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Brainchild P41 User Manual

Brainchild P41
100 pages
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User's ManualUser's Manual
P41 / P91
Auto-Tune Fuzzy / PID
Profiling Controller
P41 / P91
Auto-Tune
Fuzzy / PID
Profiling
Controller
UM0P411D
DIN EN ISO 9001
Certificate: 01 100 98505
R
L
R
LISTED
U

Table of Contents

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Brainchild P41 Specifications

General IconGeneral
Power Supply24 VDC
CommunicationRS-485, Ethernet
Operating Voltage24 VDC
Analog Input Pins8
Communication InterfacesRS-485, Ethernet

Summary

Chapter 1 Overview

General

Provides an overview of the Fuzzy Logic plus PID profiling controller series and its features.

Front Panel Description

Details the layout and components of the controller's front panel, including displays and buttons.

Key Operation Flowchart

Illustrates the sequence of key presses for navigating modes and parameters.

Parameter Descriptions

Lists and describes various parameters, their addresses, ranges, default values, and data types.

Chapter 2 Installation

Unpacking and Mounting

Guides through the process of unpacking the unit and preparing for panel mounting.

Mounting Dimensions

Provides diagrams showing the required panel cutout and overall dimensions for P41 and P91.

Wiring Precautions

Outlines essential safety and procedural guidelines for wiring the controller.

Rear Terminal Connections

Shows the wiring diagrams for rear terminal connections for both P41 and P91 models.

Power and Sensor Input Wiring

Illustrates the correct methods for connecting power supply and sensor inputs to the controller.

Control Output 1 Wiring

Details wiring for Output 1, covering relay, Triac (SSR), pulsed voltage, linear current, and linear voltage types.

Control Output 2 Wiring

Details wiring for Output 2, covering relay, Triac (SSR), pulsed voltage, linear current, and linear voltage types.

Alarm and Event Output Wiring

Shows how to wire alarm and event outputs to external devices, including diagrams for load and contactor connections.

Event Input and Retransmission Wiring

Illustrates wiring for event inputs and retransmission outputs, used for sending process or setpoint values.

Data Communication Wiring (RS-485)

Explains RS-485 communication interfaces and provides wiring diagrams.

Data Communication Wiring (RS-232)

Details RS-232 communication wiring and the configuration of a standard RS-232 cable.

Chapter 3 Configuration

Password and Security Settings

Describes the parameters for data security, including password and code settings.

Signal Input Configuration

Details how to select sensor types, input units, decimal points, and scale values.

Event Input Configuration

Explains how to configure the event input for various functions like RUN, HOLD, or ABORT.

Control Outputs Configuration

Outlines the configuration of different control modes (Heat/Cool, ON-OFF, PID) for the outputs.

Alarms Configuration

Describes the setup for up to three alarm outputs and their functions (process, deviation, band alarms).

Configure Home Page

Allows users to customize the display by selecting and arranging parameters for the home page.

User Calibration

Guides users through the process of calibrating the unit for improved accuracy.

Digital Filter

Explains how to use the digital filter to stabilize unstable process values.

Failure Transfer

Details how the controller handles failures like sensor breaks or A-D converter issues.

Auto-tuning

Describes the process of automatically tuning PID parameters for optimal control.

Manual Tuning

Explains how to manually adjust PID parameters when auto-tuning is insufficient.

Manual Mode Control

Allows direct manual control of heating or cooling outputs by adjusting percentage values.

Data Communication Setup

Covers Modbus RTU protocol, RS-485/RS-232 interfaces, and communication settings.

Retransmission Setup

Explains how to configure outputs for retransmitting process or setpoint values.

Output Scaling

Details how to scale linear outputs and retransmission signals based on electrical output ranges.

Chapter 4 Profiler Operation

What is a Set Point Profiler

Introduces the concept of set point profilers for varying process values over time using ramp and dwell segments.

Segment Connection Types

Illustrates combinations of ramp and dwell segments for creating profiles.

Profiler Modes

Explains the different operating modes of the profiler (Run, Hold, Static, etc.) and their indications.

Running, Holding, and Aborting Profiles

Describes how to start, pause, resume, and terminate profile execution using the controller's keys.

Viewing and Modifying Profile Progress

Explains how to monitor and adjust profile parameters like segment number and time during operation.

Start Point Configuration

Details how to specify the starting point (PV, SP1, STSP) for a profile for smooth operation.

Holdback Operation

Explains the holdback feature to freeze profiles when process values deviate from set points, with adjustable band and type.

Power Failure Recovery

Describes how the profiler behaves and recovers after a power interruption based on the PFR parameter setting.

Configuring the Profiler

Guides through the setup of global, profile, and segment parameters for creating profiles according to requirements.

Viewing and Creating a Profile

Details the steps for creating and managing profiles using the controller interface, including setting profile numbers and segment data.

Event Outputs and PID Selection

Explains how event outputs and PID parameter sets are configured and selected.

Chapter 5 Applications

Heat Treatment Oven Application

Presents a system diagram and explanation for using the controller in a heat treatment oven with multiple heaters and fan control.

Chapter 6 Specifications

Power and Input Specifications

Lists power requirements, input resolution, sampling rate, and maximum ratings for various input signals.

Sensor Lead Resistance and Break Detection

Details sensor lead resistance effects, burn-out current, and methods for detecting sensor breaks.

Input Type Characteristics

Provides accuracy and impedance details for different sensor types including Thermocouple, RTD, mA, and Voltage.

Output and Supply Specifications

Details characteristics for relay, pulsed voltage, linear outputs, and their load capacities.

DC Voltage Supply and Alarm Specifications

Outlines characteristics for DC voltage supplies, alarm relay ratings, and alarm functions.

Data Communication and Retransmission Specs

Outlines Modbus communication parameters (RS-232/RS-485) and analog retransmission details.

User Interface and Control Mode Specifications

Covers display type, keypad functions, communication ports, and available control modes (ON-OFF, P/PD, PID).

Digital Filter and Profiler Capabilities

Details the digital filter function and profiler capabilities like number of profiles and segments.

Environmental, Physical, and Approval Standards

Lists operating temperature, humidity, dimensions, weight, and compliance standards like UL, CSA, and EMC.

Chapter 7 Modbus Communications

Supported Modbus Functions

Lists available Modbus functions (03, 06, 16) and their corresponding query/response message formats.

Modbus Exception Responses

Explains how the controller responds to errors or invalid Modbus messages, including exception codes and causes.

Parameter and Number System Details

Refers to parameter descriptions, error codes, program codes, and explains the 2's complement number system.

Modbus Communication Examples

Provides practical examples of Modbus queries for reading data, performing resets, entering modes, and modifying calibration.

Chapter 8 Manual Calibration

Equipments Needed Before Calibration

Lists the necessary calibrators, test equipment, and software for performing manual calibration.

Manual Calibration Procedures

Provides step-by-step instructions for performing manual calibration for thermocouple and RTD inputs using specific signals.

Appendix A-1 Error Codes

Error Codes and Corrective Actions

Lists common error codes, their descriptions, and recommended corrective actions for troubleshooting.

Appendix A-2 Warranty and Returns

Warranty Information

Outlines the terms and conditions of the product warranty, including coverage and limitations.

Returns Policy

Explains the procedure for returning products, emphasizing the need for a Return Material Authorization (RMA) form.

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