 Kbits/sec Data Bits : 7 or 8 bits Parity Bit : None, Even or Odd Stop Bit : 1 or 2 bits Communication Buffer : 160 bytes

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User Interface
Single 4-digit LED Display Keypad : 4 keys for C91 and C92, 3 keys for C21 Programming Port : For automatic setup, calibration and testing Communication Port : Connection to PC for supervisory control

Control Mode
Output 1 : Reverse ( heating ) or direct ( cooling ) action Output 2 : PID cooling control, cooling P band 50~300% of PB, dead band -36.0 ~ 36.0 % of PB ON-OFF : 0.1 - 90.0 ( LF ) hysteresis control ( P band = 0 ) P or PD : 0 - 100.0 % offset adjustment PID : Fuzzy logic modified Proportional band 0.1 ~ 900.0 LF. Integral time 0 - 1000 seconds Derivative time 0 - 360.0 seconds Cycle Time : 0.1 - 90.0 seconds Manual Control : Heat (MV1) and Cool (MV2) Auto-tuning : Cold start and warm start Failure Mode : Auto-transfer to manual mode while sensor break or A-D converter damage Ramping Control : 0 - 900.0 LF/minute or 0 - 900.0 LF/hour ramp rate

Digital Filter
Function : First order Time Constant : 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60 seconds programmable

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Environmental & Physical

Operating Temperature : -10 BC to 50 BC Storage Temperature : -40 BC to 60 BC Humidity : 0 to 90 % RH ( non-condensing ) Insulation Resistance : 20 Mohms min. ( at 500 VDC ) Dielectric Strength : 2000 VAC, 50/60 Hz for 1 minute 2 Vibration Resistance : 10 - 55 Hz, 10 m/s for 2 hours Shock Resistance : 200 m/s 2 ( 20 g ) Moldings : Flame retardant polycarbonate Dimensions : C21-----50mm(W) X 26.5mm(H) X 110.5mm(D), 98 mm depth behind panel C91-----48mm(W) X 48mm(H) X 94mm(D), 86 mm depth behind panel C92-----45mm(W) X 92mm(H) X 127mm(D) Weight : C21----- 120 grams C91----- 140 grams C92----- 270 grams

Approval Standards
Safety : UL61010C-1 CSA C22.2 No. 24-93 EN61010-1 ( IEC1010-1 ) Protective Class : IP65 front panel for C21 IP30 front panel for C91, all indoor use. IP20 for terminals and housing with protective cover. EMC: EN61326

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Chapter 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 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 Registers Query ( from master ) 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 Response ( from slave )

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

CRC16 Hi CRC16 Lo Function 06: Preset single Register Query ( from master ) Slave address (0-255) Function code (6) Register address Hi (0) Register address Lo (0-79) Data Hi Data Lo CRC16 Hi CRC16 Lo Response ( from slave )

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Function 16: Preset Multiple Registers Query ( from master ) Slave address (0-255) Function code (16) Starting address of register Hi (0) Starting address of register Lo (0-79) 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 Response ( from slave )

CRC16 Hi CRC16 Lo

CRC16 Hi CRC16 Lo

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7-2 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 Cause

Function code is not supported by the controller Illegal data address Register address out of range Illegal data value Data value out of range or attempt to write a read-only or protected data

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7-3 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 O2TY O2FT O2HY SP1 SP2 SP3 LOCK INPT UNIT DP INLO INHI SP1L SP1H SHIF FILT DISP PB TI TD OUT1 O1TY O1FT O1HY CYC1 OFST RAMP RR OUT2 Parameter Set point 1 Set point 2 Set point 3 Lock code Input sensor selection Measuring unit Decimal point position Low scale value for linear input High scale value for linear input Low limit of SP1 High limit of SP1 PV shift value Filter time constant Display form ( for C21 ) P ( proportional ) band Integral time Derivative time Output 1 function Output 1 signal type Output 1 failure transfer Output 1 ON-OFF hysteresis Output 1 cycle time Offset value for P control Ramp function Ramp rate Output 2 function Reserved Output 2 signal type Output 2 failure transfer Output 2 ON-OFF hysteresis Scale Low *4 *7 *6 0 0 0 0 *4 *4 *4 *4 *4 0 0 *5 0 0.0 0 0 *5 0.0 0.0 0 *5 0 0 0 *5 Scale High *4 *7 *6 65535 65535 65535 65535 *4 *4 *4 *4 *4 65535 65535 *5 65535 6553.5 65535 65535 *5 6553.5 6553.5 65535 *5 65535 65535 65535 *5 Notes R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W

-1999.9 4553.6

-1999.9 4553.6

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Register Parameter Address Notation

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 HOUR ALMD ALHY ALFT COMM ADDR BAUD DATA PARI STOP SEL1 SEL2 SEL3 SEL4 SEL5 SEL6 SEL7 SEL8 ADLO ADHI RTDL RTDH CJLO CJHI CYC2 CPB DB ALFN

Parameter Output 2 cycle time Cooling P band Heating-cooling dead band Alarm function Reserved 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

Scale Low 0.0 0 0 0 0 *5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Scale High 6553.5 65535 65535 65535 65535 *5 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535 65535

Notes R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W R/W

-1999.9 4553.6

-1999.9 4553.6 -1999.9 4553.6 -1999.9 4553.6 -1999.9 4553.6

Cold junction calibration low coefficient -199.99 455.36 Cold junction calibration high coefficient -1999.9 4553.6 Reserved Reserved Working hours of the controller 0 0 0 65535 65535 65535

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Register Parameter Address Notation

61 62 63 64 65 66 BPL1 BPL2 CJCL PV SV MV1

Parameter Bumpless transfer of OP1 Bumpless transfer of OP2 Cold junction signal low Process value Current set point value OP1 control output value

Scale Low 0.00 0.00 0.000 *4 *4 0.00

Scale High 655.35 655.35 65.535 *4 *4

Notes R R R R

R Read only, unless in 655.35 manual control 655.35 Read only, unless in manual control R R R R R/W R/W R/W R/W R R R R

67

MV2

OP2 control output value

0.00

68 69 70 71 72 73 74 75 76 77 78 79

TIMER EROR MODE PROG CMND JOB1 JOB2 JOB3

Remaining time of dwell timer Error code *1 Operation mode & alarm status *2 Program code *3 Command code Job code Job code Job code Reserved Reserved Reserved Reserved

-1999.9 4553.6 0 0 0.00 0 0 0 0 0 0 0 0 65535 65535 655.35 65535 65535 65535 65535 65535 65535 65535 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'0X00 = Alarm status is off H'010X = Calibration mode H'0x01 = Alarm status is on H'020X = Auto-tuning mode H'030X = Manual control mode The alarm status is shown in H'040X = Failure mode MV2 instead of MODE for models C21, C91 and C92.
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*3: The PROG Code is defined in the following table: Model No. BTC-9100 BTC-8100 BTC-4100 BTC-7100 C21 C91 C92 6.XX PROG Code 11.XX 12.XX 13.XX 33.XX 34.XX 35.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 and SV: Conditions Scale low Scale high Non-linear input -1999.9 4553.6 Linear input Linear input Linear input Linear input DP = 0 DP = 1 DP = 2 DP = 3 -19999 45536 -1999.9 4553.6 -199.99 455.36 -19.999 45.536

*5: The scale high/low values are defined in the following table for PB, O1HY, RR, O2HY and ALHY: Non-linear Linear input Linear input Linear input Linear input Conditions input DP = 0 DP = 1 DP = 2 DP = 3 Scale low Scale high 0.0 6553.5 0 65535 0.0 6553.5 0.00 655.35 0.000 65.535

*6: The scale high/low values are defined in the following table for SP3: Conditions Scale low Scale high ALFN=1 Non-linear Linear input Linear input Linear input Linear input (TIMR) input DP = 0 DP = 1 DP = 2 DP = 3 -1999.9 -1999.9 -19999 4553.6 4553.6 45536 -1999.9 -199.99 -19.999 4553.6 455.36 45.536

*7: The scale high/low values are defined in the following table for SP2: For C21, C91and C92 OUT2=1 Non-linear Linear input Linear input Linear input Linear input Conditions (TIMR) input DP = 0 DP = 1 DP = 2 DP = 3 Scale low Scale high
72

-1999.9 -1999.9 -19999 4553.6 4553.6 45536

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-1999.9 -199.99 -19.999 4553.6 455.36 45.536

For BTC-9100, BTC-8100, BTC-7100 and BTC-4100 Conditions Scale low Scale high Non-linear input -1999.9 4553.6 Linear input Linear input Linear input Linear input DP = 0 DP = 1 DP = 2 DP = 3 -19999 45536 -1999.9 4553.6 -199.99 455.36 -19.999 45.536

7-4 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: 65535 ( A SL) M= SH-SL A= SH-SL 65535 M + SL

7-5 Communication Examples :

Example 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:

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01

10

00

00

00

34

68

4F 19 4E 83

4E

83

Addr. Func. Starting Addr. No. of words Bytes SP1=25.0 SP2=10.0 SP3=10.0 00 00 LOCK=0 00 01 INPT=1 00 00 UNIT=0 00 01 4D 6D 51 C4 DP=1 INLO=-17.8 INHI=93.3 00 64 PB=10.0 00 01 O1HY=0.1 00

4D 6D 63 21 4E 1F 00 02 00 00 SP1L=-17.8 SP1H=537.8 SHIF=0.0 FILT=2 DISP=0 00 64 TI=100 00 FA 00 00 00 00 TD=25.0 OUT1=0 O1TY=0 4E 1F O1FT=0

00 B4 00 FA 00 00 CYC1=18.0 OFST=25.0 RAMP=0

00 00 00 02 00 RR=0.0 OUT2=2

00 00 4E 1F 00 01 00 B4 00 64 4E 1F O2TY=0 O2FT=0 O2HY=0.1 CYC2=18.0 CPB=100 DB=0 00 02 ALFN=2 00 00 00 00 ALMD=0 00 01 ALHY=0.1 00 00 PARI=0 00 07 SEL5=7 00 00 ALFT=0 00 00 STOP=0 00 08 SEL6=8 01 00 COMM=1 02 00 SEL1=2 0A 00 SEL7=10

00 01 00 02 00 01 ADDR=1 BAUD=2 DATA=1 00 03 00 04 00 06 SEL2=3 SEL3=4 SEL4=6 00 11 SEL8=17 Hi Lo CRC16

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Example 2: Read PV, SV, MV1, MV2, TIMER, EROR and MODE Send the following message to the controller via the COMM port or programming port: 03 Addr. Func. 00 H'40 00 07 Hi Lo

Starting Addr.

No. of words

CRC16

Example 3: Perform Reset Function (same effect as pressing R key) Query 06 Addr. Func. 00 H'48 H'68 H'25 Hi Lo

Register Addr.

Data Hi/Lo

CRC16

Example 4: Enter Auto-tuning Mode Query 06 Addr. Func. 00 H'48 H'68 H'28 Hi Lo

Register Addr.

Data Hi/Lo

CRC16

Example 5: Enter Manual Control Mode Query 06 Addr. Func. 00 H'48 H'68 H'27 Hi Lo

Register Addr.

Data Hi/Lo

CRC16

Example 6: Read All Parameters Query 03 Addr. Func. 00 00 00 H'50 Hi Lo

Starting Addr.

No. of words

CRC16

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Table A.1 Error Codes and Corrective Actions

Error Display Code 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 / or TI = 0 ) 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.

10 11 14

Communication error: bad function Correct the communication code software to meet the protocol requirements. Don't issue an over-range Communication error: register register address to the slave. 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 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. Fail to perform auto-tuning function 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. 5. Don't set a zero value for TI. 6. Touch RESET key

15

26

29 30

EEPROM can't be written correctly Return to factory for repair. 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 Return to factory for repair.

39

Replace input sensor.

40

Return to factory for repair.

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WARRANTY
Brainchild Electronic Co. is pleased to offer suggestions on the use of its various products. However, Brainchild makes no warranties or representations of any sort regarding the fitness for use, or the application of its products by the Purchaser. The selection, application or use of Brainchild products is the Purchaser's responsibility. 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 to be free from defects in material and workmanship for two years after delivery to the first purchaser for use. An extended period is available with extra cost upon request. Brainchild's sole responsibility under this warranty, at Brainchild's option, is limited 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, misuse or abuse.

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

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BRAINCHILD Electronic Co., Ltd. 6F., No.209, Chung Yang Rd., Nan Kang Dist., Taipei, Taiwan, R.O.C. Tel: 886-2-27861299 Fax: 886-2-27861395 web site: http://www.brainchild.com.tw