User's Manual User's Manual

User's Manual
BTC-2500
Self-Tune Fuzzy / PID
Process / Temperature Controller
BRAINCHILD
UM25001G
Warning Symbol
The Symbol calls attention to an operating procedure, practice, or the like, which, if not correctly performed or
adhered to, could result in personal injury or damage to or destruction of part or all of the product and system.
Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met.
Use the Manual

Installers Read Chapter 1, 2
Basic Function User Read Chapter 1, 3, 5
Enhanced Function User Read Chapter 1, 3, 4, 5
System Designer Read All Chapters
Expert User Read Page 11
2 UM25001C
CONTENTS
Page No Page No
Chapter 1 Overview
1-1 Features 4 3-21 Manual Tuning 61
1-2 Ordering Code 7 3-22 Signal Conditioner DC Power Supply 64
1-3 Programming Port and DIP Switch 8 3-23 Manual Control 65
1-4 Keys and Displays 9 3-24 Display Mode 66
1-5 Menu Overview 11 3-25 Heater Current Monitoring 67
1-6 System Modes 12 3-26 Reload Default Values 67
1-7 Parameter Description 13
Chapter 4 Programming the Full Function
Chapter 2 Installation 4-1 Event Input 68
2-1 Unpacking 21
4-2 Second Set Point 69
2-2 Mounting 21
4-3 Second PID Set 70
2-3 Wiring Precautions 22
4-4 Ramp & Dwell 71
2-4 Power Wiring 23
4-5 Remote Set Point 73
2-5 Sensor Installation Guidelines 24
4-6 Differential Control 74
2-6 Thermocouple Input Wiring 25
4-7 Output Power Limits 75
2-7 RTD Input Wiring 26
4-8 Data Communication 76
2-8 Linear DC Input Wiring 26
4-9 Analog Retransmission 77
2-9 CT / Heater Current Input Wiring 28
4-10 Digital Filter 78
2-10 Event Input wiring 29
4-11 Sleep Mode 79
2-11 Output 1 Wiring 30
4-12 Pump Control 80
2-12 Output 2 Wiring 32
4-13 Remote Lockout 81
2-13 Alarm 1 Wiring 34
2-14 Alarm 2 Wiring 35 Chapter 5 Applications
2-15 RS-485 36 5-1 Pump / Pressure Control 82
2-16 RS-232 37 5-2 Variable Period Full Wave SSR ( VPFW SSR ) 84
2-17 Analog Retransmission 38 5-3 Heat Only Control 86
2-18 Programming Port 39 5-4 Cool Only Control 87
5-5 Heat - Cool Control 88
Chapter 3 Programming the Basic Function
5-6 Ramp & Dwell 90
3-1 Input 1 40
5-7 Remote Set Point 92
3-2 OUT1 & OUT2 Types 41
5-8 Differential Control 93
3-3 Rearrange User Menu 42
5-9 Dual Set Point / PID 94
3-4 Display SV Instead of PV 42
5-10 RS-485 96
3-5 Heat Only Control 43
5-11 RS-232 98
3-6 Cool Only Control 44
5-12 Retransmit 99
3-7 Heat - Cool Control 45
3-8 Dwell Timer 47 Chapter 6 Calibration 100
3-9 Process Alarms 48
3-10 Deviation Alarms 50 Chapter 7 Error Codes & Troubleshooting 104
3-11 Deviation Band Alarms 51 Chapter 8 Specifications 107
3-12 Heater Break Alarm 52
3-13 Loop Break Alarm 53 Appendix
3-14 Sensor Break Alarm 54 A-1 Menu Existence Conditions 110
3-15 SP1 Range 54 A-2 Factory Menu Description 113
3-16 PV1 Shift 55 A-3 Glossary 115
3-17 Failure Transfer 56 A-4 Index 122
3-18 Bumpless Transfer 57 A-5 Memo 125
3-19 Self-tuning 58 A-6 Warranty 127
3-20 Auto-tuning 59
UM25001C 3
Chapter 1 Overview
1 1 Features
High accuracy 18-bit input A D Unique
High accuracy 15-bit output D A Valuable
Fast input sample rate (5 times / second)
Two function complexity levels
User menu configurable
Pump control
Fuzzy + PID microprocessor-based control
Automatic programming
Differential control
Auto-tune function
Self-tune function
Sleep mode function
" Soft-start " ramp and dwell timer
Programmable inputs( thermocouple, RTD, mA, VDC )
Analog input for remote set point and CT
Event input for changing function & set point
Programmable digital filter
Hardware lockout + remote lockout protection
Loop break alarm
Heater break alarm
Sensor break alarm + Bumpless transfer
RS-485, RS-232 communication
Analog retransmission
Signal conditioner DC power supply
A wide variety of output modules available
Safety UL / CSA / IEC1010 1
EMC / CE EN61326
Front panel sealed to NEMA 4X & IP65
BTC-2500 Fuzzy Logic plus PID microprocessor-based controller, incorporates a bright,

easy to read 4-digit LED display, indicating process value. The Fuzzy Logic technology
enables a process to reach a predetermined set point in the shortest time, with the
minimum of overshoot during power-up or external load disturbance. The units are
housed in a 1/32 DIN case, measuring 24 mm x 48 mm with 98 mm behind panel depth.
The units feature three touch keys to select the various control and input parameters.
Using a unique function, you can put at most 5 parameters in front of user menu by using
SEL1 to SEL5 contained in the setup menu. This is particularly useful to OEM's as it is easy
to configure menu to suit the specific application.
BTC-2500 is powered by 11-26 or 90 - 264 VDC / AC supply, incorporating a 2 amp.

control relay output, 5V logic alarm output and a 2 amp. alarm relay output as standard
whereby second alarm can be exceptionally configured into second output for cooling
purpose or dwell timer. Alternative output options include SSR drive, triac, 4 - 20 mA and 0
- 10 volts. BTC-2500 is fully programmable for PT100, thermocouple types J, K, T, E, B, R,
S, N, L, 0 - 20mA, 4 -20mA and voltage signal input, with no need to modify the unit. The
input signals are digitized by using a 18-bit A to D converter. Its fast sampling rate allows
the BTC-2500 to control fast processes such as pressure and flow. Self tune is
incorporated. The self- tune can be used to optimize the control parameters as soon as
undesired control result is observed. Unlike auto-tuning, Self-tune will produce less
disturbance to the process during tuning, and can be used any time.
4 UM25001D
Digital communications RS-485, RS-232 or 4 - 20 mA retransmission are available as an
additional option. These options allow BTC-2500 to be integrated with supervisory control
system and software, or alternatively drive remote display, chart recorders or data-
loggers.
Three kinds of method can be used to program BTC-2500. 1. Use keys on front panel
to program the unit manually, 2. Use a PC and setup software to program the unit via
RS-485 or RS-232 COMM port and 3. Use P11A, a hand-held programmer, to program
the unit via programming port.
In last nearly a hundred years although PID control has been used and proved to be an
efficient controlling method by many industries, 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,
these systems may be variable from time to time. In order to overcome the imperfection
of PID control, the Fuzzy Technology is introduced. What is the Fuzzy Control ? It works
like a good driver. Under different speeds and circumstances, he can control a car well
with experiences he had before and does not require the knowledge of kinetic theory of
motion. The Fuzzy Logic is a linguistic control which is different from the numerical PID
control. It controls the system by experiences and does not need to simulate the system
precisely as been controlled by PID.
PID + FUZZY CONTROL

MV PV
PROCESS _
+
PID SV
+
+
FUZZY
Figure 1.1
Fuzzy Rule
Fuzzy PID System Block
Language
information
Digital Fuzzy Inference Digital
Fuzzifier Engine Defuzzifier
information information
The function of Fuzzy Logic is to adjust PID parameters internally in order to make
manipulation output value MV more flexible and adaptive to various processes.
The Fuzzy Rule may work like these:
If temperature difference is large, and temperature rate is large, then MV is large.
If temperature difference is large, and temperature rate is small, then MV is small.
PID + Fuzzy Control has been proven to be an efficient method to improve the control
stability as shown by the comparison curves below:
UM25001C 5
PID control with properly tuned
PID + Fuzzy control
Temperature
Set point
Figure 1.2 Fuzzy PID

Enhances Control
Warm Up Load Disturbance Stability
Time
6 UM25001C
1 2 Ordering Code
BTC-2500-
Power Input 1 2 3 4 5 6
4: 90 - 264 VAC, 50/60 HZ
5: 11 - 26 VAC or VDC
9: Special Order Communications
Alarm 1
0: None
Signal Input 1: 5V Logic 1: RS-485
1: Standard Input Output 2: RS-232 **
Input 1 - Universal Input 9: Special order 3: Retransmit 4-20mA/0-20mA *
Thermocouple: J, K, T, E, B, 4: Retransmit 1 - 5V / 0 - 5V *
R, S, N, L 5: Retransmit 0 - 10V
RTD: PT100 DIN, PT100 JIS Output 1 9: Special order
Current: 4 - 20mA, 0 - 20 mA.
0: None Output 2 / Alarm 2
Voltage: 0 - 1V, 0 - 5V, 1 - 5V,
1: Relay rated 2A/240VAC
0 - 10V 0: None
2: Pulsed voltage to
Input 2 - ** 1: Form A Relay 2A/240VAC
drive SSR, 5V/30mA
CT: 0 - 50 Amp. AC Current 2: Pulsed voltage to
3: Isolated
Transformer drive SSR, 5V / 30mA
***
Voltage Input: 0 - 1V, 0 - 5V,
4 - 20mA / 0 - 20mA *
3: Isolated 4 - 20mA / 0 - 20mA*
4: Isolated 1 - 5V / 0 - 5V *
1 - 5V, 0 - 10V. 4: Isolated 1 - 5V / 0 - 5V *
5: Isolated 0 - 10V
Event Input ( EI ) 5: Isolated 0 - 10V
6: Triac Output
6: Triac Output, 1A / 240VAC, SSR
1A / 240VAC,SSR
9: Special Order 7: Isolated 20V / 25mA DC
C: Pulsed voltage to
Output Power Supply
drive SSR, 14V/40mA
8: Isolated 12V / 40 mA DC
9: Special order
Output Power Supply
Example 9: Isolated 5V / 80mA DC
BTC-2500-411111 Output Power Supply
90 - 264 operating voltage C: Pulsed voltage to
Input: Standard Input drive SSR, 14V/40mA
Output 1: Relay A: Special order
Output 2: Relay
Alarm 1: 5V Logic Output * Range set by front keyboard
RS- 485 Communication Interface ** Alternative between RS-232 and Input 2
*** Need to order an accessory CT94-1 if
Heater Break detection is required.
Accessories
CT94-1 = 0 - 50 Amp. AC Current Transformer
OM95-3 = Isolated 4 - 20 mA / 0 - 20 mA Analog Output Module Related Products
OM95-4 = Isolated 1 - 5V / 0 - 5V Analog Output Module SNA10A = Smart Network Adaptor for Third
OM95-5 = Isolated 0 - 10V Analog Output Module Party Software, Converts 255
OM94-6 = Isolated 1A / 240VAC Triac Output Module ( SSR ) channels of RS-485 or RS-422 to
OM94-7 = 14V/40mA SSR Drive Module RS-232 Network
DC94-1 = Isolated 20V / 25mA DC Output Power Supply SNA10B = Smart Network Adaptor for BC-Net
DC94-2 = Isolated 12V / 40mA DC Output Power Supply Software, Converts 255 channels
DC94-3 = Isolated 5V / 80mA DC Output Power Supply of RS-485 or RS-422 to RS-232
CM94-1 = Isolated RS-485 Interface Module Network
CM94-2 = Isolated RS-232 Interface Module SNA12A = Smart Network Adapter for
CM94-3 = Isolated 4 - 20 mA / 0 - 20 mA Retransmission Module programming port to RS-232
CM94-4 = Isolated 1 - 5V / 0 - 5V Retransmission Module interface
CM94-5 = Isolated 0 - 10V Retransmission Module BC-Set = Configuration Software
CC94-1 = RS-232 Interface Cable (2M)
CC91-3 = Programming Port Cable
UM25001G = BTC-2500 User's Manual
UM25001G 7
1 3 Programming Port and DIP Switch
Front Access Hole

Rear
Panel
Terminal
1 2 3 4
ON DIP
Figure 1.3 Access Hole
Overview
The programming port is used to connect to

SNA12A for automatic programming, also can be
connected to ATE system for automatic testing &
calibration.
DIP Switch
:ON :OFF
1 2 3 4
TC, RTD, mV
Input 1 0-1V, 0-5V, 1-5V, 0-10V

Select
0-20 mA, 4-20 mA
All parameters are Unlocked
Only SP1, SEL1 SEL5 * are unlocked Table 1.1 DIP Switch
Lockout
Only SP1 is unlocked Configuration
All Parameters are locked
Factory Default Setting
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.
When the unit leaves the factory, the DIP switch is set so that TC & RTD are selected for input
1 and all parameters are unlocked.
Lockout function is used to disable the adjustment of parameters as well as operation of

calibration mode. However, the menu can still be viewed even under lockout condition.
* SEL1- SEL5 represent those parameters which are selected by using SEL1, SEL2,...SEL5
parameters contained in Setup menu. Parameters been selected are then allocated at the
beginning of the user menu.
8 UM25001G
1 4 Keys and Displays
The unit is programmed by using three keys on the front panel. The available key functions are listed in following table.
Table 1.2 Keypad Operation
TOUCHKEYS FUNCTION DESCRIPTION
Press and release quickly to increase the value of parameter.

Up Key
Press and hold to accelerate increment speed.
Press and release quickly to decrease the value of parameter.

Down Key
Press and hold to accelerate decrement speed.
Scroll Key Select the parameter in a direct sequence.
Allow access to more parameters on user menu, also used to Enter manual
Press
Enter Key mode, auto-tune mode, default setting mode and to save calibration data
for at least 3 seconds during calibration procedure.
Press Reset historical values of PVHI and PVLO and start to record the peak process
Start Record Key
for at least 6 seconds value.
Press Reverse Scroll Key Select the parameter in a reverse sequence during menu scrolling.
Press Mode Key Select the operation Mode in sequence.
Reset the front panel display to a normal display mode, also used to leave
Press Reset Key the specific Mode execution to end up the auto-tune and manual control
execution, and to quit the sleep mode.
Press The controller enters the sleep mode if the sleep function ( SLEP ) is enabled
Sleep Key
for at least 3 seconds ( select YES ).
By entering correct security code to allow execution of engineering programs.

Press Factory Key This function is used only at the factory to manage the diagnostic reports.
The user should never attempt to operate this function.
How to display a 5-digit number ?

4-digit Display For a number with decimal point the
Output 1 to display process value, display will be shifted one digit right:
Indicator set point value, menu symbol, -199.99 will be displayed by -199.9
parameter value, control output 4553.6 will be displayed by 4553
value and error code etc.
Output 2 For a number without decimal point

O1
Indicator O2
the display will be divided into two
Alarm 1 A1
alternating phases:
Indicator -19999 will be displayed by:
3 Silicone Rubber Buttons
BTC-2500 C
for ease of control setup
and set point adjustment.
Figure 1.4 Front Panel Description
45536 will be displayed by:

Table 1.3 Display Form of Characters
A E I N S X
B F J O T Y
C G K P U Z
-9999 will be displayed by:
c H L Q V ?
D h M R W =
: Confused Character
UM25001C 9
Power On
All segments of display and Figure 1.5 Display Sequence of

indicators are left off for 0.5
Initial Message
second.
BTC-2500 C
O1
O2
A1 All segments of display and
indicators are lit for 2 seconds.
BTC-2500 C
O1
O2
A1 Program Code
Display program code of the
product for 2.5 seconds.
BTC-2500 C Each display stays for 1.25 seconds
O1
The left diagram shows program
O2 no. 0 ( for BTC-2500 ) with version Program Version
A1 35.
Program No.
BTC-2500 C
Display Date Code and Serial

O1
O2
number for 2.5 seconds.
Each display stays for 1.25 seconds Date Code
A1
The left diagram shows Year 1998,

BTC-2500 C
Month July ( 7 ), Date 31'st and
Serial number 192. This means that
O1 the product is the 192 'th unit
produced on July 31'st, 1998. Date (31'st)
O2
A1 Note that the month code A stands for Month (December)
October, B stands for November and C Year (1999)
stands for December.
BTC-2500 C
O1
O2
A1
Display the used hours for 2.5
seconds.
The 6-digit number of hour is indicated
BTC-2500 C by two successive displays and each
one stays for 1.25 seconds.
O1
O2 The left diagram shows that the
A1 unit has been used for 23456.2
hours since production.
BTC-2500 C
10 UM25001C
1 5 Menu Overview
*3 PV Value User
or SV Value
Menu *2
SEL1
SEL2
SEL3
SEL4
*1 SEL5
Setup FUNC for 3

COMM seconds
Menu *1
PROT
ADDR TIME
BAUD
A1SP
DATA A1DV
PARI A2SP
Hand (Manual) for 3 seconds STOP
A2DV
Control AOFN
RAMP
AOLO
Mode AOHI
OFST
H REFC
C IN1 SHIF
IN1U
PB1
DP1 TI1
Auto-tuning IN1L TD1
Mode IN1H CPB
Press for 3 seconds to enter IN2 DB
the auto-tuning mode IN2U
SP2
DP2 PB2
IN2L TI2
IN2H TD2
OUT1 O1HY
Display O1TY A1HY
Mode CYC1 A2HY
O1FT PL1
PVHI
OUT2 PL2
PVLO
O2TY
H
CYC2
C
Default O2FT
DV
A1FN
Setting PV1
A1MD
FILE PV2
Mode for PB
A1FT Display Go Home
3 seconds A2FN
TI The menu will revert to
A2MD
To execute the TD PV/SV display after keyboard
A2FT
default setting CJCT
EIFN is kept untouched for
program PVR
PVMD 2 minutes except Display
PVRH
FILT
PVRL
SELF Mode Menu and Manual
SLEP Mode Menu. However, the
Calibration SPMD menu can revert to PV / SV
SP1L display at any time by
Mode SP1H
SP2F
pressing and .
AD0
DISF
ADG
SEL1
V1G
SEL2
CJTL
SEL3
CJG
SEL4
REF1
SEL5
SR1
MA1G
V2G *1: The flow chart shows a complete listing of all parameters.
For actual application the number of available parameters
depends on setup conditions, and should be less
than that shown in the flow chart. See Appendix A-1 for the
existence conditions of each parameter.
*2: You can select at most 5 parameters put in front of the user
Apply these modes will break the control loop and change menu by using SEL1 to SEL5 contained at the bottom of
some of the previous setting data. Make sure that if the system setup menu.
is allowable to use these modes.
*3: Set DISF (display format) value in the setup menu to
determine whether PV or SV is displayed.
UM25001D
11
1 6 System Modes
The controller performs close loop control under its normal control mode condition. System Modes
The controller will maintain its normal control mode when you are operating user menu, Sleep Mode :
setup menu or display mode, reloading default values or applying event input signal. See Section 4-11.
Under certain conditions the normal control mode will transfer to an Exception Mode. Manual Mode :
The exception modes include : Sleep Mode, Manual Mode, Failure Mode, Calibration
Mode and Auto-tuning Mode. All these modes perform in an open loop control except See Section 3-23.
the auto-tuning mode which performs ON-OFF plus PID close loop control. The mode Failure Mode :
transfer is governed by the priority conditions. A lower priority mode can not alter a See Section 3-17.
higher priority mode, as shown in Figure 1.6. Calibration Mode :
See Chapter 6.
Auto-tuning Mode :
See Section 3-20.
Normal Control Mode :
? Mode
See Section 3-24, 3-26, 4-1
Priority
High
No
Sleep Mode?
Yes
No Figure 1.6
Manual Mode?
System Mode Priority
Yes
No
Failure Mode?
Yes
Low
Request Request Request
Calibration Auto-tuning Normal
Mode Mode Control
Mode
The calibration mode, auto-tuning mode and normal control mode are in the same
priority level. The sleep mode is in the highest priority.
12 UM25001C
1 7 Parameter Description
Table 1.4 Parameter Description
Contained Basic Parameter Display Parameter
Range Default
in Function Notation Format Description Value
Set point 1 100.0 C
SP1 Low: SP1L High: SP1H (212.0 F)
TIME Dwell Time Low: 0 High: 6553.5 minutes 0.0
Alarm 1 Set point 100.0 C
A1SP See Table 1.5, 1.6 (212.0 F)
-200.0 C 200.0 C 10.0 C
A1DV Alarm 1 Deviation Value Low: (-360.0 F) High: ( 360.0 F) (18.0 F)
100.0 C
A2SP Alarm 2 Set point See Table 1.5, 1.7 (212.0 F)
-200.0 C 200.0 C 10.0 C
A2DV Alarm 2 Deviation Value Low: (-360.0 F) High: ( 360.0 F) (18.0 F)
Ramp Rate 500.0 C
RAMP Low: 0 High: (900.0 F) 0.0
OFST Offset Value for P control Low: 0 High: 100.0 % 25.0

Reference Constant for 0 High: 60 2
REFC Specific Function Low:
-200.0 C High: 200.0 C
SHIF PV1 Shift (offset) Value Low: 0.0
(-360.0 F) ( 360.0 F)
PB1 Proportional Band 1 Value Low: 0 High: 500.0 C 10.0 C
(900.0 F) (18.0 F)
User TI1 Integral Time 1 Value Low: 0 High: 1000 sec 100
Menu
TD1 Derivative Time 1 Value Low: 0 High: 360.0 sec 25.0
CPB Cooling Proportional Band 1 High: 255 % 100

Value Low:
Heating-Cooling Dead Band High:
DB Negative Value= Overlap Low: -36.0 36.0 % 0
Set point 2 See Table 1.5, 1.8 37.8 C

SP2 (100.0 F)
Proportional Band 2 Value 500.0 C 10.0 C
PB2 Low: 0 High: (900.0 F) (18.0 F)
TI2 Integral Time 2 Value Low: 0 High: 1000 sec 100
TD2 Derivative Time 2 Value Low: 0 High: 360.0 sec 25.0

Output 1 ON-OFF Control 55.6 C
O1HY Hysteresis Low: 0.1 High: ( 100.0 F) 0.1
10.0 C
A1HY Hysteresis Control of Alarm 1 Low: 0.1 High: (18.0 F) 0.1
10.0 C
A2HY Hysteresis Control of Alarm 2 Low: 0.1 High: (18.0 F) 0.1
PL1 Output 1 Power Limit Low: 0 High: 100 % 100
PL2 Output 2 Power Limit Low: 0 High: 100 % 100
0 : Basic Function Mode

FUNC Function Complexity Level 1
1 : Full Function Mode
0 : No communication function
1 : RS-485 interface
2 : RS-232 interface
3 : 4 - 20 mA analog retransmission
output
Setup
COMM Communication Interface 4 : 0 - 20 mA analog retransmission 1
Menu
Type output
5 : 0 - 1V analog retransmission
output
output
output
output
PROT COMM Protocol Selection 0 : Modbus protocol RTU mode 0
UM25001D 13
Table 1.4 Parameter Description ( continued 2/7 )
Range Default
Address Assignment of Digital High: 255
ADDR Low: 1
COMM
0 : 0.3 Kbits/s baud rate
BAUD Baud Rate of Digital COMM 5 : 9.6 Kbits/s baud rate 5
Data Bit count of Digital 0 : 7 data bits

DATA 1
COMM 1 : 8 data bits
0 : Even parity
PARI Parity Bit of Digital COMM 1 : Odd parity 0
2 : No parity bit
Stop Bit Count of Digital 0 : One stop bit

STOP 0
COMM : Two stop bits
Setup 1
Menu
0 : Retransmit IN1 process value
1 : Retransmit IN2 process value
2 : Retransmit IN1 IN2 difference

process value
3 : Retransmit IN2 IN1 difference

process value
AOFN Analog Output Function 4 : Retransmit set point value 0
5 : Retransmit output 1 manipulation

value
6 : Retransmit output 2 manipulation

value
7 : Retransmit deviation(PV-SV)
Value
Analog Output Low Scale 0 C
AOLO
Value Low: -19999 High: 45536 (32.0 F)
Analog Output High Scale High: 45536 100.0 C
AOHI Low: -19999 (212.0 F)
Value
0 : J type thermocouple
1 : K type thermocouple
2 : T type thermocouple
3 : E type thermocouple
1
IN1 IN1 Sensor Type Selection 4 : B type thermocouple
(0)
5 : R type thermocouple
6 : S type thermocouple
14 UM25001C
Range Default
7 : N type thermocouple
8 : L type thermocouple
9 : PT 100 ohms DIN curve
10 : PT 100 ohms JIS curve
11 : 4 - 20 mA linear current input

1
IN1 IN1 Sensor Type Selection 12 : 0 - 20 mA linear current input (0)
13 : 0 - 1V linear Voltage input
17 : Special defined sensor curve
0 : Degree C unit
0
IN1U IN1 Unit Selection 1 : Degree F unit
(1)
2 : Process unit
0 : No decimal point
1 : 1 decimal digit
DP1 IN1 Decimal Point Selection 1
2 : 2 decimal digits
3 : 3 decimal digits
Setup
Menu High: 45536 0
IN1L IN1 Low Scale Value Low: -19999
IN1H IN1 High Scale Value Low: -19999 High: 45536 1000
0 : IN2 no function
1 : Current transformer input
4 : 0 - 1V linear voltage input
IN2 IN2 Signal Type Selection 5 : 0 - 5V linear voltage input

1
20 : Perform Event input function
IN2U IN2 Unit Selection Same as IN1U 2
DP2 IN2 Decimal Point Selection Same as DP1 1
IN2L IN2 Low Scale Value Low: -19999 High: 45536 0
IN2H IN2 High Scale Value Low: -19999 High: 45536 1000
0 : Reverse (heating ) control action

OUT1 Output 1 Function 0
1 : Direct (cooling) control action
0 : Relay output
1 : Solid state relay drive output
2 : Solid state relay output
O1TY Output 1 Signal Type 3 : 4 - 20 mA current module 0
UM25001C 15
Range Default
4 : 0 - 20 mA current module
5 : 0 - 1V voltage module
O1TY Output 1 Signal Type 6 : 0 - 5V voltage module 0

CYC1 Output 1 Cycle Time Low: 0.1 High: 100.0 sec 18.0
Select BPLS ( bumpless transfer ) or 0.0 ~ 100.0
Output 1 Failure Transfer % to continue output 1 control function as the unit BPLS
O1FT
Mode
fails, power starts or manual mode starts.
0 : Output 2 no function
1 : PID cooling control

OUT2 Output 2 Function 0
2 : Perform alarm 2 function
3 : DC power supply module

installed
O2TY Output 2 Signal Type Same as O1TY 0
CYC2 Output 2 Cycle Time Low: 0.1 High: 100.0 sec 18.0
Select BPLS ( bumpless transfer ) or 0.0 ~ 100.0
Output 2 Failure Transfer % to continue output 2 control function as the unit
O2FT BPLS
Mode
fails, power starts or manual mode starts.
0 : No alarm function
Setup
Menu 1 : Dwell timer action
2 : Deviation high alarm
3 : Deviation low alarm
4 : Deviation band out of band alarm
5 : Deviation band in band alarm
6 : IN1 process value high alarm
7 : IN1 process value low alarm

A1FN Alarm 1 Function 2
8 : IN2 process value high alarm
9 : IN2 process value low alarm
10 : IN1 or IN2 process value high

alarm
11 : IN1 or IN2 process value low
alarm
12 : IN1 IN2 difference process value
high alarm
13 : IN1 IN2 difference process value
low alarm
14 : Loop break alarm
15 : Sensor break or A-D fails
0 : Normal alarm action
1 : Latching alarm action

A1MD Alarm 1 Operation Mode 0
2 : Hold alarm action
3 : Latching & Hold action
16 UM25001D
Range Default
0 : Alarm output OFF as unit fails
Alarm 1 Failure Transfer
A1FT 1
Mode : Alarm output ON as unit fails
1
A2FN Alarm 2 Function Same as A1FN 2
A2MD Alarm 2 Operation Mode Same as A1MD 0

A2FT Alarm 2 Failure Transfer Same as A1FT
Mode 1
0 : Event input no function
1 : SP2 activated to replace SP1
2 : PB2, TI2, TD2 activated to replace

PB1, TI1, TD1
3 : SP2, PB2, TI2, TD2 activated to

replace SP1, PB1, TI1, TD1
4 : Reset alarm 1 output
EIFN Event Input Function 5 : Reset alarm 2 output 1
6 : Reset alarm 1 & alarm 2
7 : Disable Output 1
8 : Disable Output 2
9 : Disable Output 1 & Output 2
10 : Lock All Parameters
0 Use PV1 as process value

Setup
Menu 1 : Use PV2 as process value
PVMD PV Mode Selection 2 0
Use PV1 PV2 (difference) as
process value
3 Use PV2 PV1 (difference) as
process value
0 : 0 second time constant
1 : 0.2 second time constant
2 0.5 second time constant
3 1 second time constant
4 2 seconds time constant

Filter Damping Time
FILT 2
Constant of PV 5 5 seconds time constant
8 : 30 seconds time constant
9 : 60 seconds time constant
0 Self tune function disabled

Self Tuning Function
SELF 0
Selection 1 Self tune function enabled
0 Sleep mode function disabled

Sleep mode Function
SLEP 0
Selection 1 Sleep mode function enabled
UM25001C 17
Range Default
0 : Use SP1 or SP2 (depends on EIFN)
as set point
1 : Use minute ramp rate as set point
2 : Use hour ramp rate as set point

SPMD Set point Mode Selection 0
3 : Use IN1 process value as set point
4 : Use IN2 process value as set point
5 : Selected for pump control

Low: -19999 High: 45536 0 LC
SP1L SP1 Low Scale Value (32.0 LF)
SP1 High Scale Value Low: -19999 High: 45536 1000.0 LC
SP1H (1832.0 LF)
0 set point 2 (SP2) is an actual value
SP2F Format of set point 2 Value 0
1 set point 2 (SP2) is a deviation
value
0 : Display PV value
DISF Display Format
1 : Display SV value
0 : No parameter put ahead
1 : Parameter TIME put ahead
2 : Parameter A1SP put ahead
3 Parameter A1DV put ahead
4 Parameter A2SP put ahead
5 : Parameter A2DV put ahead
6 : Parameter RAMP put ahead
7 : Parameter OFST put ahead

Setup
Menu SEL1 Select 1'st Parameter 8 : Parameter REFC put ahead 0
9 Parameter SHIF put ahead
10 Parameter PB1 put ahead
11 Parameter TI1 put ahead
12 : Parameter TD1 put ahead
13 Parameter CPB put ahead
14 Parameter DB put ahead
15 Parameter SP2 put ahead
16 : Parameter PB2 put ahead
17 Parameter TI2 put ahead
18 Parameter TD2 put ahead
SEL2 Select 2'nd Parameter Same as SEL1 0
SEL3 Select 3'rd Parameter Same as SEL1 0
SEL4 Select 4'th Parameter Same as SEL1 0
SEL5 Select 5'th Parameter Same as SEL1 0

A to D Zero Calibration -360 High: 360
AD0 Coefficient Low:
A to D Gain Calibration -199.9 High: 199.9
ADG Coefficient Low:
Calibration Voltage Input 1 Gain
Mode V1G Low: -199.9 High: 199.9
Calibration Coefficient
Menu Cold Junction Low
CJTL Temperature Calibration Low: -5.00 BC High: 40.00 LC
Coefficient
18 UM25001D
UM25001C
Range Default
Cold Junction Gain -199.9 199.9
CJG Low: High:
Calibration Coefficient
Reference Voltage 1
REF1 Calibration Coefficient for Low: -199.9 High: 199.9
RTD 1
Calibration Serial Resistance 1

Mode SR1 Calibration Coefficient for Low: -199.9 High: 199.9
Menu RTD 1
mA Input 1 Gain Calibration -199.9 High: 199.9
MA1G Low:
Coefficient
V2G Voltage Input 2 Gain
Calibration Coefficient Low: -199.9 High: 199.9
Historical Maximum Value of Low: -19999 High: 45536
PVHI
PV
Historical Minimum Value of -19999 High: 45536
PVLO Low:
PV
MV1 Current Output 1 Value Low: 0 High: 100.00 %
MV2 Current Output 2 Value Low: 0 High: 100.00 %

Current Deviation (PV-SV) -12600 High: 12600
DV Low:
Value
PV1 IN1 Process Value Low: -19999 High: 45536
Display
Mode PV2 IN2 Process Value Low: -19999 High: 45536
Menu 500.0 LC
PB Current Proportional Band 0 High:
Low: (900.0 LF)
Value
TI Current Integral Time Value Low: 0 High: 4000 sec
Current Derivative Time 0 High: 1440 sec
TD Low:
Value
Cold Junction Compensation
CJCT Temperature Low: -40.00 LC High: 90.00 LC
PVR Current Process Rate Value Low: -16383 High: 16383
PVRH Maximum Process Rate Value Low: -16383 High: 16383
PVRL Minimum Process Rate Value Low: -16383 High: 16383
UM25001C 19
Input Type J_TC K_TC T_TC E_TC B_TC R_TC S_TC
-120 LC
Range Low (-184 -200 LC -250 LC -100 LC 0 LC 0 LC 0 LC
LF) (-328 LF) (-418 LF) (-148 LF) (32 LF) (32 LF) (32 LF)
Range High 1000 LC 1370 LC 400 LC 900 LC 1820 LC 1767.8 LC 1767.8 LC
(1832 LF) (2498 LF) (752 LF) (1652 LF) (3308 LF) (3214 LF) (3214 LF)
Table 1.5 Input ( IN1 or IN2 ) Range
Input Type N_TC L_TC PT.DN PT.JS CT Linear ( V, mA)
or SPEC
-250 LC
Range Low (-418 -200 LC -210 LC -200 LC
LF) (-328 LF) (-346 LF) (-328 LF) 0 Amp -19999
Range High (2372 LLC

1300 900 LC 700 LC 600 LC
F) (1652 LF) (1292 LF) (1112 LF) 90 Amp 45536
If A1FN = PV1.H, PV1.L PV2.H,PV2.L P1.2.H, P1.2.L

D1.2.H, D1.2.L
Table 1.6 Range Determination for A1SP
Range of A1SP IN1 IN2 IN1, IN2
same as range of
P1.2.H, P1.2.L
If A2FN = PV1.H, PV1.L PV2.H,PV2.L D1.2.H, D1.2.L
Table 1.7 Range Determination for A2SP
Range of A2SP IN1 IN2 IN1, IN2
same as range of
If PVMD = PV1 PV2 P1 2, P2 1

Range of SP2 IN1 IN2 IN1, IN2 Table 1.8 Range Determination for SP2
same as range of
Exception: If any of A1SP, A2SP or SP2 is configured with respect to

CT input, its adjustment range is unlimited.
20 UM25001C
Chapter 2 Installation
Dangerous voltages capable of causing death are sometimes present

in this instrument. Before installation or beginning any troubleshooting
procedures the power to all equipment must be switched off and isolated. Units
suspected of being faulty must be disconnected and removed to a properly
equipped workshop for testing and repair. Component replacement and internal
adjustments must be made by a qualified maintenance person only.
To minimize the possibility of fire or shock hazards, do not expose this

instrument to rain or excessive moisture.
Do not use this instrument in areas under hazardous conditions such as

excessive shock, vibration, dirt, moisture, corrosive gases or oil. The ambient
temperature of the areas should not exceed the maximum rating specified in Chapter 8.
2 1 Unpacking
Upon receipt of the shipment remove the unit from the carton and inspect the
unit for shipping damage.
If any damage due to transit , report and claim with the carrier.
Write down the model number, serial number, and date code for future reference
when corresponding with our service center. The serial number (S/N) and date
code (D/C) are labeled on the box and the housing of control.
2 2 Mounting
Make panel cutout to dimension shown in Figure 2.1.
Take both mounting clamps away and insert the controller into panel cutout.
Install the mounting clamps back. Gently tighten the screws in the clamp till the
controller front panels is fitted snugly in the cutout.
MOUNTING
CLAMP
45 +0.5
_
0
+0.3
22.2 _
0
SCREW
Panel
12.5mm 98.0mm
10.0mm
Figure 2.1
Mounting Dimensions
UM25001C 21
2 3 Wiring Precautions
* Before wiring, verify the label for correct model number and options. Switch
off the power while checking.
* Care must be taken to ensure that maximum voltage rating specified on the
label are not exceeded.
* It is recommended that power of these units to be protected by fuses or circuit

breakers rated at the minimum value possible.
* All units should be installed inside a suitably grounded metal enclosure to

prevent live parts being accessible from human hands and metal tools.
* All wiring must conform to appropriate standards of good practice and local
codes and regulations. Wiring must be suitable for voltage, current, and
temperature rating of the system.
* The " stripped " leads as specified in Figure 2.2 below are used for power and
sensor connections.
* Beware not to over-tighten the terminal screws.

* Unused control terminals should not be used as jumper points as they may
be internally connected, causing damage to the unit.
* Verify that the ratings of the output devices and the inputs as specified in
Chapter 8 are not exceeded.
* Electric power in industrial environments contains a certain amount of noise in

the form of transient voltage and spikes. This electrical noise can enter and
adversely affect the operation of microprocessor-based controls. For this
reason we strongly recommend the use of shielded thermocouple extension
wire which connects the sensor to the controller. This wire is a twisted-pair
construction with foil wrap and drain wire. The drain wire is to be attached to
ground at one end only.
2.0mm
0.08" max.
Figure 2.2 Lead Termination
4.5 ~ 7.0 mm
0.18" ~ 0.27"
OUT2
ALM2
OUT1 ALM1
_ _
+
ALM1(LOGIC OUTPUT)
1 2 3 4 5 6 7
L N
90-264 VAC 2A/240 VAC 2A/240 VAC
47-63 Hz,15VA
V ,CT
TC+ EI _,TC _ V+ ,CT+ AO+ AO
PTA PTB PTB EI+,COM TX1 TX2 Figure 2.3 Rear Terminal
8 9 10 11 12 13 14
_ _ Connection Diagram
+
ALM1
RTD
_ V
+
A B B
_
+
V
_ CT
+
I CAT. I I
22 UM25001C
2 4 Power Wiring
The controller is supplied to operate at 11-26 VAC / VDC or 90-264VAC.Check
that the installation voltage corresponds with the power rating indicated on the
product label before connecting power to the controller.
Fuse
90 ~ 264 VAC or
11 ~ 26 VAC / VDC
1 2 3 4 5 6 7
Figure 2.4
Power Supply Connections
8 9 10 11 12 13 14
This equipment is designed for installation in an enclosure which provides

adequate protection against electric shock. The enclosure must be connected
to earth ground.
Local requirements regarding electrical installation should be rigidly observed.

Consideration should be given to prevent from unauthorized person access to
the power terminals.
UM25001C 23
2 5 Sensor Installation Guidelines
Proper sensor installation can eliminate many problems in a control system. The
probe should be placed so that it can detect any temperature change with
minimal thermal lag. In a process that requires fairly constant heat output, the
probe should be placed closed to the heater. In a process where the heat
demand is variable, the probe should be closed to the work area. Some
experiments with probe location are often required to find this optimum position.
In a liquid process, addition of a stirrer will help to eliminate thermal lag. Since
the thermocouple is basically a point measuring device, placing more than one
thermocouple in parallel can provide an average temperature readout and
produce better results in most air heated processes.
Proper sensor type is also a very important factor to obtain precise

measurements. The sensor must have the correct temperature range to meet
the process requirements. In special processes the sensor might need to have
different requirements such as leak-proof, anti-vibration, antiseptic, etc.
Standard sensor limits of error are A 4degrees F ( A 2degrees C ) or 0.75% of

sensed temperature (half that for special ) plus drift caused by improper
protection or an over-temperature occurrence. This error is far greater than
controller error and cannot be corrected on the sensor except by proper
selection and replacement.
24 UM25001C
2 6 Thermocouple Input Wiring
Thermocouple input connections are shown in Figure 2.5. The correct type of
thermocouple extension lead-wire or compensating cable must be used for the entire
distance between the controller and the thermocouple, ensuring that the correct
polarity is observed throughout. Joints in the cable should be avoided, if possible.
If the length of thermocouple plus the extension wire is too long, it may affect the
temperature measurement. A 400 ohms K type or a 500 ohms J type thermocouple
lead resistance will produce 1 degree C temperature error approximately.
5
ON
1 2 3 4 6 7
1
2
3
Figure 2.5
8 9 10 11 12 13 14
4
Thermocouple Input Wiring
DIP Switch +
The colour codes used on the thermocouple extension leads are shown in Table 2.1.
Table 2.1 Thermocouple Cable Colour Codes
Thermocouple Cable British American German French

Type Material BS ASTM DIN NFE
Copper ( Cu ) + white + blue + red + yellow

T Constantan blue red brown blue
( Cu-Ni ) * blue * blue * brown * blue
Iron ( Fe ) + yellow + white + red + yellow

J Constantan blue red blue black
( Cu- Ni ) * black * black * blue * black
Nickel-Chromium
+ brown + yellow + red + yellow
( Ni-Cr )
K blue red green purple
Nickel-Aluminum
* red * yellow * green * yellow
( Ni-Al )
+ white + black + red + yellow

R Pt-13%Rh,Pt
blue red white green
S Pt-10%Rh,Pt
* green * green * white * green
+grey +red
Pt-30%Rh Use Use
B red grey
Pt-6%Rh Copper Wire Copper Wire
* grey * grey
* Colour of overall sheath
UM25001C 25
2 7 RTD Input Wiring
RTD connection are shown in Figure 2.6, with the compensating lead connected to
terminal 9. For two-wire RTD inputs, terminals 9 and 10 should be linked. The
three-wire RTD offers the capability of lead resistance compensation provided that the
three leads should be of same gauge and equal length.
Two-wire RTD should be avoided, if possible, for the purpose of accuracy. A 0.4
ohm lead resistance of a two-wire RTD will produce 1 degree C temperature
error.
1 2 3 4 5 6 7 1 2 3 4 5 6 7
ON
1
2
Figure 2.6
RTD Input Wiring
3
8 9 10 11 12 13 14 8 9 10 11 12 13 14
4
DIP Switch RTD RTD
Three-wire RTD Two-wire RTD
2 8 Linear DC Input Wiring

DC linear voltage and linear current connections for input 1 are shown in Figure
2.7 and Figure 2.8 .
DC linear voltage and linear current connections for input 2 are shown in Figure
2.9 and Figure 2.10 .
ON
1
1 2 3 4 5 6 7
Figure 2.7
2
Input 1 Linear Voltage Wiring

3
4
8 9 10 11 12 13 14
DIP Switch +
0~1V, 0~5V
1~5V, 0~10V
26 UM25001C
ON
1
1 2 3 4 5 6 7
2
Figure 2.8
3
Input 1 Linear Current Wiring

4
8 9 10 11 12 13 14
DIP Switch 0~20mA or

4~20mA +
1 2 3 4 5 6 7
Figure 2.9
Input 2 Linear Voltage Wiring
8 9 10 11 12 13 14
0~1V, 0~5V +
1~5V, 0~10V
1 2 3 4 5 6 7
Figure 2.10
Input 2 Linear Current Wiring
8 9 10 11 12 13 14
R=250 ohms IN2= 0 5V or 1 5V

0~20mA or
4~20mA
+
UM25001C 27
2 9 CT / Heater Current Input Wiring
Heater 1
Heater 2
Heater 3
Contactor
Heater Supply Current Transformer
CT94 1
+ Fuse
1 2 Mains
supply
DIN Rail 1 2 3 4 5 6 7
Figure 2.11
8 9 10 11 12 13 14
CT Input Wiring for
Single Phase Heater
CT Signal Input
Contactor
Three Phase
Heater Power
Fuse
Mains
Current Transformer
supply
CT94 1 1 2 3 4 5 6 7
+
1 2
Figure 2.12
8 9 10 11 12 13 14
CT Input Wiring for
Three Phase Heater
+
CT Signal Input
DIN Rail
Make sure that the total current through CT94-1 not exceed 50A rms.
28 UM25001C
2 10 Event Input wiring
1 2 3 4 5 6 7 1 2 3 4 5 6 7
Figure 2.13
Event Input Wiring
8 9 10 11 12 13 14 8 9 10 11 12 13 14
Switch Input
Open Collector
Input
The event input can accept a switch signal as well as an open collector signal. The
event input function ( EIFN ) is activated as the switch is closed or an open collector (
or a logic signal ) is pulled down.
Also refer to Section 4-1 for event input function.
UM25001C 29
2 11 Output 1 Wiring
Max. 2A
Resistive
Load 120V/240V
Mains Supply
1 2 3 4 5 6 7
8 9 10 11 12 13 14
Relay Output Direct Drive Figure 2.14

Output 1 Wiring
120V /240V
Mains Supply
1 2 3 4 5 6 7
Three
Phase
8 9 10 11 12 13 14 Heater
Power
Three Phase No Fuse Relay or Triac (SSR)
Delta Contactor Breaker Output to Drive
Heater Contactor
Load
SSR
30mA/5V + Load
120V /240V
Pulsed
_ Mains Supply
Voltage
+ _
1 2 3 4 5 6 7 Internal Circuit
5V
8 9 10 11 12 13 14
33 5 + Pulsed Voltage to Drive SSR
33 6
0V
30 UM25001C
+
0 - 20mA,
Load
4 - 20mA
+
1 2 3 4 5 6 7
8 9 10 11 12 13 14
Maximum Load 500 ohms Linear Current
0 - 1V, 0 - 5V Load
1 - 5V, 0 - 10V
+
1 2 3 4 5 6 7
8 9 10 11 12 13 14
Minimum Load 10 K ohms
Linear Voltage
Max. 1A / 240V
Load 120V /240V
Mains Supply
Triac
1 2 3 4 5 6 7
8 9 10 11 12 13 14
Triac (SSR) Output

Direct Drive
UM25001C 31
2 12 Output 2 Wiring
Max. 2A
Resistive
Load 120V/240V
Mains Supply
1 2 3 4 5 6 7
8 9 10 11 12 13 14
Relay Output Direct Drive Figure 2.15

Output 2 Wiring
120V /240V
Mains Supply
1 2 3 4 5 6 7
Three
Phase
8 9 10 11 12 13 14 Heater
Power
Three Phase No Fuse Relay or Triac (SSR)
Delta Contactor Breaker Output to Drive
Heater Contactor
Load
SSR
+ Load
30mA/5V 120V /240V
Pulsed _ Mains Supply
Voltage
+ _
1 2 3 4 5 6 7
Internal Circuit
5V
8 9 10 11 12 13 14
Pulsed Voltage to Drive SSR
33 3 +
33 4
0V
32 UM25001C
+
0 - 20mA,
Load
4 - 20mA
+
1 2 3 4 5 6 7
8 9 10 11 12 13 14
Maximum Load 500 ohms Linear Current
0 - 1V, 0 - 5V Load
1 - 5V, 0 - 10V
+
1 2 3 4 5 6 7
8 9 10 11 12 13 14
Minimum Load 10 K ohms
Linear Voltage
Max. 1A / 240V
Load 120V /240V
Mains Supply
Triac
1 2 3 4 5 6 7
8 9 10 11 12 13 14
Triac (SSR) Output

Direct Drive
UM25001C 33
2 13 Alarm 1 Wiring
5V DC Max. 2A
Relay Resistive
Load 120V/240V
Mains Supply
1 2 3 4 5 6 7
Figure 2.16
Alarm 1 Wiring
8 9 10 11 12 13 14
Single Phase Load
5V DC
Relay
120V /240V
Mains Supply
1 2 3 4 5 6 7
Three
Phase
8 9 10 11 12 13 14 Heater
Power
Three Phase No Fuse
Internal Circuit Breaker
Delta Contactor
Heater
5V
Load
7 + Three Phase Load

1K
0V 14
34 UM25001C
2 14 Alarm 2 Wiring
Max. 2A
Resistive
Load 120V/240V
Mains Supply
1 2 3 4 5 6 7
Figure 2.17
Relay Output Direct Drive
Alarm 2 Wiring
8 9 10 11 12 13 14
120V /240V
Mains Supply
1 2 3 4 5 6 7
Three
Phase
8 9 10 11 12 13 14 Heater
Power
Three Phase No Fuse
Delta Contactor Breaker
Heater
Load
Relay Output to
Drive Contactor
UM25001C 35
2 15 RS-485
Figure 2.18
RS-485 to RS-232
RS-485 Wiring
1 2 3 4 5 6 7
network adaptor
SNA10A or
8 9 10 11 12 13 14 SNA10B
TX1 TX2 RS-485 RS-232
TX1
TX2
PC
Twisted-Pair Wire
1 2 3 4 5 6 7
8 9 10 11 12 13 14
TX1 TX2
Max. 247 units can be linked
1 2 3 4 5 6 7
8 9 10 11 12 13 14
TX1 TX2
Terminator
220 ohms / 0.5W
36 UM25001C
2 16 RS-232
1 2 3 4 5 6 7
PC
8 9 10 11 12 13 14
Figure 2.19
RS-232 Wiring
COM TX1 TX2
9-pin
RS-232 port
CC94-1
Note: If the BTC-2500 is configured for RS-232 communication, the input 2

and EI ( Event Input ) are disconnected internally. The unit can no longer
perform event input function (EIFN) and input 2 function.
When you insert a RS-232 module (CM94-2) to the connectors on CPU board
(C250), the jumper J51 and J52 must be modified as following: J52 must be
shorted and J51 must be cut and left open. Location of jumper is shown in the
following diagram.
Jumper
J52
J51
Figure 2.20
U52
Location of Jumper J51/J52

1 2 3 4
SW51
ON DIP
CN54
CN55
Display
1
If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable must
be modified according to the following circuit diagram.
To DTE(PC) RS-232 Port
1 DCD
BTC-2500
1 2 RD
6
TX1 RD 3 TD Figure 2.21
TX1 9 2
7 4 DTR Configuration of RS-232
TX2 TD 3
TX2 10 8 5 GND Cable
4
9
6 DSR
COM GND 5 7 RTS
COM 14
8 CTS
9 RI
Female DB-9
UM25001C 37
2 17 Analog Retransmission
1 2 3 4 5 6 7
The total effective resistance of serial

loads can't exceed 500 ohms.
8 9 10 11 12 13 14
+ Load Load Indicators

+ + PLC's Figure 2.22 Analog
0 - 20mA, Load Recorders
Retransmission Wiring
4 - 20mA Data loggers
+ Inverters etc.
Retransmit Current
1 2 3 4 5 6 7
The total effective resistance of parallel
loads should be greater than 10K Ohms.
8 9 10 11 12 13 14
+ Load
Indicators
1 - 5 V, 0 - 5V PLC's
0 - 10V Load
Recorders
+ + + Data loggers
Load Inverters etc.
Retransmit Voltage
38 UM25001C
2 18 Programming Port
See Figure 1.3 in Section 1-3 to find the programming port location.
1 2 3 4
ON DIP
Programmer
connector and
ATE connector
inserted here Programmer
P11A
Access hole INPT1

on the
bottom view
Figure 2.23 Programming
Port Wiring
Switch Unit SW6400
DMM HP 34401A
Calibrator Fluke 5520A
NOTE
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.
UM25001C 39
Chapter 3 Programming the Basic Function
This unit provides an useful parameter " FUNC " which can be used to select If you don't need:
the function complexity level before setup. If the Basic Mode ( FUNC = BASC ) (1) Second setpoint
is selected for a simple application, then the following functions are ignored (2) Second PID
and deleted from the full function menu: (3) Event input
RAMP, SP2, PB2, TI2, TD2, PL1, PL2, COMM, PROT, ADDR, BAUD, DATA, (4) Soft start (RAMP)
PARI, STOP, AOFN, AOLO, AOHI, IN2, IN2U, DP2, IN2L, IN2H, EIFN, PVMD, (5) Remote set point
FILT, SLEP, SPMD and SP2F. (6) Complex process value
(7) Output power limit
Basic Mode capabilities: (8) Digital communication
(1) Input 1: Thermocouple, RTD, Volt, mA (9) Analog retransmission
(2) Input 2: CT for heater break detection (10) Power shut off (Sleep Mode)
(3) Output 1: Heating or Cooling ( Relay, SSR, SSRD, Volt, mA ) (11) Digital filter
(4) Output 2 : Cooling ( Relay, SSR, SSRD, Volt, mA ), DC Power supply. (12) Pump control
(5) Alarm 1: Relay for Deviation, Deviation Band, Process, Heater Break, Loop (13) Remote lockout
Break, Sensor Break, Latch, Hold or Normal Alarm.
then you can use Basic Mode.
(6) Alarm 2: Relay for Deviation, Deviation Band, Process, Heater Break, Loop
Break, Sensor Break, Latch, Hold or Normal Alarm.
(7) Dwell Timer
(8) Heater Break Alarm
(9) Loop Break Alarm
(10) Sensor Break Alarm
(11) Failure Transfer
(12) Bumpless Transfer
(13) PV1 Shift
(14) Programmable SP1 Range
(15) Heat-Cool control
(16) Hardware Lockout
(17) Self-Tune
(18) Auto-Tune
(19) ON-OFF, P, PD, PI, PID Control
(20) User Defined Menu (SEL)
(21) Manual Control
(22) Display Mode
(23) Reload Default Values
(24) Isolated DC Power Supply
(25) PV or SV Selection
3 1 Input 1
Press to enter Setup Mode. Press to select parameter. The upper
display indicates the parameter symbol, and the lower display indicates the
selection or the value of parameter.
IN1 : Selects the sensor type and signal type for Input 1.
Range: ( Thermocouple ) J_TC, K_TC, T_TC, E_TC, B_TC, R_ TC, S_TC, IN1
N_TC, L_TC
( RTD ) PT.DN, PT.JS
(Linear ) 4-20, 0-20, 0-1V, 0-5V, 1-5V, 0-10
Default : J_TC if LF is selected, K_TC if LC is selected.
IN1U: Selects the process unit for Input 1. IN1U

Range: LC, LF, PU ( process unit ) If the unit is neither LC nor LF, then
selects PU.
Default: LC or L F.
DP1 : Selects the location of the decimal point for most ( not all ) process DP1
related parameters.
Range: ( For T/C and RTD ) NO.DP, 1-DP
( For Linear ) NO.DP, 1-DP, 2-DP, 3-DP
Default: 1-DP
40 UM25001C
IN1L : Selects the low scale value for the Linear type input 1. IN1L
Hidden if : T/C or RTD type is selected for IN1.
IN1H : Selects the high scale value for the Linear type input 1. IN1H
Hidden if : T/C or RTD type is selected for IN1.
How to use IN1L and IN1H :

If 4 - 20 mA is selected for IN1,let SL specifies the input signal low ( ie. 4 mA ),
SH specifies the input signal high ( ie. 20 mA ), S specifies the current input
signal value, the conversion curve of the process value is shown as follows :
process value
IN1H
Figure 3.1 Conversion Curve for
PV1
Linear Type Process Value
IN1L
input signal
SL S SH
S SL
Formula : PV1 = IN1L + ( IN1H IN1L )
SH SL
2
Example : A 4-20 mA current loop pressure transducer with range 0 - 15 kg/cm
is connected to input 1, then perform the following setup :
IN1 = 4 - 20 IN1L = 0.0
IN1U = PU IN1H = 15.0
DP1 = 1-DP
Of course, you may select other value for DP1 to alter the resolution.
3 2 OUT1 & OUT2 Types

O1TY : Selects the signal type for Output 1.
The selection should be consistent with the output 1 module installed.
The available output 1 signal types are :
RELY : Mechanical relay
SSRD : Pulsed voltage output to drive SSR O1TY
SSR : Isolated zero-switching solid state relay
4 - 20 : 4 - 20 mA linear current output
0 - 20 : 0 - 20 mA linear current output
0 - 1 V : 0 - 1 V linear voltage output O2TY
0 - 5 V : 0 - 5 V linear voltage output
1 - 5 V : 1 - 5 V linear voltage output
0 - 10V : 0 - 10 V linear voltage output
O2TY : Selects the signal type for Output 2
The selection should be consistent with the output 2 module installed.
The available output 2 signal types are the same as for O1TY.
The range for linear current or voltage may not be very accurate. For 0 % output,
the value for 4 - 20 mA may be 3.8 mA to 4 mA; while for 100 % output, the value
for 4 - 20 mA may be 20 mA to 21 mA. However, this deviation will not degrade
the control performance at all.
UM25001C 41
3 3 Rearrange User Menu
The conventional controllers are designed with a fixed parameters' scrolling. If SEL1
you need a more friendly operation to suit your application, the manufacturer
will say " sorry " to you. The BTC-2500 has the flexibility for you to select those
parameters which are most significant to you and put these parameters in the SEL2
front of display sequence.
SEL1 : Selects the most significant parameter for view and change.
SEL2 : Selects the 2'nd significant parameter for view and change. SEL3
SEL3 : Selects the 3'rd significant parameter for view and change.
SEL4 : Selects the 4'th significant parameter for view and change.
SEL5 : Selects the 5'th significant parameter for view and change. SEL4
Range : NONE, TIME, A1.SP, A1.DV, A2.SP, A2.DV, RAMP, OFST,
REFC, SHIF, PB1, TI1, TD1, C.PB, DB, SP2, PB2, TI2, TD2
When using the up-down key to select the parameters, you may not obtain
SEL5
all of the above parameters. The number of visible parameters is dependent
on the setup condition. The hidden parameters for the specific application are
also deleted from the SEL selection.
Example :
A1FN selects TIMR
A2FN selects DE.HI
PB1 = 10
TI1 = 0
SEL1 selects TIME
SEL2 selects A2.DV
SEL3 selects OFST
SEL4 selects PB1
SEL5 selects NONE
Now, the upper display scrolling becomes :
PV
3 4 Display SV Instead of PV
In certain applications where set point value (SV) is more important than DISF
process value (PV) for the user, the parameter DISF ( display format ) then can
has two values:
be used to achieve this purpose.
Press keys to enter setup menu , then press several times
until appears on the display. If you need the process value to be Display process
displayed, then select by using or key for DISF, If you need set value
point value instead of process value to be displayed, then select for Display set point
DISF. Also refer to the flow chart in Section 1-5 to see the location of DISF. value
42 UM25001D
3 5 Heat Only Control
Heat Only ON-OFF Control : Select REVR for OUT1, Set PB1 to 0, SP1 is used Setup ON-OFF :
to adjust set point value, O1HY is used to adjust dead band for ON-OFF OUT1 =
control, TIME is used to adjust the dwell timer ( enabled by selecting TIMR for PB1 = 0
A1FN or A2FN ). The output 1 hysteresis ( O1HY ) is enabled in case of PB1 = Adjust :SP1, O1HY, TIME( if enabled)
0 . The heat only on-off control function is shown in the following diagram :
PV
SP1+O1HY/2
SP1 Dead band = O1HY

SP1 O1HY/2
Figure 3.2 Heat Only

Time
OUT1 Action ON-OFF Control
ON
OFF
Time
The ON-OFF control may introduce excessive process oscillation even if
hysteresis is minimized to the smallest. If ON-OFF control is set ( ie. PB1 = 0 ),
TI1, TD1, CYC1, OFST, CPB and PL1 will be hidden and have no function to the
system. The manual mode, auto-tuning, self-tuning and bumpless transfer will
be disabled too.
Heat only P ( or PD ) control : Select REVR for OUT1, set TI1 to 0, SP1 is used Setup P:
to adjust set point value, TIME is used to adjust the dwell timer ( enabled by OUT1 =
selecting TIMR for A1FN or A2FN ). OFST been enabled in case of TI1 = 0 TI1 = 0
is used to adjust the control offset ( manual reset ). Adjust CYC1 according to CYC1 ( if RELAY, SSRD or SSR is
the output 1 type ( O1TY ).Generally, CYC1= 0.5 ~ 2 sec for SSRD and SSR, selected for O1TY )
CYC1=10 ~ 20 sec for relay output .CYC1 is ignored if linear output is selected
for O1TY. O1HY is hidden if PB1 is not equal to 0. Adjust :
OFST Function : OFST is measured by % with range 0 - 100.0 %. In the steady SP1, OFST, TIME ( if enabled ),
state ( ie. process has been stabilized ) if the process value is lower than the PB1 ( = 0 ), TD1
set point a definite value, say 5 C, while 20 C is used for PB1, that is lower 25
%, then increase OFST 25 %, and vice versa. After adjusting OFST value, the
process value will be varied and eventually, coincide with set point.
Using the P control ( TI1 set to 0 ), the auto-tuning and self-tuning are disabled.
Refer to section 3-21 " manual tuning " for the adjustment of PB1 and TD1.
Manual reset ( adjust OFST ) is not practical because the load may change
from time to time and often need to adjust OFST repeatedly. The PID control
can avoid this situation.
Heat only PID control : Selecting REVR for OUT1, SP1 is used to adjust set Setup PID :
point value. TIME is used to adjust the dwell timer ( enabled by selecting OUT1 =
TIMR for A1FN or A2FN ). PB1 and TI1 should not be zero. Adjust CYC1 O1TY
according to the output 1 type ( O1TY ). Generally, CYC1 = 0.5 ~ 2 sec for CYC1 ( if RELAY, SSRD or SSR is
selected for O1TY )
SSRD and SSR, CYC1 = 10 ~ 20 sec for relay output. CYC1 is ignored if
SELF = NONE or YES
linear output is selected for O1TY. Adjust:
In most cases the self-tuning can be used to substitute the auto-tuning. See SP1, TIME ( if enabled ), PB1 ( = 0 ),
Section 3-19. If self-tuning is not used ( select NONE for SELF ), then use TI1 ( = 0 ), Td1.
auto-tuning for the new process, or set PB1, TI1 and TD1 with historical values. Auto-tuning:
See section 3-20 for auto-tuning operation. If the control result is still Used for new process. during initial
unsatisfactory, then use manual tuning to improve the control . See section tuning
3-21 for manual tuning. BTC-2500 contains a very clever PID and Fuzzy
Self-tuning:
algorithm to achieve a very small overshoot and very quick response to the
Used for a process any time.
process if it is properly tuned.
Manual Tuning:
May be used if self-tuning and
auto-tuning are inadequate.
UM25001C 43
3 6 Cool Only Control
ON-OFF control, P ( PD ) control and PID control can be used for cool control. Setup Cool Control :
Set OUT1 to DIRT ( direct action ). The other functions for cool only ON-OFF OUT1 =
control, cool only P ( PD ) control and cool only PID control are same as
descriptions in section 3-5 for heat only control except that the output variable
( and action ) for the cool control is inverse to the heat control, such as the
following diagram shows:
PV
SP1+O1HY/2
SP1 Dead band = O1HY

SP1 O1HY/2
OUT1 Action Time
ON
Figure 3.3 Cool Only
OFF ON-OFF Control
Time
Refer to section 3-5 in which similar descriptions for heat only control can be
applied to cool only control.
44 UM25001C
3 7 Heat-Cool Control
The Heat-Cool Control can use one of 6 combinations of control modes. Setup of parameters for each control
mode are shown in the following table.
Heat Cool Setup Values

Control Modes
Uses Uses OUT1 OUT2 O1HY OFST PB1 TI1 TD1 CPB DB A2FN A2MD A2HY
DE.HI
Heat : ON-OFF
OUT1 OUT2 REVR =AL2 =0 or NORM
Cool : ON-OFF
PV1.H
DE.LO
Heat : ON-OFF
OUT2 OUT1 DIRT =AL2 =0 =0 or NORM
Cool : P ( PD )
PV1.L
DE.LO
Heat : ON-OFF
OUT2 OUT1 DIRT =AL2 =0 =0 or NORM
Cool : PID
PV1.L
DE.HI
Heat : P ( PD )
OUT1 OUT2 REVR =AL2 =0 =0 or NORM
Cool : ON-OFF
PV1.H
DE.HI
Heat : PID
OUT1 OUT2 REVR =AL2 =0 =0 or NORM
Cool : ON-OFF
PV1.H
Heat : PID
OUT1 OUT2 REVR COOL =0 =0
Cool : PID
: Don't care
: Adjust to meet process Table 3.1 Heat-Cool Control Setup
requirements
NOTE : The ON-OFF control may result excessive overshoot and undershoot problems in the process. The P ( or PD )
control will result in a deviation process value from the set point. It is recommended to use PID control for the Heat-Cool
control to produce a stable and zero offset process value.
Other Setup Required : O1TY, CYC1, O2TY, CYC2, A2SP, A2DV

O1TY & O2TY are set in accordance with the types of OUT1 & OUT2 installed. CYC1 & CYC2 are selected according to
the output 1 type ( O1TY ) & output 2 type ( O2TY ).
Generally, selects 0.5 ~ 2 sec. for CYC1, if SSRD or SSR is used for O1TY; 10 ~ 20 sec. if relay is used for O1TY, and
CYC1 is ignored if linear output is used. Similar condition is applied for CYC2 selection.
If OUT2 is configured for ON-OFF control ( by selecting = AL2 ), the OUT2 acts as alarm output, and the process alarm
as well as deviation alarm ( see section 3-9 & 3-10 ) can be used. Adjust A2SP to change set point if process alarm is
used, and adjust SP1 ( with preset A2DV ) to change set point if deviation alarm is used.
Examples:
Heat PID+Cool ON-OFF : Set OUT1= REVR, OUT2= =AL2, A2FN= PV1.H, A2MD=NORM, A2HY=0.1, PB1=0,
TI1=0,TD1=0, and set appropriate values for O1TY and CYC1.
Heat PID+Cool PID : set OUT1=REVR, OUT2=COOL, CPB=100, DB=-4.0, PB1=0, TI1=0 TD1=0, and set appropriate
values for O1TY, CYC1, O2TY, CYC2.
If you have no idea about a new process, then use self-tuning program to optimize the PID values by selecting YES for
SELF to enable the self-tuning program .See section 3-19 for self-tuning description. You can use the auto-tuning
program for the new process or directly set the appropriate values for PB1, TI1 & TD1 according to the historical records
for the repeated systems. If the control behavior is still inadequate, then use manual tuning to improve the control. See
section 3-21 for manual tuning.
UM25001D 45
CPB Programming : The cooling proportional band is measured by % of PB with range 1~255. Initially set 100% for
CPB and examine the cooling effect. If cooling action should be enhanced then decrease CPB, if cooling action is
too strong then increase CPB. The value of CPB is related to PB and its value remains unchanged throughout the
self-tuning and auto-tuning procedures.
Adjustment of CPB is related to the cooling media used. For air is used as cooling media, adjust CPB at 100(%).
For oil is used as cooling media, adjust CPB at 125(%). For water is used as cooling media, adjust CPB at 250(%).
DB Programming: Adjustment of DB is dependent on the system requirements. If more positive value of DB (

greater dead band ) is used, an unwanted cooling action can be avoided but an excessive overshoot over the set
point will occur. If more negative value of DB ( greater overlap ) is used, an excessive overshoot over the set point
can be minimized but an unwanted cooling action will occur. It is adjustable in the range -36.0% to 36.0 % of PB1 (
or PB2 if PB2 is selected ). A negative DB value shows an overlap area over which both outputs are active. A
positive DB value shows a dead band area over which neither output is active.
46 UM25001D
3 8 Dwell Timer
Alarm 1 or alarm 2 can be configured as dwell timer by selecting TIMR for
A1FN or A2FN, but not both, otherwise Er07 will appear. As the dwell timer is
Error Code
configured, the parameter TIME is used for dwell time adjustment.
The dwell time is measured in minute ranging from 0 to 6553.5 minutes. Once
the process reaches the set point the dwell timer starts to count from zero until
time out.The timer relay will remain unchanged until time out. The dwell timer
operation is shown as following diagram.
PV
SP1
Figure 3.4 Dwell Timer Function
Time
A1 or A2
TIME
ON
OFF
Time
Timer starts
If alarm 1 is configured as dwell timer, A1SP, A1DV, A1HY and A1MD are hidden.
Same case is for alarm 2.
Example :
Set A1FN=TIMR or A2FN=TIMR but not both.
Adjust TIME in minutes
A1MD ( if A1FN=TIMR ) or A2MD ( if A2FN=TIMR ) is ignored in this case.
If alarm 1 is selected for dwell timer, an external 5V DC relay is required to drive
AC load.
UM25001C 47
3 9 Process Alarms
There are at most two independent alarms available by adjusting OUT2. If
=AL2 is selected for OUT2, then OUT2 will perform alarm 2 function. Now
Error Code
A2FN can't be selected with NONE, otherwise Er06 will be displayed.
A process alarm sets an absolute trigger level ( or temperature ). When the
process ( could be PV1, PV 2 or PV1-PV2 ) exceeds that absolute trigger level
an alarm occurs. A process alarm is independent from set point.
Adjust A1FN ( Alarm 1 function ) in setup menu. One of 8 functions can be
selected for process alarm. These are : PV1.H, PV1.L, PV2.H, PV2.L, P1.2.H,
P1.2.L, D1.2.H, D1.2.L. When the PV1.H or PV1.L is selected the alarm
examines the PV1 value. When the PV2.H or PV2.L is selected the alarm
examines the PV2 value. When the P1.2.H or P1.2.L is selected the alarm
occurs if the PV1 or PV2 value exceed the trigger level. When the D1.2.H or
D1.2.L is selected the alarm occurs if the PV1-PV2 ( difference ) value exceeds
the trigger level. The trigger level is determined by A1SP ( Alarm 1 set point )
and A1HY ( Alarm 1 hysteresis value ) in User Menu for alarm 1. The hysteresis
value is introduced to avoid interference action of alarm in a noisy environment.
Normally A1HY can be set with a minimum ( 0.1 ) value.
A1DV and/or A2DV are hidden if alarm 1 and/or alarm 2 are set with process
alarm.
Normal Alarm : A1MD = NORM

When a normal alarm is selected, the alarm output is de-energized in the 8 Types of Process Alarms :
non-alarm condition and energized in an alarm condition. PV1.H, PV1.L, PV2.H, PV2.L, P1.2.H,
P1.2.L, D1.2.H, D1.2.L
Latching Alarm : A1MD = LTCH
If a latching alarm is selected, once the alarm output is energized, it will Process Alarm 1
remain unchanged even if the alarm condition is cleared. The latching alarms Setup : A1FN, A1MD
are disabled when the power is shut off or if event input is applied with proper Adjust : A1SP, A1HY
selection of EIFN. Trigger level = A1SPA1/2 A1HY
Holding Alarm : A1MD = HOLD Process Alarm 2

A holding alarm prevents an alarm from power up. The alarm is enabled Setup : OUT2, A2FN, A2MD
only when the process reaches the set point value ( may be SP1 or SP2, Adjust : A2SP, A2HY
See section 4-1 event input ). Afterwards, the alarm performs same Trigger level = A2SPA1/2 A2HY
function as normal alarm.
Latching / Holding Alarm : A1MD = LT.HO Reset Latching alarm

A latching / holding alarm performs both holding and latching function. 1. Power off
2. Apply Event input in accordance
with proper selection of EIFN
Examples:
A1SP = 200 A1HY = 10.0
A1MD = NORM A1FN = PV1.H
Process proceeds
205 205 ON 205 205 205

Figure 3.5
195 195 195 195 OFF 195 Normal Process Alarm
48 UM25001C
( 3-9 2'nd page )
A1SP = 200 A1HY = 10.0

A1MD = LTCH A1FN = PV1.H
Process proceeds
205 205 ON 205 205 205

195 195 195 195 195
Figure 3.6
Latching Process Alarm
A1SP = 200 A1HY = 10.0 SP1 = 210

A1MD = HOLD A1FN = PV1.L
Process proceeds
210 210 210 210

205 205 205 205 205 OFF 205
195 195 195 195 ON 195 195
Figure 3.7
Holding Process Alarm
A1SP = 200 A1HY = 10.0 SP1 = 210

A1MD = LT.HO A1FN = PV1.L
Process proceeds
210 210 210 210

205 205 205 205 205 205
195 195 195 195 ON 195 195 Figure 3.8
Latching / Holding
Process Alarm
Although the above descriptions are based on alarm 1, the same conditions can
be applied to alarm 2.
UM25001C 49
3 10 Deviation Alarm
OUT2 can be configured as alarm 2 by selecting=AL2. If OUT2 selects=AL2,
then output 2 will perform alarm 2 function. Now A2FN can't be selected with Error Code
NONE, otherwise Er06 will appear.
A deviation alarm alerts the user when the process deviates too far from set 2 Types of Deviation Alarms :
point. The user can enter a positive or negative deviation value ( A1DV, A2DV ) DE.HI, DE.LO
for alarm 1 and alarm 2. A hysteresis value ( A1HY or A2HY ) can be selected to
avoid interference problem of alarm in a noisy environment. Normally, A1HY Deviation Alarm 1
and A2HY can be set with a minimum ( 0.1 ) value. Setup : A1FN, A1MD
Trigger levels of alarm are moving with set point. Adjust : SP1, A1DV, A1HY
For alarm 1, Trigger levels=SP1+A1DVA1/2 A1HY. Trigger levels=SP1+A1DVA1/2A1HY
For alarm 2, Trigger levels=SP1+A2DVA1/2 A2HY.
A1SP and/or A2SP are hidden if alarm 1 and/or alarm 2 are set with deviation Deviation Alarm 2 :
alarm. One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2. Setup : OUT2, A2FN, A2MD
These are: Normal alarm, Latching alarm, Holding alarm and Latching/Holding Adjust : SP1, A2DV, A2HY
alarm. See Section 3-9 for descriptions of these alarm modes. Trigger levels=SP1+A2DVA/2A2HY
Examples:
A1FN = DE.HI, A1MD = NORM, SP1 = 100, A1DV=10, A1HY=4
Process proceeds
112 112 ON 112 112 112

108 108 108 108 OFF 108
Figure 3.9
100 100 100 100 100
Normal Deviation Alarm
A1FN = DE.HI, A1MD = LTCH, SP1 = 100, A1DV=10, A1HY=4

Process proceeds
112 112 ON 112 112 112

108 108 108 108 108 Figure 3.10
100 100 100 100 100 Latching Deviation Alarm
A1HY = DE.LO, A1MD = HOLD, SP1 = 100, A1DV= -10, A1HY=4

Process proceeds
100 100 100 100 100 100 100 Figure 3.11 Holding
92 92 92 92 92 92 OFF 92
Deviation Alarm
88 88 88 88 ON 88 88 88
A1HY= DE.LO, A1MD = LT.HO, SP1 = 100, A1DV= -10, A1HY=4

Process proceeds
100 100 100 100 100 100 100 Figure 3.12

92 92 92 92 92 92 92 Latching /Holding
88 88 88 88 ON 88 88 88 Deviation Alarm
50 UM25001C
3 11 Deviation Band Alarm
A deviation band alarm presets two reference levels relative to set point. Two 2 Types of Deviation Band Alarms:
types of deviation band alarm can be configured for alarm 1 and alarm 2. These DB.HI, DB.LO
are deviation band high alarm ( A1FN or A2FN select DB.HI ) and deviation
Deviation Band Alarm 1 :
band low alarm ( A1FN or A2FN select DB.LO ). If alarm 2 is required, then
select =AL2 for OUT2. Now A2FN can't be selected with NONE, otherwise Setup: A1FN, A1MD
Er06 will appear. A1SP and A1HY are hidden if alarm 1 is selected with Adjust: SP1, A1DV
deviation band alarm. Similarly, A2SP and A2HY are hidden if alarm 2 is Trigger levels= SP1 A A1DV
selected with deviation band alarm. Deviation Band Alarm 2 :
Trigger levels of deviation band alarm are moving with set point. For alarm 1,
Setup : OUT2, A2FN, A2MD
trigger levels=SP1AA1DV. For alarm 2, trigger levels=SP1AA2DV.
One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2. These Adjust : SP1, A2DV
are : Normal alarm, Latching alarm, Holding alarm and Latching/Holding alarm. Trigger levels = SP1 A A2DV
See Section 3-9 for descriptions of these alarm modes.
Error Code
Examples:
A1FN = DB.HI, A1MD = NORM, SP1 = 100, A1DV = 5
Process proceeds
105 105 105 ON 105 OFF 105

100 100 100 100 100 Figure 3.13
ON 95 OFF 95 95 95 95 Normal Deviation
Band Alarm
A1FN = DB.LO, A1MD = LTCH, SP1 = 100, A1DV = 5

Process proceeds
105 105 105 105 105 105

100 100 100 100 100 100 Figure 3.14
95 ON 95 95 95 95 95 Latching Deviation
Band Alarm
A1FN = DB.HI, A1MD = HOLD, SP1 = 100, A1DV = 5

Process proceeds
105 105 105 ON 105 OFF 105 105

Figure 3.15
100 100 100 100 100 100
Holding Deviation
95 95 95 95 95 ON 95
Band Alarm
A1FN = DB.HI, A1MD = LT.HO, SP1 = 100, A1DV = 5

Process proceeds
105 105 105 ON 105 105 105

100 100 100 100 100 100 Figure 3.16
95 95 95 95 95 95 Latching /Holding
Deviation Band Alarm
UM25001D 51
3 12 Heater Break Alarm
A current transformer ( parts No. CT94-1 ) should be installed to detect the Heater Break Alarm 1
heater current if a heater break alarm is required. The CT signal is sent to Setup : IN2 = CT
input 2, and the PV2 will indicate the heater current in 0.1 Amp. resolution. A1FN = PV2.L
The range of current transformer is 0 to 50.0 Amp. A1MD = NORM
For more detailed descriptions about heater current monitoring, please see A1HY = 0.1
Section 3-25. Adjust : A1SP
Trigger levels : A1SP A1/2 A1HY
Heater Break Alarm 2

Example: Setup : IN2 = CT
A furnace uses two 2KW heaters connected in parallel to warm up the process. A2FN = PV2.L
The line voltage is 220V and the rating current for each heater is 9.09A. If we A2MD = NORM
want to detect any one heater break, set A1SP=13.0A, A1HY=0.1 A2HY = 0.1
A1FN=PV2.L, A1MD=NORM, then Adjust : A2SP
Trigger levels : A2SP A1/2 A2HY
Limitations :
1. Linear output can't use heater break
alarm.
No heater breaks 1 heater breaks 2 heaters breaks 2. CYC1 should use 1 second or
longer to detect heater current reliably.
Alarm ! Alarm !
20 30 20 30 20 30
Figure 3.17
10 40 10 40 10 40
Heater Break Alarm
A A A
0 50 0 50 0 50
52 UM25001C
3 13 Loop Break Alarm
A1FN selects LB if alarm 1 is required to act as a loop break alarm. Similarly, if Loop Break Alarm 1
alarm 2 is required to act as a loop break alarm, then set OUT2 with=AL2 and Setup : A1FN = LB
A1FN with LB. A1MD = NORM, LTCH
TIME, A1SP, A1DV and A1HY are hidden if alarm 1 is configured as a loop break
alarm. Similarly, TIME, A2SP, A2DV and A2HY are hidden if alarm 2 is configured Loop Break Alarm 2
as a loop break alarm. Setup : OUT2 = =AL2
One of 4 kinds of alarm modes can be selected for alarm 1 and alarm 2. These A2FN = LB
are : Normal alarm, Latching alarm, Holding alarm and Latching/Holding alarm. A2MD = NORM, LTCH
However, the Holding mode and Latching/Holding mode are not recommended
to be chosen for loop break alarm since loop break alarm will not perform
holding function even if it is set with holding or latching/holding mode. See
Section 3-9 for the descriptions of these alarm modes.
Loop Break Conditions are detected during a time interval of 2TI1 ( double of
integral time, but 120 seconds maximum ). Hence the loop break alarm
doesn't respond quickly as it occurs. If the process value doesn't increase ( or
decrease ) while the control variable MV1 has reached to its maximum ( or
minimum ) value within the detecting time interval, a loop break alarm ( if
configured ) will be actuated.
Heater Sensor
Process
Figure 3.18
Switching Loop Break Sources
Device
Controller
Loop Break Sources : Sensor, Controller, Heater, Switching Device
Loop Break Alarm ( if configured ) occurs when any following condition

happens:
1. Input sensor is disconnected ( or broken ).
2. Input sensor is shorted.
3. Input sensor is defective.
4. Input sensor is installed outside ( isolated from ) the process.
5. Controller fails ( A-D converter damaged ).
6. Heater ( or generally, chiller, valve, pump, motor etc. ) breaks or fails or
uninstalled.
7. Switching device ( used to drive heater ) is open or shorted.
UM25001C 53
3 14 Sensor Break Alarm
Alarm 1 or alarm 2 can be configured as sensor break alarm by selecting SENB Sensor Break Alarm 1
for A1FN or A2FN. If alarm 2 is required for sensor break alarm, then Setup: A1FN=SENB
OUT2 should be selected with =AL2. A1MD=NORM, LTCH
The sensor break alarm is activated as soon as failure mode occurs. Refer to Hidden: TIME, A1SP, A1DV
Section 3-17 for failure mode conditions. Note that A-D failure also creates a A1HY
sensor break alarm. TIME,A1SP, A1DV, and A1HY are hidden if alarm 1 is
configured as a sensor break alarm. Similarly, TIME, A2SP, A2DV and A2HY are Sensor Break Alarm 2
hidden if alarm 2 is configured as a sensor break alarm. Setup: OUT2= =AL2
One of 4 kinds of alarm modes can be selected for sensor break alarm. These A2FN=SENB
are: Normal alarm, Latching alarm, Holding alarm and Latching/Holding alarm. A2MD=NORM, LTCH
However, the Holding alarm and Latching/Holding alarm are not recommended Hidden: TIME , A2SP, A2DV
to be chosen for sensor break alarm since sensor break alarm will not perform A2HY
holding function even if it is set with holding or latching/holding mode. See
Section 3-9 for the descriptions of these alarm modes.
3 15 SP1 Range
SP1L ( SP1 low limit value ) and SP1H ( SP1 high limit value ) in setup menu
are used to confine the adjustment range of SP1. Setup : SP1L, SP1H
Example : A freezer is working in its normal temperature range -10 C to -15 C.

In order to avoid an abnormal set point, SP1L and SP1H are set with the
following values:
SP1L = -15 C SP1H = -10 C
Now SP1 can only be adjusted within the range from -10 C to -15 C.
IN1H ( or sensor range high )
SP1H
SP1 Figure 3.19 SP1 Range
SP1L
IN1L ( or sensor range low )
54 UM25001C
3 16 PV1 Shift
In certain applications it is desirable to shift the controller display value from
its actual value. This can be easily accomplished by using the PV1 shift
function.
Press the " scroll " key to the parameter SHIF. The value you adjust here, either
positive or negative, will be added to the actual value. The SHIF function will
alter PV1 only.
Here is an example. A process is equipped with a heater, a sensor and a
subject to be warmed up. Due to the design and position of the components in
the system, the sensor could not be placed any closer to the part. Thermal
gradient ( different temperature ) is common and necessary to an extent in any
thermal system for heat to be transferred from one point to another. If the
difference between the sensor and the subject is 35 C, and the desired
temperature at the subject to be heated is 200 C, the controlling value or the
temperature at the sensor should be 235 C. You should input -35 C as to
subtract 35 C from the actual process display. This in turn will cause the
controller to energize the load and bring the process display up to the set point
value.
Subject Subject Subject

Heater Heater Heater
Heat Heat Heat

Transfer Transfer Transfer
165 C 165 C 200 C
200 C 200 C 235 C
Sensor Sensor Sensor
C C C
35 C temperature Adjust SHIF Display is stable

difference is observed SHIF= -35 C SHIF= -35 C
SHIF= 0 Supply more heat PV=SV
Figure 3.20
PV1 Shift Application
UM25001C 55
3 17 Failure Transfer
Failure Mode Occurs as :
The controller will enter failure mode as one of the following conditions occurs:
1. SB1E
1. SB1E occurs ( due to the input 1 sensor break or input 1 current below 1mA
2. SB2E
if 4-20 mA is selected or input 1 voltage below 0.25V if 1-5 V is selected ) if
3. ADER
PV1, P1-2 or P2-1 is selected for PVMD or PV1 is selected for SPMD.
2. SB2E occurs ( due to the input 2 sensor break or input 2 current below 1mA Failure Transfer of outout 1 and output 2
if 4-20 mA is selected or input 2 voltage below 0.25V if 1-5 V is selected ) if occurs as :
PV2, P1-2 or P2-1 is selected for PVMD or PV2 is selected for SPMD. 1. Power start ( within 2.5 seconds )
3. ADER occurs due to the A-D converter of the controller fails. 2. Failure mode is activated
3. Manual mode is activated
The output 1 and output 2 will perform the failure transfer function as one of the 4. Calibration mode is activated
following conditions occurs:
1. During power starts ( within 2.5 seconds ). Failure Transfer of alarm 1 and alarm 2
2. The controller enters the failure mode. occurs as :
3. The controller enters the manual mode. 1. Failure mode is activated
4. The controller enters the calibration mode.
Failure Transfer Setup :
1. O1FT
Output 1 Failure Transfer, if activated, will perform : 2. O2FT
1. If output 1 is configured as proportional control ( PB1 = 0 ), and BPLS is 3. A1FT
selected for O1FT, then output 1 will perform bumpless transfer. Thereafter 4. A2FT
the previous averaging value of MV1 will be used for controlling output 1.
2. If output 1 is configured as proportional control ( PB1 = 0 ), and a value of
0 to 100.0 % is set for O1FT, then output 1 will perform failure transfer.
Thereafter the value of O1FT will be used for controlling output 1.
3. If output 1 is configured as ON-OFF control ( PB1 = 0 ), then output 1 will be
driven OFF if O1FN selects REVR and be driven ON if O1FN selects DIRT.
Output 2 Failure Transfer, if activated, will perform :

1. If OUT2 selects COOL, and BPLS is selected for O1FT, then output 2 will
perform bumpless transfer. Thereafter the previous averaging value of MV2
will be used for controlling output 2.
2. If OUT2 selects COOL, and a value of 0 to 100.0 % is set for O2FT, then
output 2 will perform failure transfer. Thereafter the value of O1FT will be
used for controlling output 2.
Alarm 1 Failure Transfer is activated as the controller enters failure mode.

Thereafter the alarm 1 will transfer to the ON or OFF state preset by A1FT.
Exception: If Loop Break (LB) alarm or sensor Break (SENB) alarm is
configured for A1FN, the alarm 1 will be switched to ON state independent
of the setting of A1FT. If Dwell Timer (TIMR) is configured for A1FN, the alarm 1
will not perform failure transfer.
Alarm 2 Failure Transfer is activated as the controller enters failure mode.

Thereafter the alarm 2 will transfer to the ON or OFF state preset by A2FT.
Exception: If Loop Break (LB) alarm or sensor Break (SENB) alarm is
configured for A2FN, the alarm 2 will be switched to ON state independent
of the setting of A2FT. If Dwell Timer (TIMR) is configured for A2FN, the alarm 2
will not perform failure transfer.
56 UM25001C
3 18 Bumpless Transfer
The bumpless transfer function is available for output 1 and output 2 ( provided Bumpless Transfer Setup :
that OUT2 is configured as COOL ). 1. O1FT = BPLS
2. O2FT = BPLS
Bumpless Transfer is enabled by selecting BPLS for O1FT and/or O2FT and
activated as one of the following cases occurs :
Bumpless Transfer Occurs as :
1. Power starts ( within 2.5 seconds ).
1. Power Starts ( within 2.5 seconds )
2. The controller enters the failure mode. See section 3-17 for failure mode
2. Failure mode is activated
descriptions.
3. Manual mode is activated
3. The controller enters the manual mode. See section 3-23 for manual mode
4. Calibration mode is activated
descriptions.
4. The controller enters the calibration mode. See chapter 6 for calibration
mode descriptions.
As the bumpless transfer is activated, the controller will transfer to open-loop
control and uses the previous averaging value of MV1 and MV2 to continue
control.
Without Bumpless Transfer
PV Power interrupted
Sensor break
Set point
Figure 3.21 Benefits of Bumpless
Large Transfer
deviation
Time
Since the hardware and software need time to be initialized, the control is
abnormal as the power is recovered and results in a large disturbance to
the process. During the sensor breaks, the process loses power.
With Bumpless Transfer
PV Power interrupted
Sensor break
Set point
Load varies
Small
deviation
Time
After bumpless transfer configured, the correct control variable is applied Warning :After system fails,
immediately as the power is recovered, the disturbance is small. During the never depend on bumpless
sensor breaks, the controller continues to control by using its previous value. If
transfer for a long time,
the load doesn't change, the process will remain stable. Thereafter, once the
load changes, the process may run away. Therefore, you should not rely on a
otherwise it might cause a
bumpless transfer for a longer time. For fail safe reason, an additional alarm problem to the system to run
should be used to announce the operator when the system fails. For example, away.
a Sensor Break Alarm, if configured, will switch to failure state and announces
the operator to use manual control or take a proper security action when the
system enters failure mode.
UM25001C 57
3 19 Self tuning
The Self-tuning which is designed by using an innovative algorithm provides an Self-tune Menu
alternative option for tuning the controller. It is activated as soon as SELF is
selected with YES. When Self-tuning is working, the controller will change its
working PID values and compares the process behavior with previous cycle. If Selects
the new PID values achieve a better control, then changing the next PID values
in the same direction, otherwise, changing the next PID values in reverse Disable Self-tuning
direction. When an optimal condition is obtained, the optimal PID values will be or
stored in PB1, TI1, TD1 or PB2, TI2, TD2 which is determined by Event Input
conditions. See Section 4-1. When Self-tuning is completed, the value of SELF Enable Self-tuning
will be changed from YES to NONE to disable self-tuning function.
When the Self-tuning is enabled, the control variables are tuned slowly so that Default
the disturbance to the process is less than auto-tuning. Usually, the Self-tuning SELF=NONE
will perform successfully with no need to apply additional auto-tuning.
Exceptions: The Self-tuning will be disabled as soon as one of the following

conditions occurs:
1. SELF is selected with NONE.
2. The controller is used for on-off control, that is PB=0.
3. The controller is used for manual reset, that is TI=0.
4. The controller is under loop break condition.
5. The controller is under failure mode (e.g. sensor break).
6. The controller is under manual control mode.
7. The controller is under sleep mode.
8. The controller is being calibrated.
If the self-tuning is enabled, the auto-tuning can still be used any time. The self-
tuning will use the auto-tuning results for its initial values.
Benefits of Self-tuning: Benefits of Self-tune:

1. Unlike auto-tuning, Self-tuning will produce less disturbance to the process. 1. Less disturbance to the process.
2. Unlike auto-tuning, Self-tuning doesn't change control mode during tuning 2. Perform PID control during tuning
period. It always performs PID control. period.
3. Changing set point during Self-tuning is allowable. Hence, Self-tuning can 3. Available for ramping set point
be used for ramping set point control as well as remote set point control control and remote set point
where the set point is changed from time to time. control.
Operation:
The parameter SELF is contained in setup menu. Refer to Section 1-5 to
obtain SELF for initiating a self-tuning.
58 UM25001C
3 20 Auto tuning
The auto-tuning process is performed at set point.
The process will oscillate around the set point during tuning process.
Set a set point to a lower value if overshooting beyond the normal
process value is likely to cause damage.
The auto-tuning is applied in cases of :
* Initial setup for a new process
* The set point is changed substantially from the previous auto-tuning
value
* The control result is unsatisfactory
Operation : Applicable Conditions :
1. The system has been installed normally. PB1=0, TI1=0 if PB1,TI1,TD1
2. Use the default values for PID before tuning. assigned
The default values are : PB1=PB2=18.0 F
TI1=TI2=100 sec, TD1=TD2=25.0 sec, Of course, you can use other PB2=0, TI2=0, if PB2, TI2, TD2
reasonable values for PID before tuning according to your previous assigned
experiences. But don't use a zero value for PB1 and TI1 or PB2 and
TI2, otherwise, the auto-tuning program will be disabled.
3. Set the set point to a normal operating value or a lower value if
overshooting beyond the normal process value is likely to cause
damage.
4. Press until appears on the display.
5. Press for at least 3 seconds. The upper display will begin to flash
and the auto-tuning procedure is beginning.
NOTE :
Any of the ramping function, remote set point or pump function, if used,
will be disabled once auto-tuning is proceeding.
Procedures:
The auto-tuning can be applied either as the process is warming up
( Cold Start ) or as the process has been in steady state ( Warm Start ).
See Figure 3.22.
If the auto-tuning begins apart from the set point ( Cold Start ), the unit Pre-tune Function Advantage:
enters Warm-up cycle. As the process reaches the set point value, the Consistent tuning results can be
unit enters waiting cycle. The waiting cycle elapses a double integral obtained
time ( TI1 or TI2, dependent on the selection, see Section 4.1 ) then it
enters a learning cycle. The double integral time is introduced to allow
the process to reach a stable state. Before learning cycle, the unit
performs pre-tune function with a PID control. While in learning cycle the
unit performs post-tune function with an ON-OFF control. Learning
cycle is used to test the characteristics of the process. The data are
measured and used to determine the optimal PID values. At the end of
the two successive ON-OFF cycles the PID values are obtained and
automatically stored in the nonvolatile memory.
After the auto-tuning procedures are completed, the process display
will cease to flash and the unit revert to PID control by using its new PID
values.
During pre-tune stage the PID values will be modified if any unstable
phenomenon which is caused by incorrect PID values is detected.
Without pre-tune stage, like other conventional controller, the tuning
result will be strongly related to the time when the auto-tuning is
applied. Hence different values will be obtained every time as auto-
tuning is completed without pre-tune. It is particularly true when the
auto-tuning are applied by using cold start and warm start.
UM25001C 59
Auto-tuning Auto-tuning
Begins Complete
Warm-up Waiting
PV
Cycle Cycle Learning Cycle New PID Cycle
=2 Integral
Time
Set Point Figure 3.22
Auto-tuning Procedure
Pre-tune Stage Post-tune Stage
PID Control ON-OFF Control PID Control
Time
Cold Start
Auto-tuning Auto-tuning
Begins Complete
Pre-tune Stage
Waiting
PV
Cycle Learning Cycle New PID Cycle
=2 Integral
Time
Set Point
Pre-tune
Stage Post-tune Stage
PID Control ON-OFF Control PID Control
Time
Warm Start
If the auto-tuning begins near the set point ( warm start ), the unit passes the
warm-up cycle and enters the waiting cycle. Afterward the procedures are same
as that described for cold start.
Auto-Tuning Error
If auto-tuning fails an ATER message will appear on the upper display in cases of : Auto-Tuning Error
If PB exceeds 9000 ( 9000 PU, 900.0 LF or 500.0 LC ).
or if TI exceeds 1000 seconds.
or if set point is changed during auto-tuning procedure.
or if event input state is changed so that set point value is changed.
Solutions to
1. Try auto-tuning once again.
2. Don't change set point value during auto-tuning procedure.
3. Don't change event input state during auto-tuning procedure.
4. Use manual tuning instead of auto-tuning. ( See section 3-21 ).
5. Touch any key to reset message.
60 UM25001C
3 21 Manual Tuning
In certain applications ( very few ) using both self-tuning and auto-tuning to
tune a process may be inadequate for the control requirement, then you can
try manual tuning.
Connect the controller to the process and perform the procedures according
to the flow chart shown in the following diagram. Figure 3.23
Manual Tuning
Procedure
Use initial PID values
to control the process
Wait and Examine Wait and Examine

the Process the Process
Is Is
No steady state No steady state
reached ? reached ?
Yes Yes
Does No Does
the process No the process
oscillate ? oscillate ?
Yes Yes
1 Flag 0 Flag PB1 PBu
Oscillating period Tu
2PB1 PB1 0.5PB1 PB1

Load new PID values
1.7 PBu PB1
Tu TI1
0.3 Tu TD1
Wait and Examine
the Process
Is
END
No steady state
reached ?
Yes
Does
the process No NOTE :
oscillate ? The final PID values can't be zero.
If PBu=0 then set PB1=1.
Yes If Tu < 1 sec, then set TI1=1 sec.
No No
Flag=0 ? Flag=1 ?
Yes Yes
1.6PB1 PB1 0.8PB1 PB1
The above procedure may take a long time before reaching a new steady state
since the P band was changed. This is particularly true for a slow process. So
the above manual tuning procedures will take from minutes to hours to obtain
optimal PID values.
UM25001C 61
The PBu is called the Ultimate P Band and the period of oscillation Tu is called
the Ultimate Period in the flow chart of Figure 3.23 . When this occurs, the
process is called in a critical steady state. Figure 3.24 shows a critical steady
state occasion.
If PB=PBu
PV the process sustains to oscillate
Figure 3.24 Critical Steady
Set point State
Tu
Time
If the control performance by using above tuning is still unsatisfactory, the

following rules can be applied for further adjustment of PID values :
ADJUSTMENT SEQUENCE SYMPTOM SOLUTION

Slow Response Decrease PB1 or PB2
(1) Proportional Band ( P )
PB1 and/or PB2 High overshoot or
Increase PB1 or PB2
Oscillations
Slow Response Decrease TI1 or TI2
(2) Integral Time ( I )
TI1 and/or TI2 Instability or
Increase TI1 or TI2 Table 3.2 PID Adjustment Guide
Oscillations
Slow Response or
(3) Derivative Time ( D ) Decrease TD1 or TD2
Oscillations
TD1 and/or TD2
High Overshoot Increase TD1 or TD2
Figure 3.25 shows the effects of PID adjustment on process response.
P action
PV PB too low
Perfect
Set point
Figure 3.25 Effects of PID
Adjustment
PB too high
Time
62 UM25001C
I action
TI too high
PV
Figure 3.25 (Continued )

Set point
Effects of PID Adjustment
Perfect
TI too low
Time
D action
TD too low
PV
Perfect
Set point
TD too high
Time
UM25001C 63
3 22 Signal Conditioner DC Power Supply
Three types of isolated DC power supply are available to supply an external transmitter or
sensor. These are 20V rated at 25mA, 12V rated at 40 mA and 5V rated at 80 mA. The DC
voltage is delivered to the output 2 terminals.
Two-line Transmitter
+
Set
OUT2=
(DC Power Supply)
+
1 2 3 4 5 6 7
Figure 3.26
8 9 10 11 12 13 14 DC Power Supply Applications
4 - 20mA
Three-line Transmitter
Bridge Type
or sensor
Sensor
OUT COM IN
+ +
1 2 3 4 5 6 7 1 2 3 4 5 6 7
8 9 10 11 12 13 14 8 9 10 11 12 13 14
+ +
V or mA
Caution:
Don't use the DC power supply beyond its rating current to avoid damage.
Purchase a correct voltage to suit your external devices. See ordering code in section 1-2.
64 UM25001C
3 23 Manual Control
The manual control may be used for the following purposes:
( 1 ) To test the process characteristics to obtain a step response as well as an
impulse response and use these data for tuning a controller.
( 2 ) To use manual control instead of a close loop control as the sensor fails or
the controller's A-D converter fails. NOTE that a bumpless transfer can not
be used for a longer time. See section 3-18.
( 3 ) In certain applications it is desirable to supply a process with a constant
demand.
Operation:
Press until ( Hand Control ) appears on the display. Means
Press for 3 seconds then the upper display will begin to flash and the lower MV1=38.4 %
display will show . The controller now enters the manual control mode. for OUT1 ( or Heating )
Pressing the lower display will show and alternately where
indicates output 1 ( or heating ) control variable value MV1 and Means
indicates output 2 ( or cooling ) control variable value MV2. Now you can use MV2=7.63 %
up-down key to adjust the percentage values for H or C. for OUT2 ( or Cooling )
The controller performs open loop control as long as it stays in manual control
mode. The H value is exported to output 1 ( OUT1 ) and C value is exported to
output 2 provided that OUT2 is performing cooling function ( ie. OUT2 selects
COOL ).
Exception
If OUT1 is configured as ON-OFF control ( ie. PB1=0 if PB1 is assigned or
PB2=0 if PB2 is assigned by event input ), the controller will never perform
manual control mode.
Exit Manual Control

To press keys the controller will revert to its previous operating mode
( may be a failure mode or normal control mode ).
UM25001C 65
3 24 Display Mode
Operation
Press several times until ( Display ) appears on the display.
Then press to enter the display mode. You can select more parameters to
view by pressing or pressing in reverse sequence . The system
mode of the controller and its operation will remain unchanged.
Entering the Display Mode, the upper display will show the parameter value
and the lower display will show the parameter symbol except and
. shows the percentage value for output 1 and shows
the percentage value for output 2 on the lower display while the upper display
shows the current process value.
PVHI/PVLO show the historical extreme ( maximum or minimum ) values of

the process on the upper display. The historical extreme values are saved in a
nonvolatile memory even if it is unpowered. Press for at least 6 seconds to
reset both the historical values PVHI and PVLO and begin to record new
peak process values.
MV1/MV2 show the process value on the upper display and shows
the percentage control value for the output 1, shows the percentage
control value for the output 2.
DV shows the difference value between process and set point ( ie. PV-SV ). PVHI
This value is used to control the output 1 and output 2.
PVLO
PV1 shows the process value of input 1 on the upper display. MV1
PV2 shows the process value of input 2 on the upper display. MV2
PB shows the current proportional band value used for control. DV
TI shows the current integral time used for control. PV1
TD shows the current derivative time used for control. PV2

Since the controller is performing FUZZY control the values of PB, TI, and PB
TD may change from time to time.
TI
CJCT shows the temperature at the cold junction, measured in LC TD
independent of the unit used.
CJCT
PVR Shows the changing rate of the process in LC ( LF or PU ) per minute. PVR
It may be negative if the process is going down.
PVRH
PVRH/PVRL The maximum and minimum changing rate of the process since
power up, are measured in LC ( LF or PU ) per minute. PVRH is a positive PVRL
value while PVRL is a negative value.
NOTE
The controller will never revert to its PV/SV display from Display Mode unless
you press the keys.
66 UM25001C
3 25 Heater Current Monitoring
A current transformer, CT94-1, should be equipped to measure the heater Accessory Installed:
current. Select CT for IN2. The input 2 signal conditioner measures the heater CT94-1
current during the heater is powered and the current value will remain Setup
unchanged during the heater is unpowered. The PV2 will indicate the heater IN2=CT
current. About how to read PV2 value, please refer to section 3-24. O1TY or O2TY=RELY, SSRD or SSR
CYC1 or CYC2 >1 sec
NOTES
If the heater to be measured is controlled by output 1, then CYC1 should Limitations
select 1 second or longer and O1TY should use RELY, SSRD or SSR . Similarly, 1. Linear output type can't be used.
if the heater to be measured is controlled by output 2, then CYC2 should 2. CYC1 ( or CYC2 ) should select 1
select 1 second or longer and O2TY should use RELY, SSRD or SSR to second or longer to detect heater
provide an adequate time for A to D converter to measure the signal. current reliably.
Since CT94-1 can detect a full-wave AC current only, a DC or half-wave AC 3. Only full-wave AC current can be
can't be measured. detected.
3 26 Reload Default Values

The default values listed in Table 1.4 are stored in the memory as the product
leaves the factory. In certain occasions it is desirable to retain these values
after the parameter values have been changed. Here is a convenient tool to
reload the default values.
Operation
Press several times until . Then press . The upper display will FILE 0
show .Use up-down key to select 0 to 1. If BC unit is required, select 0 BC Default File
for FILE and if BF unit is required, select 1 for FILE. Then Press for at least 3
seconds. The display will flash a moment and the default values are reloaded. FILE 1
BF Default File
CAUTION
The procedures mentioned above will change the previous setup data. Before
doing so, make sure that if it is really required.
UM25001C 67
Chapter 4 Programming the Full Function
4 1 Event Input
Refer to Section 2-10 for wiring an event input.
The Event input accepts a digital type signal. Two types of signal : (1) relay or
Terminals:
switch contacts and (2) open collector pull low, can be used to switch the
event input. 11 Event input +
One of ten functions can be chosen by using ( EIFN ) contained in 10 Event input
setup menu.
NONE : Event input no function

If chosen, the event input function is disabled. The controller will use PB1, TI1 EIFN
and TD1 for PID control and SP1 ( or other values determined by SPMD ) for
the set point. 0 NONE
1 SP2
SP2: If chosen, the SP2 will replace the role of SP1 for control. 2 PID2
PID2: If chosen, the second PID set PB2, TI2 and TD2 will be used to replace 3 SP.P2
PB1, TI1 and TD1 for control. 4 RS.A1
5 RS.A2
SP.P2: If chosen, the SP2, PB2, TI2 and TD2 will replace SP1, PB1, TI1 and
TD1 for control. 6 R.A1.2
7 D.O1
NOTE: If the second PID set is chosen during Auto-tuning and/or Self-tuning 8 D.O2
procedures, the new PID values will be stored in PB2, TI2 and TD2. 9 D.O1.2
10 LOCK
RS.A1: Reset Alarm 1 as the event input is activated. However, if alarm 1
condition is still existent, the alarm 1 will be retriggered again while the event
input is released.
RS.A2: Reset Alarm 2 as the event input is activated. However, if alarm 2
condition is still existent, the alarm 2 will be retriggered again while the event
input is released.
R.A1.2: Reset both Alarm 1 and Alarm 2 as the event input is activated.
However, if the alarm 1 and/or alarm 2 are still existent, the alarm 1 and/or
alarm 2 will be triggered again while the event input is released.
The RS.A1, RS.A2 and R.A1.2 are particularly suitable to be used for a
Latching and/or Latching/Holding alarms.
D.O1: Disable Output 1 as the event input is activated. The output 1 control
variable MV1 is cleared to zero.
D.O2: Disable Output 2 as the event input is activated. The output 2 control
variable MV2 is cleared to zero.
D.O1.2: Disable both Output 1 and Output 2 by clearing MV1 and MV2 values
as soon as the event input is activated.
When any of D.O1, D.O2 or D.O1.2 is selected for EIFN, the output 1 and/or
output 2 will revert to their normal conditions as soon as the event input is
released.
LOCK: All parameters are locked to prevent from being changed. See Section
4-13 for more details.
68 UM25001C
SP2F Function: Define format of SP2 value . If SP2F in the setup menu is SP2F=Format of SP2 Value
selected with ACTU, the event input function will use SP2 value for its second ACTU: SP2 is an actual value
set point. If SP2F is selected with DEVI, the SP1 value will be added to SP2. DEVI: SP2 is a deviation value
The sum of SP1 and SP2 (SP1+SP2) will be used by the event input function
for the second set point value. In certain applications it is desirable to move
second set point value with respect to set point 1 value. The DEVI function for
SP2 provides a convenient way in this case.
Modification from RS-232 to Event input:

Because of limitation of pin number, pin 11 is used for both Event input and
RS-232. If you want to change function of BTC-2500 from RS-232 to event
input, you must modify jumper J51 and J52 on CPU board by opening jumper
J52 and shorting jumper J51. Refer to Section 2-16 for the location of jumper
J51/J52.
4 2 Second Set Point

In certain applications it is desirable to change the set point automatically
without the need to adjust the set point. You can apply a signal to event input
Apply Signal To
terminals ( pin 10 and pin 11 ).The signal applied to event input may come
from a Timer, a PLC, an Alarm Relay, a Manual Switch or other devices. Select 11 Event input +
SP2 for EIFN which is contained in setup menu. 10 Event input
This is available only with the case that SP1.2, MIN.R or HR.R is used for
SPMD, where MIN.R and HR.R are used for the ramping function.
See Section 4-4. Setup
EIFN choose SP2 or SP.P2
Application 1: A process is required to be heated at a higher temperature as
soon as its pressure exceeds a certain limit. Set SPMD=SP1.2, EIFN=SP2 ( or
Availability
SP.P2 if the second PID is required for the higher temperature too ).
The pressure gauge is switched ON as it senses a higher pressure. Connect SPMD choose
the output contacts of the pressure gauge to the event input. SP1 is set with a
normal temperature and SP2 is set with a higher temperature. Choose ACTU or
for SP2F.
or
Application 2: An oven is required to be heated at 300 LC from eight o'clock
AM to six o'clock PM. After six o'clock PM it is desirable to be maintained at
80 LC. Use a programmable 24 hours cycle timer for this purpose. The timer Format of SP2 Value
output is used to control event input. Set SPMD=SP1.2, and EIFN=SP2 ( or SP2F choose
SP.P2 if the second PID is required to be used for the second set point ).
Actual Value
SP1 is set with 300 LC and SP2 is set with 80 LC. Choose ACTU for SP2F. After or Deviation Value
six o'clock PM the timer output is closed. The event input function will select
SP2 ( =80 LC) to control the process.
Refer to Section 4-1 for more descriptions about SP2F function.
UM25001C 69
4 3 Second PID Set
In certain applications the process characteristics is strongly related to its
process value. The BTC-2500 provides two set of PID values. When the
Apply Signal To
process is changed to different set point, the PID values can be switched to
another set to achieve an optimum condition. 11 Event input +
10 Event input
Auto-tuning Second PID
The optimal PID values for a process may vary with its process value and set Setup
point. Hence if a process is used for a wide range of set point, dual PID values EIFN choose PID2 or SP.P2
are necessary to optimize the control performance. If the first PID set is
selected ( event input is not applied ) during auto-tuning procedure, the PID
values will be stored in PB1, TI1 and TD1. Similarly, if the second PID set is
selected ( event input is applied while PID2 or SP.P2 is selected for EIFN )
during auto-tuning, the PID values will be stored in PB2, TI2 and TD2 as soon
as auto-tuning is completed.
Application 1: Programmed by Set Point

Choose SP.P2 for EIFN then both set point and PID values will be switched to EIFN= SP.P2
another set simultaneously. The signal applied to event input may come from
a Timer, a PLC, an Alarm Relay, a Manual Switch or other devices.
Application 2: Programmed by Process Value

If the process value exceeds a certain limit, 500 C for example, it is desirable EIFN= PID2
to use another PID values to optimize the control performance. You can use a
process high alarm to detect the limit of the process value. Choose PV1H for Alarm output Controls the Event
A1FN, A1MD selects NORM, adjust A1SP to be equal to 500 C, and choose input
PID2 for EIFN. If the temperature is higher than 500 C, then alarm 1 is
activated. The alarm 1 output is connected to event input, the PID values will
change from PB1, TI1 and TD1 to PB2, TI2 and TD2.
Refer to Section 5-9 for more details. See Section 5-9
70 UM25001C
4 4 Ramp & Dwell
Ramp
The ramping function is performed during power up as well as any time the set SPMD Choose
point is changed. Choose MINR or HRR for SPMD, the unit will perform the
Unit / minute
ramping function. The ramp rate is programmed by using RAMP which is
or Unit / hour
contained in user menu.
Example without Dwell Timer Adjust

Select MINR for SPMD, IN1U selects C, DP1 selects 1-DP, Set RAMP=10.0. RAMP
SP1 is set to 200 C initially, and changed to 100 C after 30 minutes since
power up. The starting temperature is 30 C. After power up the process is
running like the curve shown below:
PV
200
C
Figure 4.1 RAMP Function
100
C
30
C
Time
0 17 30 40 (minutes)
Note: When the ramp function is used, the lower display will show the current
ramping value. However it will revert to show the set point value as soon as the
up or down key is touched for adjustment. The ramping value is initiated to
process value either power up or RAMP and /or set point are changed. Setting
RAMP to zero means no ramp function at all.
Dwell
The Dwell timer can be used separately or accompanied with a Ramp. If A1FN A1FN or A2FN Choose
selects TIMR, the alarm 1 will act as a dwell timer. Similarly, alarm 2 will act as
a dwell timer if A2FN selects TIMR. The timer is programmed by using TIME TIMER
which is contained in user menu. The Timer starts to count as soon as the
process reaches its set point, and triggers an alarm as time out. Here is an Adjust
example.
TIME
Example without Ramp
Select TIMR for A1FN, IN1U selects F, DP1 selects NODP, Set TIME=30.0
SP1 is set to 400 F initially, and corrected to 200 F before the process
reaches 200 F. As the process reaches set point ( ie. 200 F ) the timer starts
to count. The TIME value can still be corrected without disturbing the Timer
before time out. The TIME is changed to 40.0 after 28 minutes since the
process reached its set point. The behavior of process value and alarm 1 are
shown below.
SP1 changed to 200 F

PV reaches set point
TIME changed to 40.0
200 F
28 PV
minutes
Alarm 1 ON Figure 4.2 Dwell Timer
Alarm 1 OFF
Time (minutes)
40
minutes
UM25001C 71
Once the timer output was energized it will remain unchanged until power
down or an event input programmed for resetting alarm is applied.
Note: The TIMR can't be chosen for both A1FN and A2FN simultaneously, Error Code.
otherwise an error code will produce.
Ramp & Dwell

A ramp may be accompanied with a dwell timer to control the process. Here is
an example.
Example with Ramp & Dwell

Select HRR for SPMD, IN1U selects PU, DP1 select 2-DP, Set RAMP=60.00
A2FN selects TIMR, Set TIME=20.0 As power is applied the process value
starts from 0.00 and set SP1=30.00, SP2=40.00. The timer output is used to
control event input
PV
40.00
30.00
PV
Figure 4.3 Ramp
Accompanied with a Dwell Timer
Time (minutes)
0 30 50 60
Alarm 2 ON
Alarm 2 OFF
72 UM25001C
4 5 Remote Set Point
SPMD selecting PV1 or PV2 will enable the BTC-2500 to accept a remote set Setup
point signal. If PV1 is selected for SPMD, the remote set point signal is sent to FUNC=FULL
Input 1, and Input 2 is used for process signal input. If PV2 is selected for SPMD=PV2, PVMD=PV1
SPMD, the remote set point signal is sent to Input 2, and Input 1 is used for or SPMD=PV1, PVMD=PV2
process signal. To achieve this, set the following parameters in the Setup
menu.
Case 1: Use Input 2 to accept remote set point

FUNC=FULL
IN2, IN2U, DP2, IN2L, IN2H, are set according to remote signal.
PVMD=PV1
IN1, IN1U, DP1, are set according to the process signal
IN1L, IN1H if available, are set according to the process signal
SPMD= PV2
Case 2: Use Input 1 to accept remote set point

FUNC=FULL
IN1, IN1U, DP1, IN1L, IN1H, are set according to remote signal.
PVMD=PV2
IN2, IN2U, DP2, are set according to the process signal
IN2L, IN2H if available, are set according to the process signal
SPMD= PV1
Note: If PV1 are chosen for both SPMD and PVMD, an Error Code will Error Message
appear. If PV2 are chosen for both SPMD and PVMD, an Error Code
will appear. You should not use these cases, otherwise, the BTC-2500 will not
control properly.
UM25001C 73
4 6 Differential Control
In certain applications it is desirable to control a second process such that its
Setup
process value always deviates from the first process with a constant value. To
achieve this, set the following parameter in the Setup menu. PVMD=P1-2
or PVMD=P2-1
FUNC=FULL
SPMD=SP1.2
IN1,IN1L,IN1H are set according to input 1 signal
IN2,IN2L,IN2H are set according to input 2 signal
IN1U, DP1, IN2U, DP2, are set according to input 1 and input 2 signal
PVMD=P1-2 or P2-1
SPMD=SP1.2
The response of PV2 will be parallel to PV1 as shown in the following diagram
PV
PV1
PV2
Figure 4.4
PV=PV1 PV2 Relation between PV1 and PV2
or PV2 PV1 for a Differential Control
Set point=SP1 or SP2
=Set point
Time
The PV display will indicate PV1-PV2 value if P1-2 is chosen for PVMD, or
PV2-PV1 value if P2-1 is chosen for PVMD. If you need PV1 or PV2 to be
displayed instead of PV, you can use the Display Mode to select PV1 or PV2 to
be viewed. See Section 3-24.
Error Messages Error Message

If PVMD selects P1-2 or P2-1, while SPMD selects PV1 or PV2, an
Error Code will appear.
In this case the signals used for input 1 and input 2 should be the same unit
and same decimal point, that is, IN1U=IN2U, DP1=DP2, otherwise
Error Code will appear.
74 UM25001C
4 7 Output Power Limits
In certain system the heater ( or cooler ) is over-designed such that the
Menu
process is too heavily heated or cooled. To avoid an excessive overshoot
and/or undershoot you can use the Power Limit function. PL1
Output 1 power limit PL1 is contained in User Menu. If output 2 is not used for PL2
cooling ( that is COOL is not selected for OUT2 ), then PL2 is hidden. If the
controller is used for ON-OFF control, then both PL1 and PL2 are hidden.
Operation:
Press for 3 seconds, then press several times to reach PL1 and PL2.
The PL1 and PL2 are adjusted by using up-down keys with range 0 - 100%.
Example:
OUT2=COOL, PB1=10.0 BC, CPB=50, PL1=50, PL2=80
The output 1 and output 2 will act as following curves:
MV1
100%
50% Figure 4.5

Power Limit Function
PV
10 C
OUT1
MV2
100%
80%
PV
5 C
OUT2
NOTE:
The adjusting range of MV1 ( H ) and MV2 ( C ) for manual control and/or failure
transfer are not limited by PL1 and PL2.
UM25001C 75
4 8 Data Communication
Two types of interface are available for Data Communication. These are RS-485 Benefits:
RS-485 and RS-232 interface. Since RS-485 uses a differential architecture to Long distance
drive and sense signal instead of a single ended architecture which is used for Multi-units
RS-232, RS-485 is less sensitive to the noise and suitable for a longer
distance communication. RS-485 can communicate without error over 1 km
distance while RS-232 is not recommended for a distance over 20 meters. RS-232 Benefits:
Direct Connection to a PC
Using a PC for data communication is the most economic way. The signal is
transmitted and received through the PC communication Port ( generally RS- Order BTC-2500-XXXXX1
232 ). Since a standard PC can't support RS-485 port, a network adaptor ( for RS-485
such as SNA10A, SNA10B ) has to be used to convert RS-485 to RS-232 for a
PC if RS-485 is required for the data communication. But there is no need to Order BTC-2500-XXXXX2
be sad. Many RS-485 units ( up to 247 units ) can be connected to one RS- for RS-232
232 port; therefore a PC with 4 comm ports can communicate with 988 units. It
is quite economic.
Setup RS-485 Setup

Enters the setup menu. FUNC=FULL
Select FULL ( Full function ) for FUNC. COMM=485
Select 485 for COMM if RS-485 is required, or 232 if RS-232 is required. Select PROT=RTU
RTU ( ie. Modbus protocol RTU mode ) for PROT. Set individual address as ADDR=Address
for those units which are connected to the same port. BAUD=Baud Rate
Set the Baud Rate ( BAUD ), Data Bit ( DATA ), Parity Bit ( PARI ) and Stop Bit ( DATA=Data Bit Count
STOP ) such that these values are accordant with PC setup conditions. PARI=Parity Bit
STOP=Stop Bit Count
NOTE: If the BTC-2500 is configured for RS-232 communication, the EI ( Event
Input ) and input 2 are disconnected internally. The unit can no longer perform RS-485 Terminals
event input function ( EIFN ) and other input 2 functions. 12 TX1
When you insert a RS-232 module (CM94-2) to the connectors on CPU board 13 TX2
(C250), you also need to modify the jumper J51 and J52 according to Section
2-16.
If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable
RS-232 Setup
should be modified for proper operation of RS-232 communication according FUNC=FULL
to Section 2-16. COMM=232
PROT=RTU
ADDR=Address
BAUD=Baud Rate
DATA=Data Bit Count
PARI=Parity Bit
STOP=Stop Bit Count
RS-232 Terminals
12 TX1
13 TX2
11 COM
76 UM25001C
4 9 Analog Retransmission
The Analog Retransmission is available for model number BTC-2500-XXXXXN Setup Menu
Where N=3,4 or 5. See Ordering Code in section 1-2. FUNC
COMM
Setup
AOFN
Select FULL for FUNC in the setup menu.
COMM selects a correct output signal which should be accordant with the AOLO
retransmission option used. Five types of retransmission output are available. AOHI
These are : 4-20 mA, 0-20mA, 0-5V, 1-5V and 0-10V. There are 8 types of
parameters that can be retransmitted according to the Analog Function (
Terminals
AOFN ) selected. These are : PV1, PV2, PV1 PV2, PV2 PV1, SV, MV1, MV2
12 AO+
and PV SV. Refer to Table 1.4 for a complete description. AOLO selects a
value corresponding to output zero and AOHI selects a value corresponding 13 AO
to output SPAN.
How to Determine Output Signal:

AOLO and AOHI are set to map to output signal LOW SL ( e.g. 4mA ) and
output signal High SH ( e.g. 20mA ) respectively. The analog output signal
AOS corresponding to an arbitrary value of parameter AOV is determined by
the following curve.
Output
Signal
SH
AOS Figure 4.6
SL Conversion Curve
for Retransmission
Parameter Value
AOLO AOV AOHI
Formula: AOS=SL+( AOV AOLO ) SH SL

AOHI AOLO
AOHI AOLO
AOV=AOLO+( AOS SL )
SH SL
Notes: NOTES
The setup values used for AOHI and AOLO must not be equal, otherwise,
incorrect value will happen. However, AOHI can be set either higher or lower AOHI=AOLO
than AOLO. If AOHI is set higher than AOLO it could result in a direct AOHI>AOLO:
conversion. If AOHI is set lower than AOLO it could result in a reverse Direct Conversion
conversion. AOHI<AOLO:
Reverse Conversion
Example
A control uses 4-20 mA analog output to retransmit difference value between
input 1 and input 2 ( PV1 PV2 ). It is required that if the difference value is -
100, 4mA will be exported, and if the difference value is 100, 20mA will be
exported. Make the following Setup for BTC-2500:
IN1U=PU, DP1=NODP, IN2U=PU, DP2=NODP, FUNC=FULL, COMM=4-20,
AOFN=P1-2, AOLO=-100, AOHI=100
UM25001C 77
4 10 Digital Filter
In certain application the process value is too unstable to be read. To improve Menu
this a programmable low pass filter incorporated in the BTC-2500 can be used. FILT
This is a first order filter with time constant specified by FILT parameter which
is contained in setup menu. The default value of FILT is 0.5 sec. before
shipping. Adjust FILT to change the time constant from 0 to 60 seconds. 0 Filter is used to stabilize the
second represents no filter is applied to the input signal. The filter is process display.
characterized by the following diagram.
PV1
FILT=0
1 sec
FILT=1
Figure 4.7
Filter Characteristics
FILT=30 1 sec
Time
Note
The Filter is available only for PV1, and is performed for the displayed value
only. The controller is designed to use unfiltered signal for control even if Filter
is applied. A lagged ( filtered ) signal, if used for control, may produce an
unstable process.
78 UM25001C
4 11 Sleep Mode
To Enter Sleep Mode: Sleep Mode Features:
FUNC selects FULL to provide full function. Shut off display
SLEP selects YES to enable the sleep mode. Shut off outputs
Press for 3 seconds, the unit will enter its sleep mode. Green Power
During sleep mode: Replace Power Switch
(1) Shut off all display except a decimal point which is lit periodically.
(2) Shut off all outputs and alarms. Setup Menu
FUNC=FULL
To Exit Sleep Mode: SLEP=YES
(1) Press to leave the sleep mode.
(2) Disconnect the power.
Sleep Function can be used to replace a power switch to reduce the system cost.
Default: SLEP=NONE, Sleep mode is disabled.
Note: If the Sleep mode is not required by your system, the SLEP should select
NONE to disable sleep mode against undesirable occurrence.
UM25001C 79
4 12 Pump Control
Pump Control function is one of the unique features of BTC-2500. Using this PUMP: A Cost Effective
function the pressure in a process can be controlled excellently. The pressure yet Perfect Solution
in a process is commonly generated by a pump driven by a variable speed
motor. The complete system has the following characteristics which affects the
control behavior: 1, The system is very noisy. 2, The pressure is changed very
rapidly. 3, The pump characteristics is ultra nonlinear with respect to its speed.
4, The pump can't generate any more pressure as its speed is lower than half
of its rating speed. 5, An ordinary pump may slowly lose the pressure even if
the valves are completely closed.
Obviously a conventional controller can't fulfill the conditions mentioned above.

Only the superior noise rejection capability in addition to the fast sampling rate
owned by BTC-2500 can realize such application. To achieve this, set the
following parameters in the setup menu:
FUNC=FULL Key menu

EIFN=NONE SPMD
PVMD=PV1 SP2F
FILT=0.5 REFC
SELF=NONE
SP2
SPMD=PUMP
SP2F=DEVI
and program the following parameters in the user menu:
REFC= Reference constant

SP2= A negative value is added to SP1 to obtain the set point for idle
state
Since the pump can't produce any more pressure at lower speed, the pump Pump Control Features:
may not stop running even if the pressure has reached the set point. If this 1. Minimum oscillation of pressure
happens, the pump will be over worn out and waste additional power. To avoid 2. Rapidly stabilized
this, the BTC-2500 provides a Reference Constant REFC in the user menu. If 3. Guaranteed pump stop
PUMP is selected for SPMD, the controller will periodically test the process by 4. Programmable pump stopping
using this reference constant after the pressure has reached its set point. If the interval
test shows that the pressure is still consumed by the process, the controller
will continue to supply appropriate power to the pump. If the test shows that
the pressure is not consumed by the process, the controller will gradually
decrease the power to the pump until the pump stops running. As this
happens, the controller enters idle state. The idle state will use a lower set
point which is obtained by adding SP2 to SP1 until the pressure falls below
this set point. The idle state is provided for the purpose of preventing the
pump from been restarted too frequently. The value of SP2 should be negative
to ensure a correct function.
The pump functions are summarized as follows:

1. If the process is demanding material ( ie. lose pressure ), the controller
will precisely control the pressure at set point.
2. If the process no longer consumes material, the controller will shut off the
pump as long as possible.
3. The controller will restart the pump to control the pressure at set point as
soon as the material is demanded again while the pressure falls below a
predetermined value ( ie. SP1+SP2 ).
80 UM25001C
Programming Guide:
1. Perform auto-tuning to the system under such condition that the material
( ie. pressure ) is exhausted at typical rate. A typical value for PB1 is about
2
10 Kg/cm , TI1 is about 1 second, TD1 is about 0.2 second.
2. If the process oscillates around set point after auto-tuning, then increase
PB1 until the process can be stabilized at set point. The typical value of PB1
is about half to two times of the range of pressure sensor.
3. Increase FILT ( Filter ) can further reduce oscillation amplitude. But a value
of FILT higher than 5 ( seconds ) is not recommended. A typical value for FILT
is 0.5 or 1 .
4. Close the valves and examine that if the controller can shut off the pump
each time. The value of REFC is adjusted as small as possible so that the
controller can shut off the pump each time when all the valves are closed. A
typical value for REFC is between 3 and 5.
5. An ordinary pump may slowly lose the pressure even if the valves are
completely closed. Adjust SP2 according to the rule that a more negative
value of SP2 will allow the pump to be shut off for a longer time as the valves
are closed. A typical value for SP2 is about -0.50 Kg/cm 2 .
An Example is given in section 5-1 for pump control.
4 13 Remote Lockout
The parameters can be locked to prevent from being changed by using either Remote Lockout:
Hardware Lockout (see Section 1-3) or Remote Lockout or both. If you need 1.Connect external switch to terminal
the parameters to be locked by using an external switch (remote lockout 10 and 11 .
function), then connect a switch to terminals 10 and 11 (see Section 2-10), and 2. Set LOCK for EIFN
choose LOCK for EIFN (see Section 4-1). 3. Lock all parameters
If remote lockout is configured, all parameters will be locked as the external

switch is closed. When the switch is left open, the lockout condition is
determined by internal DIP switch (hardware lockout, see Section 1-3).
Hardware Lockout: Can be used only during initial setup.

Remote Lockout: Can be used any time.
UM25001C 81
Chapter 5 Applications
5 1 Pump / Pressure Control

A regulated water supply system is widely used in residence, water plant, PUMP: A Cost Effective
chemical plant, electrical plant, semiconductor plant ... etc. Taking the yet Perfect Solution
advantage of PUMP function, the BTC-2500 can be used for these
applications to achieve an economical yet versatile solution. Here is an
example:
BTC-2500-4137XX Pressure
Reservoir
O1 2
Kg/cm
O2
A1 Figure 5.1
Pressure A water Supply System
Sensor
BTC-2500 C
OUT1 IN1 OUT2
DC20V
4-20
mA 4-20 mA Water
Speed
Control Pump
Motor
3
AC AC
Inverter
Water
2
The water pressure is required to be controlled at 10 Kg/cm , to achieve this,
the following devices are used for this example:
Inverter: To supply a variable frequency AC voltage to the motor.
Motor: A 3- induction motor.
Pump: An economical type
Pressure Sensor: A three-wire or two-wire type pressure transducer with 0-20
Kg/cm 2 range.
Pressure Reservoir: Providing a smoother pressure for the system.
BTC-2500-4137XX: Order a BTC-2500 with standard input, 4-20 mA output 1,

20V DC output 2 for sensor power.
82 UM25001C
Set the following parameters in the setup menu:
FUNC=FULL
COMM: optional
IN1=4-20
IN1U=PU
DP1=2-DP
IN1L=0
IN1H=20.00
IN2=NONE
OUT1=REVR
O1TY=4-20
O1FT=0
OUT2=DCPS
A1FN: optional
EIFN=NONE
PVMD=PV1
FILT=1
SELF=NONE
SLEP=NONE
SPMD=PUMP
SP1L=5.00
SP1H=15.00
SP2F=DEVI
Adjust the following parameters in the user menu:
A1SP: optional Key menu:

REFC= 3 SPMD
PB1=10.00 SP2F
TI1=1 REFC
SP2
TD1=0.2
SP2= -0.50
PL1=100
Also refer to Section 4-12 for more details.
UM25001C 83
5 2 Variable Period Full Wave SSR ( VPFW SSR )
VPFW SSR is a variable period full wave solid-state relay. It can provide a zero
cross output with superior controllability compared to a conventional SSR with
a fixed time base. The block diagram of VPFW SSR is shown as follows:
AC AC
Input Output
+ Figure 5.2
Block Diagram of VPFW SSR
Pulsed Voltage
Control Input
Unlike a conventional SSR, the VPFW SSR always give the output an even number of
half cycles ( full wave ) as shown in the following diagram.
VPFW SSR Conventional SSR
Control Input
Power Input Figure 5.3 VPFW SSR

vs. Conventional SSR
Power Output
The VPFW switches the load without DC current, hence minimize the harmonic NOTES:
current and stress on the load. The load life is prolonged. 1.The VPFW SSR can be used to drive
resistant load and some types of
inductance load such as relay,
contactor, magnetic switch, solenoid
As the duty cycle ( ie. output power level ) of the control input is small, the off
valve etc. However, it can not drive
period will be extended to keep the output resolution so that the conversion
Motor and Capacitance Load.
error is minimized. As low as 0.1% of timing error can be achieved. Hence,
2. Only AC power can supply VPFW
VPFW SSR is particularly suitable for a smoother control.
SSR, otherwise, it will not operate
properly.
84 UM25001C
The advantages of VPFW SSR over conventional SSR are summarized as
following table:
Functions VPFW SSR Conventional SSR

Zero Cross Switching Yes Yes
Time Base Variable Fixed
A1% ( for 1 sec. Table 5.1
Proportional Timing Error A0.1%
cycle time ) Function Comparison between
Control Achievement Excellent Good Conventional SSR and VPFW SSR
Half on Cycles Even Even and Odd

DC Load Current Zero Nonzero
Harmonic Current Low Higher
Stress on the Load Low Higher
Load ( Heater ) Life Longer Shorter
The output 1 and output 2 of BTC-2500 can be connected to VPFW SSR

directly provided that a pulsed voltage drive output ( BTC-2500-XX2XXX or
BTC-2500-XXX2XX ) is ordered.
Here is an example:
BTC-2500-XX22XX
OUT1=REVR
O1TY=SSRD
O1
O2 CYC1=1.0 (sec )
Figure 5.4
A1 OUT2=COOL
VPFW SSR Application Example
O2TY=SSRD
BTC-2500 C CYC2=1.0 (SEC )
_ _
+
VPFW SSR
AC Power
Three phase VPFW SSR's are also available upon request.
UM25001C 85
5 3 Heat Only Control
An oven is designed to dry the products at 150 C for 30 minutes and then
stay unpowered for another batch. A BTC-2500 equipped with dwell timer is
used for this purpose. The system diagram is shown as follows :
Set
SP1=150.0
TIME=30.0
Oven
O1
T/C
O2
C
A1
Heater Figure 5.5

Heat Control Example
BTC-2500 C
4 3 6 5
Mains
Supply
OUT1
ON
Timer ( ALM2 ) OFF
To achieve this function set the following parameters in the setup menu.
FUNC=BASC (Basic function )
IN1=K_TC
IN1U= C
DP1=1_DP
OUT1=REVR
O1TY=RELY
CYC1=18.0
O1FT=BPLS
A2FN=TIMR
A2FT=ON
SELF=NONE
Auto-Tuning is performed at 150 C for a new oven.
86 UM25001C
5 4 Cool Only Control
A BTC-2500 is used to control a refrigerator at temperature below 0 BC. To ON-OFF control
avoid the set point adjustment beyond the interesting range, SP1L is set at - Direct Control Action
10 BC and SP1H is set at 0 BC. The temperature is lower than the ambient, a
cooling action is required. Hence select DIRT for OUT1. Since output 1 is used
to drive a magnetic contactor, O1TY selects RELY. A small temperature
oscillation is tolerable, hence use ON-OFF control to reduce the over-all cost.
To achieve ON-OFF control, PB1 is set with zero and O1HY is set at 0.1 BC.
Setup Summary:
Refrigerator
FUNC=BASC
IN1=PT.DN
IN1U= C
DP1=1-DP
OUT1=DIRT RTD
O1TY=RELY
SP1L=-10 C
SP1H= 0 C
User Menu: Mains

PB1=0 ( C ) Supply
O1HY=0.1 ( C )
8 9 10 5 6
O1
O2
A1
Figure 5.6
Cooling Control Example
BTC-2500 C
UM25001D 87
5 5 Heat-Cool Control
An injection mold required to be controlled at 120 C to ensure a consistent
quality for the parts. An oil pipe is buried in the mold. Since plastics is injected
at higher temperature ( e.g. 250 C ), the circulation oil needs to be cooled as
its temperature rises. Here is an example:
Injection Mold
Plastics
120 C
Figure 5.7
Heat-Cool Control Example
Oil
Pump
Oil Tank
Freezer RTD
Heater
Supply
4-20 mA
OUT2
OUT1
O1 IN1
O2
A1
BTC-2500 C
88 UM25001C
The PID Heat-Cool is used for the above example.
To achieve this set the following parameters in the Setup Menu: Key Menu
FUNC=BASC FUNC
IN1
IN1=PT.DN
IN1U
IN1U= C
DP1
DP1=1-DP OUT1
OUT1=REVR O1TY
O1TY=RELY CYC1
CYC1=18.0 (sec ) O1FT
O1FT=BPLS OUT2
OUT2=COOL O2TY
O2TY=4-20 O2FT
O2FT=BPLS SELF
SELF=STAR SP1
CPB
Adjust SP1 at 120.0 C , CPB at 125 ( % ) and DB at -4.0 (%). DB
Apply Auto-tuning at 120 C for a new system to get an optimal PID values.
See Section 3-20.
Adjustment of CPB is related to the cooling media used. If water is used as

cooling media instead of oil, the CPB is set at 250 (%). If air is used as cooling
media instead of oil, the CPB is set at 100 (%).
Adjustment of DB is dependent on the system requirements. More positive
value of DB will prevent unwanted cooling action, but will increase the
temperature overshoot. while more negative value of DB will achieve less
temperature overshoot, but will increase unwanted cooling action.
UM25001D 89
5 6 Ramp & Dwell
Example 1: Temperature cycling Chamber
A chamber is used to test the temperature cycling effect on the personal
computers. An external cycle timer is used to control the event input for
switching the set point. The products under test are required to stay at 60 C
for 1 hour and -10 C for 30 minutes. The transition interval between high-low
temperature is required to be 5 minutes. Make the following setup:
EIFN=SP.P2
A1FN=TIMR
OUT1=REVR, Relay Output
OUT2=COOL, 4-20mA Output
SPMD=MINR
IN1U= C
DP1=1-DP
The circuit diagram and its temperature profile are shown below:
Chamber Figure 5.8

A Temperature Cycling Chamber
Freezer
RTD
Heater
3 AC
1 Inverter
Mains + 5V DC
Relay
1 2 3 4 5 6 7
ON
65
8 9 10 11 12 13 14
OFF
35
TIME=60.0 (minutes )
SP1=60.0 C
SP2=-10.0 C Cycle Timer
CPB=100 (%)
RAMP=14.0 ( C/minute )
90 UM25001C
60 minutes 60 minutes
60 C 60 C
Figure 5.9
Temperature Profile
-10 C -10 C of Chamber
30 35
5 minutes minutes 65 minutes minutes
BTC-2500 provides 4-20 mA signal to control the speed of the Inverter.SP.P2

being chosen for EIFN is for the purpose of accomplishing a dual PID control.
You can perform auto-tuning twice at SP1 and SP2 for initial setup to the dual
PID values. Refer sections 3-20 and 4-3.
Example 2: Programmable Bread Baking Oven

Bread is baked in batches. A ramp is incorporated to control the thermal
gradient to suit for making the bread. A dwell timer is used to shut off the oven
power and announce the baker. The system is configured as shown in the
following diagram.
AC Relay
Heater 220VAC
Mains
Baking ON
Oven OFF
+ Heater
1 2 3 4 5 6 7 Figure 5.10
A Bread Baking Oven
8 9 10 11 12 13 14
5V DC
Relay
+
Push ON switch to start a batch. The temperature will rise with a ramp rate
determined by RAMP value. Bread is baked with the set point temperature for
a definite time which is programmed by TIME value, and then the power is
shut off. The temperature profile is shown in the following Figure.
40 A1FN=TIMR
minutes 40
PV SPMD=MINR Figure 5.11
minutes
180 C Time=40.0 ( minutes ) Temperature Profile
180 C of Baking Oven
RAMP=30.0 ( C/min )
Alarm 1: Form B Relay
30 C/min
30 C
Restart a
new batch
5 45 Cooling Time
down ( minutes )
UM25001C 91
5 7 Remote Set Point
An on-line multiple zone oven is used to dry paint. Since heat demand is
various at different position in the production line, multiple zones with
individual controls should be used to ensure a consistent temperature profile.
If you order a BTC-2500 with a retransmission unit for the master controller,
and retransmit its set point to the input 2 of the rest of slave controllers, each
zone will be synchronized with the same temperature. Here is an example:
To Control To Control To Control To Control

Zone 1 Heater Zone 2 Heater Zone 3 Heater Zone 4 Heater
OUT1 OUT1 OUT1 OUT1
O1 O1 O1 O1
O2 O2 O2 O2
A1 A1 A1 A1
Figure 5.12
BTC-2500 C BTC-2500 C BTC-2500 C BTC-2500 C Remote Set Point
Application
13 + 12 10 + 11 10 + 11 10 + 11
Master Slave Slave Slave
For master unit For slave units

FUNC= FULL FUNC= FULL
COMM= 1 5 V IN2= 1 5 V
AOLO= 0 C IN2L= 0 C
AOHI = 300 C IN2H= 300 C
PVMD= PV1 PVMD= PV1
SPMD= SP1.2 SPMD= PV2
Note: AOHI and IN2H should be set with values higher than the set point range used.
92 UM25001C
5 8 Differential Control
In certain applications it is desirable to control a second process such that its
process value always deviates from the first process with a constant value.
Water tank 1 is 5.12 meters height and water tank 2 level is desirable to be
maintained at 1 meter lower than tank 1 level.
FUNC= FULL
IN1, IN1L, IN1H : According to Sensor 1 signal
IN1U= PU
DP1= 2-DP
IN2, IN2L, IN2H : According to Sensor 2 signal ( Current signal has to be converted to a voltage
signal through a shunt resistor before sending to the controller input)
IN2U= PU
DP2= 2-DP
OUT1= REVR
O1TY= 4 20
PVMD= P1-2
SPMD=SP1.2
From Controller Output

Water Tank 1
Level Sensor 1
5.12 M Height
Figure 5.13
Outlet Differential Control Example
SV=1.00
PV=1.00
4-20 mA Valve Control Output
PV1=5.12 Water Tank 2
PV2=4.12 Level Sensor 2
OUT1
O1
O2
A1
4.12 M Height
Outlet
BTC-2500 C
IN1 IN2
Adjust SP1( here is 1.00 ) to control the difference between PV1 and PV2.
Choosing P1-2 for PVMD, the PV display will show the difference value ( PV1-
PV2 ) between PV1 and PV2, and this value will be stabilized to the set point (
here is 1.00 ).
If you need PV1 or PV2 instead of PV, you can use the Display Mode to select
PV1 or PV2 to be displayed. See Section 3-24. The above diagram indicates
PV2 instead of PV.
UM25001C 93
5 9 Dual Set Point / PID
The BTC-2500 will switch between the two PID sets based on the process
value, the set point or either of the event input. As the control ramps up to the
higher process value, the process characteristics changes. As this happens,
the original PID values are no longer valid. To achieve optimal control over the
entire range, a second PID set is used.
Example 1: Single Set Point / Dual PID

A heat treating furnace is used over the range of 400 C to 1200 C.
( 1 ) Set the following parameters in the Setup menu:
FUNC= FULL
A1FN= PV1H
A1MD= NORM
EIFN= PID2
PVMD= PV1
SPMD= MINR
( 2 ) Adjust the following parameters in the User menu:
A1SP= 800 C
A1HY= 1.0 C
PL1= 100 ( % )
RAMP: According to the process requirement
SP1: According to the process requirement
( 3 ) Tune first PID set at SP1= 500 C and tune second PID set at SP1=1100 C,
or set the proper values for PB1, TI1, TD1, PB2, TI2 and TD2 directly
according to the previous records to eliminate auto-tuning sequence.
The circuit diagram and its temperature profile are shown as follows :
AC power
Figure 5.14
Dual PID Furnace
1 2 3 4 5 6 7
To Heater
8 9 10 11 12 13 14 Furnace Power
Heater Input
Alarm 1 controls
Event input
C Process Value
Use PID 1
800 Figure 5.15

Dual PID Crossover
PID Crossover Value Use PID 2
Time
94 UM25001C
Example 2: Dual Set Point / PID
A heat treating furnace is required to harden the mold at a high temperature (
1000 C ) for 30 minutes, then the mold is cooled down with a programmable
ramp ( 20 C / minute ) toward a lower set point ( 200 C ). Use the dual set
point / PID and ramp / dwell functions for this application.
( 1 ) Set the following parameters in the Setup menu:
FUNC= FULL
A1FN= TIMR
EIFN= SP.P2
PVMD= PV1
SPMD= MINR
( 2 ) Adjust the following parameters in the User menu:
TIME= 30.0 ( Minutes )
RAMP= 20.0 ( C/Minute )
SP1= 1000 C
SP2= 200 C
PL1= 100 ( % )
( 3 ) Set the proper values for PB1, TI1, TD1,PB2, TI2 and TD2 directly according
to the previous records. For a new system tune first PID set at SP1=800 C
and tune second PID set at SP2=400 C.
The circuit diagram is same as shown in Figure 5.14. The temperature profile
is shown as below:
C 30 40
minutes minutes
1000
Figure 5.16
Dual Set Point /PID Profile
200
Use SP1,PID1 Use SP2,PID2
Time ( Minutes )
UM25001C 95
5 10 RS-485
A tile making plant has 5 production lines. Each production line is equipped
with 16 units of BTC-2500 to control the temperature for the kiln. They are
desirable to program the controllers and monitor the process in the control
room for the purpose of improving the quality and productivity. A cost effective
solution for the above application is to use 80 units of BTC-2500-XXXXX1 plus
a SNA10B Smart Network Adaptor and BC-Net PC based software for this
purpose.
The system is installed as shown in the following diagram.
Kiln 1
1 2 16 Figure 5.17
O1 O1 O1 RS-485 Applications
O2 O2 O2
A1 A1 A1
BTC-2500 C BTC-2500 C BTC-2500 C
TX1 TX2 TX1 TX2 TX1 TX2 TX1 TX2
Control Room
Terminator, 220 ohms/0.5W
Kiln 2 PC
TX1 Kiln 3 ( BC-Net )
Kiln 4
TX2
RS-232
Kiln 5
SNA10B
65 66 80
O1 O1 O1
TX2 TX1
O2 O2 O2
A1 A1 A1
BTC-2500 C BTC-2500 C BTC-2500 C
TX1 TX2 TX1 TX2 TX1 TX2 TX1 TX2
Twisted-pair wire, max. distance 1 Km
96 UM25001C
Setup Setup Menu
Enters the setup mode to configure each BTC-2500. Choose FULL for FUNC, FUNC
485 for COMM, RTU for PROT and select an unequal address ( ADDR ) for each COMM
unit. Use the same values of BAUD, DATA, PARI and STOP for BTC-2500's,
PROT
SNA10B and BC-Net. Also refer to Section 2-15 and Section 4-8.
ADDR
Taking the advantage of BC-Net software, the operator can monitor the BAUD
process on the PC screen, program the set point as well as other control DATA
parameters such as PID values, down load the ramp and soak profile to the
PARI
controllers, execute the manual control or trigger an auto-tuning.....etc. , and
print out a report as required. The historical data can be saved in the floppy STOP
disc, hard disc or a CD for permanent storage purpose.
UM25001C 97
5 11 RS-232
Suppose a chemical experiment is performed in a laboratory. And an engineer Setup Menu
desires to find out the relation between the chemical reaction and temperature. FUNC
He uses a BTC-2500 to control the temperature of the solution under test. A COMM
testing report containing the relation between the concentration and
PROT
temperature is particularly interested.
ADDR
BAUD
For a single unit application it is adequate to order a BTC-2500-xxxxx2 with
RS-232 communication and a BC-Net software. By using the BC-Net software DATA
the temperature data can be viewed and stored in a file. The user can PARI
program the temperature as well as other control parameters such as PID STOP
values. He can setup the controller, down load a ramp and soak profile, also
execute the manual control or auto-tuning procedure ..... etc. The results can
be printed out or stored in a file for the future reference.
Refer to Section 2-16 for installation and Section 4-8 for setup procedure.
98 UM25001C
5 12 Retransmit
An air-conditioned room uses two units of BTC-2500 to control its temperature
and humidity. The temperature and humidity are required to be recorded on a
chart recorder. The interesting ranges for these two quantity are: 20 C to 30 C
and 40% RH to 60% RH. The recorder inputs accept 0 - 5 V signal.
To achieve this, set the following parameters in the Setup menu.

UNIT 1: UNIT 2:
FUNC= FULL FUNC= FULL
COMM= 0 - 5V COMM= 0 - 5V
AOFN=PV1 AOFN=PV1
AOLO=20.0 ( C ) AOLO=40.0 ( % )
AOHI= 30.0 ( C ) AOHI= 60.0 ( % )
IN1= PTDN IN1= 0 - 1 V (According to humidity sensor )
IN1U= C IN1U= PU
DP1= 1-DP DP1= 1-DP
SP1= 25.0 SP1= 50.0

SP1L= 20.0 SP1L= 40.0
SP1H= 30.0 C SP1H= 60.0 %RH
O1 O1
O2 O2
A1 A1
BTC-2500 C BTC-2500 C
12 13 12 13
Retransmission Output
0-5V + + 0-5V
Figure 5.18
Retransmission Application
Chart Recorder
1. 20-30 C 2. 40-50%
SP1L and SP1H are used to limit the adjustment range of set point.
UM25001C 99
Chapter 6 Calibration
Do not proceed through this section unless there is a definite need to
re-calibrate the controller. Otherwise, all previous calibration data will be
lost. Do not attempt recalibration unless you have appropriate calibration
equipment. If calibration data is lost, you will need to return the controller
to your supplier who may charge you a service fee to re-calibrate the
controller.
Entering calibration mode will break the control loop. Make sure that if
the system is allowable to apply calibration mode.
Equipments needed before calibration:

(1) A high accuracy calibrator ( Fluke 5520A Calibrator recommended )
with following functions:
0 - 100 mV millivolt source with A0.005 % accuracy
0 - 10 V voltage source with A0.005 % accuracy
0 - 20 mA current source with A0.005 % accuracy
0 - 300 ohm resistant source with A0.005 % accuracy
(2) A test chamber providing 25 BC - 50 BC temperature range
(3) A switching network ( SW6400, optional for automatic calibration )
(4) A calibration fixture equipped with programming units ( optional for
automatic calibration )
(5) A PC installed with calibration software BC-Net and Smart Network
Adaptor SNA10B ( optional for automatic calibration )
The calibration procedures described in the following section are a step by step
manual procedures.
Since it needs 30 minutes to warm up an unit before calibration, calibrating the

unit one by one is quite inefficient. An automatic calibration system for small
quantity as well as for unlimited quantity is available upon request.
100 UM25001C
Manual Calibration Procedures
* Perform step 1 to enter calibration mode.

Step 1. Set the lockout DIP switch to the unlocked condition ( both switches
3 and 4 are off ).
Press both scroll and down keys and release them quickly. The
operation mode menu will appear on the display. Repeat the operation
several times until appear on the display.
Press scroll key for at least 3 seconds , the display will show
and the unit enters calibration mode . The output 1 and output 2 use
their failure transfer values to control.
* Perform step 2 to calibrate Zero of A to D converter and step 3 to

calibrate gain of A to D converter. The DIP switch is set for T/C input.
Step 2. Short terminals 9 and 10 , then press scroll key for at least 3 seconds. DIP Switch Position
ON
The display will blink a moment and a new value is obtained.
T/C input
Otherwise, if the display didn't blink or if the obtained value is equal to 1 2 3 4
-360 or 360, then the calibration fails.

Step 3. Press scroll key until the display shows . Send a 60mV signal
to terminals 9 and 10 in correct polarity . Press scroll key for at
least 3 seconds . The display will blink a moment and a new value is
obtained . Otherwise , if the display didn't blink or if the obtained value
is equal to -199.9 or 199.9, then the calibration fails.
* Perform step 4 to calibrate voltage function ( if required ) for input 1.
Step 4. Change the DIP switch for the Voltage input. Press scroll key until DIP Switch Position
ON
the display shows . Send a 10 V signal to terminals 9 and
0 10V input
10 in correct polarity. Press scroll key for at least 3 seconds . The 1 2 3 4
display will blink a moment and a new value is obtained . Otherwise,

if the display didn't blink or if the obtained value is equal to -199.9 or
199.9 , then the calibration fails.
* Perform both steps 5 and 6 to calibrate RTD function ( if required )

for input 1.
Step 5. Change the DIP switch for the RTD input . Press scroll key until the DIP Switch Position
ON
display shows . Send a 100 ohms signal to terminals 8, 9
RTD input
and 10 according to the connection shown below: 1 2 3 4
8
100 ohms
9 BTC-2500 Figure 6.1
10 RTD Calibration
Press scroll key for at least 3 seconds . The display will blink a
moment, otherwise the calibration fails.
UM25001E 101
Step 6. Press scroll key and the display will show . Change the
ohm's value to 300 ohms .Press scroll key for at least 3 seconds.
The display will blink a moment and two values are obtained for SR1
and REF1 (last step). Otherwise, if the display didn't blink or if any
value obtained for SR1 and REF1 is equal to -199.9 or 199.9 ,
then the calibration fails.
* Perform step 7 to calibrate mA function ( if required ) for input 1.

Step 7. Change the DIP switch for mA input. Press scroll key until the display DIP Switch Position
shows .Send a 20 mA signal to terminals 9 and 10 in ON
correct polarity. Press scroll key for at least 3 seconds . The display mA input
1 2 3 4
will blink a moment and a new value is obtained . Otherwise , if the
display didn't blink or if the obtained value is equal to -199.9 or 199.9,
then the calibration fails.
* Perform step 8 to calibrate voltage as well as CT function ( if required )

for input 2.
Step 8. Press scroll key until the display shows . Send a 10 V signal to
terminals 10 and 11 in correct polarity. Press scroll key for at least 3
seconds . The display will blink a moment and a new value is obtained .
Otherwise , if the display didn't blink or if the obtained value is equal
to -199.9 or 199.9 , then the calibration fails.
* Perform step 9 to calibrate offset of cold junction compensation, if

required. The DIP switch is set for T/C input.
Step 9. Setup the equipments according to the following diagram for DIP Switch Position
calibrating the cold junction compensation. Note that a K type ON
TC input
thermocouple must be used. 1 2 3 4
5520A K+
9
Calibrator BTC-2500
K-TC 10 Figure 6.2
K
Cold Junction
Stay at least 20 minutes in still- Calibration Setup
air room
room temperature 25 A 3 LC
The 5520A calibrator is configured as K type thermocouple output with

internal compensation. Send a 0.00 LC signal to the unit under
calibration.
102 UM25001C
The unit under calibration is powered in a still-air room with
temperature 25 3 C. Stay at least 20 minutes for warming up. The
DIP Switch is located at TC input .
Perform step 1 stated above, then press scroll key until the display
shows . Apply up/down key until value 0.00 is obtained .
Press scroll key at least 3 seconds. The display will blink a moment
and a new value is obtained . Otherwise , if the display didn't blink
or if the obtained value is equal to -5.00 or 40.00, then the calibration
fails.
* Perform step 10 to calibrate gain of cold junction compensation if

required, otherwise , perform step 10N to use a nominal value for the
cold junction gain if a test chamber for calibration is not available.
Step 10. Setup the equipments same as step 9. The unit under calibration is
powered in a still-air room with temperature 50A3 BC. Stay at least 20
minutes for warming up . The calibrator source is set at 0.00 LC with
internal compensation mode.
Perform step 1 stated above , then press scroll key until the display
shows . Apply up/down key until value 0.0 is obtained. Press
scroll key for at least 3 seconds . The display will blink a moment and
a new value is obtained. Otherwise , if the display didn't blink or if
the obtained value is equal to -199.9 or 199.9, then the calibration
fails.
This setup is performed in a high temperature chamber, hence it is
recommended to use a computer to perform the procedures.
Step 10N. Perform step 1 stated above , then press scroll key until the display
shows . Apply up/down key until value 0.1 is obtained.
Press scroll key for at least 3 seconds. The display will blink a moment
and the new value 0.0 is obtained. Otherwise , the calibration fails.
Caution: It is not recommended to use this step 10N, since the cold junction
gain is not able to achieve rated accuracy by this step.
* Final step
Step 11. Set the DIP switch to your desired position ( refer to section 1-3 ).
Automatic Calibration Procedures

The programming port ( See Section 2-18 ) of BTC-2500 can be used for
automatic calibration.
The equipments required for automatic calibration are available upon request.
UM25001C 103
Chapter 7 Error Codes & Troubleshooting
This procedure requires access to the circuitry of a live power unit. Dangerous accidental contact with line voltage
is possible. Only qualified personnel are allowable to perform these procedures. Potentially lethal voltages are
present.
Troubleshooting Procedures :
(1) If an error message is displayed, refer to Table 7.1 to see what cause it is and apply a corrective action to the
failure unit.
(2) Check each point listed below. Experience has proven that many control problems are caused by a defective
instrument.
Line wires are improperly connected
*No voltage between line terminals
*Incorrect voltage between line terminals
*Connections to terminals are open, missing or loose
*
*Thermocouple is open at tip
Thermocouple lead is broken
*Shorted thermocouple leads
*Short across terminals
*Open or shorted heater circuit
*Open coil in external contactor
*Burned out line fuses
*Burned out relay inside control
*Defective solid-state relays
*Defective line switches
*Burned out contactor
*Defective circuit breakers
*
(3) If the points listed on the above chart have been checked and the controller does not function properly, it is
suggested that the instrument be returned to the factory for inspection.
Do not attempt to make repairs without qualified engineer and proper technical information . It may create
costly damage. Also , it is advisable to use adequate packing materials to prevent damage in transportation.
(4) Dismantle the controller according to Figure 7.1 .
Refer to Table 7.2 for some probable causes and actions.
1 Press both sides of the latch located on rear

terminal block.Hold tightly and remove the terminal
block from the housing.
2 Expand the rear edge of the housing by
using a tool. Pull out the PCB from the housing.
Figure 7.1
Dismantling the Controller
O1
O2
A1
BTC-2500 C
104 UM25001C
Table 7.1 Error Codes and Corrective Actions
Error Display Error Description Corrective Action
Code Symbol
Illegal setup values been used: PV1 is used for both PVMD Check and correct setup values of PVMD and SPMD. PV
1 and SPMD. It is meaningless for control. and SV can't use the same value for normal control
Illegal setup values been used: PV2 is used for both PVMD
2 Same as error code 1
and SPMD. It is meaningless for control
Illegal setup values been used: P1-2 or P2-1 is used for Check and correct setup values of PVMD and SPMD.
PVMD while PV1 or PV2 is used for SPMD. Dependent Difference of PV1 and PV2 can't be used for PV while PV1
3
values used for PV and SV will create incorrect result or PV2 is used for SV
of control
Illegal setup values been used: Before COOL is used for Check and correct setup values of OUT2, PB1, PB2, TI1,
OUT2, DIRT ( cooling action ) has already been used for TI2 and OUT1. IF OUT2 is required for cooling control, the
4 OUT1, or PID mode is not used for OUT1 ( that is PB1 or control should use PID mode ( PB = 0, TI = 0 ) and OUT1
PB2 = 0, and TI1 or TI2 = 0 ) should use reverse mode (heating action), otherwise, don't
use OUT2 for cooling control
Illegal setup values been used: unequal IN1U and IN2U or Check and correct setup values of IN1U, IN2U, DP1, DP2,
unequal DP1 and DP2 while P1-2 or P2-1 is used for PVMD PVMD, SPMD, A1FN or A2FN. Same unit and decimal point
5 should be used if both PV1 and PV2 are used for PV, SV,
or, PV1 or PV2 is used for SPMD or, P1.2.H, P1.2.L, D1.2.H
or D1.2.L are used for A1FN or A2FN. alarm 1 or alarm 2.
Illegal setup values been used: OUT2 select =AL2 but Check and correct setup values of OUT2 and A2FN. OUT2
6 will not perform alarm function if A2FN select NONE.
A2FN select NONE
Illegal setup values been used: Dwell timer (TIMR) is Check and correct setup values of A1FN and A2FN. Dwell
7 timer can only be properly used for single alarm output.
selected for both A1FN and A2FN.
Correct the communication software to meet the protocol
10 Communication error: bad function code
requirements.
11 Communication error: register address out of range Don't issue an over-range register address to the slave.
12 Communication error: access a non-existent parameter Don't issue a non-existent parameter to the slave.
14 Communication error: attempt to write a read-only data Don't write a read-only data or a protected data to the slave.
Communication error: write a value which is out of range to
15 a register Don't write an over-range data to the slave register.
1.The PID values obtained after auto-tuning procedure are

out of range. Retry auto-tuning.
2.Don't change set point value during auto-tuning
26 Fail to perform auto-tuning function procedure.
3. Don't change Event input state during auto-tuning
procedure.
4.Use manual tuning instead of auto-tuning.
29 EEPROM can't be written correctly Return to factory for repair.
Input 2 ( IN2 ) sensor break, or input 2 current below 1 mA

38 if 4-20 mA is selected, or input 2 voltage below 0.25V if Replace input 2 sensor.
1 - 5V is selected
Input 1 ( IN1 ) sensor break, or input 1 current below 1 mA

39 if 4-20 mA is selected, or input 1 voltage below 0.25V if Replace input 1 sensor.
1 - 5V is selected
40 A to D converter or related component(s) malfunction Return to factory for repair.
UM25001C 105
Table 7.2 Common Failure Causes and Corrective Actions
Symptom Probable Causes Corrective Actions

- Clean contact area on PCB
1) Keypad no function -Bad connection between PCB & keypads
- Replace keypads
- No power to instrument - Check power line connections
2) LED's will not light - Power supply defective - Replace power supply board
3) Some segments of the display or - LED display or LED lamp defective - Replace LED display or LED lamp
LED lamps not lit or lit erroneously. - Related LED driver defective - Replace the related transistor or IC chip
- Analog portion or A-D converter defective - Replace related components or board
4) Display Unstable - Thermocouple, RTD or sensor defective - Check thermocouple, RTD or sensor
- Intermittent connection of sensor wiring - Check sensor wiring connections
- Wrong sensor or thermocouple type, wrong - Check sensor or thermocouple type and if
5) Considerable error in temperature input mode selected. proper input mode was selected
indication - Analog portion of A-D converter defective - Replace related components or board
6) Display goes in reverse direction

- Reversed input wiring of sensor - Check and correct
( counts down scale as process warms )
- No heater power ( output ), incorrect output - Check output wiring and output device
device used - Replace output device
7) No heat or output
- Output device defective - Replace output fuse
- Open fuse outside of the instrument
8) Heat or output stays on but indicator - Output device shorted, or power service - Check and replace
reads normal shorted
- CPU or EEPROM ( non-volatile memory ) - Check and replace

9) Control abnormal or operation incorrect defective. Key switch defective - Read the setup procedure carefully
- Incorrect setup values
- Suppress arcing contacts in system to

- Electromagnetic interference ( EMI ), or eliminate high voltage spike sources.
10) Display blinks; entered values change
Radio Frequency interference ( RFI ) Separate sensor and controller wiring from
by themselves
- EEPROM defective " dirty " power lines, ground heaters
- Replace EEPROM
106 UM25001C
Chapter 8 Specifications
Power
90 264 VAC, 47 63 Hz, 15VA, 7W maximum Input 2
11 26 VAC / VDC, 15VA, 7W maximum Resolution : 18 bits
Input 1 Sampling Rate : 1.66 times / second
Resolution : 18 bits Maximum Rating : -2 VDC minimum, 12 VDC maximum
Sampling Rate : 5 times / second Temperature Effect : A1.5 uV/ BC
Maximum Rating : -2 VDC minimum, 12 VDC maximum Common Mode Rejection Ratio ( CMRR ): 120dB
( 1 minute for mA input ) Normal Mode Rejection Ratio ( NMRR ): 55dB
Temperature Effect : A1.5 uV/ BC for all inputs except
mA input Sensor Break Detection :
A3.0 uV/ BC for mA input below 0.25V for 1 - 5V input,
Sensor Lead Resistance Effect : unavailable for other inputs.
T/C: 0.2uV/ohm
3-wire RTD: 2.6 LC/ohm of resistance difference of two Sensor Break Responding Time : 0.5 second
leads
2-wire RTD: 2.6 LC/ohm of resistance sum of two leads
Burn-out Current : 200 nA
Characteristics:
Common Mode Rejection Ratio ( CMRR ): 120dB Accuracy Input
Normal Mode Rejection Ratio ( NMRR ): 55dB Type Range
@ 25 C Impedance
Sensor Break Detection :
A2 %
Sensor open for TC, RTD and mV inputs, CT94-1 0 50.0 A of Reading 265 K
below 1 mA for 4-20 mA input, A0.2 A
below 0.25V for 1 - 5 V input,
unavailable for other inputs. V -1.3V 11.5V A0.05 % 265 K
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: Input 3 (Event Input )
Logic Low : -10V minimum, 0.28V maximum.
Accuracy Input
Type Range Logic High : Open or 0.32V minimum, 10V maximum
@ 25 C Impedance
External pull-down Resistance : 200 K maximum
-120 C 1000 C
J A2 LC 2.2 M External pull-up Resistance : not necessary
( -184 F 1832 F ) Functions : Select second set point and/or PID,
-200 C 1370 C reset alarm 1 and/or alarm 2,
K A2 LC 2.2 M
( -328 F 2498 F ) disable output 1 and/or output 2,
-250 C 400 C remote lockout.
T A2 LC 2.2 M
( -418 F 752 F )
-100 C 900 C Output 1 / Output 2
E A2 LC 2.2 M
( -148 F 1652 F )
Relay Rating : 2A/240 VAC, life cycles 200,000 for
resistive load
A2 LC
0 C 1820 C Pulsed Voltage : Source Voltage 5V,
B ( 200 C 2.2 M
( - 32 F 3308 F ) current limiting resistance 66 .
1820 C )
0 C 1767.8 C A2 LC Linear Output Characteristics
R 2.2 M
( - 32 F 3214 F )
Type Zero Span Load
0 C 1767.8 C Capacity
S A2 LC 2.2 M Tolerance Tolerance
( - 32 F 3214 F )
-250 C 1300 C 4-20 mA 3.8-4 mA 20-21 mA 500 max.
N A2 LC 2.2 M
( -418 F 2372 F ) 0-20 mA 0 mA 20-21 mA 500 max.
-200 C 900 C
L ( -328 F 1652 F ) A2 LC 2.2 M 0 5V 0V 5 5.25 V 10 K min.
PT100 -210 C 700 C 1 5V 0.95 1 V 5 5.25 V 10 K min.
A0.4 LC 1.3 K
( DIN ) ( -346 F 1292 F ) 0 10 V 0V 10 10.5 V 10 K min.
PT100 -200 C 600 C
A0.4 LC 1.3 K
( JIS ) ( -328 F 1112 F )
mV -8mV 70mV A0.05 % 2.2 M
mA -3mA 27mA A0.05 % 70.5
V -1.3V 11.5V A0.05 % 302 K
UM25001C 107
Linear Output Resolution : 15 bits
Resolution : 15 bits Accuracy : A0.05 % of span A0.0025 %/ LC
Output Regulation : 0.01 % for full load change Load Resistance :
Output Settling Time : 0.1 sec. ( stable to 99.9 % ) 0 - 500 ohms ( for current output )
Isolation Breakdown Voltage : 1000 VAC 10 K ohms minimum ( for voltage output )
Temperature Effect : A0.0025 % of SPAN / LC Output Regulation : 0.01 % for full load change
Output Settling Time : 0.1 sec. (stable to 99.9 % )
Triac ( SSR ) Output Isolation Breakdown Voltage : 1000 VAC min.
Rating : 1A / 240 VAC Integral Linearity Error : A0.005 % of span
Inrush Current : 20A for 1 cycle Temperature Effect : A0.0025 % of span/ LC
Min. Load Current : 50 mA rms Saturation Low : 0 mA ( or 0V )
Max. Off-state Leakage : 3 mA rms Saturation High : 22.2 mA ( or 5.55V, 11.1V min. )
Max. On-state Voltage : 1.5 V rms Linear Output Range :0-22.2mA(0-20mA or 4-20mA)
Insulation Resistance : 1000 Mohms min. at 500 VDC 0-5.55V ( 0 - 5V, 1 - 5V )
Dielectric Strength : 2500 VAC for 1 minute 0 - 11.1 V ( 0 - 10V )
DC Voltage Supply Characteristics ( Installed at Output 2 ) User Interface

Ripple Dual 4-digit LED Displays : Upper 0.4" ( 10 mm ),
Type Tolerance Max. Output Isolation
Current Voltage Barrier Lower 0.3 " ( 8 mm )
Keypad : 3 keys
20 V A0.5 V 25 mA 0.2 Vp-p 500 VAC Programming Port :For automatic setup, calibration
12 V A0.3 V 40 mA 0.1 Vp-p 500 VAC and testing
Communication Port : Connection to PC for
5V A0.15 V 80 mA 0.05 Vp-p 500 VAC
supervisory control
Alarm 1/ Alarm 2 Control Mode

Alarm 1 : 5V DC logic output, max. source current 100mA, Output 1 : Reverse ( heating ) or direct ( cooling )
short circuit unprotected. action
Alarm 2 Relay : Form A, Max. rating 2A/240VAC, Output 2 : PID cooling control, cooling P band 1~
life cycles 200,000 for resistive load. 255% of PB
Alarm Functions : Dwell timer, ON-OFF : 0.1 - 100.0 ( LF ) hysteresis control
Deviation High / Low Alarm, ( P band = 0 )
Deviation Band High / Low Alarm, P or PD : 0 - 100.0 % offset adjustment
PV1 High / Low Alarm, PID : Fuzzy logic modified
PV2 High / Low Alarm, Proportional band 0.1 ~ 900.0 LF.
PV1 or PV2 High / Low Alarm, Integral time 0 - 1000 seconds
PV1-PV2 High / Low Alarm, Derivative time 0 - 360.0 seconds
Loop Break Alarm, Cycle Time : 0.1 - 100.0 seconds
Sensor Break Alarm. Manual Control : Heat (MV1) and Cool (MV2)
Alarm Mode : Normal, Latching, Hold, Latching / Hold. Auto-tuning : Cold start and warm start
Dwell Timer : 0 - 6553.5 minutes Self-tuning : Select None and YES
Failure Mode : Auto-transfer to manual mode while
sensor break or A-D converter damage
Data Communication Sleep Mode : Enable or Disable
Interface : RS-232 ( 1 unit ), RS-485 ( up to 247 units ) Ramping Control : 0 - 900.0 LF/minute or
Protocol : Modbus Protocol RTU mode 0 - 900.0 LF/hour ramp rate
Address : 1 - 247 Power Limit : 0 - 100 % output 1 and output 2
Baud Rate : 0.3 ~ 38.4 Kbits/sec Pump / Pressure Control : Sophisticated functions
Data Bits : 7 or 8 bits provided
Parity Bit : None, Even or Odd Remote Set Point : Programmable range for voltage
Stop Bit : 1 or 2 bits or current input
Communication Buffer : 50 bytes Differential Control : Control PV1-PV2 at set point
Analog Retransmission
Functions : PV1, PV2, PV1-PV2, PV2-PV1, Set Point, Digital Filter
MV1, MV2, PV-SV deviation value Function : First order
Output Signal : 4-20 mA, 0-20 mA, 0 - 1V, 0 - 5V, Time Constant : 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60
1 - 5V, 0 - 10V seconds programmable
108 UM25001D
Environmental & Physical
Operating Temperature : -10 C to 50 C
Storage Temperature : -40 C to 60 C
Humidity : 0 to 90 % RH ( non-condensing )
Insulation Resistance : 20 Mohms min. ( at 500 VDC )
Dielectric Strength : 2000 VAC, 50/60 Hz for 1 minute
2
Vibration Resistance : 10 - 55 Hz, 10 m/s for 2 hours
2
Shock Resistance : 200 m/s ( 20 g )
Moldings : Flame retardant polycarbonate
Dimensions :50mm(W) X 26.5mm(H) X 110.5mm(D),
98.0 mm depth behind panel
Weight : 120 grams
Approval Standards
Safety : UL873 ( 11'th edition, 1994 )
CSA C22.2 No. 24-93
EN61010-1 ( IEC1010-1 )
Protective Class :
NEMA 4X ( IP65 ) front panel, indoor use,
IP 20 housing and terminals
EMC: EN61326
UM25001C 109
A 1 Menu Existence Coditions
Menu Existence Conditions Table
Parameter
Menu Existence Conditions
Notation
SP1 Exists unconditionally
TIME Exists if A1FN selects TIMR or A2FN selects TIMR
A1SP Exists if A1FN selects PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H or D12L
A1DV Exists if A1FN selects DEHI, DELO, DBHI, or DBLO
A2SP Exists if A2FN selects PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H or D12L
A2DV Exists if A2FN selects DEHI, DELO, DBHI, or DBLO
RAMP Exists if SPMD selects MINR or HRR
Exists if TI1 is used for control (depends on Event input and EIFN selection) but TI1= 0 and
OFST PB1=0 or if TI2 is used for control (depends on Event input and EIFN selection) but TI2= 0
and PB2=0
REFC Exists if SPMD selects PUMP
SHIF
Exists unconditionally
PB1
User
TI1
Menu Exists if PB1= 0
TD1
CPB, DB Exists if OUT2 select COOL
SP2 Exists if EIFN selects SP2 or SPP2, or if SPMD selects PUMP
PB2 Exists if EIFN selects PID2 or SPP2
TI2
Exists if EIFN selects PID2 or SPP2 provided that PB2= 0
TD2
If PID2 or SPP2 is selected for EIFN, then O1HY exists if PB1= 0 or PB2 = 0. If PID2 or SPP2
O1HY
is not selected for EIFN, then O1HY exists if PB1= 0
A1HY Exists if A1FN selects DEHI, DELO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H, or D12L
A2HY Exists if A2FN selects DEHI, DELO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, D12H, or D12L
If PID2 or SPP2 is selected for EIFN, then PL1 exists if PB1= 0 or PB2 = 0. If PID2 or SPP2
PL1
is not selected for EIFN, then PL1 exists if PB1= 0
PL2 Exists if OUT2 selects COOL
110 UM25001D
Menu Existence Conditions Table ( continued 2/3 )
Parameter
Notation
FUNC Exists unconditionally
COMM Exists if FUNC selects FULL
PROT
ADDR
BAUD
Exists if COMM selects 485 or 232
DATA
PARI
STOP
AOFN Exists if COMM selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10
AOLO
Exists if COMM selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10 and AOFN is not MV1 and MV2
AOHI
IN1
IN1U Exists unconditionally
Setup DP1
Menu
IN1L
Exists if IN1selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10
IN1H
IN2 Exists if FUNC selects FULL
IN2U
DP2
Exists if IN2 selects 4-20, 0-20, 0-1V, 0-5V, 1-5V, or 0-10
IN2L
IN2H
OUT1
O1TY
CYC1 Exists unconditionally
O1FT
OUT2
O2TY
CYC2 Exists if OUT2 selects COOL
O2FT
UM25001C 111
Menu Existence Conditions Table ( continued 3/3 )
Parameter
Notation
A1FN Exists unconditionally
Exists if A1FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H, P12L,
A1MD
D12H, D12L, LB or SENB
A1FT Exists if A1FN is not NONE
A2FN Exists unconditionally
Exists if A2FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H, P12L,
A2MD
D12H, D12L, LB or SENB
A2FT Exists if A2FN is not NONE
EIFN
PVMD Exists if FUNC selects FULL

Setup
FILT
Menu
SELF Exists unconditionally
SLEP
Exists if FUNC selects FULL
SPMD
SP1L
Exists unconditionally
SP1H
SP2F Exists if EIFN selects SP2 or SPP2, or if SPMD selects PUMP
SEL1
SEL2
SEL3 Exists unconditionally
SEL4
SEL5
112 UM25001D
A 2 Factory Menu Description
Parameter Display Default

Parameter Description Range
Notation Format Value
EROR Current Error Code Low: 0 High: 40
PROG Program Identification Code Contains Program Low: 0 High: 15.99

Number and Version Number
MODE Contains Lockout Status Code and Current System Low: 0 High: 3.5
Mode
CMND Command Password Low: 0 High: 65535
JOB Job Password Low: 0 High: 65535
DRIF Warm-up Drift Calibration Factor Low: -5.0 C High: 5.0 C
AD0 A to D Zero Calibration Coefficient Low: -360 High: 360
ADG A to D Gain Calibration Coefficient Low: -199.9 High: 199.9
V1G Voltage Input 1 Gain Calibration Coefficient Low: -199.9 High: 199.9
Cold Junction Low Temperature Calibration -5.00 LC
CJTL Low: High: 40.00 LC
Coefficient
CJG Cold Junction Gain Calibration Coefficient Low: -199.9 High: 199.9
REF1 Reference Voltage 1 Calibration Coefficient for RTD 1 Low: -199.9 High: 199.9
SR1 Serial Resistance 1 Calibration Coefficient for RTD 1 Low: -199.9 High: 199.9
MA1G mA Input 1 Gain Calibration Coefficient Low: -199.9 High: 199.9
V2G Voltage Input 2 Gain Calibration Coefficient Low: -199.9 High: 199.9
SIG1 * Point 1 Signal Value of Special Sensor Low: -19999 High: 45536
IND1 * Point 1 Indication Value of Special Sensor Low: -19999 High: 45536
TYPE * Signal Type of Special Sensor Low: 0 High: 3
DATE Manufacturing Date of Product Low: 0 High: 3719
NO Serial Number of Product Low: 1 High: 999
* These parameters are available only if IN1 selects SPEC.
UM25001C 113
Parameter Display Default
Parameter Description Range
Notation Format Value
HOUR Working Hour Value Low: 0 High: 65535 Hours
HRLO Fractional Hour Value Low: 0 High: 0.9 Hour
ERR1 Historical Error Record 1 Low: 0 High: FFFF 0
ERR2 Historical Error Record 2 Low: 0 High: FFFF 0
DELI ASCII Input Delimiter Low: 0000 High: 007F 000A
BPL1 OUT1 Bumpless Transfer Value Low: 0 High: 100.00 %
BPL2 OUT2 Bumpless Transfer Value Low: 0 High: 100.00 %
CJCL Sense Voltage of Cold Junction Calibration Low Low: 31.680 High: 40.320 mV
114 UM25001C
A 3 Glossary
Abosolute zero: The lowest theoretical temperature. At Automatic reset (Integral): The integral function of a
absolute zero, a body would have no molecular motion control that automatically compensates for the
of heat energy. Absolute zero is the zero point on the difference between the set point and the actual process
Rankine and Kelvin scale. (-273.15 C or -459.67 F) temperature. A signal moves the proportional band
up or down to correct for the droop or offset error.
AC: Alternating Current; an electric current that reverses
direction at regularly occurring intervals. Automatic tuning (of control parameters): A control that
calculates the optimum PID parameters with a built-in
Accuracy software algorithm to eliminate manual tuning efforts.
Calibration accuracy: The potential error of a device
compared to a physical constant or agency AWG: American Wire Gauge.
standard. Bandwidth: A symmetrical region around the set point in
Control accuracy: Maintaining a process at the desired which proportional control occurs.
setting. The errors or combination of errors in the
Baud rate: In serial communications, the rate of
entire system including the sensor, control, power,
information transfer in bits per second.
load and design inefficiencies affect control accuracy.
Display accuracy: The amount of potential error Blackbody: A theoretical object that radiates the maximum
between a measured value and the control's amount of energy at a given temperature, and absorbs
displayed value. all the energy incident upon it. A blackbody is not
Set point accuracy: The potential error between a necessarily black. (The name blackbody was chosen
measured value and the control setting. because the color black is defined as the total
absorption of light [energy].)
Alarm: A control condition or function, indicating that the
process is a predetermined amount above or below the Boiling point: The temperature at which a substance in
set point. the liquid phase transforms to the gaseous phase;
commonly refers to the boiling point of water which is
Alpha ( ): The average percent change in resistance per 100 C (212 F) at sea level.
degree of a pure metal resistance device between 0
and 100 C. Usually designated by the Greek letter Btu: British Thermal Unit. The quantity of thermal energy
alpha, with units of ohm/ohm/ C. The common alpha required to raise one pound of water 1 F at or near its
for a platinum RTD is 0.00385 ohm/ohm/ C. maximum density (39.1 F).
Bumpless transfer: The smooth, automatic transition from
Ambient compensation: The design of an instrument such
automatic control (closed loop) to manual control (open
that changes in ambient temperature do not affect the
loop). The control output is maintained during the
readings of the instrument.
transfer.
Ambient temperature: The average or mean temperature Burst proportioning: A fast-cycling output form on a time
of the surrounding air which comes in contact with the proportioning controller (typically adjustable from .2 to
equipment and instruments under test. 4 seconds) used in conjunction with a solid state relay
Ampere (amp): A unit used to define the rate of flow of to prolong the life of heaters by minimizing thermal
electricity (current) in a circuit; units are one coulomb stress.
(6.25 x 1018 electrons) per second. Calender-van Dusen equation: An equation that defines
the resistance-temperature value of any pure metal that
Analog indication: A meter with graduated scale and a
takes the form of R T = R O (1 + AT + BT 2 ) for values
pointer that moves to indicate process condition.
between the ice point (0 C) and the freezing point of
Analog output: A voltage or current signal that is a antimony (630.7 C) and the form R T = R O [1 + AT +
continuous function of the measure parameter. BT 2 + C( T-100)T 2 ] between the oxygen point (-183.0
C) and the ice point (0 C).
Analog set point: Potentiometer adjustment of the control
setting. Calibration: The process of adjusting an instrument so that
the indication is accurate compared to the actual value.
ANSI: American National Standards Institute
Calorie: The quantity of thermal energy required to raise
Anti-reset windup: This is a feature in a three-mode PID one gram of water 1 C at 15 C.
controller which prevents the integral (auto reset) circuit
from functioning when the temperature is outside the Cascade: Control in which the output of a secondary or
proportional band. inner control loop is the set point for a primary or outer
loop. The primary loop, in turn, determines the control
ASME: American Society of Mechanical Engineers. action.
ASTM: American Society for Testing and Materials.
UM25001C 115
CE: A mark that designates compliance with European Dead band: 1. For chart recorders: the minimum change
Union (EU) requirements for products sold in Europe. of input signal required to cause a deflection in the
pen position. 2. For temperature controllers: the
Celsius: (Centigrade) A temperature scale with 0 C
temperature band where heat is turned off upon rising
defined as the ice point and 100 C as the boiling point
temperature and turned on upon falling temperature
of water at sea level.
expressed in degrees. The area where no heating (or
cfm: The volumetric flow rate of a liquid or gas in cubic cooling) takes place.
feet per minute.
Default parameters: The parameters, or programmed
Chatter: The rapid cycling on and off of a relay in a control instructions, permanently stored in microprocessor
process due to insufficient bandwidth in the controller. software to provide a data base.
Closed loop control: A control system in which process
temperature changes are detected by a sensor. The Derivative: (See Rate)
feedback from the sensor allows the control make
Deviation: The difference between the value of the
adjustments for accurate system regulation.
controlled variable and the value at which it is being
Cold junction compensation: A temperature sensitive controlled.
device that prevents changes in the ambient
temperature from affecting the cold junction of a Deviation alarm: An offset value that follows the set point.
thermocouple. If the set point is 350 F and the Deviation alarm value
is +20 F, the alarm value would be 350 F plus 20 F
Common mode rejection ratio: The ability of an instrument
(or 370 F), See Process alarm.
to reject interference from a common voltage at the
input terminals with relation to ground. Expressed in dB Dielectric strength: An amount of voltage that an insulating
(decibels). material can withstand before an electrical breakdown
Control loop: The basic control loop of any automatic occurs.
control system consists of:
Differential: In an on/off control, the temperature difference
1) variable (process)
expressed in degrees between where the control
2) sensor
switches off and the control switches on.
3) error detector (of control)
4) control Differential control: A controller can control one process
5) final control element (relay, SSR, SCR) in relation to the difference of a second process.
6) temperature indication
DIN: Deutsche Industrial Norms. A German agency that
Control mode: The method in which the control restores sets engineering and dimensional standards that now
the system temperature to set point. On/Off, has worldwide recognition.
proportional, and PID are the most common control
modes. Drift: A change in a value over a long period due to
changes in factors such as ambient temperature, time
CT: Current Transformer or line voltage.
Current proportioning: A 4-20 milliamp (typical) current Droop: In time proportioning controls, the difference in
output which provides a current proportional to the temperature between the set point and where the
amount of control required. system temperature stabilizes. Corrected by automatic
Current transformer: A transformer, intended for measuring or manual reset.
purposes, designed to generate a current at its
secondary winding which is proportional to the current Dual output: The primary output will regulate the process
at the primary winding. temperature. A secondary output will be utilized for
process cooling or as an alarm.
Cycle time: The time usually expressed in seconds for a
controller to complete one on/off cycle. Duty cycle: Percentage of "load ON time" relative to total
cycle time.
Data logging: Recording a process variable over an
extended period of time. Efficiency: The amount of useful output versus energy
input.
DC: Direct Current; An electric current flowing in one
direction and constant in value. Electrical interference: Electrical noise induced upon the
signal wires that obscures the wanted information
signal.
116 UM25001C
Electromagnetic Compatibility (EMC): A system meets fpm: Flow velocity in feet per minute.
three requirements: 1. It does not cause interference fps: Flow velocity in feet per second.
with other systems, 2. It is not susceptible to emissions
from other systems and 3. It does not cause Freezing point: The temperature at which the substance
interference with itself. goes from the liquid phase to the solid phase.
Electromagnetic interference (EMI): An electrical and Frequency: The number or event occurrences or cycles
magnetic noise which can be generated when over a specified period of time.
switching inductive devices, lightning, radio wave
radiation, electrostatic discharge etc. Fuse: A device that interrupts power in a circuit when an
overload occurs.
emf: Electromotive force. A rise in (electrical) potential
Fuzzy logic: An artificial intelligence technique that allows
energy. The principal unit is the volt.
control decisions to be made upon approximate or
Emissivity: The ratio of energy emitted by an object to incomplete information. Fuzzy logic is a continuous
the energy emitted by a blackbody at the same decision making function that can prevent initial
temperature. The emissivity of an object depends overshoot and set point differentials.
upon its material and surface texture; a polished metal Gain: The amount of amplification used in an electrical
surface can have an emissivity around 0.2, and a circuit.
piece of wood can have an emissivity around 0.95.
GIGA: The prefix for one billion (G).
Endothermic: Absorbs heat. A process is said to be
endothermic when it absorbs heat. gph: The volumetric flow rate in gallons per hour.
Error: The difference between the correct or desired gpm: The volumetric flow rate in gallons per minute.
value and the actual reading or value taken.
Ground: 1. The electrical neutral line having the same
Event input: A programmable On/Off input used to signal potential as the surrounding earth. 2. The negative
peripheral equipment or a process. side of dc power supply. 3. Reference point for an
electrical system.
Event output: A programmable On/Off output used to
signal peripheral equipment or a process. Grounded junction: A thermocouple junction in which the
Exothermic: Gives off heat. A process is said to be sheath and conductors are welded together forming a
exothermic when it releases heat. completely sealed integrated junction.
Heat: Thermal energy expressed in Calories, Btu's or
Fahrenheit: A temperature scale with 32 F defined as the
Joules.
ice point and 212 F as the boiling point of water at sea
level. Heat of fusion: The amount of energy required to change
Filter: A low pass filter designed to minimize display one pound of a material from a solid to a liquid without
fluctuations. an increase in temperature. Expressed in Btu/lb.
Flow rate: speed or velocity of fluid movement. Heat of vaporization: The amount of energy required to
change one pound of a material from a liquid to a vapor
FM: Factory Mutual Research Corp. An organization without an increase in temperature. Expressed in Btu/lb.
which sets industrial safety standards.
Heat sink: 1. Thermodynamic. A body which can absorb
FM-approved: An instrument that meets a specific set of thermal energy. 2 Practical. A finned piece of metal
specifications established by Factory Mutual Research used to dissipate the heat of solid state components
Corp. mounted on it.
Form A: Single Pole Single Throw relay that only utilizes Heat transfer: The process of thermal energy flowing
the N.O. and common contacts. These contacts close from a body of high energy to a body of low energy.
when the relay coil is energized. The contacts open Means of transfer are: Conduction, the two bodies in
when power is removed from the control. contact; Convection, a form of conduction where the
two bodies in contact are of different phases, i.e; solid
Form B: Single Pole Single Throw relay that only utilizes and gas; Radiation, all bodies emit infrared radiation
the N.C. and common contacts. These contacts will
open when the relay coil is energized. The contacts will Heat treating: A process for treating metals where heating
close when power is removed from the control. to a specific temperature and cooling at a specific rate
changes the properties of the metal.
Form C: Single Pole Double Throw. Utilizes the N.O., N.C.
and common contacts. The user has the option of Hertz (Hz): Unit in which frequency is expressed.
wiring for a Form A or Form B contact. Refer to the Form Synonymous with cycles per second.
A and Form B above for more information.
UM25001C 117
Hi-Pot test : To apply a high voltage to an electrical Kilo: The prefix for one thousand (K).
conductor to test the surrounding insulation.
Kilowatt (kw): 1000 watts or 3412Btu per hour.
Hysteresis: In ON/OFF control, the temperature change Lag: 1. A time delay between the output of a signal and
necessary to change the output from full ON to full OFF. the response of the instrument to which the signal is
Hunting: Oscillation or fluctuation of process temperature sent. 2. A time relationship between two waveforms
between set point and process variable. where a fixed reference point on one wave occurs
after the same point of the reference wave.
IAE: Integrated absolute error
Least Significant Digit (LSD): The digit farthest to the right
Ice point: The temperature at which pure water freezes. in a display.
0 C, 32 F, 273.16K.
Linearity: The deviation of an instrument's response from
IE: Integrated error a straight line.
Load: The electrical demand of a process expressed as
Impedance: The total opposition in a circuit to the flow of
power (watts), current (amps) or resistance (ohms).
electrical current. Measured in ohms and represented
by "Z". Manual reset: The adjustment on a proportional control
which shifts the proportional band in relation to the set
Infrared: Or radiation is the exchange of energy by
point to eliminate droop of offset errors.
electromagnetic waves. The infrared spectrum extends
from the deep red end of the visible spectrum to the Maximum operating temperature: The maximum
microwave region of the radio spectrum, the portion temperature at which an instrument or sensor can be
adjacent to the visible spectrum is of importance to safely operated.
heating. Radiant heat transfer can be very efficient in
Maximum power rating: The maximum power in watts
directing energy from the heat source to an object.
that a device can safely handle.
Integral: (See Automatic Reset). Measuring junction: The thermocouple junction referred
to as the hot junction that is used to measure an
Interchangeability error: A measurement error that can
unknown temperature.
occur if two or more probes are used to make the
same measurement. It is caused by a slight variation Mechanical relay: An electromechanical device that
in characteristics of different probes. completes or breaks a circuit by opening or closing
Intrinsically safe: An instrument which will not produce electrical contacts.
any spark or thermal effects under normal or abnormal 6
Mega: The prefix for one million (M) (10 ).
conditions that will ignite a specified gas mixture.
Melting point: The temperature at which a substance
IPTS-68: International Practical Temperature Scale of transforms from a solid phase to a liquid phase.
1968. Fixed points in thermometry set by the 1968
General Conference of Weights and Measures. Mico: The prefix for one millionth (10 -6 ).
ISA: Instrument Society of America. Microamp: 10 -6 amps (one millionth of an amp).
ISE: Integrated squared error Micron: 10 -6 meters (one millionth of a meter).
Isolation: Electrical Separation Microprocessor: The central processing unit (CPU) that
Isothermal: A process or area that maintains a constant performs the logic operations in a micro-computer
temperature. system. The microprocessor in a process or instrument
control decodes instructions from the stored program,
ITS-90: International Temperature Scale of 1990 performs algorithmic and logic functions, and produces
signals and commands.
Joule : The basic unit of thermal energy. 1 Joule equals 1
ampere passed through a resistance of 1 ohm for 1 Milli: The prefix for one thousandth (10 -3 )
second.
Milliamp: 10 -3 amps (one thousandth of an amp).
Junction: A thermocouple junction is the point at which
-3
two alloys are joined. A typical thermocouple circuit Millivolt: 10 volts (one thousandth of a volt).
would have a measuring and a reference junction.
NEC: National Electrical Code
Kelvin: The unit of absolute or thermodynamic temperature
scale. Zero Kelvin is absolute zero, where all molecular NEMA: National Electrical Manufacturer's Association
activity stops. No " " symbol is used. 0 C= 273.15K;
100 C =373.15K.
118 UM25001C
NEMA 4X: A front panel rating designating the control as Proportional control mode: When process temperature
washdown capable and corrosion resistance. approaches set point and enters the proportional band,
the output is switched on and off at the established
NIST: National Institute of Standards and Technology,
cycle time. The change in power to the load provides a
United states Department of Commerce.
throttling action which results in less temperature
Noise: Undesirable electrical interference on the signal overshoot.
wires.
Ramp: A programmed rise or fail in temperature at a
Noise suppression: A device used to reduce electrical
constant rate.
interference.
Normal-mode rejection ratio: The ability of an instrument Range: An area between two limits in which a
to reject interference usually of line frequency (50-60 measurement or control action takes place. Typically
Hz) across its input terminals. expressed in upper and lower limits.
NPT: National Pipe Thread. Rankine ( R): An absolute temperature scale based upon
the Fahrenheit scale with 180 between the ice point
Offset: The difference in temperature between the set
and boiling point of water. 459.69 R=0 F.
point and the actual process temperature. Also,
referred to as droop. Rate (derivative): A control function that measures the rate
of increase or decrease of the system temperature and
ohm: The unit of electric resistance. brings the control into an accelerated proportioning
On/off controller: A controller whose action is fully on or action. This mode prevents an overshoot condition at
fully off. initial heat-up and with system disturbances.
Open Loop Control: A control system with no sensing Rate time: The interval over which the system temperature
feedback. is sampled for the derivative function.
Overshoot: Excursion of temperature above the set point.
Reference junction: The cold junction in a thermocouple
Phase: A time-based relationship between a periodic circuit which is held at a stable known temperature.
function and a reference. In electricity, it is expressed The standard reference temperature is 0 C (32 F);
in angular degrees to describe the voltage or current however, other temperatures can be used.
relationship of two alternating waveforms.
Relay (mechanical): An electromechanical device that
Phase proportioning: A form of temperature control completes or interrupts a circuit by physically moving
where the power supplied to the process is controlled electrical contacts into contact with each other.
by limiting the phase angle of the line voltage.
Relay (solid state): A solid state switching device which
PID: Three mode temperature control proportional, completes or interrupts a circuit electrically with no
integral, (automatic reset), derivative(rate). moving parts.
Polarity: In electricity, the quality of having two oppositely
Repeatability: The ability of a probe or instrument to give
charged poles, one positive and one negative.
the same output or reading under repeated identical
Potentiometer: 1. A variable resistor often used to control conditions.
a circuit. 2. A balancing bridge used to measure Resistance: The resistance to the flow of electric current
voltage. measured in ohms ( ). For a conductor resistance is
Primary standard (NBS): The standard reference units a function of diameter, resistivity ( an intrinsic property
and physical constants maintained by the National of the material ) and length.
Bureau of Standards upon which all measurement
Resolution sensitivity: The amount of temperature change
units in the United States are based.
that must occur before the control actuates. It may be
Process alarm: A fixed alarm or secondary set point value expressed in temperature or as a percentage of the
independent of the primary set point. Should a process control's scale.
value exceed this value, an alarm condition would
Response time (Time constant): The time required by a
register.
sensor to reach 63.2% of a step change in temperature
Process variable: The parameter being controlled or under a specified set of conditions. Five time constants
measured such as temperature, relative humidity, flow, are required for the sensor to stabilize at 99.3 % of the
level, pressure, etc. step change value.
Proportional band: A temperature band in degrees within Retransmit output: Analog output scaled to the process or
which a control's proportioning function is active. the set point value.
UM25001C 119
RFI: Radio frequency interference. Surge current: A current of short duration occurring when
power is initially applied to capacitive or resistive loads,
RS232 or RS485 output signal: A serial interface suitable
usually lasting no more than several cycles.
for connection between a digital control and a personal
computer, a host computer or printer. Temperature gradient: The range of temperature variations
RTD: A temperature sensing probe of finely wound at various physical locations throughout a thermal
platinum wire that displays a linear resistance change system.
for a corresponding temperature change. The resistance
Tera: The prefix for one trillion (T).
increases as the temperature rises. A base resistance
of 100 ohms at 32 F is the industry (DIN) standard. Thermal expansion: An increase in size due to an
increase in temperature expressed in units of an
Saturation temperature: The boiling temperature of a increase in length or increase in size per degree, i.e.,
liquid at the existing pressure. inches/inch/degree C.
SCFM: Volumetric flow rate in cubic feet per minute at 60
Thermal lag: The time delay in the distribution of heat
F (15 C) and standard atmospheric pressure.
throughout a thermal system.
SCR: Silicone Controlled Rectifier
Thermal system: A regulated environment consisting of a
Secondary standard: A standard of unit measurement heat source, heat transfer medium, sensing device and
derived from a primary standard. a process variable control instrument.
Sensitivity: The minimum change in input signal to which Thermistor: A temperature sensing probe made of a
an instrument can respond. mixture of metal oxides and encapsulated in epoxy or
Set point: Control setting to achieve or maintain glass. A large change in resistance is exhibited
temperature. proportional to a change in temperature. The resistance
Sheath thermocouple: A thermocouple made out of usually decreases as temperature rises.
mineral-insulated thermocouple cable which has an
Thermocouple: A temperature sensing probe consisting
other metal sheath.
of the junction of two dissimilar metals which has a
Shield: Material surrounding a conductor(s) to prevent millivolt output proportional to the difference in
electrostatic or EMI from external sources. temperature between the "hot" junction and the lead
wires (cold junction).
Slide wire feedback: A potentiometer that varies the
resistance to control a valve position. Thermocouple break protection: Fail-safe operation that
assures output shutdown upon an open thermocouple
Soak: To raise the temperature of a metal object in a condition.
heated environment to produce a metallurgical change.
Thermowell: A closed-end tube designed to protect
Soft start: Reduces voltage on initial start-up which
temperature sensors from harsh environments, high
reduces power to the heaters. If heater has
pressure, and flows. They can be installed into a system
accumulated moisture internally during a shut down,
by pipe thread or welded flange and are usually made
soft start will allow heater to dry before full voltage is
of corrosion-resistant metal or ceramic material
applied so as to extend heater life.
depending upon the application.
Solid State Relay (SSR): A solid state switching device Transducer: A device which converts the parameter
which completes or breaks a circuit electrically with no being measured into another form which is its output.
moving parts. For example, a thermocouple transforms heat into a
Span: The difference between the upper and lower limits millivolt output.
of a range expressed in the same units as the range.
Transmitter (two-wire): A device which is used to transmit
Specific gravity: The ratio of mass of any material to the temperature data from either a thermocouple or RTD
mass of the same volume of pure water at 4 C. via a two-wire current loop. The loop has an external
power supply and the transmitter acts as a variable
Specific Heat: The ratio of thermal energy required to raise
resistor with respect to its input signal.
the temperature of a particle 1 degree to the thermal
energy required to raise an equal mass of water 1 Triac: A solid state switching device used to switch
degree. alternating current wave forms.
SSR: Solid state relay (see relay, solid state). Triple point (water): The thermodynamic state where all
three phases, solid, liquid, and gas may all be present
Stability: The ability of an instrument or sensor to maintain
in equilibrium. The triple point of water is at .01 C.
a constant output when a constant input is applied.
120 UM25001C
TTL: Transistor-to-transistor logic. A form of solid state
logic which uses only transistors to form the logic
gates.
UL: Underwriters Laboratories, Inc. An independent
laboratory that establishes standards for commercial
and industrial products.
Ultraviolet: That portion of the electromagnetic spectrum
below blue light (380 nanometers).
Undershoot: Excursion of temperature below set point.
Ungrounded junction: A thermocouple junction fully
insulated from the sheath.
Viscosity: The inherent resistance of a substance to flow
Volt: The (electrical) potential difference between two
points in a circuit. The fundamental unit is derived as
work per unit charge (V=W/Q). One volt is the
potential difference required to move one coulomb of
charge between two points in a circuit while using one
joule of energy.
Voltage: An electrical potential which is measured in volts.
VPFW SSR: A type of Solid State Relay with Variable
Period and Full Wave switching characteristics.
Wattage: A measurement of electrical power. In a resistive
circuit, VI=W (See Ohms Law formulas).
Working standard: A standard of unit measurement
calibrated from either a primary or secondary standard
which is used to calibrate other devices or make
comparison measurements.
Zero voltage switching: The making or breaking of circuit
timed such that the transition occurs when the voltage
waveform crosses zero voltage; typically it is only found
in solid state switching devices.
UM25001C 121
A 4 Index
A1DV: 11, 13, 18, 47, 48, 50, 51, 53 Auto-tuning: 11, 12, 43, 45, 46, 58 CT: 4, 20, 22, 28, 40, 52, 67, 102
54, 110 59, 60, 61, 68, 70, 81, 86, 89, 91,
94, 97, 98, 105, 108 Current transformer: 7, 15, 28, 52, 67
A1FN: 11, 16, 17, 20, 42, 43, 47, 48,
49, 50, 51, 52, 53, 54, 56, 70, 71, Automatic calibration: 100, 103 CYC1: 11, 16, 43, 45, 52, 67, 85, 86,
72, 83, 86, 90, 91, 94, 95, 105 89
Automatic programming: 4, 8
A1FT: 11, 17, 56, 86 CYC2: 11, 16, 45, 67, 85
Baud: 14, 76, 108
A1HY: 11, 13, 47, 48, 49, 50, 51, 52, DATA:11, 14, 40, 76, 97, 98
53, 54, 94 BAUD: 11, 14, 40, 76, 97, 98
DC power supply: 4, 16, 40, 64
A1MD: 11, 16, 17, 47, 48, 49, 50, 51, BC-Net: 7, 96, 97, 98, 100
52, 53, 54, 70, 94 Dead band: 13, 43, 44, 46
Bumpless transfer: 4, 40, 43, 56,
A1SP: 11, 13, 18, 20, 47, 48, 49, 50, 57, 65 Default: 8, 9, 11, 12, 13, 14, 15,
51, 52, 53, 54, 70, 83, 94 16, 17, 18, 19, 40, 58, 59, 67,
Calibration mode: 8, 12, 56, 57, 100, 78, 79
A2DV: 11, 13, 18, 45, 48, 50, 51, 53 101
54 Deviation alarm: 45, 50
Chamber: 90, 91, 100, 103
A2FN: 11, 17, 20, 42, 43, 45, 47, 48, Deviation band alarm: 51
50, 51, 52, 53, 54, 56, 71, 72, 105 CJCT: 11, 19, 66
Differential control: 4, 74, 93, 108
A2FT: 11, 17, 56 CJG: 11,19
Digital filter: 4, 40, 78, 108
CJTL: 11, 18
A2MD: 11, 17, 45, 47, 48, 50, 51, 52, Display mode: 9, 11, 12, 40, 66, 74
53, 54 Colour codes: 25 93
A2SP: 11, 13, 18, 20, 45, 48, 50, 51, COMM: 5, 11, 13, 14, 40, 76, 77, 83 DP1: 11, 15, 40, 41, 71, 72, 73, 74, 77
52, 53, 54 92, 97, 98, 99 83, 86, 87, 89, 90, 93, 99, 105
AD0: 11, 18 Communication: 4, 5, 7, 13, 37, DV: 11, 13, 18, 19, 42, 45, 47, 48, 50,
40, 76, 98, 105, 108 51, 53, 54, 66
Adaptive: 5
Contactor: 28, 30, 32, 34, 35, 84, 87 Dwell timer: 4, 16, 40, 43, 47, 56,
ADDR: 11,14, 40, 76, 97, 98, 105 104 71, 72, 86, 91, 105, 108
ADG: 11,18 Control: 4, 5, 6, 7, 8, 9, 11, 12, 13, 15, EIFN: 11, 17, 18, 29, 37, 40, 48, 68,
16, 18, 21, 22, 23, 24, 25, 39, 40, 69, 70, 76, 80, 81, 83, 90, 91, 94,
Alarm 1: 7, 9, 13, 16, 17, 34, 40, 47 41, 42, 43, 44, 45, 53, 55, 56, 57, 95
48, 49, 50, 51, 52, 53, 56, 68, 70, 58, 59, 60, 61, 62, 65, 66, 67, 68,
71, 91, 94, 105, 107 69, 70, 72, 73, 74, 75, 77, 78, 80, Error code: 47, 48, 50, 51, 72, 73, 74
81, 82, 84, 85, 86, 87, 88, 89, 90, 104, 105
Alarm 2: 7, 9, 13, 16, 17, 35, 40, 47, 91, 92, 93, 94, 96, 97, 98, 99, 100,
48, 49, 50, 51, 52, 53, 54, 56, 68, 101, 102, 104,105, 106, 108 Event input: 4, 7, 12, 17, 29, 37, 40,
71, 72, 105, 107, 108 48, 58, 60, 65, 68, 69, 70, 72, 76,
Cooling control: 16, 105, 108 90, 94, 105, 107
AOFN: 11, 14, 40, 77, 99
CPB: 11, 13, 18, 37, 42, 45, 46, 75, Exception mode: 12
AOHI: 11, 14, 40, 77, 92, 99 89, 90
Failure mode: 12, 54, 56, 57, 58, 65,
AOLO: 11, 14, 40, 77, 92, 99 DB: 11, 13, 42, 45, 46, 51, 76, 89, 108
107, 108, 110
Auto-tune: 4, 9, 40 Failure transfer: 16, 17, 40, 56, 75, 101
Critical steady state: 62
122 UM25001D
FILT: 11, 17, 40, 78, 80, 81, 83, 108 Linear current: 15, 26, 27, 31, 33, 41 OUT2: 11, 16, 22, 41, 45, 48, 50,
51, 53, 54, 56, 57, 64, 65, 75,
Flow: 4, 11, 61, 62 Linear DC input wiring: 26 82, 83, 85, 88, 89, 90, 105
Freezer: 54, 88, 90 Linear output: 43, 45, 52, 67, 107, 108 Output 1: 7, 9, 13, 14, 15, 16, 17,
19, 30, 40, 41, 43, 45, 56, 57, 65,
FUNC: 9, 11, 13, 40, 73, 74, 76, 77, Linear voltage: 15, 26, 27, 31, 33, 41 66, 67, 68, 75, 82, 85, 87, 101,
79, 80, 83, 86, 87, 89, 92, 93, 94, 107, 108
95, 97, 98, 99 Lockout: 4, 8, 40, 81, 101, 107
Output 2: 7, 9, 13, 14, 16, 17, 19, 32,
Furnace: 52, 94, 95 Loop break: 4, 16, 40, 53, 56, 58, 108 40, 41, 45, 50, 56, 57, 64, 65, 66,
67, 68, 75, 82, 85, 101, 107, 108
Fuzzy logic: 4, 5, 108 Loop break alarm: 4, 16, 40, 53, 108
Oven: 5, 69, 86, 91, 92, 104
Fuzzy + PID: 4 MA1G: 11, 19
Parameter description: 3, 13, 14, 15,
Heat-cool control: 40, 45, 88 MA2G: 11, 19 16, 17, 18, 19
Heater break: 4, 7, 40, 52 Manual control (hand control mode): PARI: 5, 11, 14, 40, 76, 85, 97, 98,
9, 40, 57, 58, 65, 75, 97, 98, 108 108
Heater current: 28, 52, 67
Manual tuning: 43, 45, 60, 61, 105 PB: 11, 19, 46, 58, 60, 62, 66, 105,
Humidity: 99, 109 108
Menu overview: 11
Idle state: 80 PB1: 11, 13, 17, 18, 42, 43, 45, 46, 56,
Mini jumper and DIP switch: 8 58, 59, 61, 62, 65, 68, 70, 75, 81,
IN1: 11, 14, 15, 16, 18, 19, 20, 40, 83, 87, 94, 95, 105
41, 54, 71, 72, 73, 74, 77, 82, Mold: 88, 95
83, 86, 87, 88, 89, 93, 99, 105 PB2: 11, 13, 17, 18, 40, 42, 46, 58,
Mounting: 21 59, 62, 65, 68, 70, 94, 95, 105
IN1H: 11, 15, 41, 54, 73, 74, 83, 93
MV1: 19, 53, 56, 57, 65, 66, 68, 75, P(or PD) control: 4, 12, 13, 18, 40,
IN1L: 11, 15, 41, 54, 73, 74, 83, 93 77, 108 43, 57, 65, 80, 81
IN1U: 11, 15, 40, 41, 71, 72, 73, 74, MV2: 19, 56, 57, 65, 66, 68, 75, 77, PID adjustment: 62, 63
77, 83, 86, 87, 89, 90, 93, 99, 105 108
PID control: 5, 6, 40, 43, 44, 45, 58,
IN2: 11, 14, 15, 16, 18, 19, 20, 40, O1FT: 11, 16, 56, 57, 83, 86, 89 59, 60, 68, 91
52, 67, 73, 74, 77, 83, 92, 93, 105
O1HY: 11, 13, 43, 44, 45, 87 PL1: 11, 13, 40, 43, 75, 83, 94, 95
IN2H: 11, 15, 40, 73, 74, 92, 93
O1TY: 11, 15, 16, 41, 43, 45, 67, 83, PL2: 11, 13, 40, 75
IN2L: 11, 15, 40, 73, 74, 92, 93 85, 86, 87, 89, 93
Power wiring: 23
IN2U: 11, 15, 40, 73, 74, 77, 93, 105 O2FT: 11, 16, 56, 57, 89
Pressure: 4, 41, 69, 80, 81, 82, 108
Input 1: 3, 7, 8, 18, 19, 26, 27, 40, 41 O2TY: 11, 16, 41, 45, 67, 85, 89
56, 66, 73, 74, 77, 101, 102, 105, Process alarm: 45, 48, 49
107 OFST: 11, 13, 18, 42, 43, 45
Programming port: 5, 8, 39, 103,
Input 2: 7, 19, 26, 27, 40, 52, 56, 66, On-off control: 13, 43, 44, 45, 56, 108
67, 73, 74, 77, 92, 102, 105, 107 58, 59, 60, 65, 75, 87
PROT: 4, 11, 13, 40, 76, 97, 98
Installation: 21, 23, 24, 98 Ordering code: 7, 64, 77
Pulsed voltage: 7, 30, 32, 41, 84, 85
Inverter: 38, 82, 90, 91 OUT1: 11, 15, 22, 41, 43, 44, 45, 107
65, 75, 82, 83, 85, 86, 87, 88,
Keys and displays: 9 89, 90, 92, 93, 105 Pump/pressure control: 4, 18, 40,
80, 81, 82, 108
Level: 4, 12, 13, 40, 48, 50, 51, 52,
68, 84, 93
UM25001D 123
PVHI: 9, 11, 19, 66 Second PID: 40, 68, 69, 70, 94, 95 SP2: 11, 13, 17, 18, 20, 40, 42, 48,
68, 69, 72, 74, 80, 81, 83, 90, 91,
PV1: 11, 13, 17, 19, 20, 40, 41, 45, Second set point: 69, 107 95
48, 49, 55, 56, 66, 70, 73, 74, 77,
78, 80, 83, 92, 93, 94, 95, 99, 105, SEL1: 4, 8, 11, 18, 42 SP2F: 11,18, 40, 69, 80, 83
108
SEL2: 8, 11, 18, 42 SPMD: 11, 18, 40, 56, 68, 69, 71, 72,
PV1 shift: 13, 40, 55 73, 74, 80, 83, 90, 91, 92, 93, 94,
SEL3: 11, 18, 42 95, 105
PV2: 11, 17, 19, 20, 48, 52, 56, 66,
67, 73, 74, 77, 92, 93, 105, 108 SEL4: 11, 18, 42 SR1: 11, 19, 102
PVLO: 9, 11, 19, 66 SEL5: 4, 8, 11, 18, 42 SSR: 4, 7, 30, 31, 32, 33, 40, 41
43, 45, 67, 84, 85, 108
PVMD: 11, 17, 20, 40, 56, 73, 74, 80 SELF: 11, 17, 43, 45, 58, 80, 83, 86,
83, 92, 93, 94, 95, 105 89 SSRD: 40, 41, 43, 45, 67, 85
PVR: 11, 19, 66 Self-tune: 4, 40, 58 STOP: 11, 14, 40, 76, 97, 98
PVRH: 11, 19, 66 Self-tuning: 43, 45, 46, 58, 61, 68 System modes: 12
108
PVRL: 11, 19, 66 TD: 11, 19, 37, 63, 66
Sensor installation guidelines: 24
RAMP: 11, 13, 18, 40, 42, 71, 72, 90, TD1: 11, 13, 17, 18, 42, 43, 45, 58,
91, 94, 95 Sensor break: 4, 16, 40, 54, 56, 57, 59, 61, 62, 68, 70, 81, 83, 94, 95
58, 105, 107, 108
Ramp: 4, 13, 18, 40, 42, 58, 59, 69, TD2: 11, 13, 17, 18, 40, 42, 58, 59,
71, 72, 90, 91, 94, 95, 97, 98, 108 Sensor break alarm : 4, 40, 54, 57, 62, 68, 70, 94, 95
108
Ramp & Dwell: 71, 72, 90 Thermocouple input wiring: 25
Setup menu: 4, 8, 11, 12, 48, 54, 58,
Rearrange user menu: 42 68, 69, 73, 74, 76, 77, 78, 79, 80, 83, TI: 11, 19, 58, 60, 63, 66, 105
86, 89, 92, 93, 94, 95, 97, 98, 99
Recorder: 5, 38, 99 TI1: 11, 13, 17, 18, 42, 43, 45, 53, 59,
SHIF: 11, 13, 18, 42, 55 61, 62, 68, 70, 81, 83, 94, 95, 105
REF1: 11, 19, 102
Sleep mode: 4, 9, 12, 17, 40, 58, TI2: 11, 13, 17, 18, 40, 42, 58, 59, 62,
REFC: 11, 13, 18, 42, 80, 81, 83 79, 108 68, 70, 94, 95, 105
Refrigerator: 87 SLEP: 9, 11, 17, 40, 79, 83 TIME: 11, 13, 18, 42, 43, 47, 53, 54, 71
72, 86, 90, 91, 95
Relay: 4, 7, 15, 30, 32, 34, 35, 40, 41 Smart network adaptor: 7, 96
43, 45, 47, 68, 69, 70, 84, 90, 91 Triac: 4, 7, 30, 31, 32, 33, 108
104, 107, 108 SNA10A: 7, 36, 76
User menu: 4, 8, 9, 11, 12, 42, 48,
Reload default value: 40, 67 SNA10B: 7, 36, 76, 96, 97, 100 71, 75, 80, 83, 87, 94, 95
Remote lockout: 4, 40, 81,107 Soft-start: 4 Ultimate p band: 62
Remote set point: 4, 40, 58, 59, 73, SP1: 8, 13, 17, 18, 40, 43, 44, 45, 47 Ultimate period: 62
92, 108 48, 49, 50, 51, 54, 68, 69, 71, 72,
74, 75, 80, 86, 89, 90, 91, 92, 93, Unpacking: 21
Retransmission: 4, 5, 7, 13, 38, 40, 77 94, 95, 99
92, 99, 108 V1G: 11, 18
SP1H: 11, 13, 18, 54, 83, 87, 99
RS-232: 4, 5, 7, 13, 36, 37, 69, 76, V2G: 11, 19
96, 98, 108 SP1L: 11, 13, 18, 54, 83, 87, 99
Valve control: 93
RS-485: 4, 5, 7, 13, 36, 76, 77, 96, SP1 range: 40, 54
108 VPFW SSR: 84, 85
RTD input wiring: 26 Water tank: 93
124 UM25001D
A 5 Memo
Use the following Table as a master copy for your settings.
Contained Parameter Display Your setting Contained Parameter Display Your setting
in Notation Format in Notation Format
SP1 COMM
TIME PROT
A1SP ADDR
A1DV BAUD
A2SP DATA
A2DV PARI
RAMP STOP
OFST AOFN
REFC AOLO
SHIF AOHI
PB1 IN1
User Setup
TI1 IN1U
Menu Menu
TD1 DP1
CPB IN1L
DB IN1H
SP2 IN2
PB2 IN2U
TI2 DP2
TD2 IN2L
O1HY IN2H
A1HY OUT1
A2HY O1TY
PL1 CYC1
PL2 O1FT
Setup
Menu FUNC
UM25001D 125
Contained Parameter Display Your setting Contained Parameter Display Your setting
in Notation Format in Notation Format
OUT2 AD0
O2TY ADG
CYC2 V1G
O2FT Calibra- CJTL
tion
A1FN CJG
Mode
A1MD Menu REF1
A1FT SR1
A2FN MA1G
A2MD V2G
A2FT MA2G
EIFN PVHI
Setup PVMD PVLO
Menu
FILT MV1
SELF MV2
SLEP DV
SPMD PV1
Display
SP1L Mode PV2
Menu
SP1H PB
SP2F TI
DISF TD
SEL1 CJCT
SEL2 PVR
SEL3 PVRH
SEL4 PVRL
SEL5
126 UM25001C
A 6 Warranty
WARRANTY
Brainchild Electronic Co. is pleased to offer suggestions on the use of its various products. However, Brainchild makes no
warranties or representations of any sort regarding the fitness for use, or the application of its products by the Purchaser. The
selection, application or use of Brainchild products is the Purchaser's responsibility. No claims will be allowed for any
damages or losses, whether direct, indirect, incidental, special or consequential. Specifications are subject to change
without notice. In addition, Brainchild reserves the right to make changes without notification to Purchaser to materials or
processing that do not affect compliance with any applicable specification. Brainchild products are warranted to be free
from defects in material and workmanship for two years after delivery to the first purchaser for use. An extended period is
available with extra cost upon request. Brainchild's sole responsibility under this warranty, at Brainchild's option, is limited to
replacement or repair, free of charge, or refund of purchase price within the warranty period specified. This warranty does
not apply to damage resulting from transportation, alteration, misuse or abuse.
RETURNS
No products return can be accepted without a completed Return Material Authorization ( RMA ) form.
UM25001C 127
BRAINCHILD Electronic Co., Ltd.
6F., No.209, Chung Yang Rd., Nan Kang Dist., Taipei, Taiwan, R.O.C.
Tel: 886-2-27861299
Fax: 886-2-27861395
web site: http://www.bcmfg.com
http://www.brainchild.com.tw

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BTC-2500 Fuzzy Logic plus PID microprocessor-based controller, incorporates a bright,

BTC-2500 is powered by 11-26 or 90 - 264 VDC / AC supply, incorporating a 2 amp.

PID + FUZZY CONTROL

PID + Fuzzy control

Figure 1.2 Fuzzy PID

Front Access Hole

The programming port is used to connect to

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

All parameters are Unlocked

All Parameters are locked

Factory Default Setting

Lockout function is used to disable the adjustment of parameters as well as operation of

Press and release quickly to increase the value of parameter.

Press and release quickly to decrease the value of parameter.

Scroll Key Select the parameter in a direct sequence.

Press Mode Key Select the operation Mode in sequence.

By entering correct security code to allow execution of engineering programs.

How to display a 5-digit number ?

Output 2 For a number without decimal point

45536 will be displayed by:

All segments of display and Figure 1.5 Display Sequence of

Display Date Code and Serial

The left diagram shows Year 1998,

Setup FUNC for 3

OFST Offset Value for P control Low: 0 High: 100.0 % 25.0

CPB Cooling Proportional Band 1 High: 255 % 100

Set point 2 See Table 1.5, 1.8 37.8 C

TD2 Derivative Time 2 Value Low: 0 High: 360.0 sec 25.0

PL1 Output 1 Power Limit Low: 0 High: 100 % 100

PL2 Output 2 Power Limit Low: 0 High: 100 % 100

0 : Basic Function Mode

1 : 0.6 Kbits/s baud rate

2 : 1.2 Kbits/s baud rate

3 : 2.4 Kbits/s baud rate

4 : 4.8 Kbits/s baud rate

BAUD Baud Rate of Digital COMM 5 : 9.6 Kbits/s baud rate 5

6 : 14.4 Kbits/s baud rate

7 : 19.2 Kbits/s baud rate

8 : 28.8 Kbits/s baud rate

9 : 38.4 Kbits/s baud rate

Data Bit count of Digital 0 : 7 data bits

PARI Parity Bit of Digital COMM 1 : Odd parity 0

Stop Bit Count of Digital 0 : One stop bit

1 : Retransmit IN2 process value

2 : Retransmit IN1 IN2 difference

3 : Retransmit IN2 IN1 difference

AOFN Analog Output Function 4 : Retransmit set point value 0

5 : Retransmit output 1 manipulation

6 : Retransmit output 2 manipulation

9 : PT 100 ohms DIN curve

10 : PT 100 ohms JIS curve

11 : 4 - 20 mA linear current input

14 : 0 - 5V linear Voltage input

15 : 1 - 5V linear Voltage input

16 : 0 - 10V linear Voltage input

17 : Special defined sensor curve