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Brainchild P41 User Manual Download Page 2

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UM0P411A

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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.

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.

Installers

System Designer

Expert User

Installers

System Designer

Expert User

Read Chapter 1, 2

Read All Chapters

Read Page 15,16

Read Chapter 1, 2

Read All Chapters

Read Page 15,16

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.

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.

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

Copyright

February 2007, 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.

a

Copyright

February 2007, 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.

a

This manual is applicable for the products with software version
12 and later version.

This manual is applicable for the products with software version
12 and later version.

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Summary of Contents for P41

Page 1: ...User s Manual User s Manual P41 P91 Auto Tune Fuzzy PID Profiling Controller P41 P91 Auto Tune Fuzzy PID Profiling Controller UM0P411D DIN EN ISO 9001 Certificate 01 100 98505 R L R LISTED U ...

Page 2: ...e equipment at a preset process condition in order to preclude possible damage to products or system 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 Information in this...

Page 3: ...r 7 Modbus Communications 7 1 Functions Supported 86 7 2 Exception Responses 88 7 3 Parameter Table 88 7 4 Number System 89 7 5 Communication Example 89 1 1 General 5 1 2 Ordering Code 9 1 3 Programming Port 11 1 4 Keys and Displays 12 1 5 Key Operation Flowchart 15 1 6 Parameter Descriptions 17 2 1 Unpacking 32 2 2 Mounting 32 2 3 Wiring precautions 34 2 4 Power Wiring 36 2 5 Sensor Input Wiring ...

Page 4: ...2 24 Configuration of RS 232 Cable 43 Figure 3 1 Conversion Curve for Linear Type Process Value 45 Figure 3 2 Heat Only ON OFF Control 47 Figure 3 3 Heat cool Control 49 Figure 3 4 Process high alarm 1 operation 51 Figure 3 5 Process low alarm 1 operation 51 Figure 3 6 Deviation high alarm 1 operation 52 Figure 3 7 Deviation low alarm 1 operation 52 Figure 3 8 Deviation band alarm 1 operation 53 F...

Page 5: ...ltage to drive external device The units are fully programmable for PT100 and thermocouple types J K T E B R S N L C P 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 There are more functions than the heating and cooling control could be configured for the controller outputs these incl...

Page 6: ...h segment can be configured as a ramp or a dwell soak segment or defining a repeat number of cycles at arbitray location within the profile and finally terminated by an end segment The user can edit a currently running profile Maximum Capacity of Program Maximum Capacity of Program There are at most 9 profiles can be defined and 288 segments totally available for all profiles The profiles are divi...

Page 7: ...tput The ASIC technology provides improved operating performance low cost enhanced reliability and higher density B 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 Control Fuzzy Control The function of Fuzzy control is to adjust PID parameters from time to time in ...

Page 8: ...s provided to prevent the unit from being changed abnormally Bumpless Transfer 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 Digital Filter Digital Filter A first order low pass filter with a programmable time constant is used to improv...

Page 9: ...al order P91 1 2 Ordering Code 1 2 Ordering Code 0 Panel mount IP50 standard 1 Panel mount IP65 water resistant rubber installed 2 DIN rail mount with IP50 for P91 only 3 DIN rail mount with IP65 for P91 only 0 Panel mount IP50 standard 1 Panel mount IP65 water resistant rubber installed 2 DIN rail mount with IP50 for P91 only 3 DIN rail mount with IP65 for P91 only Options 0 None 1 Relay rated 2A...

Page 10: ...1 Isolated RS 485 Interface Module for P41 Output 5 CM94 2 Isolated RS 232 Interface Module for P41 Output 5 CM94 3 Isolated 4 20mA 0 20mA Retrans Module for P41 Output 5 CM94 5 Isolated 0 10V Retrans Module for P41 Output 5 CM97 1 Isolated RS 485 Interface Module for P91 Output 5 CM97 2 Isolated RS 232 Interface Module for P91 Output 5 CM97 3 Isolated 4 20mA 0 20mA Retrans Module for P91 Output 5...

Page 11: ...n 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 UM0P411A 11 Front Panel Rear Terminal Access Hole Access Hole 1 3 4 6 Figure 1 2 Programming Port Overview Figure 1 2 Programming Port Overview 2 5 ...

Page 12: ... process value 2 Reset the latching alarm once the alarm condition is removed 3 Stop the manual control mode auto tuning mode and off mode then enters the static mode 4 Clear the message of communication error holdback time out error and auto tuning error 5 To reset new profile start segment to 1 00 after earlier profile is completed when RUN and HLD LED s are blinking together ENTER KEY Press for...

Page 13: ... segment Running dwell segment profile held or in static mode Both off Figure 1 3 Front Panel Description Figure 1 3 Front Panel Description UM0P411B 13 OP1 OP2 OP3 RUN P91 C F HLD 4 Buttons for ease of control setup and set point adjustment Running ramp up segment Running ramp down segment Running dwell segment profile held or in static mode Both off Upper Display to display process value menu sy...

Page 14: ...code display The unit will display the program code for 2 5 seconds during power up The display shows program number 37 with program version 12 The program no for P41 is 37 and for P91 is 38 UM0P411A 14 P41 Out3 Out4 Out2 Out1 RUN HLD 58 28 LC LC LF LF ...

Page 15: ...Operation Flowchart ASP1 PASS ASP2 ASP3 INPT DP UNIT PB1 TI1 TD1 DLAY CYC1 PV Home Page Home Page Mode Page Mode Page 58 PV TIME CYCL PV PV MODE Profile run mode Profile hold mode Static mode Automatic tuning PID1 mode Manual mode Off mode Home Display Home Display Automatic tuning PID2 mode Using key to select desired mode then 5sec Enters the selected mode Profile Page Profile Page 15 ...

Page 16: ...libration 5 sec Complete calibration procedure for the low point calibration Low Calibration Page Low Calibration Page High Calibration Page High Calibration Page UM0P411C INPT UNIT DP INLO SPLO FILT O1HY INHI O1FT SPHI EIFN CYC1 OP1L OP1H OUT2 O2FT CYC2 PB1 PB2 OUT1 TI1 TI2 TD1 TD2 OFST CPB DB OP2L OP2H O3FT OUT3 OUT4 O4FT OUT5 REH4 REL4 OP4H OP4L OP5L OP5H REL5 REH5 ADDR BAUD PARI ALF1 A1MD A1HY...

Page 17: ...m 2 10 0 C 18 0 F B B Set point for alarm 3 10 0 C 18 0 F B B ASP2 ASP3 Password entry 1 SP1 Controller Static mode Set point value Low SPLO High SPHI 25 0 C 77 0 F B B Profile number Segment number Register Address 0 Data type R W 1 2 3 5 6 7 R W PFSG Low 32768 High 32767 Low 32768 High 32767 R W R W R W 4 Low 0 High 9999 R W UM0P411A R W R 1 00 PASS INPT 0 1 2 3 4 5 6 T type T C E type T C B typ...

Page 18: ... 1 2 3 1 No decimal point 1 decimal digit 2 decimal digits 3 decimal digits Parameter Notation Parameter Description Range Default Value Register Address Data type 9 10 R W R W INPT Input sensor selection 8 1 0 R W MODE 11 Operation mode 0 Profile run mode 1 Profile hold mode 2 Static mode 3 Automatic tuning PID1 mode 4 Automatic tuning PID2 mode 6 Off mode R W 0 5 Manual mode INLO INHI Input low ...

Page 19: ...3 1 second time constant 2 0 5 second time constant 2 3 Output 1 function Parameter Notation Parameter Description Range Default Value Register Address Data type 16 17 14 EIFN 15 0 No function 1 Heating on off control 4 Cooling on off control 2 Heating time proportioning control 3 Heating linear control 5 Cooling time proportioning control 6 Cooling linear control 0 No function 1 Program run mode ...

Page 20: ...w 0 High 100 0 0 OP1H High limit value for output 1 Low 0 High 120 0 100 0 Parameter Notation Parameter Description Range Default Value Register Address Data type 19 20 21 22 23 24 25 26 PB1 TI1 TD1 Proportional band value 2 10 0 C 18 0 F L L Low 0 High 500 0 C 900 0 F L L Integral time value 2 Derivative time value 2 100 25 0 Low 0 Low 0 High 3600 sec High 900 0 sec 27 28 29 PB2 TI2 TD2 Offset va...

Page 21: ...lap 0 Low 36 0 High 36 0 DB OP2L Low limit value for output 2 Low 0 High 100 0 0 OP2H High limit value for output 2 Low 0 High 120 0 100 0 37 38 39 40 41 1 Alarm 2 output 0 No function Output 3 function OUT3 3 42 Output 3 failure transfer status 0 43 O3FT 0 1 Output 3 ON as unit fails Output 3 OFF as unit fails UM0P411A R W R W R W R W R W R W R W R W Reserved Reserved 4 DC power supply output OUT...

Page 22: ... 54 Retransmission low scale value for output 5 Low 32768 High 32767 0 0 C 32 0 F B B R W 55 Retransmission high scale value for output 5 Low 32768 High 32767 10 0 0 C 212 0 F B B R W REL5 REH5 Output 5 function 0 51 OUT5 0 1 Output 4 ON as unit fails Output 4 OFF as unit fails R W 50 1 Communication port 0 No function 2 Retransmit process value 3 Retransmit set point value R W R W R W Reserved UM...

Page 23: ...ation Parameter Description Range Default Value Register Address Data type 57 58 ALF1 0 Process high alarm 1 Process low alarm 2 Deviation high alarm 3 Deviation low alarm 4 Deviation band high low alarm Alarm 1 function 2 5 End of profile alarm 6 Hold mode alarm 7 Static mode alarm 59 Alarm 1 operation mode 0 Low 0 1 High 50 0 C 90 0 F L L 0 1 C 0 2 F L L A1HY Hysteresis control for alarm 1 A1MD ...

Page 24: ... F L L Hysteresis control for alarm 2 A2MD A2HY 63 64 65 2 Deviation high alarm 3 Deviation low alarm 4 Deviation band high low alarm Alarm 3 function for P41 only 0 Process high alarm 1 Process low alarm 2 ALF3 ALF3 66 5 End of profile alarm 6 Hold mode alarm 7 Static mode alarm Alarm 3 operation mode for P41 only A3MD 67 R W R W R W R W R W Reserved UM0P411A 0 0 24 0 Normal alarm action 1 Latchi...

Page 25: ...ed for home page A2HY selected for home page A3HY selected for home page DLAY Selected for home page OFST selected for home page O1HY selected for home page TI2 selected for home page 8 Select 2 nd parameter for home page Same as SEL1 0 SEL2 Same as SEL1 0 SEL3 7 PB2 selected for home page 6 TD1 selected for home page Select 1 st parameter for home page 0 1 2 5 No parameter selected 0 INPT selecte...

Page 26: ... SEL1 0 SEL6 75 76 77 R W R W R W CODE 78 Security code for parameter protection Low 0 High 9999 0 unprotected 1000 home page unprotected 0 R W 79 Reserved 80 Set point value at start of each profile 1 Controller set point value SP1 2 Start set point value STSP 0 STAR 0 Current process value PV R W END Set point value at end of each profile 0 Final set point value for each program 1 Controller set...

Page 27: ... High SPHI Unit for ramp segment 0 Hours Minutes 1 Minutes Seconds 2 units per minute 3 units per hour 86 PROF Profile number selected for view Low 1 High 9 1 R W 87 88 HBBD RMPU Holdback band Low 1 High 555 C 999 F L L R W R W R W R W R W R W 89 90 DLLU Unit for dwell segment 0 Hours Minutes 1 Minutes Seconds 91 Segment number Low 0 High 15 PROF 1 4 31 PROF 5 7 63 PROF 8 9 SGNO SGTY 92 Segment ty...

Page 28: ...R W R W R W 94 RTRR Low 0 High 5999 R W Time duration or Ramp rate for ramp segment HBTY 98 SEG Target segment number for the jump segment Low 0 High 15 PROF 1 4 31 PROF 5 7 63 PROF 8 9 R W Repeat number of cycles for the jump and end segment CYCL Low 1 High 9999 10000 infinite R W 99 100 FSP Final set point for the end segment Low SPLO High SPHI R W 101 OFSTL R W 102 OFSTH R W 103 ADLO R W Offset...

Page 29: ... calibration low coefficient RTD calibration high coefficient Cold junction calibration low coefficient Cold junction calibration high coefficient Low 1999 high 1999 Low 1999 high 1999 Low 5 00 high 40 00 Low 1999 high 1999 Reserved Bumpless transfer value of MV2 Low 0 High 100 00 Low 0 High 7552 CALO R CAHI 116 R Input signal value during low point calibration Input signal value during high point...

Page 30: ...1 1 1 132 STAT Mode and operation status word Bit 0 Profile run mode Bit 1 Profile hold mode Bit 2 Static mode Bit 3 Automatic tuning mode Bit 4 Manual mode Bit 5 Off mode Bit 6 Failure mode Bit 7 Profile running up Bit 8 Profile runing down Bit 9 Profile soaking Bit 10 Alarm 1 active Bit 11 Alarm 2 active Bit 12 Alarm 3 active Bit 13 Event 1 on Bit 14 Event 2 on Bit 15 Event 3 on R 133 EROR Error...

Page 31: ... code of the product R 142 CMND Command code R W Low 32768 High 32767 Low 32768 High 32767 143 JOB Job code R W Low 32768 High 32767 SPSG Low SPLO High SPHI R 138 Time remaining for the current segment TIME Low 00 00 High 99 59 R 139 Cycle remaining for the current loop CYCL Low 1 High 9999 10000 infinite R 141 HBTR Holdback time remaning for the current segment R Low 0 High 99 59 UM0P411A 31 ...

Page 32: ...s should not exceed the maximum rating specified in Chapter 6 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 2 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the un...

Page 33: ...el Cutout P41 Figure 2 1 Mounting Dimensions Figure 2 1 Mounting Dimensions UM0P411A 33 P91 45 mm 45 mm Panel Cutout 104 8mm Panel 11 5mm Panel Mount Panel Mount 104 8mm 11 5mm 62 0mm 6 5mm 7 5mm 48 0mm P91 Rail Mount Rail Mount ...

Page 34: ...mum 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 The torque...

Page 35: ...r ambient Use copper conductors except on T C input L CAT I I EI Out4 _ UM0P411A _ 35 C NO TX1 TXD TX1 TXD TX2 RXD TX2 RXD COM Out5 _ 1 2 3 4 5 6 7 8 9 10 11 12 I B B A RTD V OP3 90 250VAC 47 63 Hz 12VA 90 250VAC 47 63 Hz 12VA L N C NO C NO _ OP2 _ 13 14 15 RS 232 TXD TX1 TX2 RXD COM RS 485 OP1 PTA TC V PTB mA TC V PTB mA TC V PTB mA TC V PTB mA 50 C max air ambient Use copper conductors except on...

Page 36: ...Wiring 18 4 19 5 20 6 P41 P91 PTA TC V PTB mA TC V PTB mA TC V PTB mA TC V PTB mA B B A RTD _ _ V _ TC V mA RTD Figure 2 7 Sensor Input Wiring Figure 2 7 Sensor Input Wiring 2 6 Control Output Wiring 2 6 Control Output Wiring 3 4 P41 P91 9 10 LOAD 120V 240VAC Mains Supply 120V 240VAC Mains Supply Figure 2 8 Output 1 Relay or Triac SSR to Drive Load Figure 2 8 Output 1 Relay or Triac SSR to Drive L...

Page 37: ... P41 P91 9 10 Figure 2 9 Output 1 Relay or Triac SSR to Drive Contactor Figure 2 9 Output 1 Relay or Triac SSR to Drive Contactor Load 120V 240V Mains Supply 120V 240V Mains Supply SSR 30mA 5V Pulsed Voltage 30mA 5V Pulsed Voltage Internal Circuit Internal Circuit 5V 0V 33 33 Figure 2 10 Output 1 Pulsed Voltage to Drive SSR Figure 2 10 Output 1 Pulsed Voltage to Drive SSR 3 4 P41 P91 9 10 UM0P411A...

Page 38: ... Figure 2 11 Output 1 Linear Current Figure 2 11 Output 1 Linear Current Figure 2 12 Output 1 Linear Voltage Figure 2 12 Output 1 Linear Voltage LOAD 120V 240VAC Mains Supply 120V 240VAC Mains Supply Figure 2 13 Output 2 Relay or Triac SSR to Drive Load Figure 2 13 Output 2 Relay or Triac SSR to Drive Load 3 4 P41 P91 9 10 3 4 P41 P91 9 10 5 6 P41 P91 11 12 UM0P411A 38 ...

Page 39: ...Triac SSR to Drive Contactor Load 120V 240V Mains Supply 120V 240V Mains Supply SSR 30mA 5V Pulsed Voltage 30mA 5V Pulsed Voltage Internal Circuit Internal Circuit 5V 0V 33 33 Figure 2 15 Output 2 Pulsed Voltage to Drive SSR Figure 2 15 Output 2 Pulsed Voltage to Drive SSR Maximum Load 500 ohms Maximum Load 500 ohms 0 20mA 4 20mA 0 20mA 4 20mA Load Figure 2 16 Output 2 Linear Current Figure 2 16 O...

Page 40: ...0V 240VAC Mains Supply 120V 240VAC Mains Supply Relay Output to Drive Contactor Relay Output to Drive Contactor 120V 240V Mains Supply 120V 240V Mains Supply No Fuse Breaker No Fuse Breaker Three Phase Heater Power Three Phase Heater Power Three Phase Delta Heater Load Three Phase Delta Heater Load Contactor Figure 2 19 Alarm Output to Drive Contactor Figure 2 19 Alarm Output to Drive Contactor P4...

Page 41: ...nt Input wiring 3 6 P41 P91 EI switch 2 9 Retransmission Output Wiring 2 9 Retransmission Output Wiring 11 12 Figure 2 21 Retransmit 4 20 0 20 mA Wiring Figure 2 21 Retransmit 4 20 0 20 mA Wiring 13 14 P41 P91 Minimum Load 10K ohms for voltage Maximum Load 500 ohm for current 13 14 LOAD UM0P411A 41 ...

Page 42: ...or 220 ohms 0 5W Max 247 units can be linked Max 247 units can be linked RS 232 PC SNA10A or SNA10B SNA10A or SNA10B RS 485 to RS 232 network adaptor RS 485 to RS 232 network adaptor Twisted Pair Wire Twisted Pair Wire Figure 2 22 RS 485 Wiring Figure 2 22 RS 485 Wiring P91 13 14 TX1 TX2 P91 13 14 TX1 TX2 P91 13 14 P41 13 14 P41 13 14 P41 ...

Page 43: ...pin RS 232 cable instead of CC94 1 the cable must be modified according to the following circuit diagram 1 2 3 4 5 6 7 8 9 TX1 RD TX2 TD COM GND Female DB 9 Female DB 9 To DTE PC RS 232 Port To DTE PC RS 232 Port 1 DCD 2 RD 3 TD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI 1 DCD 2 RD 3 TD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI Figure 2 24 Configuration of RS 232 Cable Figure 2 24 Configuration of RS 232 Cable P...

Page 44: ...0 Any value 1000 All parameters are changeable Only Home page parameters are changeable All parameters are changeable All parameters are not changeable CODE 1000 CODE Others Table 3 1 Password operation 3 2 Signal Input 3 2 Signal Input INPT Range UNIT Range DP Range INLO Selects the sensor type or signal type for signal input thermocouple J_TC K_TC T_TC E_TC B_TC R_TC S_TC N_TC L_TC C_TC P_TC RTD...

Page 45: ...ample A 4 20 mA current loop pressure transducer with range 0 15 kg cm is connected to input then perform the following setup 2 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 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 Event Input 3 3 Event Input The Event input accepts a ...

Page 46: ...s in static mode or run mode Event input close Performs failure transfer function Event input open Unit will perform normal PID operation 6 OFF Applies when unit is in static mode or run mode Event input close All outputs alarm turn off profile stops running Event input open If running profile resumes where it was put into off condition outputs alarms active again as per configuration 7 PASS Appli...

Page 47: ... OFF Adjust to meet process requirements Table 3 2 Heat Cool control configuration value Table 3 2 Heat Cool control configuration value Heat Only ON OFF Control Select for OUT1 and O1HY is used for adjusting the dead band of ON OFF control The heat only on off control function is shown in the following diagram Heat Only ON OFF Control Select for OUT1 and O1HY is used for adjusting the dead band o...

Page 48: ...ad may change from time to time and you need to adjust OFST often The PID control can avoid this defect Heat only P or PD control OFST Function O1HY is hidden L L The ON OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest If ON OFF control is set PB1 TI1 TD1 PB2 TI2 TD2 CYC1 CYC2 OFST CPB and DB will be hidden and have no function to the system T...

Page 49: ... TD1 If the control result is still unsatisfactory then perform manual tuning to improve the control See section 3 11 for manual tuning The unit contains a algorithm to achieve a to the process if it is tuned properly very clever PID and fuzzy very small overshoot and very quick response Heat only PID control Set or for OUT1 and non zero value of proportional band and integral time Perform auto tu...

Page 50: ...ut Power Process value 100 DB 0 CPB PB1 or PB2 Output 1 Output 2 Output 2 Output 1 Case 3 Case 3 0 Output Power Process value 100 SV A1HY PB1 or PB2 Output 1 Output 2 Output 2 Output 1 Case 4 Case 4 OUT2 ALM1 ALF1 ASP1 A1HY Figure 3 3 Heat cool Control Figure 3 3 Heat cool Control Output 2 OFF Output 2 ON UM0P411A 49 ...

Page 51: ...e Heat Cool control to produce a stable and zero offset process value Other configuration required CYC1 CYC2 O1FT and O2FT CYC1 is adjusted according to the type of output device Generally select 0 5 2 sec for CYC1 if solid state relay drive or solid relay is installed for output1 10 20 sec if relay is installed for output1 and CYC1is ignored if linear output is selected Similar condition is appli...

Page 52: ...e process high alarm operation Figure 3 4 Process high alarm 1 operation Figure 3 4 Process high alarm 1 operation Output 2 on off Alarm value ASP1 ASP1 A1HY OUT2 ALM1 Output 2 on off Figure 3 5 Process low alarm 1 operation Figure 3 5 Process low alarm 1 operation Output 2 on off Process value Alarm value ASP1 A1HY ASP1 Output 2 on off A Process low alarm is independent of set point When the proc...

Page 53: ...V ASP1 SV ASP1 A1HY Output 2 on off Figure 3 7 Deviation low alarm 1 operation Figure 3 7 Deviation low alarm 1 operation Output 2 on off SV ASP1 A1HY SV ASP1 Output 2 on off Alarm value SV set point value Process value A deviation low alarm alerts the operator when the process deviates too low from set point value When the process is lower than SV ASP1 ASP1 is negative value a deviation low alarm...

Page 54: ...shows the deviation band alarm 1 opertion Figure 3 8 Deviation band alarm 1 operation Figure 3 8 Deviation band alarm 1 operation Output 2 on off Process value Alarm value SV ASP1 SV ASP1 A1HY Output 2 on off Alarm value SV ASP1 SV ASP1 A1HY SV set point value The above description is based on alarm 1 which is selected for output 2 the operations of alarm 2 and alarm 3 are same as alarm1 In the ab...

Page 55: ...or OUT4 latching A direct acting alarm output is off even if an alarm condition may occur on power up This will prevail until the alarm condition returns to the inactive condition thereafter the alarm will operate normally holding The output state is inverted as a reverse alarm output is selected for OUT2 OUT3 or OUT4 holding A direct acting and alarm performs both holding and latching alarm funct...

Page 56: ... calibration conditions after shipment Purpose of user calibration Purpose of user calibration The basic calibration of the unit is highly stable and set for life User calibration allows you to offset the permanent factory calibration to either 1 Calibrate the unit to meet your reference standard 2 Match the calibration of the unit to that of a particular transducer or sensor input 3 Calibrate the...

Page 57: ...gnal Figure 3 9 Two point user calibration Figure 3 9 Two point user calibration The two points construct a straight line For the reason of accuracy it is best to calibrate with the two points as far as possible After user calibration is complete the input type will be stored in the memory If the input type is changed a calibration error will occur and an error code is displayed UM0P411A 56 ...

Page 58: ...y produce an unstable process Note Time PV 1 sec 1 sec 1 sec 1 sec FILT 30 FILT 0 FILT 1 Figure 3 10 Filter Characteristics Figure 3 10 Filter Characteristics 3 8 Digital Filter 3 8 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 consta...

Page 59: ...be used for controlling output 1 3 If output 1 is configured as ON OFF control ie HONF or CONF is selected for OUT1 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 1 Failure Transfer Output 2 Failure Transfer if activated will perform 1 If OUT2 is configured as CTPC or CLIN and BPLS is selected for O2FT then output 2 will perfor...

Page 60: ...ect values for the configuration page Nonzero value for PB and TI should be set Set a correct password for the unit 2 Set EIFN PID2 if a second set of PID is required to be tuned 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 Then enters the A T mode The upper display will begin to flash and the auto tuning...

Page 61: ... requirement then you can try 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 If the control performance by using auto tuning is still unsatisfa...

Page 62: ...B too high PB too high PB too low PB too low Set point Set point P action P action I action I action PV Time Perfect TI too low TI too low TI too high TI too high Set point Set point D action D action PV Time Perfect TD too high TD too high TD too low TD too low Set point Set point UM0P411A 61 ...

Page 63: ... 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 RS 485 RS 232 Two types of interface are available for Data Communication These are and interface Since RS 485 uses a differential architecture to drive and sense signal instead of a single ended architecture which is u...

Page 64: ...munication according to 3 14 Retransmission 3 14 Retransmission The profiler can output retransmit process value or set point value via its retransmission terminals RE and RE provided that the retransmission option is ordered To accomplish this you can select REPV or RESP for OUT4 or OUT5 The following parameters should be configured for retransmission OP4L Low limit value for output 4 OP4H High l...

Page 65: ...in Fig 3 12 The Out L in Fig 3 12 may be 0 mA 0V 1V or 4mA and out H may be 20mA 5V or 10V according the output module installed 0 MV1 or MV2 Electrical Output 100 Out L Case 1 Case 1 Out H Low Retransmission PV or SV Electrical Output High Out L Case 2 Case 2 Out H Figure 3 12 Output scaling function Figure 3 12 Output scaling function UM0P411A 64 ...

Page 66: ...utputs depending on the modules installed A profile is executed either once repeated a set number of times or repeated continuously If repeated a set number of times then the number of cycles must be specified as part of the profile There are four types of segment Ramp The set point ramp linearly from its current value to a new value either at a rate ramp rate or in a set time ramp time you must s...

Page 67: ...run mode the profiler varies the set point according to the stored profile values Hold In hold mode the profile is forzen at its current point In this state you can make temporary changes to any profile parameter for example a target set point a dwell time or the time remaining in the current segment Such changes will only remain effective until the profile is reset and run again when they will be...

Page 68: ...heating and cooling output values can be adjusted at the lower display by up down keys Both RUN and HLD light are off Upper display flashes Lower display showes or OFF In off mode the profiler is inactive and all the outputs are disabled That is all the control outputs alarms and event outputs are off Both RUN and HLD light are off Upper display shows OFF and flashes End The profile is complete Bo...

Page 69: ... process value because this will produce a smooth and bumpless start to the process However if you want to guarantee the time period of the first segment you should set SP1 or STSP for the start point UM0P411B 68 When profile is running if it is required to modify next segment data no need to hold the current profile modifications can be done directly from the configuration If RUN and HLD LED s ar...

Page 70: ...BBD HBTY Disables Holdback no action is taken Deviation Low Holdback holds the profile back when the process value deviates below the set point by more then the holdback band HBBD Deviation high holdback holds the profile back when the process value deviates above the set point by more than the holdback band HBBD Deviation Band Holdback is a combination of the two It holds the profile back when th...

Page 71: ...mp Profile held if HBTY set to Lo or BAND Profile held if HBTY set to Hi or BAND HBBD HBBD Holdback on negative ramp Holdback on negative ramp Profile held if HBTY set to Hi or BAND Profile held if HBTY set to Lo or BAND HBBD HBBD Holdback on dwell Holdback on dwell Figure 4 2 Holdback operation Figure 4 2 Holdback operation UM0P411A 70 ...

Page 72: ...ed to bring the process value to the set point value as soon as possible this is the best choice The two diagrams below illustrate the respective responses Fig 4 3 if power fails during a dwell segment and Fig 4 4 if it fails during a ramp segment Ramp Segment Set point Set point Time t1 Segment dwell time t1 t2 Segment dwell time t1 t2 power off power off power on power on t2 Dwell Segment Figure...

Page 73: ...wer on power on t2 Ramp Segment Dwell Segment Figure 4 5 Recovery from PV at dwell segment Figure 4 5 Recovery from PV at dwell segment Figure 4 6 Recovery from PV at ramp segment Figure 4 6 Recovery from PV at ramp segment Set point Set point Time power on power on power off power off Ramp Segment Dwell Segment Target Set point Target Set point If is selected then when power is restored the profi...

Page 74: ...er SGTY Segment type TGSP Target set point RTRR Ramp time or ramp rate P2EV PID selection and event output states HBTY Holdback type DLLT Dwell time SEG Target segment number for jump segment CYCL Repeat number of cycle FSP Final set point for the end segment Segment Data Segment Data The following parameters which apply to each segment in a specific profile 4 10 Viewing and creating a profile 4 1...

Page 75: ...hat follow SGTY segment type depend on the type of segment selected as shown in the table below The function of each parameters follows the table Parameter Segment type SGTY selected 0 RAMP 1 DLL 2 JUMP 3 END TGSP RTRR P2EV HBTY DLLT SEG CYCL FSP Table 4 3 Parameters that follow segment type Table 4 3 Parameters that follow segment type Suppose that you need a profiler to control a process The res...

Page 76: ... 12 Set point 0 In order to meet the response of profiling curve example you can make a series of setting of parameters as follow Global Data Global Data STAR STSP END OFF DLAY 0 PFR PV HBT 1 00 Profile Data Profile Data PROF 1 HBBD 50 STSP 25 0 RMPU HH MM DLLU HH MM SGNO 0 SGTY RAMP TGSP 150 0 RTRR 15 P2EV 0000 HBTY 1 SGNO 1 SGTY DLL P2EV 0000 HBTY 3 DLLT 20 Segment Data Segment Data Segment 0 Se...

Page 77: ... 20 P2EV 0000 HBTY 1 SGNO 3 SGTY DLL P2EV 0000 HBTY 3 DLLT 10 Segment 2 Segment 3 Segment 4 Segment 5 Segment 6 Segment 7 SGNO 8 SGTY DLL P2EV 1010 HBTY 3 DLLT 30 SGNO 9 SGTY RAMP TGSP 450 0 RTRR 30 P2EV 1011 HBTY 2 SGNO 10 SGTY DLL P2EV 1010 HBTY 3 DLLT 20 SGNO 11 SGTY RAMP TGSP 100 0 RTRR 11 P2EV 0001 HBTY 2 SGNO 12 SGTY END CYCL 2 FSP 100 0 Segment 8 Segment 9 Segment 10 Segment 11 Segment 12 U...

Page 78: ...ction 1 6 describes how to define event status and select PID values There are two sets of PID parameters stored in the memory If the unit is in RUN or HOLD mode the PID sets are selected by the most significant bit of parameter P2EV If the unit is in STAT mode static or controller mode the PID sets are selected by event input function EIFN If the unit is in A T mode then PB1 TI1 TD1 are selected ...

Page 79: ...s the temperature falls fast An alarm is required to announce the operator as the procedure is finished Since the condition is changing when an additional heater is turned on the PID control parameter should be different from the case of single heater A P41 profiling controller is perfectly to meet the above requirements The system diagram is shown below P41 Out3 Out4 Out2 Out1 RUN HLD 58 28 LC LC...

Page 80: ...LAY 0 PFR CONT HBT 0 05 Profile Data Profile Data PROF 1 HBBD 50 RMPU HH MM DLLU HH MM SGNO 1 SGTY RAMP TGSP 400 0 RTRR 25 P2EV 0000 HBTY 1 Segment Data Segment Data SGNO 2 SGTY DLL P2EV 0000 HBTY 3 DLLT 21 SGNO 3 SGTY RAMP TGSP 1000 0 RTRR 9 P2EV 1100 HBTY 1 SGNO 4 SGTY DLL P2EV 1100 HBTY 3 DLLT 18 SGNO 5 SGTY RAMP TGSP 25 0 RTRR 15 P2EV 0001 HBTY 2 SGNO 6 SGTY END CYCL 1 FSP 25 0 Controller Conf...

Page 81: ...d 1 5 V inputs Resolution Sampling Rate Maximum Rating Temperature Effect Sensor Lead Resistance Effect Common Mode Rejection Ratio CMRR 18 bits 5 times second 2 VDC minimum 12 VDC maximum 1 minute for mA input 1 5uV C for all inputs except mA input T C 0 2uV ohm 3 wire RTD 2 6 C ohm of resistance difference of two leads 2 wire RTD 2 6 C ohm of resistance sum of two leads 200 nA 120dB A B A L L 3 ...

Page 82: ...A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 2 C A L 0 4 C A L 0 4 C A L 0 4 C A L 0 4 C A0 05 A0 05 A L 2 C A L 2 C 0 C 1767 8 C 32 F 3214 F B B 0 C 1767 8 C 32 F 3214 F B B 250 C 1300 C 418 F 2372 F 250 C 1300 C 418 F 2372 F 200 C 900 C 328 F 1652 F 200 C 900 C 328 F 1652 F 200 C 600 C 328 F 1112 F 200 C 600 C 328 F 1112 F R S N L PT...

Page 83: ...5 V 10 10 5 V 1 5 V 1 5 V 0 10 V 0 10 V Triac SSR Output Triac SSR Output Rating Inrush Current Min Load Current Max Off state Leakage Max On state Voltage Insulation Resistance Dielectric Strength 1A 240 VAC 20A for 1 cycle 50 mA rms 3 mA rms 1 5 V rms 1000 Mohms min at 500 VDC 2500 VAC for 1 minute Rating Inrush Current Min Load Current Max Off state Leakage Max On state Voltage Insulation Resis...

Page 84: ...igh Low Alarm Deviation Band High Low Alarm PV High Low Alarm Normal Latching Hold Latching Hold 0 1 4553 6 minutes Data Communication Data Communication Interface Protocol Address Baud Rate Parity Bit Communication Buffer 256 RS 232 1 unit RS 485 up to 247 units Modbus Pro ol RTU mode 1 247 2 4 38 4 Kbits sec None Even or Odd toc bytes Interface Protocol Address Baud Rate Parity Bit Communication...

Page 85: ...ling control cooling P band 50 300 of PB dead band 36 0 36 0 of PB 0 1 90 0 F hysteresis control P band 0 0 100 0 offset adjustment Fuzzy logic modified Proportional band 0 1 900 0 F Integral time 0 1000 seconds Derivative time 0 360 0 seconds 0 1 90 0 seconds Heat MV1 and Cool MV2 Cold start and warm start Auto transfer to manual mode while sensor break or A D converter damage 0 900 0 F minute or...

Page 86: ...c Strength Vibration Resistance Shock Resistance Moldings Dimensions Weight 10 C to 50 C 40 C to 60 C 0 to 90 RH non condensing 2000m maximum Degree 2 20 Mohms min at 500 VDC 2000 VAC 50 60 Hz for 1 minute 10 55 Hz 10 m s for 2 hours 200 m s 20 g Flame retardant polycarbonate P41 96mm W X 96mm H X 65mm D 53 mm depth behind panel P91 48mm W X 48mm H X 116mm D 105 mm depth behind panel P41 250 grams...

Page 87: ...ntrollers The message formats for each function are described as follows Query from master Query Response from slave Response Slave address 1 247 Function code 3 Starting address of register Hi 0 Starting address of register Lo 0 117 128 143 No of words Hi 0 No of words Lo 1 118 CRC16 Hi CRC16 Lo Byte count Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo CRC16 Hi CRC16 Lo Function 03 Read Holding Register...

Page 88: ...rting address of register Hi 0 Starting address of register Lo 0 117 128 143 No of words Hi 0 No of words Lo 1 118 Byte count 2 236 Data 1 Hi Data 1 Lo Data 2 Hi Data 2 Lo CRC16 Hi CRC16 Lo CRC16 Hi CRC16 Lo Function 16 Preset Multiple Registers Function 16 Preset Multiple Registers UM0P411A 87 ...

Page 89: ...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 Table 7 1 Exception Code Table Table 7 1 Exception Code Table 7 3 Parameter Table 7 3 Parameter Table You can refer to for the parameter description The ...

Page 90: ...0000 3 2 1 0 1 2 15536 32767 32768 32767 10000 3 2 1 0 Table 7 2 Number Conversion Table Table 7 2 Number Conversion Table 7 5 Communication Example 7 5 Communication Example Example 1 Read the real time data register 128 141 Addr Func CRC16 03 00 0x80 00 0x0E Hi Lo Query No of words No of words Starting Addr Starting Addr Example 2 Read segment 2 data of profile 3 Addr Func CRC16 06 00 0x56 00 03...

Page 91: ...Starting Addr Example 4 Enter auto tuning mode Addr Func CRC16 06 00 0x0B 00 03 Hi Lo Query Data Hi Lo Data Hi Lo Register Addr Register Addr Example 5 Enter manual mode Addr Func CRC16 06 00 0x0B 00 05 Hi Lo Query Data Hi Lo Data Hi Lo Register Addr Register Addr Example 6 Modify the Calibration coefficient Preset the CMND register with 26668 before attempting to change the calibration coefficien...

Page 92: ...gister Addr Register Addr Example 9 Create the profile which is specified in example of Fig 4 7 Addr Func END 2 END 2 0x10 00 0x50 00 02 Query Bytes Starting Addr Starting Addr 05 0x0A 00 02 00 No of words No of words STAR 2 STAR 2 DLAY 0 DLAY 0 00 00 01 00 PFR 1 PFR 1 0x64 HBT 1 00 HBT 1 00 00 CRC16 Hi Lo Addr Func PROF 1 PROF 1 0x10 0x56 00 0x0A 00 Query Starting Addr Starting Addr 00 05 01 No o...

Page 93: ...g Addr Starting Addr 03 06 00 03 00 No of words No of words P2EV 0 CRC16 Hi Lo 0x14 00 DLLT 20 Addr Func SGTY 0 SGTY 0 0x10 00 0x5B 00 02 Query Bytes Starting Addr Starting Addr 06 0x0C 00 00 00 No of words No of words SGNO 2 SGNO 2 0xC4 0x14 00 00 00 0x09 00 01 CRC16 Hi Lo TGSP 250 0 TGSP 250 0 RTRR 20 RTRR 20 P2EV 0 P2EV 0 HBTY 1 HBTY 1 Addr Func SGTY 1 0x10 00 0x5B 00 03 Query Bytes Starting Ad...

Page 94: ...of words No of words SEG 2 CRC16 Hi Lo Addr Func SGTY 1 0x10 00 0x5B 00 06 Query Bytes Starting Addr Starting Addr 02 04 00 01 00 No of words No of words SGNO 6 CRC16 Hi Lo Addr Func HBTY 3 0x10 00 0x5F 00 00 Query Bytes Starting Addr Starting Addr 03 06 00 03 00 No of words No of words P2EV 0 CRC16 Hi Lo 0x18 00 DLLT 24 Addr Func SGTY 0 0x10 00 0x5B 00 07 Query Bytes Starting Addr Starting Addr 0...

Page 95: ...i Lo 0x14 00 DLLT 20 Addr Func SGTY 1 0x10 00 0x5B 00 0x0A Query Bytes Starting Addr Starting Addr 02 04 00 01 00 No of words No of words SGNO 10 CRC16 Hi Lo Addr Func SGTY 0 SGTY 0 0x10 00 0x5B 00 0x0B Query Bytes Starting Addr Starting Addr 06 0x0C 00 00 00 No of words No of words SGNO 11 SGNO 11 0xE8 0x0B 00 00 01 0x03 00 02 CRC16 Hi Lo TGSP 100 0 TGSP 100 0 RTRR 11 RTRR 11 P2EV 1 P2EV 1 HBTY 2...

Page 96: ...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 ...

Page 97: ... scroll key then release the display will show Send a 100 ohms signal with 3 wire to the RTD input terminals Press scroll key for at least 5 seconds The display will blink a moment Otherwise if the display didn t blink then the calibration fails Step 6 Connect a K type thermocouple to the thermocouple input terminals Press the scroll key then release the display will show Apply up down key until v...

Page 98: ...for repair 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 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 reve...

Page 99: ...acement 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 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 applica...

Page 100: ...ang Rd Nan Kang Dist Taipei Taiwan R O C 115 Tel 886 2 27861299 Fax 886 2 27861395 web site http www brainchild com tw No 209 Chung Yang Rd Nan Kang Dist Taipei Taiwan R O C 115 Tel 886 2 27861299 Fax 886 2 27861395 web site http www brainchild com tw ...

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