Brainchild PR Series User manual

PR Series Process Control Card PC201 User Guide
UMPC201A
October 2016

Page 2 of 113
Warning Symbol
The Symbol calls attention to an operating procedure, practice, or the like, which, if not
correctly performed or adhered to, could result in personal injury or damage to or destruction of part
or all of the product and system. Do not proceed beyond a warning symbol until the indicated
conditions are fully understood and met.
Preface
Original equipment manufacturer reser es the right to change information a ailable in this
document without notice. Manufacturer is not liable for any damages incurred to
equipment/personal during installation or use of equipment as explained in this document. User
must acquire sufficient knowledge & skills prior to use the equipment in the application and follow
all the local standards & regulations to meet safety requirements
Copyright
The documentation and the software included with this product are copyrighted 2016 By
Brainchild Electronic Co. Ltd. All rights are reser ed. Brainchild Electronic Co., Ltd. reser es the
right to make impro ements in the products described in this manual at any time without notice.
No part of this manual may be reproduced/ copied/ translated or transmitted in any form or by any
means without the prior written permission of Brainchild Electronic Co .,Ltd. The information we
supply is belie ed to be accurate and reliable as of this printing. Howe er, we assume no
responsibility for its use.
Contact Information
Head Office & Factory
Brainchild Electronic Co. Ltd.
209 Chongyang Road, Nangang Dist.,
Taipei 11573,Taiwan
Tel: [phone] Fax: [phone]
Website: www.brainchild.com.tw
Email: [e-mail]; ser [e-mail]
China Sales Office
Brainchild Electronic (Kunshan) Co. Ltd.
Room 405, Building #6, Huamin Gentlefolk Garden
No. 13, Qianjin Central Road, Kunshan City, Jiangsu 215300, China
Tel: [phone] Fax: [phone]
Website: www.brainchild.com.cn
Email: [e-mail] ;
ser [e-mail]

Page 3 of 113
TABLE OF CONTENTS
1 INTRODUCTION ----------------------------------------------------------------------------------------------------- 8
1.1 I NTRODUCTION ----------------------------------------------------------------------------------------------------- 8
1.2 F EATURES ----------------------------------------------------------------------------------------------------------- 8
1.3 P ROCESS C ONTROL C ARD ------------------------------------------------------------------------------------------ 9
1.3.1 Flexible Configuration of Program ------------------------------------------------------------------ 11
1.3.2 Maximum Capacity of Program --------------------------------------------------------------------- 11
1.3.3 Event Input ----------------------------------------------------------------------------------------------- 11
1.3.4 Programmable Event Outputs ----------------------------------------------------------------------- 11
1.3.5 High ccuracy ------------------------------------------------------------------------------------------- 11
1.3.6 Fast Sampling Rate ------------------------------------------------------------------------------------- 11
1.3.7 Fuzzy Control -------------------------------------------------------------------------------------------- 12
1.3.8 uto-tuning ---------------------------------------------------------------------------------------------- 12
1.3.9 Lockout Protection ------------------------------------------------------------------------------------- 12
1.3.10 Bumpless Transfer -------------------------------------------------------------------------------------- 12
1.3.11 Digital Filter --------------------------------------------------------------------------------------------- 12
1.3.12 Soft-start Ramp ----------------------------------------------------------------------------------------- 12
1.3.13 Pump Control -------------------------------------------------------------------------------------------- 12
1.4 E XPANSION I/O M ODULES FOR PID ----------------------------------------------------------------------------- 12
1.4.1 PID Control Module ------------------------------------------------------------------------------------ 12
1.5 S MART M ECHANISM --------------------------------------------------------------------------------------------- 13
1.6 P ROCESS C ONTROL C ARD PC201 O RDERING C ODE ------------------------------------------------------------- 13
1.7 S PECIFICATION ---------------------------------------------------------------------------------------------------- 14
1.7.1 Input1 ----------------------------------------------------------------------------------------------------- 14
1.7.2 Input2 ----------------------------------------------------------------------------------------------------- 15
1.7.3 Input3 (Event Input) ------------------------------------------------------------------------------------ 16
1.7.4 Output1/Output2 --------------------------------------------------------------------------------------- 16
1.7.5 larm 1/ larm 2 --------------------------------------------------------------------------------------- 17
1.7.6 Control Mode -------------------------------------------------------------------------------------------- 17
1.7.7 Digital Filter --------------------------------------------------------------------------------------------- 18
2 INSTALLATION AND WIRING----------------------------------------------------------------------------------- 19
2.1 U NPACKING ------------------------------------------------------------------------------------------------------- 19
2.2 I NPUT O UTPUT W IRING C ONNECTION --------------------------------------------------------------------------- 20
2.2.1 Wiring Precautions ------------------------------------------------------------------------------------- 20
2.2.2 PID Control Module ------------------------------------------------------------------------------------ 20
3 PROCESS CONTROL CARD FEATURES ----------------------------------------------------------------------- 22
3.1 C ONFIGURATION -------------------------------------------------------------------------------------------------- 22
3.2 C ONTROLLER ------------------------------------------------------------------------------------------------------ 22
3.3 R AMP & D WELL F UNCTION -------------------------------------------------------------------------------------- 22
3.4 O N F IELD C ALIBRATION ------------------------------------------------------------------------------------------- 22
4 PROCESS CONTROL CARD FUNCTIONS ---------------------------------------------------------------------- 23
4.1 M ENUS ------------------------------------------------------------------------------------------------------------ 23
4.2 S TATUS B AR ------------------------------------------------------------------------------------------------------- 32

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4.3 P ROCESS C ONTROL C ARD C ONFIGURATION --------------------------------------------------------------------- 33
4.3.1 Process Control Card Configuration ---------------------------------------------------------------- 34
4.3.1.1 Controller --------------------------------------------------------------------------------------------------------- 35
4.3.1.1.1 Name ---------------------------------------------------------------------------------------------------------- 36
4.3.1.1.2 Parameter ---------------------------------------------------------------------------------------------------- 36
4.3.1.1.3 Channel ------------------------------------------------------------------------------------------------------- 72
4.3.1.1.4 Sample Configuration of Process Control Card ------------------------------------------------------ 76
4.3.1.1.4.1 eat Only ON-OFF Control ------------------------------------------------------------------------- 76
4.3.1.1.4.2 Cool Only ON-OFF Control -------------------------------------------------------------------------- 78
4.3.1.1.4.3 eat Cool Control ------------------------------------------------------------------------------------ 78
4.3.1.1.4.4 eater Break Alarm ---------------------------------------------------------------------------------- 80
4.3.1.1.4.5 Loop Break Alarm ------------------------------------------------------------------------------------ 81
4.3.1.1.4.6 Sensor Break Alarm ---------------------------------------------------------------------------------- 81
4.3.1.1.4.7 Failure Transfer --------------------------------------------------------------------------------------- 82
4.3.1.1.4.8 Bumpless Transfer ----------------------------------------------------------------------------------- 83
4.3.1.1.4.9 PV1 Shift ------------------------------------------------------------------------------------------------ 84
4.3.1.1.4.10 SP1 Range --------------------------------------------------------------------------------------------- 85
4.3.1.1.4.11 Dwell Timer ------------------------------------------------------------------------------------------ 85
4.3.1.1.4.12 Process Alarms -------------------------------------------------------------------------------------- 86
4.3.1.1.4.13 Deviation Alarm ------------------------------------------------------------------------------------- 88
4.3.1.1.4.14 Deviation Band Alarm ------------------------------------------------------------------------------ 90
4.3.1.1.4.15 Event Input ------------------------------------------------------------------------------------------- 91
4.3.1.1.4.16 Second Set Point ------------------------------------------------------------------------------------ 93
4.3.1.1.4.17 Second PID Set --------------------------------------------------------------------------------------- 93
4.3.1.1.4.18 Ramp & Dwell ---------------------------------------------------------------------------------------- 94
4.3.1.1.4.19 Remote Set Point ----------------------------------------------------------------------------------- 96
4.3.1.1.4.20 Differential Control --------------------------------------------------------------------------------- 97
4.3.1.1.4.21 Output Power Limit--------------------------------------------------------------------------------- 98
4.3.1.1.4.22 Digital Filter ------------------------------------------------------------------------------------------ 98
4.3.1.1.4.23 Auto-Tuning and Manual Tuning ---------------------------------------------------------------- 99
4.3.1.2 Ramp & Dwell(Profile) ----------------------------------------------------------------------------------------- 102
4.3.1.2.1 Ramp & Dwell: --------------------------------------------------------------------------------------------- 103
4.3.1.2.2 Segments: --------------------------------------------------------------------------------------------------- 104
4.3.1.2.2.1 Ramp Segment Parameters: ---------------------------------------------------------------------- 105
4.3.1.2.2.2 Dwell Segment Parameters: ---------------------------------------------------------------------- 108
4.3.1.2.2.3 Go Back Segment Parameters: ------------------------------------------------------------------- 108
4.3.1.2.2.4 End Segment Parameters: ------------------------------------------------------------------------- 108
4.3.1.2.2.5 Time to Target Segment Parameters: ----------------------------------------------------------- 109
4.3.1.2.3 Start/End Jobs ---------------------------------------------------------------------------------------------- 109
4.3.1.2.4 Start/Stop Profile(Ramp &Dwell) ---------------------------------------------------------------------- 109
4.4 D ISPLAY ---------------------------------------------------------------------------------------------------------- 111
5 APPLICATION ----------------------------------------------------------------------------------------------------- 112
5.1 O VEN C ONTROL WITH Z ONE T EMPERATURE R ECORDING ------------------------------------------------------ 112

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Table of Figure
Figure 1-1.Fuzzy PID System Block Diagram ...................................................................................................... 9
Figure 1-2.PID System Stability with an without Fuzzy ................................................................................... 10
Figure 2-1.Process Control Car Wiring Diagram ............................................................................................. 21
Figure 3-1.Configuration Layout ..................................................................................................................... 22
Figure 4-1.Home Screen ................................................................................................................................. 23
Figure 4-2.Menu Screen ................................................................................................................................. 24
Figure 4-3.Real Time Menu ............................................................................................................................ 24
Figure 4-4.Overview Display .......................................................................................................................... 25
Figure 4-5.PID Controller Mo ule Display ....................................................................................................... 25
Figure 4-6.Display Mo es .............................................................................................................................. 26
Figure 4-7.Real Time Alarms .......................................................................................................................... 26
Figure 4-8.Historical Data Screen ................................................................................................................... 27
Figure 4-9.Event History ................................................................................................................................ 28
Figure 4-10.Report Screen ............................................................................................................................. 29
Figure 4-11.More Menu ................................................................................................................................. 29
Figure 4-12.Operate Menu ............................................................................................................................. 30
Figure 4-13.Configuration Layout ................................................................................................................... 31
Figure 4-14.More Menu ................................................................................................................................. 32
Figure 4-15.Status Bar During Logging ............................................................................................................ 32
Figure 4-16.Status Bar During Logging Stoppe ............................................................................................... 32
Figure 4-17.Status Bar uring Logging with Batch function ............................................................................. 32
Figure 4-18.Status Bar During Logging Stoppe with Batch Function ................................................................ 32
Figure 4-19.Tree Type Configuration Layout ................................................................................................... 33
Figure 4-20.Process Control Car Channel Configuration ................................................................................. 35
Figure 4-21.Process Control Car Channel Configuration ................................................................................. 36
Figure 4-22.Process Control Car Configuration Win ow ................................................................................. 37
Figure 4-23.Process Control Car Configuration Win ow for Rea only Parameter ........................................... 37
Figure 4-24.Process Control Car Channel Configuration ................................................................................. 72
Figure 4-25.Log Spee ................................................................................................................................... 74
Figure 4-26.Events with Job ........................................................................................................................... 74
Figure 4-27. Event Configuration Example ...................................................................................................... 76
Figure 4-28.Heat Only ON-OFF Control ........................................................................................................... 77
Figure 4-29.Cool Only ON-OFF Control ............................................................................................................ 78
Figure 4-30. Heater Break Alarm .................................................................................................................... 80
Figure 4-31.Without Bumpless Transfer .......................................................................................................... 83
Figure 4-32.With Bumpless Transfer ............................................................................................................... 84
Figure 4-33.PV1 SHIFT Application.................................................................................................................. 85
Figure 4-34.SP1 Range ................................................................................................................................... 85
Figure 4-35.Dwell Timer ................................................................................................................................. 86
Figure 4-36.Normal Process Alarm ................................................................................................................. 87
Figure 4-37.Latching Process Alarm ................................................................................................................ 87
Figure 4-38.Hol ing Process Alarm ................................................................................................................. 88
Figure 4-39.Latching / Hol ing Process Alarm ................................................................................................. 88
Figure 4-40.Normal Deviation Alarm .............................................................................................................. 89
Figure 4-41.Latching Deviation Alarm ............................................................................................................. 89
Figure 4-42.Hol ing Deviation Alarm .............................................................................................................. 89
Figure 4-43.Latching/Hol ing Deviation Alarm ................................................................................................ 90
Figure 4-44.Normal Deviation Ban Alarm ...................................................................................................... 90
Figure 4-45.Latching Deviation Ban Alarm .................................................................................................... 91
Figure 4-46.Hol ing Deviation Ban Alarm ..................................................................................................... 91

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Figure 4-47.Latching/Hol ing Deviation Ban Alarm ....................................................................................... 91
Figure 4-48.Ramp Function ............................................................................................................................ 94
Figure 4-49.Dwell Timer ................................................................................................................................. 95
Figure 4-50.Ramp Accompanie with Dwell Timer .......................................................................................... 96
Figure 4-51.Relationship Between PV1 & PV2 for Differential Control .............................................................. 97
Figure 4-52.Power Limit Function ................................................................................................................... 98
Figure 4-53.Filter Characteristics .................................................................................................................... 99
Figure 4-54.Process Control Mo ule Real time .............................................................................................. 100
Figure 4-55.Auto-Tuning .............................................................................................................................. 100
Figure 4-56.Auto-Tuning In progress ............................................................................................................. 101
Figure 4-57.Manual Tuning In Progress ......................................................................................................... 101
Figure 4-58.Ramp & Dwell Configuration Win ow ........................................................................................ 102
Figure 4-59.Set Point Profile ........................................................................................................................ 103
Figure 4-60.Ramp Segment .......................................................................................................................... 105
Figure 4-61.Hol Back on Dwell .................................................................................................................... 107
Figure 4-62.Hol Back on Positive Ramp ....................................................................................................... 107
Figure 4-63.Hol Back Negative Ramp .......................................................................................................... 107
Figure 4-64.Dwell Segment .......................................................................................................................... 108
Figure 4-65.Go Back Segment....................................................................................................................... 108
Figure 4-66.En Segment ............................................................................................................................. 108
Figure 4-67.Time To Target Segment ............................................................................................................ 109
Figure 4-68.Profile Start/En Job .................................................................................................................. 109
Figure 4-69.Run Profile ................................................................................................................................ 110
Figure 4-70.Profile Running.......................................................................................................................... 110
Figure 5-1.Oven Control with Zone Temperature Recor ing .......................................................................... 112
Figure 5-2. Oven Control with Zone Temperature Recor ing System .............................................................. 113

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Table of Table
Table 1-1. Input 1 Characteristics ................................................................................................................... 15
Table 1-2. Input 2 Characteristics ................................................................................................................... 16
Table 1-3. Output Characteristics ................................................................................................................... 16
Table 1-4. SSR Output Characteristics ............................................................................................................. 17
Table 2-1.Environmental Specification ........................................................................................................... 19
Table 4-1.PID Parameter List .......................................................................................................................... 47
Table 4-2.Process Control Car Input Range ................................................................................................... 48
Table 4-3.Range of A1SP ................................................................................................................................ 48
Table 4-4.Range of A2SP ................................................................................................................................ 48
Table 4-5.Range Of SP2 .................................................................................................................................. 48
Table 4-6.Mo e Selection .............................................................................................................................. 49
Table 4-7.Communication Mo e .................................................................................................................... 49
Table 4-8.Communication Protocol ................................................................................................................ 50
Table 4-9.Communication Bau Rate ............................................................................................................. 50
Table 4-10.Communication Data Length ......................................................................................................... 51
Table 4-11.Communication Parity .................................................................................................................. 51
Table 4-12.Communication Stop Bit ............................................................................................................... 51
Table 4-13 Function of AOFN ......................................................................................................................... 52
Table 4-14 Selection of IN1 Type .................................................................................................................... 53
Table 4-15.Display Unit for IN1 & IN2 ............................................................................................................. 53
Table 4-16.Decimal Digit for DP1&DP2 ........................................................................................................... 53
Table 4-17.IN2 Input ...................................................................................................................................... 54
Table 4-18.EIFN Function ............................................................................................................................... 55
Table 4-19.OUT1 Action ................................................................................................................................. 55
Table 4-20.OUT1 & OUT2 Type ....................................................................................................................... 55
Table 4-21.OUT2 Function ............................................................................................................................. 56
Table 4-22.Display Function ........................................................................................................................... 56
Table 4-23. Alarm1 & Alarm 2 Function .......................................................................................................... 57
Table 4-24.Alarm1 & Alarm2 Operation Mo e ................................................................................................ 57
Table 4-25.Alarm1 & Alarm2 Failure Transfer Mo e ....................................................................................... 58
Table 4-26.Auto Tuning ................................................................................................................................. 58
Table 4-27.Sleep Mo e .................................................................................................................................. 58
Table 4-28.PV Mo e Selection ....................................................................................................................... 59
Table 4-29.SP2 Set Point Format .................................................................................................................... 59
Table 4-30 Filter Damping Time Constant of PV .............................................................................................. 59
Table 4-31 Set Point Mo e Selection .............................................................................................................. 60
Table 4-32 SEL Selection ................................................................................................................................ 61
Table 4-33 Default File Selection .................................................................................................................... 61
Table 4-34.Error Co es an Corrective Actions................................................................................................ 68
Table 4-35 PROG CODE .................................................................................................................................. 69
Table 4-36 Mo e ........................................................................................................................................... 70
Table 4-37.Unit Determination for A1SP,A1DV,A1HY ...................................................................................... 70
Table 4-38.Unit Determination for A2SP,A2DV,A2HY ...................................................................................... 71
Table 4-39.RAMP Unit ................................................................................................................................... 71
Table 4-40 .Unit Determination of AOLO & AOHI ............................................................................................ 71
Table 4-41.Heat Cool Control Mo es .............................................................................................................. 79

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1 Introduction
1.1 Introduction
Generally most of the furnace applications require Controller and Recorder separately to
control and record the data. Some Furnaces application requires Ramp & Dwell controllers .The
new generation Paperless Recorder pro ides PID Control, Ramp & Dwell Control and Recording in
one de ice by using the new process control Card PC201 . This is a single loop controller for
Furnace applications. This will reduce Cost ,Space ,Wiring required for using controller and
Recorder separately.
1.2 Features
The Process Control Card has lot of unique Features on its hardware and Software. The
unique Features are listed below.
 PID Controller, Ramp & Dwell Controller and Recorder 3 in one De ice
 Plug and Play I/O Options
 18-bit Uni ersal input A-D for PID Control
 15-bit output D-A
 Fuzzy + PID microprocessor-based control
 Fast input sampling rate 200msec for PID Control
 Two le el of function complexity
 50 Profiles,1000 Segments in Total
 Differential control
 Auto-tuning and Self Tuning function
 Sleep mode function
 " Soft-start " Ramp and Dwell timer
 Uni ersal inputs( Thermocouple, RTD, mA, VDC )
 Analog input for remote set point and CT
 E ent input for changing function & set point
 Programmable digital filter
 Hardware lockout + remote lockout protection
 Loop break alarm
 Heater break alarm
 Sensor break alarm + Bumpless transfer
 Pump control

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 100msec Sampling rate and log speed for Data Acquisition
 Real time and Historical Trends for PV and SV
1.3 Process Control Card
The Process Control Card uses Fuzzy Logic plus PID microprocessor technology for its
control. The Fuzzy Logic plus PID microprocessor based technology enables a process to reach a
predetermined set point in the shortest time, with the minimum of o ershoot during power-up or
external load disturbance. The module can be easily plugging into the rear side IO slots of the
paperless recorder. Various control and input parameters can be configured easily by using the
touch screen menus and na igations.
This Process Control Card can be configured by using the Configuration Menu on the
de ice or by using the PC Based Configuration Software.
E en though PID control has been used and pro ed to be an efficient controlling method
by many industries for more than a decade, yet the PID is difficult to deal with some sophisticated
systems such as second and higher order systems, long time-lag systems, during set point change
and/or load disturbance circumstance etc. The PID principle is based on a mathematic modeling
which is obtained by tuning the process. Unfortunately many systems are too complex to describe
in numerical terms precisely. In addition to these, systems may be ariable from time to time. In
order to o ercome the imperfection of PID control, the Fuzzy Technology is introduced.
What is the Fuzzy Control? It works like a good dri er. Under different speeds and
circumstances, he can control a car well with experiences he had before and does not require the
knowledge of kinetic theory of motion. The Fuzzy Logic is a linguistic control which is different from
the numerical PID control. It controls the system by experiences and does not need to simulate the
system precisely as been controlled by PID.
Figure 1-1.Fuzzy PID System Block Diagram

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The function of Fuzzy Logic is to adjust PID parameters internally in order to make
manipulation output alue MV more flexible and adapti e to arious processes.PID + Fuzzy Control
has been pro en to be an efficient method to impro e the control stability as shown by the
comparison of cur es shown below.
Figure 1-2.PID System Stability with and without Fuzzy
The Fuzzy Rule works like the below.
 If temperature difference is large and temperature rate is large, then MV is large.
 If temperature difference is high and temperature rate is small, then MV is small.
By using proprietary Fuzzy modified PID technology the control loop will minimize the
o ershoot and undershoot in a shortest time.
This Process Control Card can be configured as a single set point controller (static mode)
or a ramp and dwell profiling controller (profile mode). The profile mode feature allows the user to
program up to 50 profiles with up to 32 free format Segments (ramp, dwell, jump or end) each. The
total segments a ailable for the product are 1000 segments.
The Process Control Card contains the following features.

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1.3.1 Flexible Configuration of Program
There are up to 32 segments can be defined for a profile. Each segment can be configured
as a ramp or a dwell (soak) segment or defining a repeat number of cycles at arbitrary location
within the profile and finally terminated by an end segment. The user can edit a currently running
profile.
1.3.2 Maximum Capacity of Program
There are at most 50 Profiles can be defined and 1000 segments totally a ailable for all
profiles. Each Profile can contain maximum of 32 Segments and limited to 1000 Segments in Total.
1.3.3 Event Input
The E ent input feature allows the user to select one of eight functions below.
 Enter Profile Run Mode
 Enter Profile Hold Mode
 Abort Profile Mode
 Enter Manual Mode
 Perform Failure Transfer
 Enter Off Mode
 Ad ance to the next segment
 Select second set of PID alues
1.3.4 Programmable Event Outputs
Up to 3 Relays are configurable for e ent outputs and the state of each output can be
defined for each segment and end of profile.
1.3.5 High Accuracy
This Process Control Card is manufactured with custom designed ASIC(Application
Specific Integrated Circuit ) technology which contains a 18-bit A to D con erter for high resolution
measurement ( true 0.1 F resolution for thermocouple and PT100 ) and a 15-bit D to A con erter for
linear current or oltage control output. The ASIC technology pro ides impro ed operating
performance with low cost and enhanced reliability and higher density.
1.3.6 Fast Sampling ate
The sampling rate of the input A to D con erter reaches 5 times/second (200msec). The
fast sampling rate allows this Process Control Card to control fast processes.

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1.3.7 Fuzzy Control
The function of Fuzzy control is to adjust PID parameters from time to time in order to
make manipulation output alue more flexible and adapti e to arious processes. The results are to
enable a process to reach a predetermined set point in the shortest time with the minimum of
o ershoot and undershoot during power-up or external load disturbance.
1.3.8 Auto-tuning
The auto-tuning function allows the user to simplify initial setup for a new system. A
cle er algorithm is pro ided 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 ).
1.3.9 Lockout Protection
According to actual security requirement, a password is pro ided to pre ent the unit from
being changed abnormally.
1.3.10 Bumpless Transfer
Bumpless transfer allows the controller to continue to control by using its pre ious alue as
the sensor breaks. Hence, the process can be well controlled temporarily as like the sensor is
normal.
1.3.11 Digital Filter
A first order low pass filter with a programmable time constant is used to impro e the
stability of process alue. This is particularly useful in certain application where the process alue is
too unstable to read.
1.3.12 Soft-start amp
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 alue will reach the set point with a
predetermined constant rate.
1.3.13 Pump Control
In addition the fast sampling rate, this Process Control Card has superior noise rejection
capability. So it can be used for pressure control of a Pump which is dri en by Variable Frequency
Dri es.
1.4 Expansion I/O Modules for PID
The Paperless Recorder ha e the option to use PID function on it by using the
Process Control Card in to it on the one of the 4 rear slots .
1.4.1 PID Control Module
This module is useful for single loop PID Control. This consists of Two
Signal Inputs, one E ent Input and control output and Alarm output as per the specification.

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1.5 mart Mechanism
The data is recorded in manufacturer special binary format. It is not possible to manipulate
the data. This feature guarantees the security and reliability of the recorded data .
1.6 Process Control Card PC201 Ordering Code
PC201- □ □ □ □
A B C D
A: Output 1
0: None
1: Relay 2A/240VAC
2: Pulse voltage to drive SSR, 5V/30 A
3: Isolated 4-20 A/0-20 A (OM95-3)
4: Isolated 1-5V/0-5V (OM95-4)
5: Isolated 0-10V (OM95-5)
6: Triac output 1A/240VAC,SSR
C: Pulse voltage to drive SSR, 14V/40 A (OM94-7)
B: Output 2
0: None
1: Relay 2A/240VAC
2: Pulse voltage to drive SSR, 5V/30 A
3: Isolated 4-20 A/0-20 A (OM95-3)
4: Isolated 1-5V/0-5V (OM95-4)
5: Isolated 0-10V (OM95-5)
6: Triac output 1A/240VAC,SSR
7: Isolated 20VDC/25 A power supply (DC94-1)
8: Isolated 12VDC/40 A power supply (DC94-2)
9: Isolated 5VDC/80 A power supply (DC94-3)
C: Pulse voltage to drive SSR, 14V/40 A (OM94-7)
C: Alarm 1
0: None
1: For C relay 2A/240VAC
D: Alarm 2
0: None
1: For A relay 2A/240VAC

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1.7 pecification
1.7.1 Input1
Resolution: 18 bits
Sampling Rate: 5 times / second
Maximum Rating: -2 VDC minimum, 12 VDC maximum (1 minute for mA input)
Temperature Effect: 1.5uV/°C for all inputs except mA input, ±3.0uV/°C for mA input
Sensor Lead Resistance Effect:
T/C: 0.2uV/ohm;
3-wire RTD: 2.6°C/ohm of resistance difference of two leads;
2-wire RTD: 2.6° C/ohm of resistance sum of two leads
Burn-out Current: 200nA
Common Mode Rejection Ratio (CMRR): 120dB
Normal Mode Rejection Ratio (NMRR): 55dB
Sensor Break Detection:
Sensor Open for TC, RTD and mV inputs
Sensor short for RTD input
Below 1 mA for 4-20 mA input,
Below 0.25V for 1 - 5 V input,
Una ailable for other inputs.
Sensor Break Responding Time:
Within 4 seconds for TC, RTD and mV inputs,
0.1 second for 4-20 mA and 1 - 5 V inputs.
Characteristics:
Type Range Accuracy @ 25°C Input Impedance
J -120°C to 1000°C ( -184°F to 1832°F ) ±2°C 2.2 MΩ
K -200C to 1370 C ( -328°F to 2498°F ) ±2°C 2.2 MΩ
T -250°C to 400°C ( -418°F to 752°F ) ±2°C 2.2 MΩ
E -100°C to 900°C( -148°F to 1652°F ) ±2°C 2.2 MΩ
B 0°C to 1800°C( 32°F to 3272°F ) ±2°C( 200°C to 1800° C ) 2.2 MΩ

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Type Range Accuracy @ 25°C Input Impedance
R 0°C to 1767.8°C( 32°F to 3214°F ) ±2°C 2.2 MΩ
S 0°C to 1767.8°C( 32°F to 3214°F ) ±2°C 2.2 MΩ
N -250°C to 1300°C( -418°F to 2372°F ) ±2°C 2.2 MΩ
L -200°C to 900°C( -328°F to 1652°F ) ±2°C 2.2 MΩ
PT100(DIN) -210°C to 700°C ( -346°F to 1292°F ) ±0.4°C 1.3KΩ
PT100(JIS) -200°C to 600°C( -328°F to 1112°F ) ±0.4°C 1.3Ω
mV -8mV to 70mV ±0.05% 2.2 MΩ
mA -3mA to 27mA ±0.05% 70.5Ω
V -1.3V to 11.5V ±0.05% 302KΩ
able 1-1. Input 1 Characteristics
1.7.2 Input2
Resolution: 18 bits
Sampling Rate: 5 times / second
Maximum Rating: -2 VDC minimum, 12 VDC maximum (1 minute for mA input)
Temperature Effect: 1.5uV/°C for all inputs except mA input, ±3.0uV/°C for mA input
Common Mode Rejection Ratio (CMRR): 120dB
Normal Mode Rejection Ratio (NMRR): 55dB
Sensor Break Detection:
Below 1 mA for 4-20 mA input,
Below 0.25V for 1 - 5 V input,
Una ailable for other inputs.
Sensor Break Responding Time: 0.5 Seconds
Characteristics:
Type Range Accuracy @ 25°C Input Impedance
CT94-1 0.0 to 50.0 A ±2% of Reading ±0.2A 302KΩ

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Type Range Accuracy @ 25°C Input Impedance
mA -3mA to 27mA ±0.05% 70.5Ω+(0.8V/Input Current)
V -1.3V to 11.5V ±0.05% 302KΩ
able 1-2. Input 2 Characteristics
1.7.3 Input3 (Event Input)
Logic Low: -10V minimum, 0.8V maximum.
Logic high: 2V minimum, 10V maximum
External pull-down Resistance: 400 KΩ maximum
External pull-up Resistance: 1.5 MΩ minimum
Functions: Select second set point and/or PID, Reset alarm 1 and/or alarm 2,
Disable output 1 and/or output 2, Remote lockout.
1.7.4 Output1/Output2
Relay Rating: 2A/240 VAC, life cycles 200,000 for Resisti e load
Pulsed Voltage: Source Voltage 5V, current limiting resistance 66Ω
Linear Output Characteristics:
Type Zero Tolerance Span Tolerance Load Capacity
4 to 20mA 3.8-4 mA 20-21 mA 500 Ω max
0 to 20mA 0 mA 20-21 mA 500 Ω max
0 to 5V 0 V 5 -5.25 V 10KΩ min
1 to 5V 0.95 to 1V 5 -5.25 V 10KΩ min
0 to 10V 0 V 10 - 10.5 V 10KΩ min
able 1-3. Output Characteristics
Linear Output
Resolution: 15 bits
Output Regulation: 0.01 % for full load change
Output Settling Time: 0.1 sec. (stable to 99.9 %)
Isolation Breakdown Voltage: 1000 VAC

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Temperature Effect: ±0.0025 % of SPAN /°C
Triac (SSR) Output
Rating: 1A / 240 VAC
Inrush Current: 20A for 1 cycle
Min. Load Current: 50 mA RMS
Max. Off-state Leakage: 3 mA RMS
Max. On-state Voltage: 1.5 V RMS
Insulation Resistance: 1000 MΩ minimum at 500 VDC
Dielectric Strength: 2500 VAC for 1 minute
Type Tolerance Maximum Output Current Ripple Voltage Isolation Barrier
20V ±0.5 V 25 mA 0.2 Vp-p 500 VAC
12V ±0.3 V 40 mA 0.1 Vp-p 500 VAC
5V ±0.15 V 80 mA 0.05 Vp-p 500 VAC
able 1-4. SSR Output Characteristics
1.7.5 Alarm 1/ Alarm 2
Alarm 1 Relay: Form A or Form B, Max. Rating 2A/240VAC, life cycles 100,000 for
resisti e load.
Alarm 2 Relay: Form A, Max. Rating 2A/240VAC, life cycles 200,000 for resisti e load.
Alarm Mode: Normal, Latching, Hold, Latching / Hold.
Dwell Timer: 0 - 6553.5 minutes
Alarm Functions: Dwell timer, De iation High / Low Alarm, De iation Band High / Low
Alarm, PV1 High / Low Alarm, PV2 High / Low Alarm, PV1 or PV2 High
/ Low Alarm, PV1-PV2 High / Low Alarm, Loop Break Alarm, Sensor
Break Alarm.
1.7.6 Control Mode
Output 1: Re erse (heating) or direct (cooling) action
Output 2: PID cooling control, cooling P band 1~255% of PB
ON-OFF: 0.1 - 100.0(F) hysteresis control (P band = 0)
P or PD: 0 - 100.0 % offset adjustment

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PID: Fuzzy logic modified Proportional band 0.1 ~ 900.0°F, Integral time: 0 - 1000
Seconds, Deri ati e time 0 - 360.0 seconds
Cycle Time: 0.1 - 100.0 seconds
Manual Control: Heat (MV1) and Cool (MV2)
Auto-tuning: (MV2) Cold start and warm start
Self-tuning: Select None and YES
Failure Mode: Auto-transfer to manual mode while sensor break or A-D con erter damage
Sleep Mode: Enable or Disable
Ramping Control: 0 - 900.0°F/minute or 0 - 900.0°F/hour ramp rate
Power Limit: 0 - 100 % output 1 and output 2
Pump / Pressure Control: Sophisticated functions pro ided
Remote Set Point: Programmable range for oltage or current input
Differential Control: Control PV1-PV2 at set point
1.7.7 Digital Filter
Function: First Order
Time Constant: 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60 seconds programmable

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2 In tallation and Wiring
Some times Dangerous oltages capable of causing death are present in this instrument. Before
doing installation or any troubleshooting procedures the power to the equipment must be switched off and
isolated. Units suspected of being faulty must be disconnected and remo ed 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
excessi e moisture
Do not use this instrument in areas under hazardous conditions such as excessi e shock,
ibration, dirt, moisture, corrosi e gases or oil. The ambient temperature of the areas should not
exceed the maximum rating specified in the specification
2.1 Unpacking
Upon receipt of the shipment remo e the unit from the carton and inspect the unit for
shipping damage. If any damage found then contact local representati e immediately. Note the
model number, serial number for future reference when corresponding with our ser ice center. The
serial number (S/N) is labeled on the box and the housing of Paperless Recorder
Remo e stains from this equipment using a soft, dry cloth. Do not use harsh chemicals,
olatile sol ents such as thinner or strong detergents to clean the equipment in order to a oid
deformation.
The Paperless Recorder is designed for indoor use and not in any hazardous area. It
should be kept away from shock, ibration, and electromagnetic fields such as ariable frequency
dri es, motors and transformers. It is intended to operate under the following en ironmental
conditions.
Environmental Parameter Specification
Operating Temperature 0°C to 50 °C
Humidity 20% to 90% H(Non-condensing)
Altitude 2000 M Maximum
able 2-1.Environmental Specification

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2.2 Input Output Wiring Connection
2.2.1 Wiring Precautions
Sometimes Dangerous oltages capable of causing death are present in this
instrument. Before doing installation or any troubleshooting procedures the power to the equipment
must be switched off and isolated. Units suspected of being faulty must be disconnected and
remo ed to a properly equipped workshop for testing and repair. Component replacement and
internal adjustments must be made by a qualified maintenance person only.
 Utmost Care must be taken to ensure that the maximum oltage rating specified on
the label is not exceeded.
 It is recommended to use an external fuse or an external switch rated at 2A/250
VAC for panel mount type wiring.
 The tightening torque on the Screw terminals should not exceed 0.4 N-m (3.6 Lb-in
or 4.0 Kg F-cm).
 Except Thermocouple Wiring, all other wires used to be Standard Copper
Conductor With maximum Gauge of 18AWG
 Grounding must be connected prior to turning on the Equipment with minimum of
1.6mm diameter conductor for protecti e grounding.
2.2.2 PID Control Module
This is a single loop PID Control Module which consists of Uni ersal Input.
The Modules needs to be inserted to the rear slots or removed from the rear slots at
the Power OFF condition. Failure to do so may cause damage to the module or device or
both. The De ice will automatically detect the Module at Power ON, once it is inserted in to the rear
slots.
The Module output can be configured by using the configuration Menu. The configuration
Menu can be reached by pressing Menu and then pressing More and then pressing Config key. It
will display a tree type configuration layout for easy user configuration. By using Up/Down Key and
Enter Key, PID Controller and Profile configuration window can be reached. In this window the user
can configure the Controller parameters and profiles of PID Control Module. The user can select the
desired output type and other parameters for analog output in this window.