02 - Rad-Rac-A Recirculating Air Cond Trainer Exp Man LT 10002 - Politeknik

RECIRCULATING AIR CONDITIONING
TRAINER
EXPERIMENT MANUAL
MODEL: RAD-RAC-A
Recirculating Air Conditioning Trainer Experiment Manual RAD-RAC-A
CONTENTS
CONTENTS i
1. OVERVIEW 1
2. ABOUT THE TRAINER 3

2.1. List of Items that come with the Trainer 3
2.2. Setting Up the Trainer 4
2.3. Part Identification 4
2.4. Safety Care and Maintenance 15
3. BASIC THEORY 17
3.1. Definition of Air Conditioning 17
3.2. Comfort and the Body 17
3.3. Psychrometric Properties of Air 19
3.4. The Psychrometric Chart 22
3.5. Refrigeration Process 28
3.6. Humidification 31
3.7. Air Velocity Measurement 32
4. PRE-OPERATION 35
4.1. Pre-Operation Procedure 35
4.2. Setting Up Data Acquisition Software 36
5. EXPERIMENTS 51
5.1. Recirculating Air Conditioning Trainer Familiarization 53
5.2. The Psychrometric Chart Familiarization 61
5.3. Plotting Refrigeration Cycle Into Pressure-Enthalpy (P-H) Diagram 65
5.4. System Performances Analysis, Cover The Calculation of Refrigeration Capacity,
Coefficient of Performance, Compression Ratio and Efficiency of
The Compressor 73
5.5. Cooling And Dehumidification 81
5.6. Heating 85
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5.7. Humidification 89
5.8. Effect Of Varying Cooling Load To System Performance 93
5.9. Automatic Control System 97
6. APPENDIX 99
6.1. Piping Diagram 101
6.2. Wiring Diagram 102
6.3. The Psychometric Chart 103
6.4. Thermo physical Properties of Air 104
6.5. Pressure-Enthalpy Diagram of R-134a 105
6.6. Thermodynamic Properties of R-134a 106
6.7. Symbol and Unit 109
6.8. Recovering, Evacuating, and Charging Procedures 110
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1
OVERVIEW
Labtech Recirculating Air Conditioning Trainer is a self-contained training system for

experimentation on air handling, heating, humidifying, de-humidifying, cooling and
refrigerating system. The trainer is designed for demonstrating the operation and performance
of Recirculating Air Conditioning system, so that you can simulate the different environments
and conditions within a circuit or a room type situation. You will also be able to control the
airflow for some processes such as Pre-heating, Cooling, Re-heating, Humidifying and De-
humidifying.
The main purpose of the trainer is used for investigating the prime factors that can be
controlled in a typical of air conditioning system. The unit provides data for which
thermodynamic properties of the air can be plotted on psychrometric chart, refrigeration cycle
on pressure-enthalpy diagram and determine another thermodynamic properties value.
The system is mounted on a movable bench with all components which are clearly visible and
the controls are within easy access, so you will learn and explore more about the operational
principles of Recirculating Air Conditioning Trainer. The trainer is appropriately designed
with entire comprehensive unit as media practicum in the laboratory or used for instruction in
the classroom.
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2
ABOUT THE TRAINER
2.1. LIST OF ITEMS THAT COME WITH THE TRAINER

2.1.1. Recirculating Air Conditioning Trainer
The trainer has some main components as follows:
1. Recirculating Air Conditioning Trainer (RAD-RAC-A)
2. Data Acquisition Hardware and Software (RAD-RAC-01)
3. Personal Computer Loaded with DAQ Software (RAD-RAC-02)
Figure 2.1. Recirculating Air Conditioning Trainer

2.1.2. Experiment Manual
The experiment manual provides information about the general comprehension of trainer. For
completing the exercises, this manual consists of the basic theory, pre-operation procedures,
experiments and the other references as described in appendix. After completing the
experiments, you will understand the prime factors that can be controlled in a typical of air
conditioning system including thermodynamic properties of the air that can be plotted on
psychrometric chart, refrigeration cycle on pressure-enthalpy diagram and determine another
thermodynamic properties value.
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2.2. SETTING UP THE TRAINER

Follow the procedure below for setting up the Recirculating Air Conditioning Trainer :
1. Unpack the unit from its package.
2. Please do an inventory of Recirculating Air Conditioning Trainer parts according to the
list in point 2.1 above.
3. Check the trainer to ensure there is no damage during the delivery.
4. Check the refrigeration line especially piping connections for leakage.
5. The electrical circuit of trainer is powered by 380 VAC/50Hz, 3 phase power source.
6. The cooling system uses refrigerant R-134a.
7. The steam generator requires distilled-water. It is recommended connecting the water tank
inlet to a suitable water supply and ensure that water tank is filled with enough distilled-
water (±18 liters).
8. Follow the operation procedure and experiment as guidance when operating the trainer.
2.3. PARTS IDENTIFICATION

Before operating the trainer, make sure you have understood about the functions of trainer
components. This sub-chapter will explain the general information of components as
classified in sub-chapter 2.1 above.
2.3.1. Recirculating Air Conditioning Trainer (RAD-RAC-A)
2.3.1.1. Refrigeration System
The components are as follows:
➢ Compressor
The Compressor (a refrigeration compressor) is the heart of a vapor compression
refrigeration system. It has function to raise the pressure of refrigerant and provides
the primary force to circulate the refrigerant. The refrigerant thus produces the
refrigeration effects to the evaporator, condenses into liquid form in the condenser,
and throttles to a lower pressures through the throttling device.
➢ Condenser
It is the heat-exchanger type condenser which receives heat, high-pressure refrigerant
gas from compressor and cold-gaseous refrigerant until returns to its liquid state. For
cooling gaseous refrigerant, the condensing process is carried-out in a heat exchanger
that allows the heat exchanges between refrigerant and air indirectly.
➢ Evaporator
Evaporator is part of a refrigerating system in which the refrigerant is evaporated to
absorb heat from cooling space.
➢ Thermostatic expansion valve (TXV)
It is used to control the refrigerant flows to Evaporator. TXV is operated by
temperature and pressure within evaporator. The control bulb is attached at the pipe
outlet of evaporator.
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Figure 2.4. Recirculating Air Conditioning Components
➢ Filter Drier
It receives the liquid refrigerant from the condenser, removes any moisture and filters
the foreign matters that may enter to the system.
➢ Manual valves
Manual Valves (MV) are provided in the refrigeration system. There are four manual
valves, which consist of:
a) MV1: Filter Drier Inlet Valve
b) MV2: Filter Drier Outlet Valve
c) MV3: Expansion Device Inlet
b) MV4: Condensate Drain Valve
MV1 and MV2 are used to isolate the system while doing the filter drier replacement.
They also can be used for simulating the clogged of Filter Drier. MV3 can be used for
simulating the clogged Expansion device.
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➢ Accumulator
The prime function of a suction line accumulator in a refrigeration system is holding a
percentage of the total system charge and preventing the liquid slug or excessive the
refrigerant dilution of the compressor oil.
➢ Receiver
Liquid receiver is a storage tank for liquid refrigerant. Refrigerant is pumped out of
various parts and stored in the liquid receiver during servicing. Its use makes the
quantity of refrigerant in a system less critical.
➢ Refrigerant Pressure Gauges
There are four pressure gauges to monitor the working pressure of refrigeration
system. They consist of:
PG1: Suction Pressure
PG2: Discharge Pressure
PG3: Condenser Outlet Pressure
PG4: Evaporator Outlet Pressure
➢ Sight Glass
Sight Glass is used to monitor the refrigerant state in the refrigeration system.
➢ Dual pressure control
Dual pressure control consists high pressure and low pressure controls. It is the
electrical control switch that is used for protecting the compressor.
a) High Pressure Control
High Pressure Control is installed at the high side pressure of compressor. That will
open the electrical circuit automatically if it reaches the cut-out setting.
Factory adjustment for High Pressure Control:
Cut-Out = 17.4 bar (250 psig) adjustable
Differential = 3 bar (43 psi) fixed
b) Low Pressure Control
Low Pressure Control is the electrical control switch, operated by the low side
pressure that will open the electrical circuit automatically if it reaches the cut-out
setting.
Factory adjustment for Low Pressure Control:
Cut-In = 0.5 bar (7.5 psig) adjustable
Differential = 1.6 bar (23 psi) adjustable
➢ Access Valves.
It is installed in the liquid line just before the Filter Drier. These valves are used for
recovering, evacuating/vacuum, and filling the liquid refrigerant.
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2.3.1.2. Steam Generator

Steam generator is required for humidification process. Steam is generated by boiling water in
its tank and injected to the air by using steam injector to increase the moisture content of air.
Steam generator requires fresh water (distilled-water is recommended) with content ±18 liters.
It has three electrical heater elements. When it is energized with 220-240 VAC, the heater
capacities are 1.0kW, 3kW and 5.0kW. It is selected by using a cam switch. Operation of
steam generator is controlled by thermostat. There is float switch that is used to control the
steam generator heater operation. The float switch will STOP the operation when the water is
not enough to generate the steam.
Figure 2.5. Steam Generator Tank

2.3.1.3. Air Duct
The components are as follows:
➢ Fan Motor
Fan is used to circulate air flowing through the ducting. Variety of fan speed can be
done by adjusting fan speed control.
➢ Pre-Heater
Pre-heater is required for heating process. Pre-heater has two electrical heater-
elements. When it is energized with 220-240 VAC, the heater capacities are 1 kW, 2
kW and 3kW. It is selected by using a cam switch. Operation of Pre-heater is
controlled by thermostat.
➢ Steam Injector
Steam injector is used to inject the steam that comes from the steam generator tank.
➢ Re-Heater
Re-heater is required for re-heating process. Re-heater has two electrical heater-
elements. When it is energized with 220-240 VAC, the heater capacity is 0.5kW,
1.0kW and 1.5kW. The capacity is selected by a cam switch. Operation of Re-heater
is controlled by thermostat.
2.3.1.4. Sensors and Control

There are some instruments that are used for monitoring the performance of training unit.
➢ Temperature Sensor
Some sensors that is provided are used for measuring air temperature and refrigeration
tube temperature.
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For measuring air temperature, there are six temperature sensors that are installed on
the ducting. The display is installed on the panel with temperature unit in degree
Celsius (°C).
For measuring refrigeration tube temperature, there are six temperature sensors that
are installed on the refrigeration line. The display is installed on the panel with
temperature unit in degree Celsius (°C).
Figure 2.6. Temperature Sensor
➢ Humidity sensor (hygrometer)

The hygrometer consists of five sensors that is installed on the ducting for measuring
the relative humidity, you can see both the ducting and the piping diagram. The
display is installed on the panel with relative humidity unit in percentage (%).
Figure 2.7. Humidity Sensor
➢ Air velocity sensor

Air velocity sensor is used to measure the velocity of air flow and the unit in m/s. This
sensor is installed on the duct inlet and duct outlet. The air velocity value is displayed
on the instrument and control panel.
Figure 2.8. Air Flow Sensor
➢ Refrigerant flow meter sensor

Refrigerant flow meter sensor is installed on the liquid line of refrigeration system to
measure the refrigerant flow rate. The digital display is installed on the panel to
monitor its value (in liter per minute).
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Figure 2.9. Refrigerant flow meter Sensor
2.3.1.5. Circuit Breakers Panel

The circuit breakers panel is provided as electrical safety system. There are two types of
circuit breakers that are installed on this panel:
➢ Earth Leakage Circuit Breaker (ELCB)
It is used to protect the circuit from leaking current.
➢ MCB
It is used to protect the circuit from over current and short circuit.
Figure 2.10. Circuit Breakers Panel
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2.3.1.6. Instrument and Control Panel
Figure 2.11. Instrument and Control Panel

The Instrument and Control Panel is provided as electrical system control. There are some
components that are installed on this panel:
➢ Emergency Stop
It is used to shut OFF the trainer immediately by pressing the switch.
➢ Start Switch
It is used to connect the electrical power flowing to electrical control circuit.
➢ Stop Switch
It is used to disconnect the electrical power from electrical control circuit.
➢ Power Indicator
It is used as ON/OFF indicator, the indicator is ON when the electrical power has been
distributed to electrical control circuit.
➢ Overload Indicator
It is used as trip indicator, the indicator is ON when the blower fan motor or
compressor is overload.
➢ Manual/Auto Selector Switch
It is used as a selector to change the operation mode of the system. It consists of two
operations; MANUAL and AUTO operations.
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Table 2.1 Manual/Auto Control

Manual Auto Remark
Fan Motor ✔ ✔
Compressor ✔ ✔
Pre Heater ✔ ✗
Re Heater ✔ ✗
Steam Generator ✔ ✗
VAV Damper ✔ ✔
Fresh Air Damper ✔ ✔
Modulating Valve ✔ ✔
WARNING!!! Do not change the Manual/Auto selector switch when the system is
still running. Please determine the operation-mode before running the system!
➢ Voltmeter and Selector Switch
Voltmeter is functioned as instrument for measuring the voltage (AC) of training unit
power source. It can be selected to measure AC voltage between phase to phase or
phase to neutral by using the voltmeter selector.
➢ Fan Switch and Fan Speed Control.
Fan switch is used for activating the fan speed control (inverter). While Fan Speed
Control is used for varying fan motor speed.
➢ Re-heater switch, Ammeter and Thermostat.
Re-heater switch is used for activating and selecting the re-heater load (0.5 kW, 1
kW or 1.5 kW) and the thermostat is used as re-heater temperature control. The
current consumption is shown by the re-heater on ammeter.
➢ Compressor Switch and Wattmeter.
Compressor Switch is used for activating the compressor and the watt meter is used
for measuring the compressor power consumption.
➢ Steam Generator Switch and Ammeter.
Steam Generator Switch is used for activating the steam generator heater and the
ammeter is used for measuring its current consumption.
➢ Pre-heater switch, ammeter and thermostat.
Pre-heater switch is used for activating and selecting the pre-heater load (1 kW, 2
kW or 3 kW), the thermostat is used as pre-heater temperature control. The current
consumption is shown by the pre-heater on ammeter.
➢ Air velocity Selector and Display.
Air velocity Selector is used for switching the air velocity which will be displayed
(between duct inlet air velocity and duct outlet air velocity)
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➢ Relative Humidity (RH)/Temperature Selector and Display.

RH/Temperature display is used to display the prefer temperature points in the
refrigeration system, while the selector is used to select RH/temperature point and
show on the display. RH/Temperature pick-up points are listed in Table below:
Table 2.2 RH/Temperature Points
Relative Humidity (%) Temperature (ºC)
Air Ducting
A: Inlet Air ✔ ✔
B: Mixing Air ✔ ✔
C: Before Evaporator ✔ ✔
D: After Evaporator ✔ ✔
E: Return Air ✔ ✔
F: Environmental Chamber ✔ ✔
Refrigeration Tube
1: Suction ✗ ✔
2: Discharge ✗ ✔
3: Condenser Outlet ✗ ✔
4: TXV Inlet ✗ ✔
5: Evaporator Inlet ✗ ✔
6: Evaporator Inlet ✗ ✔
➢ Refrigerant Flowmeter Switch and Display.

Refrigerant flowmeter switch is used to turn ON/OFF its display. The display is used
to show and monitor refrigerant flowrate of refrigeration system.
➢ Humidity Controller
Humidity controller is used to control or maintain the humidity level as desired.
Humidity controller will open the solenoid valve when the humidity level is below set
point level, and will close the solenoid valve when the humidity level is above the set
point level.
➢ Temperature Controller
Temperature controller is used to control or maintain the temperature level as desired.
Temperature controller will increase the blower fan speed when the temperature level
is above set point level, and will decrease the blower fan speed when the temperature
level is below the set point level.
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Figure 2.11. Steam Generator Thermostat and Solenoid Valve Switch
➢ Steam Generator Thermostat

Steam Generator Thermostat is used as steam generator tank temperature control.
➢ Solenoid Valve Switch
Solenoid Valve Switch is used to ON/OFF the solenoid valve.
2.3.2. Data Acquisition Hardware and Software (RAD-RAC-01)

Data acquisition hardware and software are used for monitoring and analysis of system
performance via USB computer interface. The software automatically calculates the air
properties in the air flowing through the ventilation duct during heating, cooling,
humidification and Dehumidification processes. The software also plots the psychrometric
chart and puts the corresponding point of the air properties onto the chart. The psychometric
charts show the reading of 6 measurement points of the air in 6 different locations in real time
for observation and analysis.
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Figure 2.12 Software Interface; (a). Flow Animation, (b). Thermodynamic Properties of Air, (c). Psycrhrometric
Chart (d). Wiring Diagram
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2.4. SAFETY CARE AND MAINTENANCE

For safety reason:
1. Do not touch the hot surface such as Compressor, Refrigerant discharge line and Steam
Generator Tank.
2. Do not put your hands on moving parts such as fan blades.
3. Wear a goggle and gloves when you are attaching or removing the gauges to transfer the
refrigerant or to check the pressures.
4. Observe all electrical safety precautions. Be careful at all times and common sense.
For long life and better trainer performance:

1. Periodically clean up the Condenser and Evaporator fins.
2. Always check the refrigerant pressure. The system should run with sufficient refrigerant.
Note: Running the Compressor with low refrigerant charge could reduce the Compressor
life and or damage the Compressor.
3. Immediately do the repair if the refrigeration system is leaking.
4. In case of the unit needs to be recharged, ensure the refrigerant is R-134a.
5. Always check the water level of steam generator tank. Ensure it is filled with distilled-
water (±18 liter) before running the system. Check the water level to estimate the
condition in the water tank. The maximum setting of steam generator thermostat is 105°C.
6. Ensure the fan motor has been activated when operating the system to prevent over
heating. For that reason the trainer is provided with the thermostats that is located at pre-
heater and re-heater area. It is recommended to set the thermostat within 50°C to prevent
the unit from damage because of over temperature.
7. Periodically test all safety components such as circuit protector and pressostat.
8. Periodically, clean up the air duct as follows.
✔ Prepare a cleaning solution of 3-4 tablespoons of baking soda mixed with warm water.
Use sponge or soft cloth, dampened with the cleaning solution, to wipe down the air
duct.
✔ Rinse with clean warm water and dry with a soft cloth.
✔ Do not use harsh chemicals, abrasives, ammonia, chlorine bleach, concentrated
detergents, solvents or metal scouring pads. Some of these chemicals may dissolve,
damage and/or discolor the air duct.
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3
BASIC THEORY
3.1. DEFINITION OF AIR CONDITIONING

Air conditioning is a combined process that performs many functions simultaneously. It
conditions the air, transports it, and introduces it to the conditioned space. It provides heating
and cooling from its central plant or rooftop units.
The American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASRAE)
define air conditioning as: “The process of treating air so as to control simultaneously its
temperature, humidity, cleanliness, and distribution to meet the requirements of the
conditioned space”.
As the definition indicates, the important actions involved in the operation of an air
conditioning system are:
• Temperature control.
• Humidity control.
• Air filtering, cleaning, and purification.
• Air movement and circulation.
This is well known that the factors have a considerable effect on human comfort in all
weather. For this reason air conditioning is used in most building, transportation facilities, and
where the human occupancy is high.
Winter heating conditions require automatic control of the heating source to maintain desired
room temperatures. Humidity control for winter conditions usually requires the addition of
moisture by using a humidifier.
Summer cooling conditions require automatic control of the air conditioning system to
maintain the desired room temperatures. Humidity control for summer conditions requires
dehumidifiers, which pass air to be cooled over cold evaporator surfaces.
In general, air filtering is the same for both summer and winter. Air filtering equipment
usually consists of very fine porous substances. Air is drawn through them to remove
contaminating particles. Filters using activated carbon and electrostatic precipitators may be
added to the usual filtering mechanisms to improve air cleaning.
In addition, many industries air-condition their plants for two reasons: for the comfort
provided and for more complete control of manufacturing processes and material. Better
control of manufacturing temperatures and relative humidity improves the quality of the
finished product.
3.2. COMFORT AND THE BODY

Comfort describes the delicate balance of feeling in the body in relationship to its
surroundings. To be comfortable describes our surroundings when we are not aware of
discomfort. Providing a comfortable atmosphere for people becomes the job of the heating
and air conditioning profession. Comfort involves four things, (1) Temperature, (2)
Humidity, (3) Air Movement and (4) Air Cleanliness. The human body has a sophisticated
control system for both protection and comfort. It can go from a warm house to –17.78º C
outside, and it starts to compensate for the surroundings. It can go from a cool house to 35º C
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outside, and it will start to adjust to keep you comfortable and from overheating. Body
adjustments are accomplished by the circulatory and respiratory systems.
When the body is exposed to a climate that is too cold, it starts to shiver, an involuntary
reaction, to warm the body. When the body gets too warm, the vessels next to the skin dilate
to get the blood closer to the surrounding air in an effort to increase the heat exchange with
the air. If this does not cool the body, it will break into a sweat. When this sweat is
evaporated, it takes heat from the body and cools it.
The body gives off and absorbs heat by the three methods of heat transfer: conduction,
convection, and radiation. Evaporation, in the form of perspiration, could be considered a
fourth way. When the surroundings are at a particular comfort condition, the body is giving
up heat at a steady rate that is comfortable. The surroundings must be cooler than the body for
the body to be comfortable.
Typical, when the body at rest (sitting) is in surroundings of 23.9º C and 50% humidity with a
slight air movement, the body is very close to being comfortable during summer conditions.
Notice that the room air at this condition is –14.7º C cooler than the human body. In winter a
different set of conditions applies (e.g., we wear more clothing). The following statements
can be used as guidelines for comfort.
1. In winter:
A. Lower temperature can be offset with higher humidity.
B. The lower the humidity is, the higher the temperature must be.
C. Air movement is more noticeable.
2. In summer:
A. When the humidity is high, air movement helps.
B. Higher temperatures can be offset with lower humidity.
3. The comfort conditions in winter and in summer are different.
4. Styles of clothes in different parts of the country make a slight difference in the
conditioned space temperature requirements for comfort. For example, in Maine the
styles would be warmer in the winter than in Georgia, so the inside temperature of a home
or office will not have the same comfort level.
5. Body metabolism varies from person to person. Women for example, are not as warm
natured as men. The circulatory system generally does not work in older people as well as
in younger people.
Human body temperature is normally 37ºC. We are comfortable when the heat level in our
body due to food intake is transferring to the surroundings at the correct rate. But certain
conditions must be met for this comfortable, or balanced, condition to exist. The human body
will be comfortable under a variety of temperature and humidity combinations.
Most people are comfortable in an atmosphere with the relative humidity between 30% and
70% and the temperature between 21°C and 29°C (70°F and 85°F). This temperature is
usually maintained in cold weather by wearing adequate clothing. In hot weather, it is
maintained by the evaporation of moisture (sweat) and by radiation from the skin surface.
However, the person is not uncomfortable because body heat is being released by moisture
evaporation from the skin surface.
The chart in Figure 3.2-1, often called a generalized comfort chart, can be used as a basis to
compare one situation with another. It shows the different combinations of temperatures and
humidity for both summer and winter.
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Figure 3.2-1. These are Generalized Comfort Charts for Different Temperature and Humidity Conditions
(Adapted from Carrier Corporation Psychrometric Chart)
3.3. PSYCHROMETRIC PROPERTIES OF AIR

Psychrometric is the study of the thermodynamic properties of most air or in other word it is
the science and practice of dealing with air mixtures and their control. The science deals
mainly with dry air and water vapor mixtures. Psychrometric deals with the specific heat of
dry air and its volume. It also deals with the heat of water, heat of vaporization or
condensation, and the specific heat of steam in reference to moisture mixed with dry air.
There are some measurable properties that must be known in psychrometric, they are dry bulb,
wet bulb, and dew point temperature. Completely, psychrometric talk about barometric or
atmospheric pressure, enthalpy, relative humidity, dry bulb temperature, wet bulb temperature,
density, moist volume, moisture content, and dew-point temperature.
An instrument that permits one to determine the relative humidity of moist air sample by
measuring its dry bulb and wet bulb temperatures is called as psychrometer. Figure 3.3-1
shows a psychrometer, which consists of two thermometers. The sensing bulb of one of the
thermometers is always kept dry and the temperature reading of it is called the dry-bulb
temperature. The other sensing bulb thermometer is wrapped with a piece of cotton wick, one
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end of which dips into a cup of distilled water. The surface of this bulb is always wet and the
temperature that this bulb measures is called the wet-bulb temperature. The dry bulb is
separated from the wet bulb by a radiation-shielding plate.
Shield Plate
Cotton Wick
Dry Bulb
Wet Bulb
Moist Air
Water Cup
Figure 3.3-1. A Psychrometer
3.3.1. Humidity
Humidity is definable as an absolute measure: the amount of water vapor in a unit of air.
Actually, air is not totally dry but there is water vapor or moisture content always present in
the air and so it’s called humidity. Surface water and rain keep moisture in the atmosphere
everywhere (even in a desert) at all times. (Remember the earth’s surface is approximately
65% water).
The moisture content in air (humidity) is measured by weight, expressed in pounds or grains
(7000 grains per pound). Air can hold very little water vapor 100% humid air at 29.92 in Hg
and 21.1º C can hold 110.5 grains (gr.) of moisture (0.01578 lb) per cubic foot. Several
methods are used to calculate the percentage of moisture in the air.
Indicating of how dry or damp the air can only be done by computing the ratio of the actual
partial vapor pressure to the saturated partial vapor pressure at the same dry bulb temperature
and pressure, and it is defined as Relative Humidity. Relative humidity is the most practical
and most used for field measurements. It is based on the weight of water vapor in a given
volume of space compared to the weight of water vapor that the same volume could hold if it
were 100% saturated. Relative humidity is stated in a percentage such as 30%, 50% and 70%.
3.3.2. Dry-Bulb and Wet-Bulb Temperature

Using a combination of dry-bulb and wet-bulb temperatures can check the moisture content of
air. Dry-bulb temperature is the sensible-heat level of air and is taken with an ordinary
thermometer. Wet-bulb temperature is taken with thermometer with a wick on the end that is
soaked with distilled water. The reading from a wet-bulb thermometer takes into account the
moisture content of the air. It reflects the total heat content of air. The thermometer will get
cooler than the dry-bulb thermometer due to the evaporation of the distilled Water. Distilled
water is used because some water has undesirable mineral deposits. Some minerals will
change the boiling temperature.
The difference between the dry-bulb reading and the wet-bulb reading is called the wet-bulb
depression. As the amount of moisture suspended in the air decreases, the wet-bulb
depression decreases and vices versa. For example, a room with dry-bulb temperature of
24.4º C and a wet-bulb temperature of 17.8º C has a wet bulb depression of 6.6ºC and a
relative humidity of 52%. If the 24.4º C dry-bulb temperature is maintained and moisture is
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added to the room so that the wet-bulb temperature rises to 23.3º C, the relative humidity
increases to 91% and the new wet-bulb depression is 1.1º C. If the wet-bulb depression is
allowed to go to 0º C (for example, 24.4º C dry bulb and 24.4º C wet bulb), the relative
humidity will be 100%.
3.3.3. Dew-Point Temperature

The dew-point temperature is the temperature at which condensation occurs (100% relative
humidity) when air is cooled at a constant pressure without adding or taking away water
vapor. For example, if you were to set a glass of warm water in a room with a temperature of
23.9º C and 50% relative humidity, the water in the glass would evaporate slowly to the room.
If you gradually cool the glass with ice, then when the glass surface temperature becomes 13º
C, water will begin to form on the surface of the glass, Figure 3.3-2. Moisture from the room
will also collect in the water in the glass and the level will begin to rise. This temperature at
which water forms is called the dew-point temperature of the glass.
Figure 3.3-2. The glass was gradually cooled until beads of water began to form on the outside of the glass.
Figure 3.3-3. The cold surface on the air conditioning coil condenses moisture from the air passed over it.
Air can be dehumidified by passing it over a surface that is below the dew-point temperature
of the air; moisture will collect on the cold surface, for example, an air conditioning coil,
Figure 3.3-3. The condensed moisture is drained. This is the moisture that you see running
out the back of a window air conditioner.
3.3.4. Superheat Gases in Air

Since air is made of several different gases, it is not a pure element or gas. Air is made up of
nitrogen (78%), oxygen (21%) and approximately 1% other gases. These gases in the air are
highly superheated. Nitrogen, for instance, boils at –195º C, and oxygen boils a –147.2º C at
atmosphere pressure. Hence, nitrogen and oxygen in the atmosphere are superheated gases –
they are superheated several hundred degrees above absolute (0º Rankine). Each gas exerts
LABTECH 21
pressure according to Dalton’s Law of Partial Pressures. Simply stated, this law says that each
gas in a mixture of gases acts independently of the other gases and the total pressure of a gas
mixture is the sum of the pressures of each gas in the mixture. More than one gas can occupy
a space at the same time.
Water vapor suspended in air is a gas that exerts its own pressure and occupies space with the
other gases. Water at 21.1º C in a dish in the atmosphere exerts a pressure of 0.7392 in. Hg.
If the water vapor pressure in the air is less than the water vapor pressure in the dish, the water
in the dish will evaporate slowly to the lower pressure area of the water vapor in the air. For
example, the room may be at a dry-bulb temperature of 21.1º C with a humidity of 30%. The
vapor pressure for the moisture suspended in the air is 0.101 psi x 2.036 = 0.206 in. Hg.
Vapor pressure for moisture in air can be found in some psychrometric charts and in saturated
water tables. When reverse pressure occurs, the action of the water vapor reverses. For
example, if the water vapor pressure in the dish is less than the pressure of the vapor in the air,
water from the air will condense into the water in the dish. When water vapor is suspended in
the air, the air is sometimes called wet air. If the air has a large amount of moisture, the
moisture can be seen (for example, fog or a cloud). Actually, the air is not wet more
accurately be called a nitrogen, oxygen, and water vapor mixture.
3.4. THE PSYCHROMETRIC CHART

Psychrometric charts provide a graphical representation of the thermodynamic properties of
moist air, various air conditioning processes, and air conditioning cycles. The charts are very
helpful during the calculation, analysis, and solution of the complicated problem encountered
in air conditioning processes and cycles. The foregoing description can all be plotted on a
psychrometric chart, Figure 3.4-1. The chart looks very complicated, but a clear plastic
straightedge and a pencil will help you understand it. See Figure 3.4-2 through 3.4-7 for some
examples of plotting of the different conditions on a psychrometric chart.
The easiest conditions to determine from room air are the wet-bulb and dry-bulb temperatures.
For example, you can take an electronic thermometer and make a wet-bulb thermometer if you
do not have one. Take two leads and tape them together with one lead about 2-in below the
other one, Figure 3.4-8. A simple wick can be made from a piece of white cotton, such as an
undershirt. Make sure that it does not have any perspiration on it. Wet the lower bulb (with
the wick on it) with distilled water that is warmer than the room air. Water from a clean
condensate drain line may be used if real distilled water is not available. Water from the city
system can be used but may give slightly wrong results. Hold the leads about 3 ft back from
the element on the end and slowly spin them in the air. The wet lead will drop to a colder
temperature than the dry lead will. Keep spinning them until the lower lead stops dropping in
temperature but is still damp. Quickly read wet-bulb and dry-bulb temperature without
touching the bulbs. Suppose the reading is 23.9º C DB (dry-bulb) and 16.9º C WB (wet-bulb).
Put your pencil point at this place on the psychrometric chart, make a dot and draw a light
circle around it so you can find the dot again.
LABTECH 22
115
0.033 0.36
110
LABTECH
0.032
105
0.031
0.030
100
PSYCHROMETRIC CHART 0.029 0.40
95
0.028
90%
30
NORMAL TEMPERATURES
AIR
0.027
90
RY
GD
0.026
80%
J/K
SI METRIC UNITS 0.45
K
85
0.025
ION
Barometric Pressure 101.325 kPa
AT
I TY
0.024
70%
UR
80
MID
T
HU
SA
0.023
E
AT
SEA LEVEL 0.50
TIV
PY
LA
0.022
75
%
AL
RE
60
Reproduced by permission of Carrier Corporation %
TH
50 0.021
EN
SENSIBLE HEAT FACTOR
25
70
0.55
0.020
0.019
65
0.018 0.60
60
0.017
%
0.65
40
DRY AIR
0.016
55
0.95
20
0.015
KJ/KG
0.70
50
0.014
% 0.75
30 0.013
40
45
0.80
0.012
0.85
35
40
0.011
15
0.90
05
-1.2
-0.4
-0.8
-0.6
-0.
-1 ENTHALPY DEVIATION
-0.2
25
0.010 0.95
-0.
30
%
20 1.00
0.009
20
25
0.008
10
C
E
15
UR 0.007
10
AT
PER
TEM 0.006
ION
5
RAT
-10
TU 10%
R SA 0.005
BO
BUL
WET
0
0
0.004
0.003
-5
-5
0.2
0.4 0.002
0.6
0.001
-10
0.8
MOISTURE CONTENT KG/KG DRY AIR
1.0
0.000
Figure 3.4-1A. Psychrometric Chart. Reproduced courtesy of Carrier Corporation.

-10 -5 0 5 10 15 20 25 30 35 40 45 50 55
0.75 0.80 DRY BULB TEMPERATURE C 0.85 0.90
BELOW C PROPERTIES AND ENTHALPY DEVIATION LINES ARE FOR ICE VOLUME M /KG DRY AIR
23
Pν=f(
ω)
ω
TEMPERATURE
WETBULB
TEMPERATURE
DEWPOINT
B
WE
TB
WATERVAPOURPRESSURE
UL
SPECIFICHUMIDITY
B
DEW POINT MOISTURE
CONTENT
Y
E DIT
LIN MI
HU
ION
VO
E
AT TIV
LU
UR LA
SAT RE
ME
DRY BULB TEMPERATURE, t
Figure 3.4-1B. Constant Property Lines Psychrometric Chart

The following information is an example of some thermodynamic properties that can be
concluded from the plotting:
1. Dry-bulb temperature 40º C
2. Wet-bulb temperature 25º C
3. Dew-point temperature 18.8º C
4. Total heat content of air 76.5 kJ/kg
5. Moisture content of air 0.014 kg/kg
6. Relative humidity 30%
7. Specific volume of air 0.907 m3/kg
Figure 3.4-2. Skeleton chart showing the dry- Figure 3.4-3. Skeleton chart showing the we4-
bulb temperature lines. From Lang, Principles of bulb lines. From Lang, Principles of Air-
Air Conditioning © 1987 by Delmar Publishers Conditioning © 1987 by Delmar Publishers Inc.
Inc.
LABTECH 24
Figure 3.4-4. Skeleton chart showing the Figure 3.4-5. Skeleton chart showing the
relative humidity lines. From Lang, Principles of moisture content of air expressed in grains per
Air-Conditioning © 1987 by Delmar Publishers pound of air. From Lang, Principles of Air-
Inc. Conditioning © 1987 by Delmar Publishers Inc.
Figure 3.4-6. Skeleton chart showing the total Figure 3.4-7. Skeleton chart showing the
heat content of air in Btu/lb. These lines are specific volume of air at different conditions.
almost parallel to the wet-bulb lines. From Lang, From Lang, Principles of Air-Conditioning ©
Principles of Air-Conditioning © 1987 by 1987 by Delmar Publishers Inc.
Delmar Publishers Inc.
Figure 3.4-8. How to Make a Wet-Bulb and Dry-Bulb Thermometer from an Electronic Thermometer.
LABTECH 25
3.4.1. Plotting on the Psychrometric Chart

The condition of air can be plotted on the psychrometric chart as it is being conditioned. The
following examples show how different applications of air-conditioning are plotted.
• Air is heated. Movement through the heating equipment can be followed as a sensible
heat direction on the chart, Figure 3.4-9.
• Air is cooled. These are no moisture removal. This shows a sensible heat direction on the
chart, Figure 3.4-10.
• Air is humidified. No heat is added or removed. An increase in moisture content and dew
point temperature shows, Figure 3.4-11.
• Air is dehumidified. No heat is added or removed. A decrease in moisture content and
dew point temperature shows, Figure 3.4-12.
• Air is cooled and humidified using an evaporative cooler. These are popular in hot, dry
climates, Figure 3.4-13.
Figure 3.4-9. Air passing through a sensible Figure 3.4-10. Air is cooled with a dry
heat exchange furnace. evaporator coil, operating above the dew-point
temperature of the air. No moisture is removed.
This is not a typical situation.
Figure 3.4-11. Spray atomizers are used to add Figure 3.4-12. Moisture is removed from the air.
moisture to the air. The dew-point temperature This is not a typical application and is shown as
and moisture content both increase. an example only.
LABTECH 26
WHEN AIR IS CONDITIONED AND THE PLOT MOVES IN THE

DIRECTION OF:
SENSIBLE HEAT IS REMOVED.
SENSIBLE HEAT IS ADDED.
LATENT HEAT IS REMOVED, MOISTURE REMOVED.
LATENT HEAT IS ADDED, MOISTURE ADDED.
Figure 3.4-14. A summation of sensible and latent heat
It can be seen that when air enters air-conditioning equipment it can be plotted on a chart.
Figure 3.4-14 shows a chart indicating that from the reference point in the middle, the air may
be conditioned to heat, cool, humidify, or dehumidify. Some apparatus will both add heat and
moisture, or cool and remove moisture. The following examples will show what happens in
the most common heating and cooling systems.
• The most common winter application is to heat and humidify. This will show both a rise
in temperature and an increase in moisture and dew point temperature, See Figure 3.4-15.
• The most common summer application is to cool and dehumidify air. A decrease in
temperature, moisture content, and dew point will take place, Figure 3.4-16.
It is very important to notice that any change in heat content or moisture content of air will
cause a change in the wet-bulb reading and, therefore, a change in the total heat content.
Figure 3.4-15. Sensible heat raises the temperature of the air from 21.1º C to 48.9º C. Moisture is evaporated
and latent heat is added to the air.
Figure 3.4-16. Removal of sensible heat cools the air. Removal of latent heat removes moisture from the air.
LABTECH 27
3.5. REFRIGERATION PROCESSES

Refrigeration is defined as the process of extracting heat from a lower-temperature heat
source, substance, or cooling medium and transferring it to a higher-temperature heat sink.
Refrigeration maintains the temperature of the heat source below that of its surroundings
while transferring the extracted heat, and any required energy input, to a heat sink,
atmospheric air, or surface water. A refrigeration system is a combination of component and
equipment connected in a sequential order to produce the refrigeration effect. The
refrigeration systems commonly used for air conditioning can be classified by the type of
input energy and the refrigeration process as follows:
• Vapor compression systems. In vapor compression systems, compressors activate the
refrigerant by compressing it to a higher pressure and higher temperature level after it has
produced its refrigeration effect. The compressed refrigerant transfers its heat to the sink
and is condensed to liquid form. This liquid refrigerant is then throttled to a low-pressure,
low temperature vapor to produce refrigerating effect during evaporation. Vapor
compression systems are the most widely adopted refrigeration systems in both comfort
and process air conditioning.
• Absorption systems. In an absorption system, the refrigeration effect is produced by
thermal energy input. After absorbing heat from the cooling medium during evaporation,
the vapor refrigerant is absorbed by and absorbent medium. This solution is then heated by
direct-fired furnace, waste heat, hot water, or steam. The refrigerant is again vaporized and
then condensed to liquid to begin the refrigeration cycle again.
• Air or gas expansion systems. In an air or gas expansion system, air or gas is compressed
to a high pressure by mechanical energy. It is then cooled and expanded to a low pressure.
Because the temperature of air or gas drops during expansion, a refrigeration effect is
produced.
Refrigeration processes indicates the change of thermodynamic properties of the refrigerant
and the energy transfer between the refrigerant and the surroundings. The following
refrigeration processes occur during the operation of vapor compression refrigerating system:
• Evaporation. In this process, the refrigerant evaporates at lower temperature then heat of
its surroundings, absorbing its latent heat of vaporization.
• Superheating. Saturated refrigerant vapor is usually superheated to ensure that liquid
refrigerant does not flow into the compressor.
• Compression. Refrigerant is compressed to a higher pressure and temperature for
condensation.
• Condensation. Gaseous refrigerant is condensed to liquid form by being de superheated,
then condensed, and finally sub cooled, transferring its latent heat of condensation to a
coolant.
• Throttling and expansion. The higher-pressure liquid refrigerant is throttled to the lower
evaporation pressure and is ready for evaporation.
3.5.1. Refrigeration Cycle

A schematic vapor compression system is shown in Figure 3.5-1A. It consists of a
compressor, a condenser, an expansion device for throttling and an evaporator. The
compressor-delivery head, discharge line, condenser and liquid line form the high-pressure
side of the system. The expansion line, evaporator, suction line and compressor-suction head
form the low-pressure side of the system.
LABTECH 28
3 2
CONDENSER
liquid line discharge line 3 CONDENSER 2
pr essure
EXPANSION
COMPRESSOR
VALVE
4 EVAPORATOR 1
expansion line suction line
EVAPORATOR
4 1
enthalpy
A B
Figure 3.5-1. Vapor Compression System Schematic and Refrigeration Cycle on Pressure-Enthalpy Diagram.
Most refrigerants undergo a series of evaporation, compression, condensation, throttling, and

expansion process, absorbing heat from a lower-temperature reservoir and releasing it to a
higher-temperature reservoir in such a way that the final state is equal in all respects to the
initial state. It is said to have undergone a closed refrigeration cycle. When air or gas
undergoes a series of compression, heat release, throttling, expansion, and heat absorption
processes, and its final state is not equal to its initial state, it is said to have undergone an open
refrigeration cycle. Figure 3.5-1B shows the refrigeration cycle on a pressure-enthalpy (p-h)
diagram.
The pressure-enthalpy diagram is the most common graphical tool for analysis and calculation
of the heat and work transfer and performance of a refrigeration cycle. A single-stage
refrigeration cycle consists of two regions: the high-pressure region (high side) and the low-
pressure (low side). The change in pressure can be clearly illustrated on the p-h diagram. Also,
both heat and work transfer of various processes can be calculated as the change of enthalpy
and state easily shown on the p-h diagram.
50.00
40.00
30.00
Sub cooled liquid Superheated vapor
20.00
region
n
region
ctio
Pressure p (Bar)
ure line
fra
10.00 e
lin
ss
uid
ne
line
at
dr y
liq
Constant temper
apor
t
5.00
d
tan
ate
s
tur
v
Con
rated
Sa
3.00
Two-phase region
Satu
2.00
1.00
vo lume line
Constant
0.50
0 20 40 60 80 100 140 180 220 260 300 340
Enthalpy (kJ/kg)
Figure 3.5-2. Skeleton of Pressure-Enthalpy

Diagram
Figure 3.5-2 is a skeleton p-h diagram for refrigerant R134a. Enthalpy h (in kJ/kg) is the abscissa, and absolute
pressure (bar), both expressed in logarithmic scale, is the ordinate. The saturated liquid line separates the sub-
cooled liquid from the two-phase region in which vapor and liquid refrigerants coexist. The saturated vapor line
separates this two-phase region from the superheated vapor. In the two-phase region, the constant-dryness-
fraction quality line subdivides the mixture of vapor and liquid.
LABTECH 29
The constant-temperature lines are nearly vertical in the sub-cooled liquid region. At higher
temperatures, they are curves near the saturated liquid line. In two-phase region, the constant
temperature lines are horizontal. In the superheated region, the constant-temperature lines
curves down sharply. Because the constant-temperature lines and constant-pressure lines in
the two-phase region are horizontal, they are closely related. The specific pressure of a
refrigerant in the two-phase region determines its temperature, and vice versa. Also in the
superheated region, the constant-entropy lines incline sharply upward, and constant volume
lines are flatter. Both are slightly curved.
3.5.2. Representation of Vapor Compression Cycle on Pressure-Enthalpy Diagram

Therefore, found convenient to represent the refrigeration cycle on pressure-enthalpy (p-h)
diagram as shown in Figure 3.5-3. Therefore, even tough the fourth process is an isentropic
one, the p-h diagram is still found convenient as the work done is given by the increase in
enthalpy.
t evap. t cond.
pressure
Critical Point
CONDENSER
high side 3 2
pressure
t comp.= const.
t cond.= const.
low side EVAPORATOR
t evap.= const.
pressure 4 1
enthalpy
(h1 h4) (h2 h1)
Figure 3.5-3. Refrigerant Cycle on Pressure–Enthalpy (P–H) Diagram
The cycle described and shown in Figure 3.5-3 is a simple saturation cycle implying that both
the states, of liquid after condensation and vapor after evaporation, are saturated and lie on the
saturated liquid and saturated vapor curves respectively. The condensation temperature
(t cond.) and evaporator temperature (t evap.), corresponding to the respective saturation
pressures of high side and pressure of low side, are also called saturated discharge temperature
and saturated suction temperature respectively. However, the actual discharge temperature
from the compressor is t comp.
The figure also shows constant temperature lines in the subcooled and superheats regions
along with constant volume lines. It may be noted that constant temperature lines in the
subcooled liquid and low pressure vapor regions are vertical as the enthalpy of the liquid and
the ideal gas are functions of temperature only and do not depend on pressure.
Further calculations of the cycle can be done as follows:
• Coefficient Of Performance or Energy for Cooling ( E C )
h1 − h4
COP for cooling, EC =
h2 − h1
• Coefficient Of Performance or Energy for Heating ( E H )

h2 − h4
COP for heating, E H =
h2 − h1
LABTECH 30
3.6. HUMIDIFICATION
When air is heated, it can be absorbing more water vapor; in addition, moisture in the air can
be increased and controlled by using humidifiers. Humidifiers add water vapor (low-
temperature steam) to the air. Humidifiers may (1) inject steam directly into air or add heat
and evaporate steam from water supplied to the conditioned space; (2) atomize or spay liquid
water, so that water evaporates and is added to the air; or (3) force air to flow over a wetted
element so that as water evaporates, it is added to the air as vapor. All these increase the
humidity ratio of the space air and, therefore, its relative humidity. One important index of a
humidifier is its humidifying capacity (m) in mass unit of water per time unit, or the rate at
which water vapor is added to the air.
If the return to a warm air furnace is about 16°C (60°F) and 25% RH, and the furnace heats
the air to 60°C (140°F), a humidifier may be used to add moisture to the warmed air. This
heated air is then mixed with the air in the room.
Controls
Power In
Humidified
Air Out
Electric
Heater
Dry Air In
Moving Wet
Filter
Water Pan Signal Light

Sw itch
Figure 3.6-1. The wet filter (porous belt) slowly moves through water in water pan. Fan forces air through the
wet belt and relative humidity increases. Some units have electric heaters to re heat-humidified
air. The humidistat controls operation of the unit. A signal light goes on when water pan is
empty.
A room humidifier is used to maintain relative humidity (percentage of moisture in the air).
The humidifier is housed in a cabinet located in the room or space in which humidity is to be
increased. The cabinet is supplied with air-in and air-out louvers. A fan circulates air through
the cabinet. A rotating screen or filter (wetted surfaces) dips into a pan or trough filled with
water. It hen exposes the wetted surfaces to the air stream. A typical humidifier is shown in
Figure 3.6-1.
Humidifying load mhu in kg/s (increase of moisture rate), is the amount of water vapor required
to be added to the air by a humidifier so as to maintain a predetermined space relative
humidity. The humidifying load (increase of moisture rate) of an air system installed with a
humidifier can be calculated as:
mhu kg/s = Q m3/s × ρkg/m3 × (ωs − ωm)
where:
mhu = humidifying load in kg /s
Q = quantity or supply volume flow rate in m3/min
ρ = density of supply air in kg/m3
ωs, ωm = moisture content of supply air and moisture of mixture air.
LABTECH 31
3.7. AIR VELOCITY MEASUREMENT

In air conditioning, heating and ventilating work, it is well known that techniques used have a
considerable result to determine air velocity. In this field, air velocity is distance traveled per
unit of time and its may be expressed in feet per minute or meter per second. Velocity
measurement can often be used with engineering handbook or design information to reveal
proper or improper performance of an airflow system.
In most air conditioning system, to move air, fans or blower are usually used. They work by
imparting motion and pressure to the air with either a screw propeller or paddle wheel action.
When force or pressure from the fan blades causes the air to move, the moving air acquires a
force or pressure component in its direction of motion due to its weight and inertia. Because
of this, a flag or streamer will stand out in the air stream. This force is called velocity
pressure. It is measured in inches of water column or water gage. In operating duct systems, a
second pressure is always present. It is independent of air velocity or movement. Known as
static pressure, it acts equally in all directions, this pressure is also measured in inches of
water column. Combination of static and velocity pressures is called total pressure, and is
expressed in the same units.
To determine velocity pressure, it is necessary to determine these affects fully and accurately.
This is usually done with an impact tube that faces directly into the air stream. This type of
sensor is frequently called a total pressure pick up since it receives the effects of both static
pressure and velocity pressure. The measurement device that usually used with incorporates
both static and a total pressure sensor in a single unit is pitot tube.
STATIC PRESSURE TOTAL PRESSURE 3
TUBE TUBE 0 1
2
FLOW ps FLOW FLOW ps hv FLOW

pt pt
ps = STATIC PRESSURE pt = TOTAL PRESSURE hv = VELOCITY PRESSURE
VELOCITY PRESS. = TOTAL PRESS. − STATIC PRESS.
Fig. 3.7-1. Types of Pressure Measurement
The air velocity can be calculated using the basic formula:

 hv 
V = 1096.7 ×  inch of water

Where :  ρ kg/m 3 

V = Air velocity (feet per minute)
hv = Velocity pressure in inches of water
ρ = Density of air in pounds per cubic foot
To determine dry air density, use the formula:

ρ = 1.325 [PB / T]
Where :
ρ = Air density in pounds per cubic foot
PB = Barometric (or absolute) static pressure in inch of mercury
T = Absolute temperature (indicated temperature in °F plus 460°)
LABTECH 32
By multiplying air velocity by the cross section area of a duct and density of air, you can
determine the air mass flow past a point in the duct per unit of time. Air mass flow rate can be
calculated using equation below:
air mass flow rate kg/s = air velocity m/s × air density kg/m3 × duct orifice area m2
m kg/s = V m/s × ρ kg/m3 × A m2
Where:
m = Air mass flow rate (kg/s)
V = Air velocity (m/s)
A = Orifice area (m2)
ρ = Air density (kg/m3) = vA-1
vA = Specific volume of the air (m3/kg)
Example:
The 30°C temperature of air flows in a conduit with 200 mm of inner diameter. By using
manometer (with pitot tube), its known that value of velocity pressure is 2 inch of water.
Determine the air mass flow rate in the conduit!
Solution:
From table properties of air, air density value at 30°C is 1.738 kg/m3. First, we must calculate
the air velocity and then the air mass flow rate. The air velocity that flows in conduit must be:
 hv   2 
V = 1096.7 ×  inch of water
 = 1096.7 ×  inch of water
 = 1176.46 feet per min (5.97 m/s)
 ρ kg/m 3   1.738 kg/m 3 
 
The air mass flow rate is:
m kg/s = 5.97 m/s × 1.738 kg/m3 × (3.14 × 0.12) m2 = 0.3258 kg/s
Electronics Air Flow Sensor

Electronics air flow sensors is also call Mass Air Flow Sensors converts the amount of air
drawn through the duct into a voltage signal. The air flow sensors are located directly in the
intake air stream and duct outlet.
There are different types of Mass Air Flow sensors. The vane air flow meter and Karmen
vortex are two older styles of air flow sensors and they can be identified by their shape. The
newer, and more common is the Mass Air Flow (MAF) sensor.
The primary components of the MAF sensor are a thermistor, a platinum hot wire, and an
electronic control circuit. The thermistor measures the temperature of the incoming air. The
hot wire is maintained at a constant temperature in relation to the thermistor by the electronic
control circuit. An increase in air flow will cause the hot wire to lose heat faster and the
electronic control circuitry will compensate by sending more current through the wire. The
electronic control circuit simultaneously measures the current flow and puts out a voltage
signal (VG) in proportion to current flow.
LABTECH 33
Figure 3.7-2. Mass Air Flow Sensor
Labtech Mass Air Flow Sensor using a precision air flow transmitter for measuring air flow.
The sensor produce analog signal corresponding to the air flow (velocity) inside the duct
chamber.
Figure 3.7-3. Air Flow Sensor (PRODUAL_IVL 10)
Technical data: Dimensions IVL 10, IVL 10-N: 50.190 mm :

Supply 24 Vac/dc (22-28Vac/dc), <1,5 VA Case w x h x d 70 x 94 x 250/ 480 mm,
Ranges air velocity 0...10 m/s stem ∅ 10 mm x 200 / 400 mm
temperature 0…70 °C Mounting by adjustable flange
Outputs 0...10 V, < 2mA
4...20 mA, < 600 ohm
LABTECH 34
4
PRE-OPERATION
4.1. PRE-OPERATION PROCEDURE

Please do the following procedures before operating the trainer:
1. Place the trainer in a room with sufficient area and ventilation.
2. Ensure that ELCB, MCB and all Switches position are OFF.
3. Observe the refrigerant pressure on pressure gauges (PG1 - PG4)
while the system is OFF.
Note: At this point please let the compressor off for at least 3 hours
before reading the gauges. The refrigerant pressure should be
around 60 to 80 psig. The pressure will be slightly changed
depending on ambient temperature. If the pressure is below 60 psig,
it means you need to add refrigerant or check the system for leakage
(see Appendix chapter as guidance for recovering, evacuating and charging process) .
4. Steam Tank
Always check the water level of steam generator tank. Ensure it is filled with distilled-
water (±18 liter) before running the system. The maximum setting of steam generator
thermostat is 105°C.
5. Set Auto / Manual selector switch to manual position.
6. Fan Speed Control is used to run the fan. Turn on the fan switch and then adjust the fan
speed control maximum or minimum. Fan speed can be adjusted by turning the speed
adjuster. A motor controller (Inverter) is used to drive and control the fan motor speed
located at the back side of trainer.
7. Pre-Heater and Re-Heater.

For activating the heaters you need to set the Thermostats above ambient temperature and
activate the Pre-Heater or Re-Heater switches.
Note: DO NOT set Thermostat more than 40°C to avoid overheating in the duct.
8. Connect the power cable. This trainer requires 3 phase powered by 380V/50Hz.
9. By turning-ON the ELCB and MCB-F1 (other MCBs are still off), please check voltage
level on Voltmeter. Make sure the voltage are within the range.
LABTECH 35
10. Before starting the trainer, ensure the crankcase heater has been energized approximately
8 hours.
4.2. SETTING UP DATA ACQUISITION SOFTWARE
Software Setup Procedure:

1. Turn ON your computer.
2. Open desktop screen from Windows 8 main menu.
3. Open Windows Explorer from Windows Taskbar.
4. Place the Installation CD into DVD-ROM drive, find out and double click RAD-RAC-
A WL-10002-02 Setup.exe file.
LABTECH 36
5. Windows will show the opening session page, click “Next” button and the process will
continue.
6. Please provide password then click “Next” to continue. The password refers to
“password.txt” file in the installation CD.
LABTECH 37
7. Click “Create a desktop icon”, mark with a checklist if you want to add an icon to
your desktop, then click “Next” button again.
8. Click “Install” button to continue the installation process.
LABTECH 38
9. You will see the progress of Installation.
10. Congratulation, you have completely installed “RAD-RAC-A” software. It means the
Air Conditioning Laboratory Trainer software has already been installed on your
laptop.
LABTECH 39
Operation Procedures of the Recirculating Air Conditioning Trainer RAD-RAC-A

Software :
1. Plugin USB data cable from RAD-RAC-A software to the laptop USB connector of
yours.
2. Open desktop screen from Windows 8 main menu and click the icon of “Air
Conditioning Laboratory Trainer (RAD-RAC-A)”.
3. You will see the opening page program and the display of Air Conditioning
Laboratory Trainer will be shown as below.
4. Device connection status is initially “Device Not Connected”.
LABTECH 40
The status will become “Device Connected” automatically when the system has been
connected to the trainer.
The system will automatically read the data from the trainer when USB data cable has
been connected to the trainer.
5. You can open Flow Animation by clicking “Flow Animation” button

and the display will be shown as below.
LABTECH 41
6. You can open Thermodynamic Properties by clicking “Thermodynamic Properties”
button and the display will be shown as below.
7. You can open Psychrometric Chart by clicking “Chart” button and

the display will be shown as below.
LABTECH 42
8. You can open Wiring Diagram by clicking “Wiring Diagram” button

9. You can save the screenshot by clicking “Screenshot” button.
Please save the screenshot in “Save Screenshot” dialogue and set the file name.
LABTECH 43
10. The display of this system can be printed and previewed to your images viewer
program by clicking the “Print Preview” button. It will be shown as below.
11. If you want to know the features of the software click “How To Use” button
LABTECH 44
12. You can set the manual data input from keyboard by clicking the “Manual Input”
button, whereas "Data Reading" button is used to set input settings with the actual data
reading from the trainer.
13. You can save the data reading by using “Data Log” button. You can either save it by
time or by data. The data will be saved on Notepad and Spreadsheet file format by the
default file name “labtech”, but you can change it in the file name textbox.
Then, to save the data reading you can click the “Data log” button as shown in the
picture below.
If you want to see content the of data log files, click browse button as shown in the
picture below.
The address of the data log files on Windows Explorer is on “Documents”.
LABTECH 45
14. You can change another skin of software interface by clicking the icon as shown in the
picture below.
We have five skins such as: black sweet, blue sky, red beauty, orange juice and green
leaf.
15. If you have internet connection you can go to the link page of Labtech website by
clicking the icon as shown in the picture below.
LABTECH 46
16. You can minimize the software interface by clicking the icon as shown in the picture
below.
Moreover, you also can maximize and normalize the software display. The maximize
feature will allow you to make your software display become full size. The normalize
feature will make your display become normal depending on your maximum computer
resolution.
The icon of maximize feature is shown as the picture below.
LABTECH 47
The icon of normalize feature is shown as the picture below.
17. If you want to exit and close the software please click “Exit and Close Application”
button , then the software will be showing confirmation dialog to exit and close
the application.
LABTECH 48
How to Manually Converting Data Acquisition to OpenOffice Spreadsheet :
1. Open file data acquisition from “Documents” folder, for example “labtech.txt” file and
select all contents of data then copy them.
2. Open the “Open Office Calc” software then “paste” them to the worksheet area.
LABTECH 49
3. You will see the “Text Import” dialog, please mark with a checklist in “Comma” for
separator and then click “OK”.
4. Finally in Open Office Calc we have a table from data logging as shown in the picture
below.
LABTECH 50
5
EXPERIMENTS
LABTECH 51
LABTECH 52
5.1. RECIRCULATING AIR CONDITIONING TRAINER

FAMILIARIZATION
OBJECTIVE
After completing this experiment you will be:
➢ Familiar with recirculating air conditioning trainer components.
➢ Able to operate the training unit with manual and auto operations.
EQUIPMENT
1. LABTECH Recirculating Air Conditioning Trainer (RAD-RAC-A).
2. Experiment Manual.
PROCEDURES
Safety Checklist
➢ Do not touch the hot surface such as Compressor and Refrigerant discharge line.
➢ Do not put your hands on moving parts such as fan blades.
➢ Observe all electrical safety precautions. Be careful at all times and common sense.
Running the System

1. Prepare the required equipment for this experiment.
2. Please refer to chapter 2 (point 2.3 Parts Identification ) for more familiarization of the
trainer parts and components.
3. Ensure that Pre-operation (see chapter 4) has been done correctly.
4. Ensure that Manual Valves; MV1 and MV2 position are in the “fully open”.
Manual Operation
5. Turn ON ELCB and MCB F1 to F9. Then observe the voltmeter reading for each
phase. Make sure the voltage reading is within the correct range.
6. Set Manual/Auto Selector to Manual position.
7. Press the START button.
Fan Motor Operation

8. Turn ON the start/stop switch of fan speed control and adjust the potentiometer to
minimum position.
9. Observe and record the air velocity meter reading into "Minimum" column of Table
5.1-1.
10. Turn the potentiometer of fan speed control to maximum position, observe and record
the air velocity meter reading into "Maximum" column of Table 5.1-1.
LABTECH 53
Table 5.1-1 Fan Motor Operation
No Measurement Point Minimum Maximum Unit
1 Duct Inlet Air Velocity m/s
2 Duct Outlet Air Velocity m/s
3 Ammeter A
Figure 5.1-1 Fan Motor Operation
Re-Heater Operation
11. Set the Re-Heater thermostat to 40ºC.
12. Set Re-heater switch to 1 (0.5 kW) position. Observe and record ammeter reading into
0.5 kW column of Table 5.1-2.
13. Set Re-heater switch to 2 (1 kW) position. Observe and record ammeter reading into 1
kW column of Table 5.1-2.
14. Set Re-heater switch to 3 (1.5 kW) position. Observe and record ammeter reading into
1.5 kW column of Table 5.1-2.
Table 5.1-2 Re-Heater Operation
No Measurement Point 0.5 kW 1 kW 1.5 kW Unit
1 Ammeter A
LABTECH 54
Figure 5.1-2 Re-Heater Operation

15. Set Re-heater switch to 0 (OFF) position.
Pre-Heater Operation
16. Set the Pre-Heater thermostat to 40ºC.
17. Set Pre-heater switch to 1 (1 kW) position. Observe and record ammeter reading into 1
Table 5.1-3 Pre-Heater Operation
No Measurement Point 1 kW 2 kW 3 kW Unit
1 Ammeter A
Figure 5.1-3 Pre-Heater Operation
LABTECH 55
20. Set Pre-heater switch to 0 (OFF) position.

Steam Generator Operation
21. Set the Steam thermostat to 105ºC.
22. Set Steam generator switch to 1 (1 kW) position. Observe and record ammeter reading
into 1 kW column in Table 5.1-4.
23. Set Steam generator switch to 2(3 kW) position. Observe and record ammeter reading
24. Set Steam generator switch to 3 (5 kW) position. Observe and record ammeter reading
25. Let the steam generator operate approximately 5 minutes.
Table 5.1-4 Steam Generator Operation
No Measurement Point 1 kW 3 kW 5 kW Unit
1 Ammeter A
Figure 5.1-4 Steam Generator Operation

26. Turn back the humidity control adjuster to 0%.
27. Set Steam generator switch to 0 (OFF) position .
LABTECH 56
Compressor Operation
28. Turn ON compressor switch. Allow the system to run approximately 5 minutes.
Figure 5.1-5 Compressor Operation

29. Observe and record the dry bulb temperature, relative humidity, compressor power and
refrigerant flowrate into Table 5.1-5:
Table 5.1-5 Compressor Operation
No Measurement Point Value Unit
Dry Bulb Temp. ºC

1 A: Inlet Air
RH %
Dry Bulb Temp. ºC

2 B: Mixing Air
RH %
Dry Bulb Temp. ºC

3 C: Before Evaporator
RH %
Dry Bulb Temp. ºC

4 D: After Evaporator
RH %
Dry Bulb Temp. ºC

5 E: Return Air
RH %
LABTECH 57
6 Suction Temperature / T1 ºC
7 Discharge Temperature / T2 ºC
8 Condenser Outlet Temperature / T3 ºC
9 TXV Inlet Temperature / T4 ºC
10 Evaporator Inlet Temperature / T5 ºC
12 Wattmeter kW
13 Refrigerant Flowmeter lpm
30. Turn OFF compressor switch and start/stop switch of fan speed control respectively.
31. After understanding the manual operation, press STOP Button and turn OFF MCB F1
respectively.
AUTO Operation
32. Set Manual/Auto Selector to AUTO position.
33. Turn ON MCB F1 and Press the START button respectively.
During AUTO operation the fan motor speed and humidifier solenoid are controlled
automatically with temperature and humidity controller.
34. Set the Humidity controller to 10% above the ambient humidity.
35. Observe the solenoid valve,
36. Set the Temperature controller to 5ºC below the ambient temperature.
37. Observe the fan speed,
38. Let the system run approximately 10 minutes.
39. Observe and record the dry bulb temperature, relative humidity, power compressor and
refrigerant flowrate into Table 5.1-6:
Table 5.1-6 Auto Operation
No Measurement Point Value Unit
Dry Bulb Temp. ºC

1 A: Inlet Air
RH %
Dry Bulb Temp. ºC

2 B: Mixing Air
RH %
Dry Bulb Temp. ºC
RH %
LABTECH 58
Dry Bulb Temp. ºC

RH %
Dry Bulb Temp. ºC

5 E: Return Air
RH %
6 Suction Temperature / T1 ºC
7 Discharge Temperature / T2 ºC
8 Condenser Outlet Temperature / T3 ºC
9 TXV Inlet Temperature / T4 ºC
12 Wattmeter kW
13 Refrigerant Flowmeter lpm
40. After understanding the Auto operation, press STOP Button.

Stopping the System
41. Turn OFF Temperature selector, MCB, and ELCB respectively.
42. Return all equipment to their respective place and clean up your working area.
LABTECH 59
LABTECH 60
5.2. THE PSYCHROMETRIC CHART FAMILIARIZATION
OBJECTIVE
After completing this experiment you will be:
➢ Familiar with psychrometric chart.
➢ Able to determine the thermodynamic properties of air such as dry bulb temperature,
wet bulb temperature, moisture content, relative humidity, dew point temperature,
specific volume and enthalpy by using the Psychrometric Chart.
DISCUSSION
The chart which shows the properties of humid air is called a psychrometric chart. The
psychrometric chart can be used to find the (1) Dry bulb temperature, (2) Wet bulb
temperature, (3) Moisture Content, (4) Relative humidity, (5) Dew point, (6) Specific Volume
and (6 ) Enthalpy (total heat) of a certain air condition. If two of these values are known
beforehand, the other values can be found with this chart. The way that the air will change
when it is heated, cooled, humidified or dehumidified can also be seen easily on the chart.
Pν=f(
ω)
ω
TEMPERATURE
WET BULB
TEMPERATURE
DEWPOINT
B
WE
TB
WATER VAPOUR PRESSURE
UL
SPECIFICHUMIDITY
B
DEW POINT MOISTURE
CONTENT
Y
E DIT
LIN MI
HU
ION
VOL
E
AT LA
TIV
UR
UM
SAT RE
E
DRY BULB TEMPERATURE, t
Figure 5.2 Skeleton of Psychrometric Chart

1. Dry bulb temperature t (°C)
Generally referred to as standard temperature this is measured with a dry bulb
thermometer (conventional thermometer). The obtained value is the dry bulb
temperature.
2. Wet bulb temperature t’ (°C)
When a dry bulb thermometer’s heat sensing section is wrapped in a piece of wet
gauze and an ample air flow (3 m/s or more) is applied, the heat applied to the wet
bulb by the air and the heat of the water vapor that evaporates from the wet bulb will
balance at an equal state. The temperature indicated at this time is called the wet bulb
temperature.
LABTECH 61
3. Moisture content (kg/kg’)

The weight (kg) of the water vapor that corresponds to the weight (kg’) of the dry air
is called the moisture content.
Mass of water vapor (kg )
Moisture Content(kg /kg ')=
mass of dry air ( kg ' )
4. Relative humidity (%)
The ratio of the water vapor pressure in the humid air and the water vapor pressure in
the saturated air at the same temperature is called the relative humidity. This is
obtained with the following formula:
Water vapor pressure in.the humid air (Pa)
RH ( percent )= x 100
water vapor pressure in.the saturated air ( Pa )
5. Dew point t” (°C)
The water content in the air will start to condense when air is cooled. The dry bulb
temperature at this time is called the dew point.
6. Specific volume (m³/kg)
The specific volume, is the volume of unit mass of dry air at a given temperature
normally expressed as m³/kg.
7. Enthalpy i (kJ/kg) (kcal/kg)
Physical matter has a set heat when it is at a certain temperature and state. This
retained heat is called the enthalpy.
EQUIPMENT
1. LABTECH Recirculating Air Conditioning Trainer (RAD-RAC-A)
2. Experiment Manual
PROCEDURES
Safety Checklist
Running the System

5. Turn ON ELCB and MCB F1 and F9. Then observe the voltmeter reading for each
LABTECH 62
8. Switch ON the start/stop switch of fan speed control and adjust the potentiometer to
Maximum position.
10. Observe and record the dry bulb temperature and relative humidity of each position
(A, B, C, D and E) into Table 5.2-1:
Table 5.2-1 Dry Bulb Temperature and Relative Humidity
Relative Humidity
No Measurement Point Dry Bulb (ºC)
(%)
1 A: Inlet Air
2 B: Mixing Air
5 E: Return Air
11. After completing the experiment, turn OFF compressor switch.
Stopping the System

12. Turn OFF and start/stop switch of fan speed control and press STOP switch
respectively. Turn OFF Temperature selector, MCB, and ELCB respectively.
LABTECH 63
QUESTION AND TASK

1. What kind of data that can be obtained from psychrometric chart?
….......................................................................................................................................
….......................................................................................................................................
2. Use data result in Table 5.2-1 and determine the thermodynamic properties of air as
follows:
Table 5.2-2 Thermodynamic Properties of Air
Measurement Dry Relative Wet Enthalpy Dew Moisture Specific

No Point Bulb Humidity Bulb (kJ/kg) Point Content Volume
Temp. (%) Temp. Temp. (kg/kg) (m3/kg)
(ºC) (ºC) (ºC)
1 A: Inlet Air
2 B: Mixing Air
3 C: Before
Evaporator
4 D: After
Evaporator
5 E: Return Air
LABTECH 64
5.3. PLOTTING REFRIGERATION CYCLE INTO PRESSURE-

ENTHALPY (P-H) DIAGRAM
OBJECTIVE
After completing this experiment, you will understand and be able to plot the refrigeration
cycle in a PH-Diagram.
DISCUSSION
The pressure-enthalpy diagram is the most common graphical tool for analysis and calculation
of the heat and work transfer and performance of a refrigeration cycle. A single-stage
refrigeration cycle consists of two regions: the high-pressure region (high side) and the low-
pressure (low side). The change in pressure can be clearly illustrated on the p-h diagram. Also,
both heat and work transfer of various processes can be calculated as the change of enthalpy
and easily shown on the p-h diagram.
50.00
40.00
30.00
Sub cooled liquid Superheated vapor
20.00
region
n
region
ctio
Pressure p (Bar)
e
fra
ature lin
10.00 e
lin
ss
uid
ne
r line
dr y
liq
Constant temper
t
5.00
ed
ta n
vapo
rat
s
tu
Con
rated
Sa
3.00
Two-phase region
Satu
2.00
1.00
t vo lume line
Constan
0.50
0 20 40 60 80 100 140 180 220 260 300 340
Enthalpy (kJ/kg)
Figure 5.3-1. Skeleton of Pressure-Enthalpy Diagram.
Pressure Gauges
There are two types of pressure reading; the gauge pressure and the absolute pressure.
Absolute pressure is used in P-H Diagram.
The absolute pressure = gauge pressure + atmospheric pressure.
If you use data PG1 (suction pressure) and PG2 (discharge pressure) that are displayed on the
trainer, you should convert it to absolute value before plotting it in PH Diagram. The gauge
reading that is shown in the trainer is in relative value (technical gauge pressure) so need to be
converted to absolute pressure
LABTECH 65
Plotting Refrigeration Cycle into Pressure-Enthalpy Diagram

I. Plotting Pressure Line
Convert gauge reading into absolute pressure and then draw a horizontal line into P-H.
Diagram as per sample below (pressure on PH-Diagram is stated in absolute value).
Note: bar (absolute) = bar + atmospheric pressure
Figure 5.3-2. Pressure Line
II. Plotting Compression Process

Mark the intersection between Suction Pressure (PG1) and Suction Temperature (T1). Mark
the intersection between Discharge Pressure (PG2) and Discharge Temperature (T2). Draw a
line connecting two points.
Figure 5.3-3. Compression Process
LABTECH 66
III.Plotting Condensation Process

Mark the intersection between Discharge Pressure (PG2) and Discharge Temperature (T2).
Mark the intersection between Condenser Outlet Pressure (PG3) and Condensing Temperature
(Tc) in the saturated liquid phase. Draw a line connecting two points.
Figure 5.3-4. Condensation Process
IV. Plotting Subcooled Line

Mark the intersection between Condenser Outlet Pressure (PG3) and Condensing Temperature
(Tc) in the saturated liquid phase. Mark the intersection between Condenser Outlet Pressure
(PG3) and Expansion Inlet Temperature (T4). Draw a line connecting two points.
Figure 5.3-5. Subcooled Process
LABTECH 67
V. Plotting Expansion Process

Mark the intersection between Condenser Outlet Pressure (PG3) and Expansion Inlet
Temperature (T4). Draw a vertical line until it intersects with Evaporator Outlet Pressure
(PG4) line.
Figure 5.3-6. Expansion Process
VI. Plotting Evaporation Process

Mark the intersection between end of expansion line and Evaporator Outlet Pressure (PG4).
Mark the intersection between Evaporator Outlet Pressure (PG4) line and Evaporating
Temperature (Te) in the saturated vapor phase. Draw a line connecting two points.
Figure 5.3-7. Evaporation Process
LABTECH 68
VII. Plotting Evaporator Superheat Line

Mark the intersection between Evaporator Outlet Pressure (PG4) and Evaporating
Temperature (Te) in the saturated vapor phase. Mark the intersection between Evaporator
Outlet Pressure (PG4) and Evaporator Outlet Temperature (T6). Draw a line connecting two
points.
Figure 5.3-8. Evaporator Superheat
VIII. Plotting Suction Line Superheat

Mark the intersection between Evaporator Outlet Pressure (PG4) and Evaporator Outlet
Temperature (T7). Mark the intersection between Suction Pressure (PG1) and Suction
Temperature (T1). Draw a line connecting two points.
Figure 5.3-9. Suction Line Superheat
LABTECH 69
EQUIPMENT
PROCEDURES
Safety Checklist
Running the System

Maximum position.
10. Observe and record the pressures and temperatures into Table 5.3-1.
Table 5.3-1 Refrigeration System Pressures and Temperatures Measurement
No. Measurement Points Value Units
1 Suction Pressure / PG1 psig
2 Discharge Pressure / PG2 psig
3 Condenser Outlet Pressure / PG3 psig
4 Evaporator Outlet Pressure / PG4 psig
5 Suction Temperature / T1 °C
6 Discharge Temperature / T2 °C
7 Condenser Outlet Temperature / T3 °C
8 Expansion Inlet Temperature / T4 °C
LABTECH 70
9 Evaporator Inlet Temperature / T5 °C
10 Evaporator Outlet Temperature / T6 °C

Stopping the System

respectively.
TASKS
1. By using data in Table 5.3-1, draw refrigeration cycle into Pressure-Enthalpy
Diagram!
Use Appendix for Pressure-Enthalpy Diagram.
Write down your analysis!
….......................................................................................................................................
….......................................................................................................................................
2. Describe refrigerant cycle and thermodynamic properties that can be obtained from
Pressure Enthalpy (P-H) diagram!
….......................................................................................................................................
….......................................................................................................................................
LABTECH 71
LABTECH 72
5.4. SYSTEM PERFORMANCES ANALYSIS, COVER THE

CALCULATION OF REFRIGERATION CAPACITY, COEFFICIENT
OF PERFORMANCE, COMPRESSION RATIO AND EFFICIENCY
OF THE COMPRESSOR
OBJECTIVE
After completing this experiment, you are expected to be able to:
• Calculate degree of Sub-cooled in the Condenser.
• Calculate degree of Sub-cooled in the Liquid Line.
• Calculate degree of superheat in the Evaporator.
• Calculate degree of superheat in the Suction Line.
• Calculate heat transfer rate
• Calculate the enthalpy value of each process.
• Calculate Coefficient of Performance (COPrefrigeration)
• Calculate Refrigerating Capacity (Qrc)
• Calculate Energy Efficiency Ratio (EER)
• Calculate the compression ratio.
DISCUSSION
I. Degree of Sub-cooled in the Condenser Calculation
Subcooled (K)= Condensing Temperature – Condenser Outlet Temperature
= tc – t3
Figure 5.4-1. Degree of Subcooled in the Condenser
LABTECH 73
II. Degree of Sub-cooled in the Liquid Line Calculation

Subcooled (K)= Condenser Outlet Temperature – Expansion Inlet Temperature
= t3 – t4
Figure 5.4-2. Degree of Subcooled in the Liquid Line
III.Degree of Superheat in the Evaporator Calculation

Superheat (K) = Evaporator Outlet Temperature – Evaporating Temperature
= t6 – te
Figure 5.4-3. Degree of Superheat in the Evaporator
LABTECH 74
IV. Degree of Superheat in the Suction Line Calculation

Superheat (K) = Suction Temperature – Evaporator Outlet Temperature
= t1 – t6
Figure 5.4-4. Degree of Superheat in the Suction Line
V. Heat Transfer Calculation
Figure 5.4-5. Enthalpy Value
LABTECH 75
Heat absorbed in the Evaporator (Qe):

Qe = h1 - h4
Work input to the Compressor (Win):
Win = h2 – h1
Heat that is rejected in the Condenser (Qc):
Qc = h2 – h3 or Qc = Qe + Win
Coefficient of Performance (COPrefrigeration) is an index of performance of a thermodynamic
cycle. It can be calculated as:
COPrefrigeration = Qe/Win
Refrigerating Capacity (Qrc) is the actual rate of heat that extracted by the refrigerant in the
evaporator. It can be calculated as:
Qrc=m(h1−h4)
Converting the refrigerant flowrate from lpm into kg/s.
(1 min.)
x refrigerant flowrate (lpm)
(60 s)
kg / s=
vl(dm³ /kg ) at expansion inlet temperature
Example:
Refrigerant Flowrate = 0.8 lpm
Expansion inlet temperature/T4 = 38 ºC
Convert lpm to kg/s as follow:
Find out the value of Specific volume of liquid (vl) at temperature 38 ºC as shown on Figure
5.4-6. (See Appendix for Thermodynamics Properties of R-134a)
Specific volume of liquid (vl) = 0.8651 dm³/kg
Note: 1 dm³ = 1 Liter
So vl = 0.8651 dm³/kg = 0.8651 Liter/kg
(1 min.)
x refrigerant flowrate (lpm)
(60 s)
kg / s=
vl( dm³ /kg ) at expansion inlet temperature
(1 min.) (0.8 litre)
x
( 60 s) ( 1 min)
kg / s=
(0.8651 dm³ )
(1 kg )
( 0.0133 Liter / s)
kg / s=
(0.8651 Liter / kg)
kg / s=0.0154
LABTECH 76
Figure 5.4-6 Specific volume of liquid (vl)at temperature 38 ºC
Calculate Energy Efficiency Ratio (EER) for the ratio of the refrigerating capacity to the rate
of electric input. It can be calculated as:
Refrigerating Capacity (Qrc)
EER=
Compressor Power Consumption (P.comp.)
Compression Ratio (CR) is a term that is used with compressor to describe the actual
difference in the low and high pressure sides of the compression cycle. It is absolute discharge
pressure that is divided by absolute suction pressure.
Discharge pressure (bar.absolute )
CR=
Suction pressure (bar.absolute )
Where:
m = Refrigerant mass flowrate (kg/s)
h = Enthalpy value (kJ/kg)
vl = Specific volume of liquid (dm³/kg)
LABTECH 77
EQUIPMENT
PROCEDURES
Safety Checklist
Running the System

Maximum position.
10. Observe and record the pressures and temperatures into Table 5.4-1:
Table 5.4-1 Refrigeration System Pressures and Temperatures Measurement
No. Measurement Points Value Units
LABTECH 78
11 Refrigerant Flowrate lpm

Stopping the System
respectively.
TASKS
By using data in Table 5.4-1, calculate the:
1. Degree of subcooled in the Condenser,
2. Degree of subcooled in the Liquid Line,
3. Degree of superheat in the Evaporator,
4. Degree of superheat in the Liquid Line,
5. Heat absorbed in the Evaporator (Qe),
6. Work input to the Compressor (Win),
7. Heat rejected in the Condenser (Qc),
8. Coefficient of Performance (COPrefrigeration),
9. Net Refrigerating Capacity (Qrc),
10. Energy Efficiency Ratio (EER),
11. Compression Ratio (CR).
See Appendix for Thermodynamics Properties of R-134a
Write down your analysis!
......................................................................................................................................
......................................................................................................................................
LABTECH 79
LABTECH 80
5.5. COOLING AND DEHUMIDIFICATION
OBJECTIVE
After completing this experiment you will be able to determine the rate of heat release from
air in cooling and dehumidification process.
EQUIPMENT
PROCEDURES
Safety Checklist
Running the System

5. Turn ON ELCB and MCB F1, F7, F8 and F9. Then observe the voltmeter reading for
each phase. Make sure the voltage reading is within the correct range.
Maximum position.
10. Observe and record the pressures and temperatures into cooling column in Table 5.5-
1:
Table 5.5-1 Cooling and Dehumidification Performances
No Measurement Point Cooling Dehumidification Unit
2 A: Inlet Air Dry Bulb Temp. ºC
LABTECH 81
RH %
C: Before Dry Bulb Temp. ºC

3
Evaporator
RH %
Dry Bulb Temp. ºC

RH %
Dry Bulb Temp. ºC

5 E: Return Air
RH %
11. Set thermostat of Re-heater to 40ºC. Then turn Re-heater switch to position No. 3
(1.5kW). Allow the system to run for 5 minutes.
12. Observe and record the pressures and temperatures into dehumidification column in
Table 5.5-1:
Using the Data Acquisition

13. Please refer to the operation of RAD-ACL2 software for data reading and
psychrometric chart plotting.
14. After completing the experiment, turn OFF Re-heater and compressor switches
respectively.
Stopping the System

respectively.
16. Turn OFF Temperature selector, MCB (F1, F7, F8, F9), and ELCB respectively.
LABTECH 82
TASKS
1. Determine the area of the duct.
Area (A m2) value is 0.0314 m2 based on the cross section area of air flow measurement
(with diameter 200mm).
2. Determine the air density at point A.
Use the psychrometric chart to plot the point into the chart. Draw the line of dry bulb
based on the temperature data vertically. Plot the intersection lines (between dry bulb line
and relative humidity curve) to determine position of the point. Draw the line parallel
with specific volume line, and then calculate the air density at this point.
ρ kg/m3 = 1 / v m3/kg
Where: ρ = Air density, v = Air specific volume
3. Determine the different enthalpy before and after evaporator.

∆h kJ/kg = hc kJ/kg - hd kJ/kg
= ……..
Where: hc= Enthalpy before evaporator hd= Enthalpy after evaporator
4. Calculate the heat that is released from the air.
Qair kJ/s = A m2 × ρ kg/m3 ×vm/s × ∆h kJ/kg
= ……..
LABTECH 83
LABTECH 84
5.6. HEATING
OBJECTIVE
After completing this experiment, you will be able to determine the rate of heat release from
the heater.
EQUIPMENT
PROCEDURES
Safety Checklist
Running the System

5. Turn ON ELCB and MCB F1, F7 and F8. Then observe the voltmeter reading for each
Maximum position.
9. Set the thermostat of Re-Heater to 40ºC.
10. Set Re-heater to 1 (0.5kW) position. Allow the system to run approximately 10
minutes.
11. Observe and record the humidity, temperatures and air velocity into 0.5 kW column in
Table 5.6-1:
12. Set Re-heater to 2 (1kW) position. Allow the system to run approximately 10 minutes.
13. Observe and record the humidity, temperatures and air velocity into 1 kW column in
Table 5.6-1:
14. Set Re-heater to 3 (1.5kW) position. Allow the system to run approximately 10
minutes.
LABTECH 85
15. Observe and record the humidity, temperatures and air velocity into 1.5 kW column in
Table 5.6-1:
Table 5.6-1 Heating Performances
No Measurement Point 0.5 kW 1 kW 1.5 kW Unit
Dry Bulb Temp. ºC

2 A: Inlet Air
RH %
Dry Bulb Temp. ºC

RH %
Dry Bulb Temp. ºC

RH %
Dry Bulb Temp. ºC

5 E: Return Air
RH %

16. Please refer to the operation of RAD-RAC-A software for data reading and
17. After completing the experiment, turn OFF Re heater switch.
Stopping the System

respectively.
19. Turn OFF Temperature selector, MCB (F1, F7and F8), and ELCB respectively.
LABTECH 86
TASKS
Area (A m2) value is 0.0314 m2 based on the cross section area of air flow measurement
2. Determine air density at point A.
based on the temperature data vertically. Plot the intersection lines (between dry bulb
line and relative humidity curve) to determine position of the point. Draw the line
parallel with specific volume line, and then calculate the air density at this point.
ρ kg/m3 = 1 / v m3/kg
3. Determine the different enthalpy after evaporator and after re-heater.
∆h kJ/kg = he kJ/kg - hd kJ/kg
= ……..
4. Calculate the heat that is released from the heater
Qheater kJ/s = A m2 × ρ kg/m3 ×Vm/s × ∆h kJ/kg
= ……..
LABTECH 87
LABTECH 88
5.7. HUMIDIFICATION
OBJECTIVE
After completing this experiment you will be able to:
• Calculate the rate of precipitation.
• Calculate the moisture content.
EQUIPMENT
PROCEDURES
Safety Checklist
Running the System

5. Turn ON ELCB and MCB F1, F2, F3 and F4 . Then observe the voltmeter reading for
each phase. Make sure the voltage reading is within the correct range.
Maximum position.
9. Set the thermostat of steam generator to 105ºC.
10. Set steam generator switch to 3 (5kW) position. Allow the system to run
approximately 10 minutes.
11. Observe and record the humidity, temperatures and air velocity into Normal column in
Table 5.7-1.
12. Turn the humidity control adjuster to 50%. At this point the modulating valve will
open and hot vapor is injected from steam injector.
LABTECH 89
13. Observe and record the humidity, temperatures and air velocity into humidification
column in Table 5.7-1.
Table 5.7-1 Humidification Performances
No Measurement Point Normal Humidification Unit
Dry Bulb Temp. ºC

2 A: Inlet Air
RH %
Dry Bulb Temp. ºC

RH %
Dry Bulb Temp. ºC

RH %
Dry Bulb Temp. ºC

5 E: Return Air
RH %

17. After completing the experiment, turn OFF steam generator switch.
Stopping the System
respectively.
19. Turn OFF Temperature selector, MCB (F1, F2, F3 and F4) and ELCB respectively.
LABTECH 90
TASKS
Area (A m2) value is 0.0314 m
2
based on cross section area of air flow measurement
2. Determine the air density at point A.
based on the temperature data vertically. Plot the intersection lines (between dry bulb
line and relative humidity curve) to determine position of the point. Draw the line
parallel with specific volume line, and then calculate the air density at this point.
ρ kg/m3 = 1 / v m3/kg
3. Determine the different enthalpy before steam injector (mixing air) and after steam
injector (before evaporator).
∆h kJ/kg = hc kJ/kg - hb kJ/kg
= ……..
4. Calculate rate of precipitation.
Qsteam kJ/s = A m2 × ρ kg/m3 ×Vm/s × ∆h kJ/kg
= ……..
5. Determine the different moisture content before steam injector (mixing air) and after
steam injector (before evaporator).
∆ωkg/kg = ωc kg/kg - ωb kg/kg
= ……..
LABTECH 91
LABTECH 92
5.8. EFFECT OF VARYING COOLING LOAD TO SYSTEM

PERFORMACE
OBJECTIVE
After completing this experiment, you will understand about the kind of refrigeration load,
and the effect of varying load to the system performance of air conditioning system.
EQUIPMENT
PROCEDURES
Safety Checklist
Running the System

5. Set the Recirculation damper to 100%.
6. Turn ON ELCB and MCB F1, F7, F8 and F9. Then observe the voltmeter reading for
each phase. Make sure the voltage reading is within correct range.
Maximum position.
10. Turn ON the compressor switch. Allow the system to run approximately 10 minutes.
11. Observe and record the parameter as shown on Table 5.8-1. Fill into Without load
column.
12. Set Re heater thermostat to 40 ºC. Then turn Re heater selector to 1 (0.5 kW) position.
Allow the system to run approximately 10 minutes.
13. Observe and record the parameter as shown on Table 5.8-1. Fill into 0.5 kW column.
14. Turn Re-heater selector to 2 (1 kW) position. Allow the system to run approximately
10 minutes.
LABTECH 93
15. Observe and record the parameter as shown on Table 5.8-1. Fill into 1 kW column.
16. Turn Re heater selector to 3 (1.5 kW) position. Allow the system to run approximately
10 minutes.
17. Observe and record the parameter as shown on Table 5.8-1. Fill into 1.5 kW column.
Figure 5.8 Load Heater Operation
LABTECH 94
Table 5.8-1 Effect of Varying Cooling Load to System Performances
With Load
Without
No Measurement Point Unit
Load
0.5 kW 1 kW 1.5 kW
2 Duct Outlet Air Velocity m/s
Dry Bulb Temp. ºC

3 A: Inlet Air
RH %
C: Before Dry Bulb Temp. ºC

4
Evaporator
RH %
D: After Dry Bulb Temp. ºC

5
Evaporator
RH %
Dry Bulb Temp. ºC

6 E: Return Air
RH %
F: Dry Bulb Temp. ºC

7 Environmental
Chamber RH %
18 Refrigerant Flowrate lpm
LABTECH 95

19. After completing the experiment, turn OFF steam generator switch.
Stopping the System
respectively.
TASKS
1. By using data in Table 5.8-1, plot the refrigeration cycle on pressure-enthalpy chart
and calculate :
a) Degree of de-superheating in the Discharge Line,
b) Degree of subcooled in the Condenser,
c) Degree of subcooled in the Liquid Line,
d) Degree of superheat in the Evaporator,
e) Degree of superheat in the Liquid Line,
f) Heat absorbed in the Evaporator (Qe),
g) Work input to the Compressor (Win),
h) Heat rejected in the Condenser (Qc),
i) Coefficient of Performance (COPrefrigeration),
j) Net Refrigerating Capacity (Qrc),
k) Energy Efficiency Ratio (EER),
l) Compression Ratio (CR), and
See Appendix for Thermodynamics Properties of R-1
2. By using data in Table 5.8-1, plot and determine the air properties on psychrometric
chart! Write down your analysis!
….......................................................................................................................................
….......................................................................................................................................
LABTECH 96
5.9. AUTOMATIC CONTROL SYSTEM
OBJECTIVES
After completing this experiment, you are expected to:
• Be familiar with automatic control system.
• Be able to monitor temperature and humidity of conditioned space.
• Explain working principle of automatic temperature and humidity control in
conditioned space.
EQUIPMENT
PROCEDURES
Safety Checklist
Running the System

2. Please refer to chapter 2 (point 2.3 Parts Identification) for more familiarization of the
5. Set the Recirculation damper to 100%.
6. Turn ON ELCB and MCB F1, F2, F3, F4, F7, F8 and F9. Then observe the voltmeter
reading for each phase. Make sure the voltage reading is within the correct range.
7. Set Manual/Auto Selector to AUTO position.
8. Press the START button.. Allow the system to run approximately 5 minutes.
Supply Fan Speed Control Scenario:
The Supply Fan speed is controlled by the room temperature set point, it is also known
as variable air volume method of control.
Supply fan speed increases when the cooling demand of chamber increases, supply fan
speed decreases when cooling demand decreases.
Cooling demand is affected by the room temperature and room temperature set point,
LABTECH 97
when the room temperature is higher than set point, the cooling demand is high and so
on, when the room temperature is lower than set point, the cooling demand is low.
Override the Temperature set Point of Temperature Controller according to the value
from table below, and complete the table.
No Temperature Set Point Supply Fan Speed (%) Air Velocity (m/s)
1 35ºC
2 30ºC
3 25ºC
4 20ºC
5 15ºC
Steam Injector Control Scenario:

Steam Injector is controlled by using Humidity Controller that have input from
Humidity Sensor, humidity controller will open or close the steam injector solenoid.
When the room humidity is higher than humidity set point, the steam injector solenoid
will be closed and so on, when the room humidity is lower than humidity set point, the
steam injector solenoid will be opened.
Set Humidity set point, as per data in table below, than complete the data.
NO Humidity Set Point Steam Injector Solenoid
1 Lower than Room humidity On / Off *
2 Equal to Room humidity On / Off *
3 Higher than Room humidity On / Off *
Stopping the System

9. Press STOP switch.
LABTECH 98
6
APPENDIX
LABTECH 99
LABTECH 100
6.1. PIPING DIAGRAM
LABTECH 101
6.2. WIRING DIAGRAM
LABTECH 102
6.3. THE PSYCHROMETRIC CHART
LABTECH 103
6.4. THERMOPHYSICAL PROPERTIES OF AIR
The values of μ. k, Cp and Pr are not strongly pressure-dependent and may be used over a
fairly wide range of pressures.
Table 6.1. Thermophysical Properties of Air At Atmospheric Pressure
Cp
ρ μ v k α
T (kJ/kg Pr
(kg/m3) (kg/ms×105) (m2/s×106) (W/mk) (m2/s×104)
(C) (K) K)
-173 100 3.9010 1.0266 0.6924 1.923 0.009246 0.02501 0.770
-123 150 2.3675 1.0099 1.0283 4.343 0.013735 0.05745 0.753
-73 200 1.7687 1.0061 1.3289 7.49 0.01809 0.10165 0.739
-23 250 1.4128 1.0053 1.488 9.49 0.02227 0.13161 0.722
27 300 1.1774 1.0057 1.983 15.68 0.02624 0.2216 0.708
77 350 0.9980 1.0090 2.075 20.76 0.03003 0.2983 0.697
127 400 0.8826 1.0140 2.286 25.90 0.03365 0.3760 0.689
177 450 0.7833 1.0207 2.284 28.86 0.03707 0.4222 0.683
227 500 0.7048 1.0295 2.671 37.90 0.04038 0.5564 0.680
277 550 0.6423 1.0392 2.848 44.34 0.04360 0.6532 0.680
327 600 0.5879 1.0551 3.018 51.34 0.04649 0.7512 0.680
377 650 0.5430 1.0635 3.177 58.51 0.04953 0.8578 0.682
427 700 0.5030 1.0752 3.322 66.25 0.05230 0.9672 0.684
477 750 0.4709 1.0856 3.481 73.91 0.05509 1.0774 0.686
527 800 0.4405 1.0978 3.625 82.29 0.05779 1.1951 0.689
577 850 0.4149 1.1095 3.765 90.75 0.06028 1.3097 0.692
627 900 0.3925 1.1212 3.899 99.3 0.06269 1.4271 0.696
677 950 0.3716 1.1321 4.023 108.2 0.06525 1.5610 0.699
727 1000 0.3524 1.1417 4.152 117.8 0.06752 1.6779 0.702
827 1100 0.3204 1.160 4.44 136.6 0.0732 1.969 0.704
927 1200 0.2947 1.179 4.92 159.1 0.0782 2.251 0.707
1027 1300 0.2707 1.197 4.93 182.1 0.0837 2.583 0.705
1127 1400 0.2515 1.214 5.17 205.5 0.0891 2.920 0.705
1227 1500 0.2355 1.230 5.40 229.1 0.0946 3.262 0.705
1327 1600 0.2211 1.248 5.63 254.5 0.100 3.609 0.705
From National Bureau of Standards (USA), Circ, 564, 1955 a.
LABTECH 104
6.5. PRESSURE – ENTHALPY DIAGRAM OF R-134a
LABTECH 105
6.6. THERMODYNAMIC PROPERTIES OF R-134a
LABTECH 106
LABTECH 107
LABTECH 108
6.7. SYMBOL AND UNIT
SYMBOL DESCRIPTION UNIT

A Area m2
V Potential difference Volt (V)
h Specific enthalpy KJ/kg
I (A) Current Ampere
m Mass flow rate Kg/s
Q Heat transfer rate (heating/cooling capacity) KJ/s
T Temperature °C
v Specific volume m3/kg
ρ Density kg/m3
v Air velocity m/s
hv Velocity Pressure inch of water
φ Relative humidity %
ω Specific humidity (moisture content) kg/kg dry air
Cos φ Power factor change or difference %
LABTECH 109
6.8. RECOVERING, EVACUATING, AND CHARGING PROCEDURES
Required Equipment:
1. Recovery Unit
2. Storage Tank
3. Vacuum Pump
4. Manifold Gauge
5. Refrigerant Scale
6. Sets of flexible hose
6.8.1. Recovering Procedure:
Figure 6.8-1. Pre-Cooling Storage Tank Connection
LABTECH 110
1. Connect flexible hoses as shown in Figure 6.8-1. Purging non-condensable gas from hose.
2. Connect the recovery unit power plug to the suitable power supply.
3. Ensure the storage tank is filled at least 2 kgs with liquid refrigerant.
4. Turn ON the recovery unit.
5. Open V5, V8, and V9. Ensure other valves are fully closed.
6. Slightly adjust the outlet valve (V6) in the recovery unit so the outlet pressure on the
recovery unit is approximately 7 bar higher than inlet pressure.
7. Ensure the outlet pressure is below 21 bar.
8. Let the unit run approximately 5 to 10 minutes.
9. After the storage tank is being cooled, close V5 and V9.
10. Turn OFF the recovery unit.
11. Disconnect flexible hose from V9 and connect to V3 on the Manifold Gauge.
12. Connect low side port (V1) and high side port (V2) on the Manifold Gauge to the system
being serviced, then connect the VAC (V4) to Vacuum Pump. See Figure 6.8-2. for detail.
LABTECH 111
Figure 6.8-2 Liquid Recovery Connection

13. Open V1, V2, V3, V4, and V10. Ensure other valves are fully closed.
14. Turn ON the Vacuum Pump.
(It is used to remove non-condensable gas that trapped in the flexible hoses).
15. Let the air and non-condensable gas removed from flexible hose.
16. Closed V1, V4 and V10 and then turn off the Vacuum Pump.
17. Open both valves in the system that are being serviced.
18. Open V5 (Turn to “liquid” position) and let the liquid refrigerant from system flow to the
storage tank. Then fully open V5 after liquid refrigerant from system has been transferred
to the storage tank.
19. Next, open V1, and V6.
20. Turn ON the recovery unit. Now, the refrigerant vapor in the system is sucked by
compressor in the recovery unit and discharges it to the storage tank. See Figure 6.8-3. for
detail.
LABTECH 112
Figure 6.8-3 Vapour Recovery Connection

21. Close V5, V6, and V8 if there is no refrigerant anymore in the system.
In case leak(s) found in the system, stop the recovery unit when the inlet pressure is
slightly above atmospheric pressure. Continuous recovery process will cause air suck
from leakage area and mix with refrigerant inside.
22. Now you can repair leak or change broken component.
6.8.2. Evacuating and Charging Procedure:

1. Connect flexible hoses as per figure 6.8-4.
LABTECH 113
Figure 6.8-4 Evacuating / Vacuum Connection

2. Open both valves in the system that are being evacuated.
3. Open all valves in the Manifold Gauge (V1 to V4), open V10 in the Vacuum Pump.
4. Ensure that Refrigerant Valve (V11) is in the fully closed position.
5. Turn ON the Vacuum Pump.
6. Let the air and non-condensable gas removed from the system.
7. After evacuating /vacuum process has completed. Close V4 and then close V10.
8. Turn OFF the Vacuum Pump.
9. Turn the refrigerant tank upside down. See Figure 6.8-5. for detail.
LABTECH 114
Figure 6.8-5. Liquid Charging

10. Fully open V11 and use V2 to control refrigerant flows to the system.
11. Ensure the system is fully charged as per specification / manufacture recommendation.
12. Close V2.
13. Now you can test the system.
14. Turn ON the system and let it run until it is stable.
15. In case the pressure is still lower below the standard or manufacture recommendation, top-
up the refrigerant to the system. See Figure 6.8-6. for detail.
LABTECH 115
Figure 6.8-6. Top Up Refrigerant
16. Open V1, fill the system until the standard operating pressure is reached.
17. If the system is running normally, close V1, V2, and V11.
18. Close both valves in the system.
19. Remove flexible hoses from the system.
20. Now, the system is ready to be used.
LABTECH 116
Abmessungen/Einbaumaße Inbetriebnahme und Bedienung Wartung und Reinigung
BEDIENUNGSANLEITUNG www.conrad.com Um eine sachgemäße Inbetriebnahme zu gewährleisten, lesen Sie vor Das Gerät ist bis auf eine gelegentliche Reinigung wartungsfrei. Überprüfen Sie
Gebrauch unbedingt diese Bedienungsanleitung mit den Sicherheits- regelmäßig die technische Sicherheit des Gerätes.
hinweisen vollständig und aufmerksam durch! Es ist anzunehmen, dass ein korrekter Betrieb nicht mehr möglich ist, wenn:
Luftfeuchteregler Version 02/06

• das Gerät und die Anschlüsse sichtbare Beschädigungen aufweisen
Best.-Nr. 19 85 32 FOX-1H ° Der Regler besitzt keinen Betriebsschalter und schaltet sich automatisch ein, sobald • nach längerer Lagerung unter ungünstigen Verhältnissen
die Betriebsspannung anliegt. • nach schweren Transportbeanspruchungen
Bestimmungsgemäße Verwendung Nach dem Einschalten erfolgt ein kurzer Selbstcheck. Die Anzeige schaltet nach ca.
1-2 Sekunden in den Normalbetrieb um und zeigt die aktuelle relative Fehlermeldungen
Der Luftfeuchteregler dient zur Erfassung und Anzeige der relativen Luftfeuchtigkeit Luftfeuchtigkeit in Prozent an. Das Gerät erkennt Fehler im System und des Fühlers selbstständig und zeigt dies
im Bereich von 20 bis 99%. Ein programmierbarer, potentialfreier Schaltausgang im Display an.
steht zur Verfügung. Somit können Lüftungssysteme oder Ventile universell gesteu- Die Programmierung des Reglers ist sehr einfach und erfolgt über drei Tasten am
ert werden. Die Feuchtigkeitserfassung erfolgt über einen externen Fühler. Die Anzeigefeld. Die Bedienung wird in zwei Bereiche unterteilt: Folgende Fehlermeldungen sind möglich:
Anzeigefarbe ist rot.
Der Luftfeuchteregler ist nur für den Einbau in Geräte, Anzeigetafeln oder • Der Einstellmodus ErI Speicherfehler. Schalten Sie das Gerät stromlos und schalten es erneut
Schaltschränke etc. vorgesehen und entspricht im eingebauten Zustand der Hier können die Schaltschwellen eingestellt werden. Der Einstellmodus ermöglicht ein. Bleibt die Fehleranzeige erhalten, so senden Sie das Gerät bitte
Schutzklasse 2 (doppelte oder verstärkte Isolation). Er darf nur im eingebauten die Änderung der Feuchtigkeitsschwelle, ohne komplizierte Programmierschritte. zum Kundendienst des Händlers.
Zustand in Betrieb genommen werden. Die Verwendung des Reglers ist in Geräten 0-E Fühlerfehler. Der Fühler weist eine Unterbrechung auf. Leitung kon-
der Schutzklasse 1 und 2 zulässig. Einbau
• Der Programmiermodus trollieren.
Die Installation darf nur durch eine Fachkraft erfolgen, die mit den entsprechenden Bereiten Sie die Einbaufläche entsprechend den Einbaumaßen vor. Hier werden die Grundparameter eingestellt. Um in diesen Modus zu gelangen, S-E Fühlerfehler. Der Fühler weist einen Kurzschluss auf. Leitung kontrol-
Vorschriften und den möglichen Gefahren vertraut ist. Die Montageöffnung muss 71 mm x 29 mm betragen. drücken Sie ca. 5 Sekunden die Taste „Set“ (D) lieren.
Das Gerät ist CE-konform und entspricht den geltenden europäischen Richtlinien. Schieben Sie die beiliegende Gummidichtung von der Anschlussseite bis zum Err Fühlerfehler. Der Fühler selbst weist eine Fehlfunktion auf. Fühler tau-
Eine Verwendung in explosionsgefährdeten Bereichen, im Freien oder Anzeigerahmen über das Gerät. schen.
Allgemein
Feuchträumen ist nicht zulässig. Der zu messenden Luftfeuchtigkeit darf nur der Setzen Sie den Regler von vorne in die Einbauöffnung.
Fühler ausgesetzt werden. Zwei Befestigungshalter liegen dem Gerät bei. Setzen Sie diese seitlich an den Durch Drücken der Programmiertaste „SET“ (D) wird das entsprechende Menü auf-
gerufen oder in den nächsten Programmierschritt weitergeschaltet. Die einstellba- Reinigen Sie das Gerät nur mit einem weichen, trockenen Tuch oder Pinsel.
Das Gerät darf nicht zur Sicherung von Menschen, Tieren oder Maschinen verwen- Regler und schieben diese bis zum gewünschten Befestigungsgrad in Richtung Verwenden Sie auf keinen Fall aggressive oder chemische Reinigungsmittel, da
det werden. Anzeige. Der Regler wird festgeklemmt. ren Parameter blinken.
Die beiden Pfeiltasten (A/B) dienen zum Ändern der Parameter. dadurch das Gehäuse angegriffen oder die Funktion beeinträchtigt werden könnte.
Zum Lösen drücken Sie die beiden zackigen Flanken der Befestigung zusammen
Der Luftfeuchteregler darf nur mit einer Wechselspannung von 230V~/50-60Hz und ziehen die Befestigungen vom Gerät. Der Einstell- oder Programmiermodus wird beendet, wenn innerhalb 10 Sekunden
keine Taste gedrückt wird oder die Taste „Set“ (D) für ca. zwei Sekunden gedrück Entsorgung
betrieben werden. Die angegebenen Schaltleistungen dürfen nicht überschritten
werden. bleibt. Im Display erscheint symbolisch “o-k“. Die Parameter werden gespeichert Elektronische Altgeräte sind Wertstoffe und gehören nicht in den
Anschlussbeispiel
Ein Betrieb unter widrigen Umgebungsbedingungen ist nicht zulässig. und bleiben auch nach dem Ausschalten erhalten. Hausmüll. Ist das Gerät am Ende seiner Lebensdauer, so entsorgen Sie
Widrige Umgebungsbedingungen sind: das Gerät gemäß den geltenden gesetzlichen Vorschriften.
• Nässe oder zu hohe Luftfeuchtigkeit, Die folgenden Programmskizzen zeigen die einzelnen Einstell- und Programmier-
• Staub und brennbare Gase, Dämpfe oder Lösungsmittel, schritte. Technische Daten
• starke Vibrationen oder Magnetfelder. Betriebsspannung . . . . . . . . . . . . . . . : 230V~ 50-60Hz
Einstellmodus Programmiermodus Betriebsstromaufnahme. . . . . . . . . . . : ca. 10 mA
Eine andere Verwendung als zuvor beschrieben ist nicht zulässig und führt zur Schaltausgang . . . . . . . . . . . . . . . . . : max. 250V~ / 3A
Beschädigung dieses Produktes. Darüber hinaus ist dies mit Gefahren, wie z.B. Regelbereich . . . . . . . . . . . . . . . . . . . : 20 bis 99% rel. Luftfeuchtigkeit
Kurzschluss, Brand, elektrischer Schlag etc. verbunden. Gewicht inkl. Fühler . . . . . . . . . . . . . . : ca. 250g
Fühlertyp . . . . . . . . . . . . . . . . . . . . . . : HS-220
Das gesamte Produkt darf nicht geändert bzw. umgebaut werden! Leitungslänge des Fühlers . . . . . . . . . : ca. 290 cm
Abmessungen . . . . . . . . . . . . . . . . . . : siehe Grafik
Die Sicherheitshinweise sind unbedingt zu beachten! Montageöffnung . . . . . . . . . . . . . . . . : 71 mm x 29 mm
Sicherheits- und Gefahrenhinweise

Ein in einem Dreieck befindliches Ausrufezeichen weist auf wichtige
Hinweise in der Bedienungsanleitung hin. Lesen Sie bitte vor
Inbetriebnahme die komplette Anleitung durch, sie enthält wichtige

Hinweise zum korrekten Betrieb.
Vergewissern Sie sich vor dem Anschluss oder vor Arbeiten am
• Bei Schäden, die durch Nichtbeachten dieser Bedienungsanleitung verursacht Gerät, dass alle Leitungen stromlos sind. Schalten Sie dazu die
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Haftung! Wiedereinschalten.
• Bei Sach- oder Personenschäden, die durch unsachgemäße Handhabung oder
Nichtbeachten der Sicherheitshinweise verursacht werden, übernehmen wir keine Der Anschluss erfolgt wie abgebildet. Beschreibung der Anzeigekürzel
Haftung! In solchen Fällen erlischt jeder Garantieanspruch.
tyP Schalttyp für den Ausgang
• Aus Sicherheits- und Zulassungsgründen (CE) ist das eigenmächtige Umbauen Schraubklemme 1 Fühleranschluss schwarze Litze (+) d = Entfeuchten: schaltet bei Überschreiten der eingestellten Luftfeuchtigkeit
und/oder Verändern des Gerätes nicht gestattet. Schraubklemme 2 Fühleranschluss weiße Litze (IN) H = Befeuchten: schaltet bei Unterschreiten der eingestellten Luftfeuchtigkeit
• Achten Sie auf eine sachgerechte Inbetriebnahme des Gerätes. Beachten Sie hier- Schraubklemme 3 Fühleranschluss gelbe Litze (-)
bei diese Bedienungsanleitung. Schraubklemme 8 Öffnerkontakt (zum Verbraucher) dIF Einstellbare, erlaubte Feuchtigkeitsabweichung (Hysterese) verhindert ein
• Das Gerät darf keinen extremen Temperaturen, Sonnenstrahlen, starken Schraubklemme 9 Schaltkontakt (230V~, L1) häufiges Schalten bei leicht schwankenden Messwerten.
Vibrationen oder Feuchtigkeit ausgesetzt werden. Schraubklemme 10 Schließkontakt (zum Verbraucher)
• Vermeiden Sie den Betrieb in der nähe von hochfrequenten Feldern (z.B. Schraubklemme 11 Netzanschluss (230V~, N) Cor Individuell einstellbare Anzeigenkorrektur
Schweißgeräte, Funkanlagen etc.). Schraubklemme 12 Netzanschluss (230V~, L1 Phase)
• Das Gerät darf nicht geöffnet oder zerlegt werden. o-k Parametereinstellungen wurden gespeichert
• Betreiben Sie das Gerät nur mit schadlosen Anschlussleitungen. Befestigen Sie den Fühler an der gewünschten Position. Beachten Sie dabei, dass
• Der Regler ist kein Spielzeug und gehört nicht in Kinderhände. das Kabel keine drehenden Teile oder scharfe Kanten berührt. Modus Anzeige Funktion Einstellbereich
Einstellung Blinkender Wert Einstellung der 20 bis 99%
Bedienelemente Kontrollieren Sie das Gerät nochmals auf richtigen Anschluss und feste Schaltschwelle
Schraubverbindungen. Programm tyP Schalttyp Entfeuchten (d)
A Einstelltaste „Abwärts“ Schließen Sie das System, in welches der Regler eingebaut wurde und schalten Sie
B Einstelltaste „Aufwärts“ Befeuchten (H)
die Stromversorgung wieder ein (Leitungsschutzschalter, Geräteschalter etc.).
C Anzeige dIF Feuchtigkeits- +/-1 bis +/-9%
D Programmiertaste abweichung Diese Bedienungsanleitung ist eine Publikation der Conrad Electronic GmbH,
Werden Verbraucher der Schutzklasse 1 angeschlossen, so muss der Klaus-Conrad-Straße 1, D-92240 Hirschau.
E Anzeige für aktiven Schaltausgang Schutzleiteranschluss separat und fachgerecht durchgeführt werden. Cor Wertkorrektur +/-10% Diese Bedienungsanleitung entspricht dem technischen Stand bei Druck-
Verlegen Sie die Fühlerleitung nicht neben Signal- oder Netz- der Anzeige legung. Änderung in Technik und Ausstattung vorbehalten.

leitungen. © Copyright 2006 by Conrad Electronic GmbH. Printed in Germany.
Dimensions/installation dimensions Taking the Device into Operation and Using it Maintenance and Cleaning
OPERATING INSTRUCTIONS www.conrad.com To ensure correct initial operation, please read these operating The product requires no servicing on your part apart from occasional cleaning.
instructions and the safety instructions carefully before using the Periodically check the technical safety of the device.
appliance! It can be assumed that risk-free operation is no longer possible if:
Version 02/06

Air Humidity Control • there is visible damage to the device or to the connections,
Item-No.. 19 85 32 FOX-1H ° The controller does not have a main switch and turns on automatically when the • the appliance has been stored under unfavourable conditions for a longer period
operating voltage is activated. of time
A short self-test takes place after activation. The display switches to normal opera- • the device has been subjected to heavy transport strain.
Intended use tion in approx. 1-2 seconds and shows the current relative air humidity in percent.
The air humidity control serves to detect and display the relative air humidity in a Error messages
range from 20 to 99%. A programmable, potential-free switching output is available. Programming the controller is very easy and takes place via three buttons on the The device detects errors in the system and the sensor itself and shows these on
This makes it possible to control ventilation systems or valves universally. The display field. The operation is divided into two parts: the display.
humidity is detected via an external sensor. The display colour is red.
The air humidity control is only intended for installation in devices, displays or • The setup mode The following error messages are possible:
switching cabinets etc. and corresponds to protection class 2 when installed (dou- Here you can set threshold limits. The setup mode enables changing the humidi-
ble or reinforced insulation). It may only be put into operation when installed. This ty limit without complicated programming steps. ErI Memory error. Turn the power of the device off and turn it on again. If
control may be operated in devices of protection class 1 and 2. the error message persists, please send the device to the retailer’s
Installation work must only be carried out by suitably qualified personnel who are • The programming mode customer service.
familiar with the hazards involved and with the relevant regulations. Installation
Here is where you set the basic parameters. To access this mode, press the but- 0-E Sensor error. The sensor is interrupted. Check the cable.
The device is CE conform and meets the respective European directives. Prepare the installation surface in acc. with the installation measures. ton „Set“ (D) for approx. 5 seconds. S-E Sensor error. The sensor is short-circuited. Check the cable.
The device must not be used in hazardous locations, damp interiors or outdoors in The installation opening must be 71 x 29 mm. Err Sensor error. The sensor itself is defect. Exchange the sensor.
the open air. Only the sensor may be exposed to measure the air humidity. Slide the enclosed rubber seal from the connection side to the display frame across General
The device may not be used to safeguard persons, animals or machines. the device. The outside of the appliance should be cleaned with a clean dry cloth or brush only.
Insert the controller into the installation opening from the front. By pressing the programming button „SET“ (D), the corresponding menu is called
up or switches to the next programming step. The parameters that can be set up Do not use abrasive or chemical cleaning agents which could damage the housing
The air humidity controller may only be operated with an alternating current of Two attachments are enclosed to the device. Place these lateral on the controller or impair operation.
and slide it towards the display up to the desired attachment degree. The controller blink.
230VDC/50-60 Hz. The maximum input volume may not be exceeded.
is fixed in place. The two arrow buttons (A/B) serve to change the parameters.
Operation is not permitted under unfavourable ambient conditions. Disposal
To loosen it, press the two spiky sides of the attachment together and pull the The set or programming mode is terminated if you do not press a button within 10
Unfavourable ambient conditions include:
attachment off the device. seconds or keep the button „Set“ (D) depressed for approx. two seconds. The dis- Old electronic devices are hazardous waste and should not be disposed of
• wetness or excessive humidity
play shows „o-k“. The parameters are saved and also remain saved after turning in household waste. When the device has become unusable, dispose of it
• dust or combustible gases, vapours or solvents
the device off. in accordance with the current statutory regulations.
• strong vibrations or magnetic fields. Connection example
The following program sketches show the individual setup and programming steps. Technical data
Uses other than those described above are not permitted. They will lead to damage
to the product. Additionally misuse may lead to short circuiting, fire, electrical Operating voltage . . . . . . . . . . . . . . . : 230V~ 50-60Hz
Setup mode Programming mode Operating current consumption . . . . . : approx. 10 mA
shocks etc.
Switching output . . . . . . . . . . . . . . . . : max. 250V~ / 3A
No part of the product must be modified or converted! Control range. . . . . . . . . . . . . . . . . . . : 20 to 99% rel. air humidity
Weight incl. sensor . . . . . . . . . . . . . . : approx. 250g
The safety instructions should be observed without fail! Sensor type . . . . . . . . . . . . . . . . . . . . : HS-220
Cable length of the sensor . . . . . . . . . : approx. 290 cm
Safety and Hazard Instructions Dimensions . . . . . . . . . . . . . . . . . . . . : see graphic
Installation opening . . . . . . . . . . . . . . : 71 mm x 29 mm
An exclamation mark in a triangle indicates important information in
these operating instructions. Please read the operating instructions
through completely before putting the device into operation. They

contain important information for correct operation.
• The guarantee will lapse if damage is incurred as a result of non-compliance with

the operating instructions! We will not assume any responsibility for consequen-
tial damage.
• We will also not assume any responsibility for damage to assets or persons caused
by improper handling or failure to observe the safety instructions! The warranty will Prior to connection or work on the device, make sure that all power
lapse in these cases. lines currentless. For this purpose, turn the automatic cutoff off and
protect it from accidental reactivation.
• For safety and licensing reasons (CE), unauthorized conversion and/or modifica-

tion of the device is not permitted. Description of the display abbreviations
• Make sure the device is put into operation correctly. Please follow the operating The connection is illustrated as follows: tyP Switching type for the output
instructions carefully in doing so. d = dehumidify: switches when the set air humidity is exceeded
• The device must not be exposed to extreme temperatures, sunlight, strong vibra- Screw clamp 1 Sensor connection black cord (+) H = humidify: switches when the set air humidity is undercut
tions or high levels of humidity. Screw clamp 2 Sensor connection white cord (IN)
• Avoid operation close to high-frequency fields (e.g. welding devices, radio sys- Screw clamp 3 Sensor connection yellow cord (-) dIF Adjustable, allowed humidity deviation (hysteresis) prevents frequent switch-
tems, etc.). Screw clamp 8 Opening contact (to the consumer) ing with slightly fluctuating measuring values.
• The product may not be opened or disassembled. Screw clamp 9 Switching contact (230V~, L1)
• Only operate the device with undamaged connection cables. Screw clamp 10 Closing contact (to the consumer) Cor Individually adjustable display correction
• The device is not a toy and has no place in the hands of children. Screw clamp 11 Mains connection (230V~, N)
Screw clamp 12 Mains connection (230V~, L1 phase) o-k Parameter settings were saved.
Controls and indicators
Attach the sensor on the desired position. Make sure that the cable does not come Mode Display Function Setting range
A Set button „Down“ into contact with rotating parts or sharp edges. Setting Blinking value Setting the 20 to 99%
B Set button „Up“ switching threshold
C Display Check the device once again for the right connection and tight screw connections. Program tyP Switching type dehumidifying (d)
D Programming button Close the system into which the controller was installed and turn the power supply humidifying (H)
E Display for active switch output back on (automatic cutoff, device switch, etc.).
dIF Humidity +/-1 to +/-9%
If consumers of protection class 1 are connected, the protective con- fluctuation
ductor must be connected separately and properly. Cor Value correction +/-10% These operating instructions are published by Conrad Electronic GmbH,
Do not install the sensor cable next to signal or net cables. of the display
Klaus-Conrad-Straße 1, D-92240 Hirschau/Germany.
The operating instructions reflect the current technical specifications at time
of print. We reserve the right to change the technical or physical specifications.
© Copyright 2006 by Conrad Electronic GmbH. Printed in Germany.
Eléments de commande Contrôlez encore une fois le branchement correct et la solidité des assemblages par Mode Affichage Fonction Plage de réglage
MODE D’EMPLOI www.conrad.com vis de l’appareil.
A Touche de réglage “ Descendre “ Fermez le système dans laquelle le régulateur a été monté et rebranchez l’alimenta- Réglage Valeur clignotante Réglage du 20 à 99%
B Touche de réglage “ Monter “ tion en courant (disjoncteur de protection de circuit, interrupteur de l’appareil, etc.). seuil d’activation
Régulateur de l’humidité Version 02/06 C Affichage Programme tyP Type de circuit Déshumidification (d)
D Touche de programmation Si des consommateurs de la classe de protection 1 sont raccordés, le Humidification (H)
atmosphérique ° E Affichage de la sortie de commutation branchement de conducteur de protection doit être effectué séparé- dIF Déviation de +/-1 à +/-9%
N° de commande 19 85 32 FOX-1H active ment et correctement.
l’humidité
Dimensions de montage Ne posez le câble de capteur pas à côté de câbles de signaux ou de Cor Correction des +/-10%
Utilisation conforme réseau. valeurs de l’affichage
Le régulateur de l’humdité atmosphérique sert à la détection et l’affichage de l’hum- Mise en service et manipulation
dité atmosphérique relative dans une plage de 20 à 99%. Une sortie de commuta- Entretien et nettoyage
tion programmable et sans potentiel est à disposition. Ainsi, les systèmes d’aération Afin de garantir une mise en service correcte, lisez attentivement Hormis un nettoyage occasionnel, l’appareil ne nécessite pas d’entretien. Contrôlez
ou les soupapes peuvent être commandés de manière universelle. La détection de l’intégralité de ce mode d’emploi ainsi que les consignes de sécurité régulièrement la sécurité technique de l’appareil.
avant d’utiliser l’appareil !
l’humidité s’effectue par un capteur externe. La couleur d’affichage est rouge.
Un fonctionnement correct n’est plus assuré lorsque :
Le régulateur de l’humidité atmosphérique n’est conçu que pour le montage dans • l’appareil et les branchements présentent de visibles endommagements
des appareils, des tableaux d’affichage ou des armoires de commande. A l’état Le régulateur ne dispose pas d’interrupteur de service et se met automatiquement • le module a été stocké pendant une période prolongée dans des conditions déplo-
monté, il correspond à la classe de protection 2 (double isolation ou isolation ren- en marche dès que la tension de service est active. rables,
forcée). L’appareil ne doit être mis en service qu’à l’état monté. L’utilisation du Après la mise en marche, une courte autovérification s’effectue. L’affichage passe • le produit a subi de sévères contraintes durant le transport
régulateur n’est admise que dans des appareil des classes de protection 1 et 2. après env. 1 à 2 secondes en service normal et affiche la valeur actuelle de l’humi-
L’installation doit être uniquement effectué par un technicien spécialisé, connais- dité atmosphérique relative en pourcent. Messages d´erreurs
sant parfaitement les prescriptions spécifiques en vigueur et les risques potentiels L’appareil détecte automatiquement les erreurs dans le système et du capteur et les
encourus. La programmation du régulateur est très facile et s’effectue à l’aide de trois touches affiche sur l’écran.
L’appareil est agréé CE et satisfait aux exigences des directives européennes en sur le champ d’affichage. La commande se divise en deux domaines :
vigueur. Les messages d’erreur suivants sont possibles :
Il est interdit d’utiliser l’appareil dans les zones à risques d’explosions, dans les • Le mode de réglage
Montage Ici les seuils d’activation peuvent être réglés. Le mode de réglage permet la modi-
locaux humides ou en plein air. Uniquement le capteur doit être exposé à l’humidi- ErI Erreur de mémorisation. Mettez l’appareil hors courant et remettez le
té à mesurer. Préparez la surface de montage de manière correspondante aux dimensions de fication du seuil d’humidité sans étapes de programmation compliqués. en marche. Si l’affichage d’erreur est maintenu, veuillez envoyer l’ap-
L’appareil ne doit pas être utilisé pour la protection d’hommes, d’animaux ou de montage. pareil au service client du commerçant.
machines. Le trou de montage doit avoir les dimensions de 71 mm x 29 mm. • Le mode de programmation 0-E Erreur de capteur. Le capteur présente une interruption. Contrôler le
Faites glisser le joint en caoutchouc fourni sur l’appareil, du côte des branchements Ici, les paramètres de base sont réglés. Pour atteindre ce mode, appuyez pendant câble.
Le régulateur de l’humidité atmosphérique ne doit fonctionner que sous une tension jusqu’au cadre de l’écran. env. 5 secondes sur la touche “ Set “ (D) S-E Erreur de capteur. Le capteur présente un court-circuit. Contrôler le
alternative de 230V~/50 à 60Hz. Les valeurs de puissance de coupure indiquées ne Insérez le régulateur par l’avant dans le trou de montage. câble.
doivent pas être dépassées. Deux supports de fixation sont fournis avec l’appareil. Appliquez-les au côté du Généralités Err Erreur de capteur. Le capteur lui-même présente un dysfonctionne-
Le fonctionnement dans des conditions ambiantes défavorables est interdit. régulateur et faites les glisser jusqu’au degré de fixation souhaité vers l’affichage. Un appui sur la touche de programmation “ SET “ (D) permet d’appeler le menu cor- ment. Remplacer le capteur.
Exemples de conditions défavorables : Le régulateur est fixé. respondant ou de avancer à l’étape suivante de programmation. Les paramètres
• présence de liquides ou humidité de l’air trop élevée, Pour le libérer, pressez les deux flancs dentés de fixation et retirez les fixations de réglables clignotent. Nettoyez l’appareil uniquement avec un chiffon doux et sec ou un pinceau. N’utilisez
• poussières et vapeurs, solvants ou gaz inflammables, l’appareil. Les deux touches à flèches (A/B) servent à modifier les paramètres. en aucun cas des nettoyants aggressifs ou chimiques car ces produits pourraient
• fortes vibrations ou champs magnétiques. Les modes de réglage ou de programmation se terminent lorsqu’aucune touche attaquer le boîtier ou nuire au bon fonctionnement de l’appareil.
Exemple de raccordement n’est actionnée dans l’espace de 10 secondes ou que la touche “ Set “ (D)est main-
Toute utilisation autre que celle décrite précédemment est interdite et peut endom- tenue enfoncée pendant env. deux secondes. L’écran affiche symboliquement “ o- Elimination
mager ce produit. De plus, elle entraîne des risques de court-circuit, d’incendie, de k “. Les paramètres sont mémorisés et le restent même après la mise hors tension. Les vieils appareils électroniques sont des biens recyclables qui ne doivent
décharge électrique, etc. pas être jetés dans une poubelle à ordures ménagères ! Si l’appareil arri-
Les esquisses de programme suivantes illustrent les différentes étapes de réglage ve au terme de sa durée de vie, il conviendra de l’éliminer conformément
L’ensemble du produit ne doit être ni modifié, ni transformé ! et de programmation. aux prescriptions légales en vigueur.
Observez impérativement les consignes de sécurité ! Mode de réglage Mode de programmation
Caractéristiques techniques
Consignes de sécurité et indications de danger Tension de service . . . . . . . . . . . . . . : 230V~ 50 à 60Hz
Consommation du courant de service : env. 10 mA
Dans ce mode d’emploi, un point d’exclamation placé dans un tri- Sortie de commutation . . . . . . . . . . . : 250V~ / 3A max.
angle signale les informations importantes. Lisez intégralement le Plage de réglage. . . . . . . . . . . . . . . . . . : 20 à 99% d’humidité atmosphérique relative
mode d’emploi avant la mise en service de l’appareil ; il contient des
Poids, capteur compris . . . . . . . . . . . : env. 250g
consignes importantes pour son bon fonctionnement. Type de capteur. . . . . . . . . . . . . . . . . : HS-220
Longueur de câble du capteur . . . . . . : env. 290 cm
• Tout dommage résultant d’un non-respect du présent mode d’emploi entraîne Dimensions . . . . . . . . . . . . . . . . . . . . : voir la représentation graphique
l’annulation de la garantie ! Nous déclinons toute responsabilité pour les dom- Trou de montage . . . . . . . . . . . . . . . . : 71 mm x 29 mm
mages consécutifs !
• De même, nous n’assumons aucune responsabilité en cas de dommages matériels
ou corporels résultant d’une utilisation de l’appareil non conforme aux spécifica-
tions ou d’un non-respect des présentes consignes de sécurité ! Dans ces cas, la Avant le branchement et toute intervention sur l’appareil, assurez-
garantie est annulée. vous que tous les câbles soient dépourvus de tension. A cet effet,
mettez hors tension les disjoncteurs de protection et assurez-vous
• Pour des raisons de sécurité et d’homologation (CE), les transformations et/ou

modifications du produit, réalisées à titre individuel, sont interdites. qu’ils ne se rétablissent pas.
• Veillez à ce que la mise en service de l’appareil soit effectuée correctement. Tenez
compte à cet effet des indications du présent mode d’emploi. Le branchement s’effectue comme illustré.
• L’appareil ne doit pas être exposé à des températures extrêmes, à des rayons du
soleil, à de fortes vibrations ou à l’humidité. Borne à vis 1 Branchement de capteur toron noir (+) Description des sigles affichés
• Eviter le fonctionnement à proximité de champs de haute fréquence (causés par Borne à vis 2 Branchement de capteur toron blanc (IN) tyP Type de circuit pour la sortie
ex. par des appareils de soudure, des installations de radio etc.). Borne à vis 3 Branchement de capteur toron jaune (-) d = deshumidification : s’active lors du dépassage de l’humidité atmosphérique
• Il est interdit d’ouvrir ou de démonter l’appareil. Borne à vis 8 Contact à ouverture (vers le consommateur) réglée
• Ne faites fonctionner l’appareil qu’en absence de tout endommagement des Borne à vis 9 Contact de commutation (230V~, L1) H = Humidification : s’active lorsque l’humidité atmosphérique réglée n’est pas
câbles de raccordement. Borne à vis 10 Contact à fermeture (vers le consommateur) atteinte
• Le régulateur n’est pas un jouet, il ne doit pas être laissé à la portée des enfants. Borne à vis 11 Branchement au réseau (230V~, N) Cette notice est une publication de la société Conrad Electronic GmbH,
Borne à vis 12 Branchement au réseau (230V~, L1 phase) dIF La déviation de l’humidité réglable et admise (hystérésis) évite une activation Klaus-Conrad-Straße 1, D-92240 Hirschau/Allemagne.
et désactivation fréquente lorsque les valeurs mesurées varient légèrement. Cette notice est conforme à la règlementation en vigueur lors de l´impression.
Fixez le capteur à l’endroit souhaité. Veillez à ce que le câble ne touche pas de Données techniques et conditionnement soumis à modifications sans aucun
pièces en rotation ou des arêtes vives. Cor Correction d’affichage individuellement réglable préalable.
o-k Les réglages des paramètres ont été mémorisés © Copyright 2006 par Conrad Electronic GmbH. Imprimé en Allemagne.
Afmetingen/inbouwmaten Ingebruikneming en bediening Onderhoud en reiniging
GEBRUIKSAANWIJZING www.conrad.com Lees voor gebruik deze gebruiksaanwijzing met de veiligheids- Afgezien van een incidentele reinigingsbeurt is het apparaat onderhoudsvrij.
instructies geheel en zorgvuldig door om een correcte inbedrijf- Controleer regelmatig de technische veiligheid van het apparaat.
stelling te kunnen garanderen. Er mag worden aangenomen dat gebruik zonder gevaar niet meer mogelijk is,
Luchtvochtigheidsregelaar Versie 02/06

wanneer
Bestelnr. 19 85 32 FOX-1H ° De regelaar is niet voorzien van een bedieningsschakelaar en schakelt automatisch • het apparaat of de aansluitsnoeren zichtbaar beschadigd zijn,
in zodra de voedingsspanning wordt ingeschakeld. • het apparaat langdurig onder ongunstige omstandigheden is opgeslagen.
Voorgeschreven gebruik Na het inschakelen volgt een korte zelftest. Het display schakelt na ca. 1-2 • het apparaat tijdens transport te zwaar is belast.
seconden over naar de normale modus en geeft de actuele relatieve
De luchtvochtigheidsregelaar dient voor het registreren en weergeven van de luchtvochtigheid in procenten weer. Foutmeldingen
relatieve luchtvochtigheid in het bereik van 20 tot 99 %. Een programmeerbare, Het apparaat signaleert zelfstandig fouten in het systeem en de voeler en geeft deze
potentiaalvrije schakeluitgang staat ter beschikking. Zo kunnen ventilatiesystemen De programmering van de regelaar is erg eenvoudig en vindt plaats via drie toetsen op het display aan.
of kleppen universeel worden geregeld. De vochtigheidsmeting vindt plaats via een op het display. De bediening wordt in twee modi onderverdeeld:
externe voeler. De indicatiekleur is rood. De volgende foutmeldingen zijn mogelijk:
De luchtvochtigheidsregelaar is alleen bestemd voor de inbouw in apparaten, • De instelmodus
visualiseringspanelen of schakelkasten en voldoet in ingebouwde toestand aan Hier kunnen de schakeldrempels worden ingesteld. In de instelmodus kan de ErI Geheugenfout. Schakel het apparaat stroomloos en schakel het
Veiligheidsklasse 2 (dubbele of versterkte isolatie). De regelaar mag alleen in vochtigheidsdrempel worden gewijzigd, zonder ingewikkelde opnieuw in. Als de foutmelding blijft, dient u het apparaat op de sturen
ingebouwde toestand in gebruik worden genomen. Het gebruik van de reglaar is programmeerprocedures. naar de klantenservice van de leverancier.
toegestaan in apparaten van de Veiligheidsklasse 1 en 2. Inbouw
0-E Fout in de voeler. De voeler laat een onderbreking zien. Controleer het
De installatie mag uitsluitend worden uitgevoerd door een vakman die vertrouwd is Maak het inbouwoppervlak gereed overeenkomstig de inbouwmaten. • De programmeermodus snoer.
met de risico’s en toepasselijke voorschriften. De montageopening moet 71 mm x 29 mm bedragen. Hier worden de basisparameters ingesteld. Om naar deze modus te gaan, drukt u S-E Fout in de voeler. De voeler laat een kortsluiting zien. Controleer het
Het apparaat is CE-goedgekeurd en voldoet daarmee aan de geldende Europese Schuif de meegeleverde rubberafdichting van de aansluitzijde tot aan het ca. 5 seconden op de toets „Set“ (D) snoer.
richtlijnen. displayframe over het apparaat. Err Fout in de voeler. De voeler zelf heeft een storing. Vervang de voeler.
Het gebruik in explosiegevaarlijke ruimten, in de open lucht of in vochtige ruimten Plaats de regelaar vanaf de voorzijde in de inbouwopening. Algemeen
is niet toegestaan. De voeler mag alleen aan de te meten luchtvochtigheid worden Twee houders worden bij het apparaat geleverd. Plaats deze aan de zijkanten van Het apparaat dient slechts met een zachte, droge doek of kwast te worden
blootgesteld. de regelaar en schuif deze tot aan de gewenste bevestigingshoek in de richting van Door te drukken op de programmeertoets „SET“ (D) wordt het betreffende menu
opgeroepen of in de volgende programmeerstap doorgeschakeld. De instelbare gereinigd. Gebruik in geen geval agressieve schoonmaakmiddelen of chemische
Het apparaat mag niet worden gebruikt ter bescherming van mensen, dieren of het display. De regelaar wordt vastgeklemd. reinigingsmiddelen, aangezien die de behuizing kunnen aantasten of de goede
machines. Om deze weer los te maken, drukt u de beide gekartelde zijkanten van de parameters knipperen.
De beide pijltoetsen (A/B) dienen voor het wijzigen van de parameters. werking kunnen schaden.
bevestigingshouder samen en trekt u de houders van het apparaat.
De luchtvochtigheidsregelaar mag alleen op een wisselspanning van 230V~/50- De instel- of programmeermodus wordt beëindigd wanneer niet binnen 10
seconden op een toets wordt gedrukt of wanneer de toets „Set“ (D) gedurende ca. Afvoeren
60Hz worden gebruikt. Het aangegeven schakelvermogen mag niet worden Voorbeeld van aansluiting
overschreden. twee seconden ingedrukt blijft. Op het display verschijnt symbolisch “o-k“. De Oude elektronische apparaten bevatten waardevolle materialen en beho-
Gebruik onder ongunstige omgevingsvoorwaarden is niet toegestaan. parameters worden opgeslagen en blijven ook na het uitschakelen bewaard. ren niet in het huisvuil. Indien het apparaat onbruikbaar is geworden, dient
Ongunstige omgevingsvoorwaarden zijn: het in overeenstemming met de geldende wettelijke voorschriften te wor-
• vocht of een te hoge luchtvochtigheid, De volgende schema’s geven de afzonderlijke instel- en programmeerstappen aan. den afgevoerd.
• stof en brandbare gassen, dampen of oplosmiddelen,
• sterke trillingen of magneetvelden. Instelmodus Programmeermodus Technische gegevens
Bedrijfsspanning . . . . . . . . . . . . . . . . : 230V~ 50-60Hz
Een andere toepassing dan hierboven beschreven is niet toegestaan en kan leiden Bedrijfsstroomopname. . . . . . . . . . . . : ca. 10 mA
tot beschadiging van dit product. Daarnaast bestaat het risico van bijv. kortsluiting, Schakeluitgang . . . . . . . . . . . . . . . . . : max. 250V~ / 3A
brand of elektrische schokken. Regelbereik . . . . . . . . . . . . . . . . . . . . : 20% tot 99%, rel. luchtvochtigheid
Gewicht incl. voeler . . . . . . . . . . . . . . : ca. 250g
Het complete product mag niet worden gewijzigd of omgebouwd! Type voeler . . . . . . . . . . . . . . . . . . . . : HS-220
Kabellengte van de voeler . . . . . . . . . : ca. 290 cm
De veiligheidsvoorschriften dienen absoluut in acht te worden genomen! Afmetingen . . . . . . . . . . . . . . . . . . . . : zie grafiek
Montageopening . . . . . . . . . . . . . . . . : 71 mm x 29 mm
Veiligheidsvoorschriften en risico’s
Een uitroepteken in een driehoek duidt op belangrijke aanwijzingen
in deze gebruiksaanwijzing. Lees voor ingebruikneming de volledige
handleiding door; deze bevat belangrijke aanwijzingen voor het juiste

gebruik. Zorg voor het aansluiten of voor werkzaamheden aan het apparaat,
dat alle kabels spanningsvrij zijn. Schakel hiervoor de
• Bij schade veroorzaakt door het niet in acht nemen van de gebruiksaanwijzing, beveiligingsschakelaar in het snoer uit en beveilig deze tegen

vervalt het recht op garantie! Voor vervolgschade die hieruit ontstaat, zijn wij niet onbedoeld inschakelen.
aansprakelijk!
• Wij kunnen niet aansprakelijk worden gesteld voor materiële schade of persoonlijk De aansluiting vindt plaats zoals op de afbeelding weergegeven. Beschrijving van de afkortingen
letsel als gevolg van ondeskundig gebruik of het negeren van de
tyP Schakeltype voor de uitgang
veiligheidsvoorschriften! In dergelijke gevallen vervalt elke aanspraak op garantie. Schroefklem 1 Voeleraansluiting zwarte draad (+) d = ontvochtigen: schakelt bij overschrijden van de ingestelde luchtvochtigheid
• Om veiligheids- en keuringsredenen (CE) is het eigenmachtig ombouwen en/of Schroefklem 2 Voeleraansluiting witte draad (IN) H = bevochtigen: schakelt bij onderschrijden van de ingestelde luchtvochtigheid
veranderen van het apparaat niet toegestaan. Schroefklem 3 Voeleraansluiting gele draad (-)
• Let op de correcte ingebruikneming van het apparaat. Neem hierbij deze Schroefklem 8 Verbreekcontact (naar verbruiker) dIF Instelbare, toegestane vochtigheidsafwijking (hysteresis) voorkomt frequent
gebruiksaanwijzing in acht. Schroefklem 9 Schakelaarcontact (230V~, L1) schakelen bij licht schommelende meetwaarden.
• Het apparaat mag niet worden blootgesteld aan extreme temperaturen, zonlicht, Schroefklem 10 Maakcontact (naar verbruiker)
sterke trillingen of vocht. Schroefklem 11 Netaansluiting (230V~, N) Cor Individueel instelbare weergavecorrectie
• Voorkom het gebruik in de buurt van hoogfrequente velden (bijv. lasapparaten, Schroefklem 12 Netaansluiting (230V~, L1 fase)
radiosystemen, etc.). o-k Parameterinstellingen worden opgeslagen
• Het apparaat mag niet worden geopend of gedemonteerd. Bevestig de voeler op de gewenste positie. Zorg hierbij dat de kabel niet door
• Gebruik het apparaat nooit met beschadigde aansluitkabels. draaiende delen of scherpe randen wordt aangeraakt. Modus Display Functie Instelbereik
• De regelaar is geen speelgoed. Houd deze buiten bereik van kinderen. Instelling Knipperende Instelling van de 20 tot 99 %
Controleer nogmaals of het apparaat goed is aangesloten en of de waarde schakeldrempel
Bedieningselementen schroefverbindingen vast zijn aangedraaid. Programma tyP Schakeltype ontvochtigen (d)
Sluit het systeem waarin de regelaar is ingebouwd en schakel de stroom weer in bevochtigen (H)
A Insteltoets „omlaag“ (snoerschakelaar, apparaatschakelaar, enz.)
B Insteltoets „omhoog“ dIF Vochtigheids- +/-1 tot +/-9% Deze gebruiksaanwijzing is een publicatie van Conrad Electronic GmbH,
C Display afwijking Klaus-Conrad-Straße 1, D-92240 Hirschau/Duitsland
Als verbruikers van Veiligheidsklasse 1 worden aangesloten, dan Deze gebruiksaanwijzing voldoet aan de technische eisen bij het ter perse
D Programmeertoets moet de aardaansluiting afzonderlijk en vakkundig worden Cor Waardecorrectie +/-10% gaan. Wijzigingen in techniek en uitrusting voorbehouden.
E Indicatie voor actieve schakeluitgang uitgevoerd. van de weergave
Leg het snoer van de voeler niet naast signaal- of netkabels. © Copyright 2006 by Conrad Electronic Benelux B.V. Printed in Germany. *02-06/HK
DIN EN ISO 9001
Certificate: 01 100 98505
UM91001A
BRAINCHILD
Warning Symbol
The Symbol calls attention to an operating procedure, practice, or the
like, which, if not correctly performed or adhered to, could result in
personal injury or damage to or destruction of part or all of the
product and system. Do not proceed beyond a warning symbol until
the indicated conditions are fully understood and met.
Use the Manual

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

Copyright a February 2002, The Brainchild Corporation, all rights
reserved. No part of this publication may be reproduced, transmitted,
transcribed or stored in a retrieval system, or translated into any
language in any form by any means without the written permission of
the Brainchild Corporation.
2 UM91001A
Contents
Page No Page No
Chapter 1 Overview Chapter 4 Applications
1-1 General -------------------------5 4-1 Heat Only Control with --
1-2 Ordering Code ---------------8 Dwell Timer ------------------51
1-3 Programming Port ------------9 4-2 Cool Only Control -----------52
1-4 Keys and Displays ---------10 4-3 Heat-Cool Control -----------53
1-5 Menu Overview -------------12
1-6 Parameter Descriptions ---13 Chapter 5 Calibration --------55
Chapter 2 Installation
Chapter 6 Specifications ----60
2-1 Unpaking ----------------------20
2-2 Mounting ----------------------20
2-3 Wiring precautions ----------22 Chapter 7
2-4 Power Wiring -----------------25 Communications-
Modbus Communications----66
2-5 Sensor Installation ---------- 7-1 Functions Supported -------66
Guidlines----------------------25 7-2 Exception Responses ------68
2-6 Sensor Input Wiring --------26 7-3 Parameter Table -------------69
2-7 Control Output Wiring -----26 7-4 Data Conversion -------------73
2-8 Alarm Wiring -----------------30 7-5 Communication Examples-73
2-9 Data Communication ------31
Appendix
Chapter 3 Programming
A-1 Error Codes ------------------76
3-1 Lockout -----------------------33 A-2 Warranty ----------------------77
3-2 Signal Input ------------------33
3-3 Control Outputs --------------34
3-4 Alarm ---------------------------39
3-5 Configure User Menu -----40
3-6 Ramp -------------------------41
3-7 Dwell Timer ------------------42
3-8 PV Shift -----------------------43
3-9 Digital Filter -------------------44
3-10 Failure Transfer -------------45
3-11 Auto-tuning ------------------46
3-12 Manual tuning -------------47
3-13 Manual Control -------------48
3-14 Data communication -----50
UM91001A 3
Figures & Tables Page No
Figure 1.1 Fuzzy Control Advantage ----------------------------------------------------------------6
Figure 1.2 Programming Port Overview ------------------------------------------------------------9
Figure 1.3 Front Panel Description -----------------------------------------------------------------11
Figure 1.4 Display of Initial Stage -------------------------------------------------------------------11
Figure 2.1 Mounting Dimensions -------------------------------------------------------------------21
Figure 2.2 Lead Termination for BTC-4100, BTC-8100 and BTC-7100---------------------23
Figure 2.3 Lead Termination for BTC-9100 -------------------------------------------------------23
Figure 2.4 Rear Terminal Connection for BTC-4100 and BTC-8100-------------------------23
Figure 2.5 Rear Terminal Connection for BTC-7100 --------------------------------------------24
Figure 2.6 Rear Terminal Connection for BTC-9100 --------------------------------------------24
Figure 2.7 Power Supply Connections ------------------------------------------------------------25
Figure 2.8 Sensor Input Wiring ----------------------------------------------------------------------26
Figure 2.9 Output 1 Relay or Triac (SSR) to Drive Load ---------------------------------------26
Figure 2.10 Output 1 Relay or Triac (SSR) to Drive Contactor -------------------------------27
Figure 2.11 Output 1 Pulsed Voltage to Drive SSR ---------------------------------------------27
Figure 2.12 Output 1 Linear Current ---------------------------------------------------------------28
Figure 2.13 Output 1 Linear Voltage ---------------------------------------------------------------28
Figure 2.14 Output 2 Relay or Triac (SSR) to Drive Load -------------------------------------28
Figure 2.15 Output 2 Relay or Triac (SSR) to Drive Contactor -------------------------------29
Figure 2.16 Output 2 Pulsed Voltage to Drive SSR ---------------------------------------------29
Figure 2.17 Output 2 Linear Current ---------------------------------------------------------------29
Figure 2.18 Output 2 Linear Voltage --------------------------------------------------------------30
Figure 2.19 Alarm Output to Drive Load ----------------------------------------------------------30
Figure 2.20 Alarm Output to Drive Contactor ----------------------------------------------------30
Figure 2.21 RS-485 Wiring ---------------------------------------------------------------------------31
Figure 2.22 RS-232 Wiring ---------------------------------------------------------------------------32
Figure 2.23 Configuration of RS-232 Cable ------------------------------------------------------32
Figure 3.1 Conversion Curve for Linear Type Process Value ---------------------------------34
Figure 3.2 Heat Only ON-OFF Control ------------------------------------------------------------35
Figure 3.3 Output 2 Deviation High Alarm --------------------------------------------------------38
Figure 3.4 Output 2 Process Low Alarm ----------------------------------------------------------38
Figure 3.5 RAMP Function ---------------------------------------------------------------------------41
Figure 3.6 Dwell Timer Function --------------------------------------------------------------------42
Figure 3.7 PV Shift Application ----------------------------------------------------------------------43
Figure 3.8 Filter Characteristics ---------------------------------------------------------------------44
Figure 3.9 Effects of PID Adjustment -------------------------------------------------------------49
Figure 4.1 Heat Control Example -------------------------------------------------------------------51
Figure 4.2 Cooling Control Example ---------------------------------------------------------------52
Figure 4.3 Heat-Cool Control Example ------------------------------------------------------------53
Figure 5.1 RTD Calibration ---------------------------------------------------------------------------57
Figure 5.2 Cold Junction Calibration Setup ------------------------------------------------------58
Table 1.1 Display Form of Characters ------------------------------------------------------------11

Table 3.1 Heat-Cool Control Setup Value ---------------------------------------------------------34
Table 3.2 PID Adjustment Guide --------------------------------------------------------------------48
Table A.1 Error Codes and Corrective Actions --------------------------------------------------66
4 UM91001A
Chapter 1 Overview
1-1 General
The Fuzzy Logic plus PID microprocessor-based controller series,
incorporate two bright, easy to read 4-digit LED displays, indicating
process value and set point value. The Fuzzy Logic technology
enables a process to reach a predetermined set point in the
shortest time, with the minimum of overshoot during power-up or
external load disturbance.
BTC-9100 is a 1/16 DIN size panel mount controller. BTC-7100 is a

72X72 DIN size panel mount controller. BTC-8100 is a 1/8 DIN size
panel mount controller and BTC-4100 is a 1/4 DIN size panel
mount controller. These units are powered by 11-26 or 90-264 VDC
/VAC supply, incorporating a 2 amp. control relay output as
standard. The second output can be used as cooling control, or an
alarm. Both outputs can select triac, 5V logic output, linear current
or linear voltage to drive external device. There are six types of
alarm plus a dwell timer can be configured for the third output.The
units are fully programmable for PT100 and thermocouple types J,
K, T, E, B, R, S, N, L with no need to modify the unit. The input signal
is digitized by using a 18-bit A to D converter. Its fast sampling rate
allows the unit to control fast processes.
Digital communications RS-485 or RS-232 ( excluding BTC-7100 )

are available as an additional option. These options allow the units
to be integrated with supervisory control system and software.
A programming port is available for automatic configuration,

calibration and testing without the need to access the keys on front
panel.
By using proprietary Fuzzy modified PID technology, the control

loop will minimize the overshoot and undershoot in a shortest
time. The following diagram is a comparison of results with and
without Fuzzy technology.
UM91001A 5
PID control with properly tuned
Temperature PID + Fuzzy control
Set
point
Figure 1.1
Fuzzy Control
Advantage
Warm Up Load Disturbance
Time
High Accuracy
The series are manufactured with custom designed ASIC(Application
Specific Integrated Circuit ) technology which contains a 18-bit A to
D converter for high resolution measurement ( true 0.1 BF resolution
for thermocouple and PT100 ) and a 15-bit D to A converter for linear
current or voltage control output. The ASIC technology provides
improved operating performance, low cost, enhanced reliability and
higher density.
Fast Sampling Rate

The sampling rate of the input A to D converter reaches 5 times/second.
The fast sampling rate allows this series to control fast processes.
Fuzzy Control
The function of Fuzzy control is to adjust PID parameters from time to
time in order to make manipulation output value more flexible and
adaptive to various processes. The results is to enable a process to
reach a predetermined set point in the shortest time, with the minimum
of overshoot and undershoot during power-up or external load
disturbance.
Digital Communication
The units are equipped with RS-485 or RS-232 interface card to
provide digital communication. By using the twisted pair wires there
are at most 247 units can be connected together via RS-485 interface
to a host computer.
6 UM91001A
Programming Port
A programming port is used to connect the unit to a hand-held
programmer or a PC for quick configuration, also can be connected
to an ATE system for automatic testing & calibration.
Auto-tune
The auto-tune function allows the user to simplify initial setup for a
new system. A clever algorithm is provided to obtain an optimal set
of control parameters for the process, and it can be applied either as
the process is warming up ( cold start ) or as the process has been
in steady state ( warm start ).
Lockout Protection
According to actual security requirement, one of four lockout levels
can be selected to prevent the unit from being changed abnormally.
Bumpless Transfer
Bumpless transfer allows the controller to continue to control by
using its previous value as the sensor breaks. Hence, the process
can be well controlled temporarily as if the sensor is normal.
Soft-start Ramp
The ramping function is performed during power up as well as any
time the set point is changed. It can be ramping up or ramping
down. The process value will reach the set point with a predetermined
constant rate.
Digital Filter
A first order low pass filter with a programmable time constant is used
to improve the stability of process value. This is particularly useful in
certain application where the process value is too unstable to be read.
SEL Function
The units have the flexibility for user to select those parameters which
are most significant to him and put these parameters in the front of
display sequence. There are at most 8 parameters can be selected
to allow the user to build his own display sequence.
UM91001A 7
1-2 Ordering Code
BTC-4100-
BTC-7100- Accessories
BTC-8100- OM94-6 = Isolated 1A / 240VAC
BTC-9100- Triac Output Module ( SSR )
Power Input OM96-3 = Isolated 4 - 20 mA /
4: 90 - 264 VAC, 50/60 HZ 0 - 20 mA Analog Output
5: 11 - 26 VAC or VDC Module
9: Special Order OM96-4 = Isolated 1 - 5V / 0 - 5V
Signal Input Analog Output Module
1: Standard Input
OM96-5 =Isolated 0 -10V Analog
Thermocouple: J, K, T, E, B, Output Module
R, S, N, L CM94-1 = Isolated RS-485
RTD: PT100 DIN, PT100 JIS Interface Module for
9: Special Order BTC-8100, BTC-4100,
Output 1 BTC-7100
0: None CM94-2 = Isolated RS-232
1: Relay rated 2A/240VAC Interface Module for
2: Pulsed voltage to drive SSR, BTC-8100, BTC-4100
5V/30mA
3: Isolated 4 - 20mA / 0 - 20mA CM97-1 = Isolated RS-485
4: Isolated 1 - 5V / 0 - 5V Interface Module for
5: Isolated 0 - 10V BTC-9100
6: Triac output 1A / 240VAC,SSR CM97-2 = Isolated RS-232
9: Special order Interface Module for
Output 2 BTC-9100
0: None DC94-1 = Isolated 20V/25mA DC
1: Form A relay 2A/240VAC Output Power Supply
2: Pulsed voltage to DC94-2 = Isolated 12V/40mA
drive SSR, 5V / 30mA
3: Isolated 4 - 20mA / 0 - 20mA DC Output Power Supply
4: Isolated 1 - 5V / 0 - 5V DC94-3 = Isolated 5V/80mA DC
5: Isolated 0 - 10V Output Power Supply
6: Triac output, 1A / 240VAC, SSR CC94-1 = RS-232 Interface
7: Isolated 20V/25mA transducer power Cable ( 2M )
supply
8: Isolated 12V/40mA transducer power
supply Related Products
9: Isolated 5V/80mA transducer power
supply SNA10A = Smart Network
A: Special order Adaptor for third party
Alarm software, which converts
0: None 255 channels of RS-485 or
1: Form C relay 2A/240VAC RS-422 to RS-232 Network.
9: Special order
Communications SNA10B = Smart Network
0: None Adaptor for BC-Net
1: RS-485 interface software, which converts
2: RS-232 interface ( not available for BTC-7100 ) 255 channels of RS-485 or
9: Special order
RS-422 to RS-232 network.
Protective Class
0: IP50 standard
1: IP65 water resistant rubber installed
8 UM91001A
1-3 Programming Port
Rear Front
Terminal Panel
Figure 1.2
Programming Port
6 4 2
Overview
5 31
Access Hole
6 4 2
5 31
A special connector can be used to touch the programming port

which is connected to a PC for automatic configuration, also can be
connected to an ATE system for automatic calibration and testing.
The programming port is used for off-line automatic setup and testing
procedures only. Don't attempt to make any connection to these pins
when the unit is used for a normal control purpose.
UM91001A 9
1- 4 Keys and Displays
KEYPAD OPERATION
SCROLL KEY :
This key is used to select a parameter to be viewed or adjusted.
UP KEY :
This key is used to increase the value of selected parameter.
DOWN KEY :
This key is used to decrease the value of selected parameter.
RESET KEY : R
This key is used to:
1. Revert the display to display the process value.
2. Reset the latching alarm, once the alarm condition is
removed.
3. Stop the manual control mode , auto-tuning mode and calibration
mode.
4. Clear the message of communication error and auto-tuning error.
5. Restart the dwell timer when the dwell timer has been time out.
6. Enter the manual control menu during failure mode occurs.
ENTER KEY : Press for 3 seconds or longer .

Press for 3 seconds to:
1. Ener setup menu. The display shows .
2. Enter manual control mode during manual control mode
is selected.
3. Enter auto-tuning mode during auto-tuning mode is
selected.
4. Perform calibration to a selected parameter during the
calibration procedure.
Press for 4.2 seconds to select manual control mode.
Press for 5.4 seconds to select auto-tuning mode.
Press for 6.6 seconds to select calibration mode.
10 UM91001A
Alarm Upper Display, to display process value,
Indicator menu symbol and error code etc.
Output 2 Process Unit Indicator
Indicator
Output 1 OP1 OP2 ALM
Indicator C F
Manual Lower Display,

Mode to display set point value,
Indicator MAN parameter value or
Auto-tuning AT control output value etc.
Indicator
R 4 Buttons for ease of
control setup and
BTC-9100 set point adjustment.
Figure 1.3 Front Panel Description
Table 1.1 Display Form of Characters

A E I N S X
B F J O T Y
C G K P U Z
c H L Q V ?
D h M R W =
: Confused Character
OP1 OP2 ALM Display program code of the product

C F for 2.5 seconds.
The left diagram shows program no. 6

for BTC-9100 with version 12.
The program no. for BTC-7100 is 13,
MAN
for BTC-8100 is 11 and for BTC-4100 is 12.
AT
R Figure 1.4
BTC-9100 Display of Initial Stage
UM91001A 11
1- 5 Menu Overview
User Setup Manual Auto-tuning Calibration
menu menu Mode Mode Mode
3 sec. 4.2 sec. 5.4 sec. 6.6 sec. 7.8 sec.

PV, SV
Release *3
*2 *1 then press
SP2 LOCK H_ _ _ ADLO
SP3 INPT
for 3 seconds ADHI
INPT UNIT to start RTDL
UNIT DP
C_ _ _
auto-tuning RTDH
DP INLO CJLO
mode.
PB INHI CJHI
TI SP1L
TD SP1H
Press
CYC1 SHIF for 3 seconds
Press for
ADDR FILT to start
PB manual control. 3 seconds to
TI perform calibration.
TD
OUT1
Apply these modes will break the control
O1TY
O1FT loop and change some of the previous
O1HY setting data. Make sure that if the system
CYC1 is allowable to apply these modes.
OFST
RAMP
RR *1: The flow chart shows a complete listing
OUT2 of all parameters. For actual application
O2TY the number of available parameters
O2FT
O2HY
depends on setup conditions, and should
CYC2 be less than that shown in the flow chart.
CPB
DB
*2: You can select at most 8 parameters put
ALFN
ALMD
in the user menu by using SEL1~SEL8
ALHY contained at the bottom of setup menu.
ALFT
COMM
*3: Release , press again for 2 seconds
ADDR
BAUD or longer (but not longer than 3 seconds),
DATA then release to enter the calibration menu.
PARI
STOP
SEL1
The user menu shown in the flow chart is
SEL2 corresponding to the default setting for
SEL3 the SEL parameters SEL1 to SEL8. SP3
SEL4 will be hidden if NONE is selected for
SEL5
SEL6
ALFN. SP2 will be hidden if alarm function
SEL7 is not selected for OUT2. The unused
SEL8 parameter will be hidden even if it is
selected by SEL parameters.
12 UM91001A
1-6 Parameter Descriptions
Parameter Parameter Description Range Default
Notation Value
25.0 BC
SP1 Set point for output 1 Low: SP1L High :SP1H (77.0BF)
Set point for output 2
Low: -19999 High :45536 10.0 BC
SP2 when output 2 performs (18.0BF)
alarm function
Set point for alarm or 10.0 BC
SP3 dwell timer output Low: -19999 High: 45536 (18.0 BF)
0 : No parameter
is locked
1 : Setup data are
Select parameters to be locked
LOCK 0
locked 2 : Setup data and
User data except Set
point are locked
3 : All data are locked
0 : J type thermocouple
1 : K type thermocouple
2 : T type thermocouple
3 : E type thermocouple
4 : B type thermocouple
5 : R type thermocouple
6 : S type thermocouple
7 : N type thermocouple
8 : L type thermocouple
1
INPT Input sensor selection 9 : PT 100 ohms DIN
curve (0)
10 : PT 100 ohms JIS
curve
11 : 4 - 20 mA linear
current input
12 : 0 - 20 mA linear
current input
13 : 0 - 60 mV linear
millivolt input
14 : 0 - 1V linear voltage
input
input
input
input
UM91001A 13
Notation Value
0 : Degree C unit
0
UNIT Input unit selection 1 : Degree F unit
(1)
2 : Process unit
0 : No decimal
point
1 : 1 decimal digit
DP Decimal point selection 1
2 : 2 decimal digits
3 : 3 decimal digits
Input low sale value High: 45486 -17.8 LC

INLO Low: -19999 ( 0 LF )
93.3 LC
INHI Input high scale value Low: INLO+50 High: 45536 (200.0 LF)
Low limit of set point -17.8 LC
SP1L Low: -19999 High: 45536 (0 LF)
value
High limit of set point 537.8 LC
SP1H Low: SP1L High: 45536 (1000 LF)
value
-200.0 LC 200.0 LC
SHIF PV shift (offset) value Low: (-360.0 LF) High:( 360.0 LF) 0.0
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
Filter damping time constant
FILT 5 2
constant of PV : 5 seconds time
constant
6 : 10 seconds time
constant
7 : 20 seconds time
constant
8 : 30 seconds time
constant
9 : 60 seconds time
constant
14 UM91001A
Notation Value
PB Proportional band value Low: 0 High: 500.0 LC 10.0 LC

(900.0 LF) (18.0 LF)
TI Integral time value Low: 0 High: 1000 sec 100
TD Derivative time value Low: 0 High: 360.0 sec 25.0
0 : Reverse (heating )
control action
OUT1 Output 1 function 0
1 : Direct (cooling)
control action
0 : Relay output
1 : Solid state relay
drive output
output
3 : 4-20 mA current
module
O1TY Output 1 signal type 4 : 0 - 20 mA current 0
module
5 : 0 - 1V voltage
module
6 : 0 - 5V voltage
module
7 : 1 - 5V voltage
module
8 : 0 - 10V voltage
module
Select BPLS ( bumpless
transfer ) or 0.0 ~ 100.0 % to
Output 1 failure transfer continue output 1 control 0
O1FT function as the unit fails, or
mode
select OFF (0) or ON (1)
for ON-OFF control.
Output 1 ON-OFF control 0.1LC
O1HY Low: 0.1 High: 50.0 BC(90.0BF)
hysteresis (0.2LF)
CYC1 Output 1 cycle time Low: 0.1 High: 90.0 sec. 18.0
OFST Offset value for P control Low: 0 High: 100.0 % 25.0
0 : No Ramp Function
1 : Use unit/minute as
RAMP Ramp function selection Ramp Rate 0
2 : Use unit/hour as
Ramp Rate
UM91001A 15
Notation Value
RR Ramp rate Low: 0 High: 500.0 LC 0.0

(900.0 LF)
0 : Output 2 No Function
2 : Deviation High Alarm
3 : Deviation Low Alarm

OUT2 Output 2 function 2
6 : Process High Alarm
7 : Process Low Alarm
8 : Cooling PID Function
0 : Relay output

drive output
output
3 : 4 - 20 mA current
module
O2TY Output 2 signal type 0
4 : 0 - 20 mA current
module
5 : 0 - 1V voltage
module
6 : 0 - 5V voltage
module
7 : 1 - 5V voltage
module
8 : 0 - 10V voltage
module
Select BPLS ( bumpless transfer )
or 0.0 ~ 100.0 % to continue
Output 2 failure 0
O2FT output 2 control function as the
transfer mode
unit fails, or select ON (0) or
OFF (1) for alarm function.
Output 2 hysteresis
0.1 LC
High: 50.0 LC
value when output 2
O2HY Low: 0.1 (90.0 LF) (0.2 LF)
performs alarm
function
CYC2 Output 2 cycle time Low: 0.1 High: 90.0 sec. 18.0
CPB Cooling proportional High: 300 % 100

band value Low: 50
16 UM91001A
Notation Value
Heating-cooling dead
DB band (negative value= Low: -36.0 High: 36.0 % 0
overlap)
0 :No alarm function

1 :Dwell timer action
2 :Deviation high alarm
3 :Deviation low alarm
Alarm function for 4 :Deviation band out of

ALFN alarm output band alarm 2
5 :Deviation band in
band alarm
6 :Process value high
alarm
7 :Process value low
alarm
0 : Normal alarm
action
1 : Latching alarm
ALMD Alarm operation mode action 0
2 : Hold alarm action
3 : Latching & Hold

action
0.1 LC
ALHY
Hysteresis control of
Low: 0.1 High: 50.0 LC
alarm (90.0 LF) (0.2 LF)
0 : Alarm output ON as
Alarm failure transfer unit fails
ALFT 0
mode 1 : Alarm output OFF as
unit fails
0 : No communication
Communication
COMM 1 : Modbus RTU mode 1
function
protocol
UM91001A 17
Notation Value
Address assignment of
ADDR digital communication Low: 1 High: 255
0 : 2.4 Kbits/s baud rate
Baud rate of digital 3 : 14.4 Kbits/s baud rate

BAUD 2
communication
Data bit count of digital 0 : 7 data bits

DATA 1
communication 1 : 8 data bits
0 : Even parity
Parity bit of digital 1 : Odd parity
PARI 0
communication
2 : No parity bit
Stop bit count of digital 0 : One stop bit

STOP 0
communication 1 : Two stop bits
0 : No parameter selected
1 : LOCK is put ahead
2 : INPT is put ahead
Select 1'st parameter for 3 : UNIT is put ahead

SEL1 2
user menu : DP is put ahead
4
5 : SHIF is put ahead
6 : PB is put ahead
7 : TI is put ahead
18 UM91001A
Prameter Parameter Description Range Default
Notation Value
8 : TD is put ahead
9 : O1HY is put ahead
10 : CYC1 is put ahead
11 : OFST is put ahead
12 : RR is put ahead
Select 1'st parameter for
SEL1 13 : O2HY is put ahead 2
user menu
14 : CYC2 is put ahead
15 : CPB is put ahead
16 : DB is put ahead
17 : ADDR is put ahead
18 : ALHY is put ahead
Select 2'nd parameter

SEL2 Same as SEL1 3
for user menu
Select 3'rd parameter
SEL3 Same as SEL1 4
for user menu
Select 4'th parameter
SEL4 Same as SEL1 6
for user menu
SEL5 Same as SEL1 7
for user menu
SEL6 Same as SEL1 8
for user menu
SEL7 Same as SEL1 10
for user menu
SEL8 Same as SEL1 17
for user menu
UM91001A 19
Chapter 2 Installation
Dangerous voltages capable of causing death are sometimes
present in this instrument. Before installation or beginning any
troubleshooting procedures the power to all equipment must be
switched off and isolated. Units suspected of being faulty must be
disconnected and removed to a properly equipped workshop for
testing and repair. Component replacement and internal
adjustments must be made by a qualified maintenance person only.
To minimize the possibility of fire or shock hazards, do not

expose this instrument to rain or excessive moisture.
Do not use this instrument in areas under hazardous

conditions such as excessive shock, vibration, dirt, moisture,
corrosive gases or oil. The ambient temperature of the areas should
not exceed the maximum rating specified in Chapter 6.
2-1 Unpacking
Upon receipt of the shipment remove the unit from the carton and
inspect the unit for shipping damage.
If any damage due to transit , report and claim with the carrier.
Write down the model number, serial number, and date code for
future reference when corresponding with our service center. The
serial number (S/N) and date code (D/C) are labeled on the box and
the housing of control.
2-2 Mounting
Make panel cutout to dimension shown in Figure 2.1.
Take 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.
20 UM91001A
Figure 2.1 Mounting Dimensions
92 mm
Panel Cutout
BTC-4100
Panel
92 mm
53 mm
Panel
92 mm
Cutout BTC-8100
Panel
45 mm
65 mm
68 mm
Panel Cutout
BTC-7100
Panel
68 mm
65 mm
UM91001A 21
Panel
45 mm
45 mm
Panel
Cutout BTC-9100
104.8mm
2 - 3 Wiring Precautions
* Before wiring, verify the label for correct model number and
options. Switch off the power while checking.
* Care must be taken to ensure that maximum voltage rating

specified on the label are not exceeded.
* It is recommended that power of these units to be protected by

fuses or circuit breakers rated at the minimum value possible.
* All units should be installed inside a suitably grounded metal

enclosure to prevent live parts being accessible from human
hands and metal tools.
* All wiring must conform to appropriate standards of good practice

and local codes and regulations. Wiring must be suitable for
voltage, current, and temperature rating of the system.
* Beware not to over-tighten the terminal screws.
* Unused control terminals should not be used as jumper points as

they may be internally connected, causing damage to the unit.
* Verify that the ratings of the output devices and the inputs as
specified in Chapter 6 are not exceeded.
22 UM91001A
3.2mm min. 7.0mm max.
Figure 2.2
Lead Termination for
BTC-4100, BTC-8100
and BTC-7100
6.0mm max.
Figure 2.3
Lead Termination
3.0mm min. for BTC-9100
90-264VAC 1 L 11
47-63 Hz
12VA 2 N 12
3 C TX1 TXD 13
+
OP1 RS-485
_ 4 NO TX2 RXD 14
RS-232
5 C COM 15
+
OP2
_ 6 NO 16
7 C 17
A
ALM 8 NO PTA 18
RTD
TC+, V+
9 NC PTB, mA+ 19 B
+
+
+
TC-, V- _ _V _
10 PTB, mA-
20 B
TC V mA RTD
Figure 2.4
Rear Terminal Connection
for BTC-4100 and BTC-8100
UM91001A 23
1 L 8
+
90-264VAC
47-63 Hz OP1
12VA 2 N 9 _
3 10 TX1
RS-485
ALM 4 11 TX2
A
5 PTA 12
RTD
TC+, V+
+
6 PTB, mA+ 13 B
+
+
+
OP2
TC-, V- _ _V _
_ 7 PTB, mA-
14 B
TC V mA RTD
Figure 2.5
Rear Terminal Connection
for BTC-7100
RS-232: TXD RXD COM

RS-485: TX1 TX2
13 14 15
1 NO L 7 90-264VAC
47-63 Hz
12VA
ALM 2 NC
N 8
3 9
+
C C
OP1
A 4 PTA NO 10 _
RTD
TC+, V+
5 C 11
+
+
B PTB, mA+
I V OP2
_ _ TC-, V-
B 6 PTB, mA-
NO 12 _
Figure 2.6
Rear Terminal Connection for BTC-9100
24 UM91001A
2 - 4 Power Wiring
The controller is supplied to operate at 11-26 VAC / VDC or 90-264
VAC. Check that the installation voltage corresponds with the power
rating indicated on the product label before connecting power to
the controller.
BTC-4100
BTC-7100
BTC-8100 BTC-9100
Fuse
L 1 L 7 90 ~ 264 VAC or
N 2 N 8 11 ~ 26 VAC / VDC
Figure 2.7 Power Supply Connections
This equipment is designed for installation in an enclosure

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

observed. Consideration should be given to prevent from
unauthorized person access to the power terminals.
2-5 Sensor Installation Guidelines

Proper sensor installation can eliminate many problems in a control
system. The probe should be placed so that it can detect any
temperature change with minimal thermal lag. In a process that
requires fairly constant heat output, the probe should be placed
closed to the heater. In a process where the heat demand is variable,
the probe should be closed to the work area. Some experiments with
probe location are often required to find this optimum position.
In a liquid process, addition of a stirrer will help to eliminate thermal

lag. Since the thermocouple is basically a point measuring device,
placing more than one thermocouple in parallel can provide an
average temperature readout and produce better results in most
air heated processes.
UM91001A 25
Proper sensor type is also a very important factor to obtain precise
measurements. The sensor must have the correct temperature range
to meet the process requirements. In special processes the sensor
might need to have different requirements such as leak-proof, anti-
vibration, antiseptic, etc.
Standard sensor limits of error are A4 degrees F (A 2 degrees C )

or 0.75% of sensed temperature (half that for special ) plus drift
caused by improper protection or an over-temperature occurrence.
This error is far greater than controller error and cannot be corrected
on the sensor except by proper selection and replacement.
2-6 Sensor Input Wiring

BTC-4100
BTC-8100 BTC-7100 BTC-9100
A
PTA 18 12 4 RTD
TC+, V+
19 13 5 B
+
+
+
PTB, mA+
TC-, V- _ _V _
20 14 6 B
PTB, mA-
TC V mA RTD
Figure 2.8 Sensor Input Wiring
2-7 Control Output Wiring
BTC-4100
BTC-8100 BTC-7100 BTC-9100
+
3 8 9 LOAD 120V/240VAC
Mains Supply
_ 4 9 10
Figure 2.9
Output 1 Relay or Triac (SSR) to Drive Load
26 UM91001A
BTC-4100
BTC-8100 BTC-7100 BTC-9100
+
3 8 9 120V /240V
_ 4 9 10 Mains Supply
Three
Phase
Heater
Power
Three Phase No Fuse
Delta Contactor Breaker
Heater
Load
Figure 2.10
Output 1 Relay or Triac (SSR) to Drive Contactor
BTC-4100
BTC-8100 BTC-7100 BTC-9100
SSR
+
3 8 9 Load
+
120V /240V
Mains Supply
4 9 10 _ _
Internal Circuit
30mA / 5V 5V
Pulsed
Voltage 33 +
33
0V
Figure 2.11 Output 1 Pulsed Voltage to Drive SSR
UM91001A 27
BTC-4100
BTC-8100 BTC-7100 BTC-9100
+
3 8 9 0 - 20mA,
Load Maximum Load
4 - 20mA
4 9 10 _ 500 ohms
Figure 2.12 Output 1 Linear Current
BTC-4100
BTC-8100 BTC-7100 BTC-9100
+
3 8 9 0 - 1V, 0 - 5V
Load
Minimum Load
1 - 5V, 0 - 10V 10 K ohms
4 9 10 _
Figure 2.13 Output 1 Linear Voltage
BTC-4100
BTC-8100 BTC-7100 BTC-9100
+
5 6 11 LOAD 120V/240VAC
Mains Supply
_ 6 7 12
Figure 2.14
Output 2 Relay or Triac (SSR) to Drive Load
28 UM91001A
BTC-4100
BTC-8100 BTC-7100 BTC-9100
+
5 6 11 120V /240V
_ 6 7 12 Mains Supply
Three
Phase
Heater
Power
Three Phase No Fuse
Heater
Load
Figure 2.15
Output 2 Relay or Triac (SSR) to Drive Contactor
BTC-4100
BTC-8100 BTC-7100 BTC-9100
SSR
+
5 6 11 Load
+
120V /240V
_ Mains Supply
6 7 12 _
Internal Circuit
30mA / 5V 5V
Pulsed
Voltage 33 +
33
0V
Figure 2.16 Output 2 Pulsed Voltage to Drive SSR
BTC-4100
BTC-8100 BTC-7100 BTC-9100
+
5 6 11 0 - 20mA,
Load Maximum Load
4 - 20mA
6 7 12 _ 500 ohms
Figure 2.17 Output 2 Linear Current
UM91001A 29
BTC-4100
BTC-8100 BTC-7100 BTC-9100
+
5 6 11 0 - 1V, 0 - 5V
Load
Minimum Load
1 - 5V, 0 - 10V 10 K ohms
6 7 12 _
Figure 2.18 Output 2 Linear Voltage
2-8 Alarm Wiring
BTC-4100
BTC-8100 BTC-7100 BTC-9100
7 3 3 LOAD 120V/240VAC
Mains Supply
8 4 1
9 5 2
Figure 2.19 Alarm Output to Drive Load
BTC-4100
BTC-8100 BTC-7100 BTC-9100
7 3 3 120V /240V
8 4 1 Mains Supply
9 5 2
Three
Phase
Heater
Power
Three Phase No Fuse
Heater
Load
Relay Output to
Drive Contactor
Figure 2.20 Alarm Output to Drive Contactor
30 UM91001A
2-9 Data Communication
BTC-4100
BTC-8100 RS-485 to RS-232
BTC-9100 BTC-7100 network adaptor
TX1
TX1 13 10 SNA10A or
SNA10B
TX2 14 TX2
11 RS-232
Twisted-Pair Wire TX1
TX2
PC
BTC-4100
BTC-8100
BTC-9100 BTC-7100
TX1
TX1 13 10
TX2 14 11 TX2
Max. 247 units can be linked
BTC-4100
BTC-8100
BTC-9100 BTC-7100
TX1
TX1 13 10
TX2
TX2 14 11 Terminator
220 ohms / 0.5W
Figure 2.21 RS-485 Wiring
UM91001A 31
RS-232
BTC-4100
BTC-8100
BTC-9100
PC
TXD 13
RXD 14
COM 15 9-pin
RS-232
port
CC94-1
Figure 2.22
RS-232 Wiring
If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable
must be modified according to the following circuit diagram.
To DTE ( PC ) RS-232 Port

BTC-4100
BTC-8100
BTC-9100 1 1 DCD
TX1 RD 6 2 RD
TXD 13 2
7 3 TD
TX2 TD
RXD 14 3 4 DTR
8 5 GND
COM 15 COM 4
GND 9 6 DSR
5 7 RTS
8 CTS
Female DB-9 9 RI
Figure 2.23
Configuration of RS-232 Cable
32 UM91001A
Chapter 3 Programming
Press for 3 seconds and release to enter setup menu. Press
to select the desired parameter. The upper display indicates the
parameter symbol, and the lower display indicates the selected value
of parameter.
3-1 Lockout
There are four security levels can be selected by using LOCK
parameter.
If NONE is selected for LOCK, then no parameter is locked.
If SET is selected for LOCK, then all setup data are locked.
If USER is selected for LOCK, then all setup data as well as user data
(refer to section 1-5) except set point are locked to prevent from being
changed.
If ALL is selected for LOCK, then all parameters are locked to prevent
from being changed.
3-2 Signal Input

INPT: Selects the sensor type or signal type for signal input.
Range: ( thermocouple ) J_TC, K_TC, T_TC, E_TC, B_TC, R_TC
S_TC, N_TC, L_TC
( RTD ) PT.DN, PT.JS
(linear ) 4-20, 0-20, 0-60, 0-1V, 0-5V, 1-5V, 0-10
UNIT: Selects the process unit
Range: LC, LF, PU( process unit ). If the unit is neither LC nor LF,
then selects PU.
DP: Selects the resolution of process value.
Range: ( for T/C and RTD ) NO.DP, 1-DP
(for linear ) NO.DP, 1-DP, 2-DP, 3-DP
INLO: Selects the low scale value for the linear type input.
INHI : Selects the high scale value for the linear type input.
How to use INLO and INHI :

If 4 - 20 mA is selected for INPT,let SL specifies the input signal low (
ie. 4 mA ), SH specifies the input signal high ( ie. 20 mA ), S specifies
the current input signal value, the conversion curve of the process
value is shown as follows :
UM91001A 33
process value
INHI
Figure 3.1
PV Conversion Curve for
Linear Type Process Value
INLO
input signal
SL S SH
S SL
Formula : PV = INLO + ( INHI INLO )
SH SL
Example : A 4-20 mA current loop pressure transducer with range
2
0 - 15 kg/cm is connected to input, then perform the
following setup :
INPT = 4 - 20 INLO = 0.00
INHI = 15.00 DP = 2-DP
Of course, you may select other value for DP to alter the
resolution.
3-3 Control Outputs

There are 4 kinds of control modes can be configured as shown in
Table 3.1
Table 3.1 Heat-Cool Control Setup Value
Control
OUT1 OUT2 O1HY O2HY CPB DB
Modes
Heat only REVR
Cool only DIRT
Heat: PID
REVR DE.HI
Cool: ON-OFF
Heat: PID
REVR COOL
Cool: PID
: Don't care :Required if ON-OFF control
:Adjust to met process is configured
requirements
34 UM91001A
Heat Only ON-OFF Control : Select REVR for OUT1, Set PB to 0,
O1HY is used to adjust dead band for ON-OFF control, The output 1
hysteresis ( O1HY ) is enabled in case of PB = 0 . The heat only
on-off control function is shown in the following diagram :
PV
SP1
Dead band = O1HY
SP1 O1HY
OUT1 Action Time
ON
OFF
Time
Figure 3.2 Heat Only
ON-OFF Control
The ON-OFF control may introduce excessive process oscillation even
if hysteresis is minimized to the smallest. If ON-OFF control is set ( ie.
PB = 0 ), TI, TD, CYC1, OFST, CYC2, CPB, DB will be hidden and have
no function to the system. The auto-tuning mode and bumpless
transfer will be disabled too.
Heat only P ( or PD ) control : Select REVR for OUT1, set TI to 0,

OFST is used to adjust the control offset ( manual reset ). O1HY is
hidden if PB is not equal to 0. OFST Function : OFST is measured by
% with range 0 - 100.0 %. In the steady state ( ie. process has been
stabilized ) if the process value is lower than the set point a definite
value, say 5 LC, while 20 LC is used for PB, that is lower 25 %,
UM91001A 35
then increase OFST 25 %, and vice versa. After adjusting OFST value,
the process value will be varied and eventually, coincide with set point.
Using the P control ( TI set to 0 ), the auto-tuning is disabled.
Refer to section 3-12 " manual tuning " for the adjustment of PB and
TD. Manual reset ( adjust OFST ) is not practical because the load may
change from time to time and often need to adjust OFST repeatedly.
The PID control can avoid this situation.
Heat only PID control : Selecting REVR for OUT1, PB and TI should
not be zero. Operate auto-tuning for the new process, or set PB, TI
and TD with historical values. See section 3-11 for auto-tuning
operation. If the control result is still unsatisfactory, then use manual
tuning to improve the control . See section 3-12 for manual tuning. The
unit contains a very clever PID and Fuzzy algorithm to achieve a very
small overshoot and very quick response to the process if it is properly
tuned.
Cool only control:ON-OFF control, P ( PD ) control and PID

control can be used for cool control. Set OUT1 to DIRT ( direct
action ). The other functions for cool only ON-OFF control, cool
only P ( PD ) control and cool only PID control are same as
descriptions for heat only control except that the output variable
( and action ) for the cool control is inverse to the heat control.
NOTE : The ON-OFF control may result excessive overshoot and

undershoot problems in the process. The P ( or PD ) control will result
in a deviation process value from the set point. It is recommended to
use PID control for the Heat-Cool control to produce a stable and zero
offset process value.
Other Setup Required : O1TY, CYC1, O2TY, CYC2, O1FT, O2FT

O1TY & O2TY are set in accordance with the types of OUT1 & OUT2
installed. CYC1 & CYC2 are selected according to the output 1 type (
O1TY ) & output 2 type ( O2TY ). Generally, selects 0.5 ~ 2 sec. for
CYC1, if SSRD or SSR is used for O1TY; 10 ~ 20 sec. if relay is used
for O1TY, and CYC1 is ignored if linear output is used. Similar condition
is applied for CYC2 selection.
36 UM91001A
You can use the auto-tuning program for the new process or directly
set the appropriate values for PB, TI & TD according to the historical
records for the repeated systems. If the control behavior is still
inadequate, then use manual tuning to improve the control. See
section 3-12 for manual tuning.
CPB Programming : The cooling proportional band is measured by %
of PB with range 50~300. Initially set 100% for CPB and examine the
cooling effect. If cooling action should be enhanced then decrease
CPB, if cooling action is too strong then increase CPB. The value of
CPB is related to PB and its value remains unchanged throughout the
auto-tuning procedures.
Adjustment of CPB is related to the cooling media used. For air is

used as cooling media, adjust CPB at 100(%).For oil is used as
cooling media, adjust CPB at 125(%). For water is used as cooling
media, adjust CPB at 250(%).
DB Programming: Adjustment of DB is dependent on the system
requirements. If more positive value of DB ( greater dead band ) is
used, an unwanted cooling action can be avoided but an excessive
overshoot over the set point will occur. If more negative value of DB (
greater overlap ) is used, an excessive overshoot over the set point
can be minimized but an unwanted cooling action will occur. It is
adjustable in the range -36.0% to 36.0 % of PB. A negative DB value
shows an overlap area over which both outputs are active. A positive
DB value shows a dead band area over which neither output is active.
Output 2 ON-OFF Control ( Alarm function ): The output 2 can also be
configured as alarm function. There are 4 kinds of alarm functions can
be selected for output 2, these are: DE.HI (deviation high alarm ),
DE.LO (deviation low alarm ), PV.HI (process high alarm ) and PV.LO
( process low alarm ). Refer to Figure 3.3 and Figure 3.4 for the
description of deviation alarm and process alarm.
UM91001A 37
PV OUT2=DE.HI
SV+SP2
SV+SP2-O2HY
OUT2 Action Time
ON
OFF
Figure 3.3 Output 2 Deviation Time

High Alarm
PV
SP2+O2HY
SP2
OUT2 Action Time
ON
OFF
Figure 3.4 Output 2 Process Time

Low Alarm
38 UM91001A
3-4 Alarm
The controller has one alarm output. There are 6 types of alarm
functions and one dwell timer can be selected, and four kinds of alarm
modes ( ALMD ) are available for each alarm function ( ALFN ).
Besides the alarm output, the output 2 can also be configured as
another alarm. But output 2 only provides 4 kinds of alarm functions
and only normal alarm mode is avaiable for this alarm.
A process alarm sets two absolute trigger levels. When the process is
higher than SP3, a process high alarm ( PV.HI ) occurs, and the alarm
is off as the process is lower than SP3-ALHY. When the process is
lower than SP3, a process low alarm ( PV.LO ) occurs and the alarm is
off as the process is higher than SP3+ALHY. A process alarm is
independent of set point.
A deviation alarm alerts the user when the process deviates too far
from set point. When the process is higher than SV+SP3, a deviation
high alarm (DE.HI) occurs and the alarm is off as the process is lower
than SV+SP3-ALHY. When the process is lower than SV+SP3, a
deviation low alarm (DE.LO) occurs and the alarm is off as the process
is higher than SV+SP3+ALHY. Trigger level of deviation alarm is
moving with set point.
A deviation band alarm presets two trigger levels relative to set point.
The two trigger levels are SV+SP3 and SV - SP3 for alarm. When the
process is higher than ( SV+SP3 ) or lower than ( SV - SP3 ), a
deviation band high alarm ( DB.HI ) occurs. When the process is within
the trigger levels, a deviation band low alarm (DB.LO) occurs.
In the above descriptions SV denotes the current set point value for
control which is different from SP1 as the ramp function is performed.
There are four types of alarm modes available for each alarm function,
these are: Normal alarm, Latching alarm, Holding alarm and Latching/
Holding alarm. They are described as follows:
UM91001A 39
Normal Alarm : ALMD = NORM
When a normal alarm is selected, the alarm output is de-energized
in the non-alarm condition and energized in an alarm condition.
Latching Alarm : ALMD = LTCH
If a latching alarm is selected, once the alarm output is energized, it
will remain unchanged even if the alarm condition is cleared. The
latching alarm is reset when the RESET key is pressed, once the alarm
condition is removed.
Holding Alarm : ALMD = HOLD
A holding alarm prevents an alarm from power up. The alarm is
enabled only when the process reaches the set point value. Afterwards
, the alarm performs same function as normal alarm.
Latching / Holding Alarm : ALMD = LT.HO
A latching / holding alarm performs both holding and latching function.
The latching alarm is reset when the RESET key is pressed, once the
alarm condition is removed.
Alarm Failure Transfer is activated as the unit enters failure mode.
Alarm will go on if ON is set for ALFT and go off if OFF is
set for ALFT. The unit will enter failure mode when sensor break
occurs or if the A-D converter of the unit fails.
3-5 Configure User Menu

The conventional controllers are designed with a fixed parameters' scrolling.
If you need a more friendly operation to suit your application, the vender
will say " sorry " to you. The series have the flexibility for you to select those
parameters which are most significant to you and put these parameters in the
front of display sequence.
SEL1~SEL8 : Selects the parameter for view and change in the user menu.
Range : LOCK, INPT, UNIT, DP, SHIF, PB, TI, TD, O1HY, CYC1, OFST,
RR, O2HY, CYC2, CPB, DB, ADDR, ALHY
When using the up-down key to select the parameters, you may not obtain
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.
40 UM91001A
Example :
OUT2 selects DE.LO PB= 100.0 SEL1 selects INPT
SEL2 selects UNIT SEL3 selects PB SEL4 selects TI
SEL5~SEL8 selects NONE Now, the upper display scrolling becomes :
PV
3 - 6 Ramp
The ramping function is performed during power up as well as any
time the set point is changed. Choose MINR or HRR for RAMP, the
unit will perform the ramping function. The ramp rate is programmed
by adjusting RR. The ramping function is disabled as soon as the
failure mode, the manual control mode, the auto-tuning mode or the
calibration mode occurs.
Example without Dwell Timer

Select MINR for RAMP, selects LC for UNIT, selects 1-DP for DP, Set
RR= 10.0. SV is set to 200 LC initially, and changed to 100 LC after 30
minutes since power up. The starting temperature is 30 LC. After
power up the process is running like the curve shown below:
PV
200
C
100
C Figure 3.5 RAMP Function
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 as power up or RR
and /or set point are changed. Setting RR to zero means no ramp
function at all.
UM91001A 41
3-7 Dwell Timer
Alarm output can be configured as dwell timer by selecting TIMR for
ALFN . As the dwell timer is configured, the parameter SP3 is used
for dwell time adjustment. The dwell time is measured in minute
ranging from 0.1 to 4553.6 minutes. Once the process reaches the set
point the dwell timer starts to count down until zero ( time out ). The
timer relay will remain unchanged until time out. The dwell timer
operation is shown as following diagram.
After time out the dwell timer will be restarted by pressing the RESET
key.
The timer stops to count during the manual control mode, failure
mode, calibration period and auto-tuning period.
PV
SP
Time
ALM power off or
SP3
touch RESET key
ON
OFF
Time
Timer starts
Figure 3.6 Dwell Timer Function

If alarm is configured as dwell timer, ALHY and ALMD are
hidden.
42 UM91001A
3 - 8 PV Shift
In certain applications it is desirable to shift the controller display
value from its actual value. This can be easily accomplished by using
the PV shift function.
The SHIF function will alter PV only.
Here is an example. A process is equipped with a heater, a sensor

and a subject to be warmed up. Due to the design and position of the
components in the system, the sensor could not be placed any closer
to the part. Thermal gradient ( different temperature ) is common and
necessary to an extent in any thermal system for heat to be
transferred from one point to another. If the difference between the
sensor and the subject is 35 LC, and the desired temperature at the
subject to be heated is 200 LC, the controlling value or the
temperature at the sensor should be 235 LC. You should input -35 LC
as to subtract 35 LC from the actual process display. This in turn will
cause the controller to energize the load and bring the process
display up to the set point value.
Subject 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 3.7
PV Shift Application
UM91001A 43
3- 9 Digital Filter
In certain application the process value is too unstable to be read. To
improve this a programmable low pass filter incorporated in the
controller can be used. This is a first order filter with time constant
specified by FILT parameter . The default value of FILT is 0.5 sec.
before shipping. Adjust FILT to change the time constant from 0 to 60
seconds. 0 second represents no filter is applied to the input signal.
The filter is characterized by the following diagram.
PV
FILT=0
1 sec
FILT=1
FILT=30 1 sec
Time
Figure 3.8
Filter Characteristics
Note
The Filter is available only for PV, and is performed for the displayed
value only. The controller is designed to use unfiltered signal for
control even if Filter is applied. A lagged ( filtered ) signal, if used for
control, may produce an unstable process.
44 UM91001A
3 -10 Failure Transfer
The controller will enter failure mode as one of the following conditions
occurs:
1. SBER occurs due to the input sensor break or input current below
1mA if 4-20 mA is selected or input voltage below 0.25V if 1-5 V is
selected .
2. ADER occurs due to the A-D converter of the controller fails.
The output 1 and output 2 will perform the failure transfer function as
the controller enters failure mode.
Output 1 Failure Transfer,

Transfer if activated, will perform :
1. If output 1 is configured as proportional control ( PB=0 ), and BPLS
is selected for O1FT, then output 1 will perform bumpless transfer.
Thereafter the previous averaging value of MV1 will be used for
controlling output 1.
2. If output 1 is configured as proportional control ( PB=0 ), and a
value of 0 to 100.0 % is set for O1FT, then output 1 will perform
failure transfer. Thereafter the value of O1FT will be used for
controlling output 1.
3. If output 1 is configured as ON-OFF control ( PB=0 ), then output 1
will transfer to off state if OFF is set for O1FT and transfer to on
state if ON is set for O1FT.
Output 2 Failure Transfer, if activated, will perform :

1. If OUT2 is configured as COOL, and BPLS is selected for O2FT,
then output 2 will perform bumpless transfer. Thereafter the previous
averaging value of MV2 will be used for controlling output 2.
2. If OUT2 is configured as COOL, and a value of 0 to 100.0 % is set
for O2FT, then output 2 will perform failure transfer. Thereafter the
value of O2FT will be used for controlling output 2.
3. If OUT2 is configured as alarm function, and OFF is set for O2FT,
then output 2 will transfer to off state, otherwise, output 2 will transfer
to on state if ON is set for O2FT.
Alarm Failure Transfer is activated as the controller enters failure mode.
Thereafter the alarm will transfer to the ON or OFF state which is
determined by the set value of ALFT.
UM91001A 45
3 -11 Auto-tuning
The auto-tuning process is performed at set point.
The process will oscillate around the set point during tuning
process. Set a set point to a lower value if overshooting beyond
the normal process value is likely to cause damage.
The auto-tuning is applied in cases of :

* Initial setup for a new process
* The set point is changed substantially from the previous auto-
tuning value
* The control result is unsatisfactory
Operation :
1. The system has been installed normally.
2. Set the correct values for the setup menu of the unit.
But don't use a zero value for PB and TI , otherwise, the
auto-tuning program will be disabled. The LOCK parameter
should be set at NONE.
3. Set the set point to a normal operating value or a lower value if
overshooting beyond the normal process value is likely to
cause damage.
4. Press and hold until appears on the display.
5. Press for at least 3 seconds. The AT indicator will begin to
flash and the auto-tuning procedure is beginning.
NOTE :
The ramping function, if used, will be disabled once auto-tuning
is proceeding.
The auto-tuning mode is disabled as soon as either failure mode
or manual control mode occurs.
46 UM91001A
Procedures:
The auto-tuning can be applied either as the process is warming
up ( Cold Start ) or as the process has been in steady state (
Warm Start ).
After the auto-tuning procedures are completed, the AT indicator
will cease to flash and the unit revert to PID control by using its
new PID values. The PID values obtained are stored in the
nonvolatile memory.
Auto-Tuning Error
If auto-tuning fails an ATER message will appear on the upper display
in cases of :
If PB exceeds 9000 ( 9000 PU, 900.0 LF or 500.0 LC ).
or if TI exceeds 1000 seconds.
or if set point is changed during auto-tuning procedure.
Solutions to
1. Try auto-tuning once again.
2. Don't change set point value during auto-tuning procedure.
3. Don't set zero value for PB and TI.
4. Use manual tuning instead of auto-tuning. ( See section 3-12 ).
5. Touch RESET key to reset message.
3 - 12 Manual Tuning
In certain applications ( very few ) using auto-tuning to tune a process
may be inadequate for the control requirement, then you can try
manual tuning.
If the control performance by using auto- tuning is still unsatisfactory,

the following rules can be applied for further adjustment of PID values :
UM91001A 47
ADJUSTMENT SEQUENCE SYMPTOM SOLUTION
Slow Response Decrease PB
(1) Proportional Band ( PB )
High overshoot or
Increase PB
Oscillations
Slow Response Decrease TI
(2) Integral Time ( TI ) Instability or
Increase TI
Oscillations
Slow Response or
Decrease TD
(3) Derivative Time ( TD ) Oscillations
High Overshoot Increase TD
Table 3.2 PID Adjustment Guide
Figure 3.9 shows the effects of PID adjustment on process response.
3 -13 Manual Control

Operation:
To enable manual control the LOCK parameter should be set with
NONE, then press for 4.2 seconds ( Hand
Control ) will appear on the display. Press for 3 seconds then the
MAN indicator will begin to flash and the lower display will show
. The controller now enters the manual control mode.
indicates output control variable for output 1, and indicates
control variable for output 2. Now you can use up-down key to adjust
the percentage values for the heating or cooling output.
The controller performs open loop control as long as it stays in manual

control mode.
Exit Manual Control
To press R key the controller will revert to its normal display mode.
48 UM91001A
PV PB too low
Perfect
Set point
P action
PB too high
Time
TI too high
PV
Set point
I action
Perfect
TI too low
Time
TD too low
PV
Perfect
Set point
D action
TD too high
Time
Figure 3.9 Effects of PID Adjustment
UM91001A 49
3 - 14 Data Communication
The controllers support RTU mode of Modbus protocol for the data
communication. Other protocols are not available for the series.
Two types of interface are available for Data Communication. These are RS-
485 and RS-232 interface. Since RS-485 uses a differential architecture to
drive and sense signal instead of a single ended architecture which is used
for RS-232, RS-485 is less sensitive to the noise and suitable for a longer
distance communication. RS-485 can communicate without error over 1 km
distance while RS-232 is not recommended for a distance over 20 meters.
Using a PC for data communication is the most economic way. The signal
is transmitted and received through the PC communication Port ( generally
RS-232 ). Since a standard PC can't support RS-485 port, a network
adaptor ( such as SNA10A , SNA10B ) has to be used to convert RS-485 to
RS-232 for a PC if RS-485 is required for the data communication. But there
is no need to be sad. Many RS-485 units ( up to 247 units ) can be
connected to one RS-232 port, therefore a PC with 4 comm ports can
communicate with 988 units. It is quite economic.
Setup
Enters the setup menu.
Select RTU for COMM . Set individual address as for those units which are
connected to the same port.
Set the Baud Rate ( BAUD ), Data Bit ( DATA ), Parity Bit ( PARI ) and Stop
Bit ( STOP ) such that these values are accordant with PC setup conditions.
If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable
should be modified for proper operation of RS-232 communication
according to Section 2-9.
50 UM91001A
Chapter 4 Applications
4 - 1 Heat Only Control with Dwell Timer
An oven is designed to dry the products at 150 BC for 30 minutes and
then stay unpowered for another batch. A BTC-8100 equipped with
dwell timer is used for this purpose. The system diagram is shown as
follows :
Set
SP1=150.0
SP3 =30.0
19 20 Oven
OP1 OP2 ALM
C F
C
MAN
AT T/C
Figure 4.1
Heater
R
Heat Control
Example
BTC-8100
9 7 4 3
Mains
Supply
OUT1
ON
Timer ( ALM ) OFF
To achieve this function set the following parameters in the setup

menu.
INPT=K_TC UNIT= L C DP=1_DP
OUT1=REVR O1TY=RELY CYC1=18.0
O1FT=BPLS ALFN=TIMR ALFT=ON
Auto-Tuning is performed at 150 LC for a new oven.
UM91001A 51
4 - 2 Cool Only Control
A BTC-8100 is used to control a refrigerator at temperature below 0
BC. The temperature is lower than the ambient, a cooling action is
required. Hence select DIRT for OUT1. Since output 1 is used to drive
a magnetic contactor, O1TY selects RELY. A small temperature
oscillation is tolerable, hence use ON-OFF control to reduce the over-
all cost. To achieve ON-OFF control, PB is set with zero and O1HY is
set at 0.1 BC.
Setup Summary: Refrigerator

INPT=PT.DN
UNIT= L C
DP=1-DP RTD
OUT1=DIRT
O1TY=RELY
Mains
Supply
User Menu: 19 20 3
PB = 0 ( LC ) 18
OP1 OP2 ALM
C F
4
O1HY=0.1 ( LC )
MAN
AT
BTC-8100
Figure 4.2
Cooling Control Example
52 UM91001A
4 - 3 Heat-Cool Control
An injection mold required to be controlled at 120 LC to ensure a
consistent quality for the parts. An oil pipe is buried in the mold. Since
plastics is injected at higher temperature ( e.g. 250 LC ), the
circulation oil needs to be cooled as its temperature rises. Here is an
example:
Injection Mold
Plastics
120 C
Oil
Pump
Oil Tank
Freezer RTD
Heater
Supply
4-20 mA
OUT2 OUT1
5,6 3 4
OP1 OP2 ALM
C F
20 INPT
19
MAN
AT 18
Figure 4.3
BTC-8100 Heat-Cool Control Example
UM91001A 53
The PID Heat-Cool is used for the above example.
To achieve this set the following parameters in the Setup Menu:
INPT=PT.DN
UNIT= LC
DP= 1-DP
OUT1=REVR
O1TY=RELY
CYC1=18.0 (sec.)
O1FT=BPLS
OUT2=COOL
O2TY=4-20
O2FT=BPLS
Adjust SV at 120.0 LC , CPB at 125 ( % ) and DB at -4.0 (%).

Apply Auto-tuning at 120 LC for a new system to get an optimal PID
values. See Section 3-11.
Adjustment of CPB is related to the cooling media used. If water is

used as cooling media instead of oil, the CPB is set at 250 (%). If air is
used as cooling media instead of oil, the CPB is set at 100 (%).
Adjustment of DB is dependent on the system requirements. More
positive value of DB will prevent unwanted cooling action, but will
increase the temperature overshoot, while more negative value of DB
will achieve less temperature overshoot, but will increase unwanted
cooling action.
54 UM91001A
Chapter 5 Calibration
Do not proceed through this section unless there is a definite
need to re-calibrate the controller. Otherwise, all previous
calibration data will be lost. Do not attempt recalibration unless
you have appropriate calibration equipment. If calibration data is
lost, you will need to return the controller to your supplier who
may charge you a service fee to re-calibrate the controller.
Entering calibration mode will break the control loop. Make sure
that if the system is allowable to apply calibration mode.
Equipments needed before calibration:

(1) A high accuracy calibrator ( Fluke 5520A Calibrator
recommended ) with following functions:
0 - 100 mV millivolt source with A0.005 % accuracy
0 - 10 V voltage source with A0.005 % accuracy
0 - 20 mA current source with A0.005 % accuracy
0 - 300 ohm resistant source with A0.005 % accuracy
(2) A test chamber providing 25 BC - 50 BC temperature range
(3) A switching network ( SWU16K, optional for automatic
calibration )
(4) A calibration fixture equipped with programming units ( optional
for automatic calibration )
(5) A PC installed with calibration software BC-Net and Smart
Network Adaptor SNA10B ( optional for automatic calibration )
The calibration procedures described in the following section are a
step by step manual procedures.
Since it needs 30 minutes to warm up an unit before calibration,

calibrating the unit one by one is quite inefficient. An automatic
calibration system for small quantity as well as for unlimited quantity is
available upon request.
UM91001A 55
Manual Calibration Procedures
* Perform step 1 to enter calibration mode.

Step 1. Set the Lock parameter to the unlocked condition ( LOCK=
NONE).
Press and hold the scroll key until appears on the
display, then release the scroll key.
Press the scroll key for 2 seconds then release,the display
will show and the unit enters calibration mode .
* Perform step 2 to calibrate Zero of A to D converter and

step 3 to calibrate gain of A to D converter.
Step 2. Short the thermocouple inpt terminals , then press scroll key
for at least 3 seconds. The display will blink a moment and
a new value is obtained. Otherwise, if the display didn't blink
or if the obtained value is equal to -199.9 or 199.9, then the
calibration fails.
Step 3. Press scroll key until the display shows . Send a 60
mV signal to the thermocouple input terminals in correct
polarity . Press scroll key for at least 3 seconds . The display
will blink a moment and a new value is obtained . Otherwise ,
if the display didn't blink or if the obtained value is equal to
-199.9 or 199.9, then the calibration fails.
* Perform both steps 4 and 5 to calibrate RTD function ( if
required ) for input .
56 UM91001A
Step 4. Press scroll key until the display shows . Send a 100
ohms signal to the RTD input terminals according to the
connection shown below:
BTC-4100
BTC-8100 BTC-7100 BTC-9100
18 12 4
100 ohms
19 13 5
20 14 6
Figure 5.1 RTD Calibration

Press scroll key for at least 3 seconds . The display will
blink a moment, otherwise the calibration fails.
Step 5. Press scroll key and the display will show . Change
the ohm's value to 300 ohms .Press scroll key for at least 3
seconds. The display will blink a moment and two values are
obtained for RTDH and RTDL ( step 4 ). Otherwise, if the
display didn't blink or if any value obtained for RTDH and
RTDL is equal to -199.9 or 199.9 , then the calibration fails.
* Perform step 6 to calibrate offset of cold junction compensation

, if required.
Step 6. Setup the equipments according to the following diagram
for calibrating the cold junction compensation. Note that a K
type thermocouple must be used.
UM91001A 57
5520A
Calibrator BTC-4100
BTC-8100 BTC-7100 BTC-9100
K-TC K+
19 13 5
20 14 6
K
Stay at least 20 minutes in still-
air room
room temperature 25 A 3 LC
Figure 5.2
Cold Junction Calibration Setup
The 5520A calibrator is configured as K type thermocouple output

with internal compensation. Send a 0.00 LC signal to the unit under
calibration.
The unit under calibration is powered in a still-air room with

temperature 25A3 BC. Stay at least 20 minutes for warming
up. Perform step 1 stated above, then press scroll key until
the display shows . Press up/down key to obtain
40.00.
Press scroll key for at least 3 seconds. The display will blink a
moment and a new value is obtained . Otherwise , if the
display didn't blink or if the obtained value is equal to -5.00 or
40.00, then the calibration fails.
* Perform step 7 to calibrate gain of cold junction compensation

if required.
Step 7. Setup the equipments same as step 6. The unit under
calibration is powered in a still-air room with temperature 50
A3 BC. Stay at least 20 minutes for warming up . The
calibrator source is set at 0.00 BC with internal compensation
mode.
58 UM91001A
Perform step 1 stated above , then press scroll key until the
display shows . Press scroll key for at least 3 seconds.
The display will blink a moment and a new value is obtained.
Otherwise , if the display didn't blink or if the obtained
value is equal to -199.9 or 199.9, then the calibration fails.
This setup is performed in a high temperature chamber, hence

it is recommended to use a computer to perform the
procedures.
Input modification and recalibration procedures for a linear

* voltage or a linear current input:
1. Remove R60(3.3K) and install two 1/4 W resistors RA and RB

on the control board with the recommended values specified
in the following table.
The low temperature coefficient resistors should be used for
RA and RB.
Input Function RA RB R60

T/C, RTD, 0~60mV X X 3.3K
0~1V 61.9K 3.92K X
0 ~ 5V, 1 ~ 5V 324K 3.92K X
0 ~ 10 V 649K 3.92K X
0~20mA, 4~20mA 39W 3.01W X
2. Perform Step 1 and Step 2 to calibrate the linear input zero.
3. Perform Step 3 but send a span signal to the input terminals

instead of 60mV. The span signal is 1V for 0~1V input, 5V for
0~5V or 1~5V input, 10V for 0~10V input and 20mA for
0~20mA or 4~20mA input.
* Final step
Step 8. Set the LOCK value to your desired function.
UM91001A 59
Chapter 6 Specifications
Power
90 264 VAC, 47 63 Hz, 12VA, 5W maximum
11 26 VAC / VDC, 12VA, 5W maximum
Input
Resolution : 18 bits
Sampling Rate : 5 times / second
Maximum Rating : -2 VDC minimum, 12 VDC maximum
( 1 minute for mA input )
Temperature Effect : A1.5uV/ BC for all inputs except
mA input
A3.0uV/ BC for mA input
Sensor Lead Resistance Effect :
T/C: 0.2uV/ohm
3-wire RTD: 2.6 LC/ohm of resistance difference of two
leads
2-wire RTD: 2.6 LC/ohm of resistance sum of two leads
Burn-out Current : 200 nA
Common Mode Rejection Ratio ( CMRR ): 120dB
Normal Mode Rejection Ratio ( NMRR ): 55dB
Sensor Break Detection :
Sensor open for TC, RTD and mV inputs,
Sensor short for RTD input
below 1 mA for 4-20 mA input,
below 0.25V for 1 - 5 V input,
unavailable for other inputs.
Sensor Break Responding Time :
Within 4 seconds for TC, RTD and mV inputs,
0.1 second for 4-20 mA and 1 - 5 V inputs.
60 UM91001A
Characteristics:
Accuracy Input
Type Range
@ 25 C Impedance
-120 C 1000 C
J A2 LC 2.2 M
( -184 F 1832 F )
-200 C 1370 C
K A2 LC 2.2 M
( -328 F 2498 F )
-250 C 400 C
T A2 LC 2.2 M
( -418 F 752 F )
-100 C 900 C
E A2 LC 2.2 M
( -148 F 1652 F )
A2 LC
0 C 1800 C
B ( 200 C 2.2 M
( 32 BF 3272 BF )
1800 C )
0 C 1767.8 C A2 LC
R 2.2 M
( 32 BF 3214 BF )
0 C 1767.8 C
S A2 LC 2.2 M
( 32 BF 3214 BF )
-250 C 1300 C
N A2 LC 2.2 M
( -418 F 2372 F )
-200 C 900 C
L ( -328 F 1652 F ) A2 LC 2.2 M
PT100 -210 C 700 C
A0.4 LC 1.3 K
( DIN ) ( -346 F 1292 F )
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 % 650 K
UM91001A 61
Output 1 / Output 2
Relay Rating : 2A/240 VAC, life cycles 200,000 for
resistive load
Pulsed Voltage : Source Voltage 5V,
current limiting resistance 66 .
Linear Output Characteristics
Type Zero Span Load

Tolerance Tolerance Capacity
4-20 mA 3.8-4 mA 20-21 mA 500W max.
0-20 mA 0 mA 20-21 mA 500W max.
0~5V 0V 5 ~ 5.25 V 10 KW min.
1~5V 0.95 ~ 1 V 5 ~ 5.25 V 10 KW min.
0 ~ 10 V 0V 10 ~10.5 V 10 KW min.
Linear Output
Resolution : 15 bits
Output Regulation : 0.02 % for full load change
Output Settling Time : 0.1 sec. ( stable to 99.9 % )
Isolation Breakdown Voltage : 1000 VAC
Temperature Effect : A0.01 % of SPAN / LC
Triac ( SSR ) Output

Rating : 1A / 240 VAC
Inrush Current : 20A for 1 cycle
Min. Load Current : 50 mA rms
Max. Off-state Leakage : 3 mA rms
Max. On-state Voltage : 1.5 V rms
Insulation Resistance : 1000 Mohms min. at 500 VDC
Dielectric Strength : 2500 VAC for 1 minute
62 UM91001A
DC Voltage Supply Characteristics ( Installed at Output 2 )
Type Tolerance Max. Output Ripple Isolation

Current Voltage Barrier
20 V A0.5 V 25 mA 0.2 Vp-p 500 VAC
12 V A0.3 V 40 mA 0.1 Vp-p 500 VAC
5V A0.15 V 80 mA 0.05 Vp-p 500 VAC
Alarm
Alarm Relay : Form C Rating
2A/240VAC, life cycles 200,000 for
resistive load.
Alarm Functions : Dwell timer,
Deviation High / Low Alarm,
Deviation Band High / Low Alarm,
PV High / Low Alarm,
Alarm Mode : Normal, Latching, Hold, Latching / Hold.
Dwell Timer : 0.1 - 4553.6 minutes
Data Communication
Interface : RS-232 ( 1 unit ), RS-485 ( up to 247 units )
Protocol : Modbus Protocol RTU mode
Address : 1 - 247
Baud Rate : 2.4 ~ 38.4 Kbits/sec
Data Bits : 7 or 8 bits
Parity Bit : None, Even or Odd
Stop Bit : 1 or 2 bits
Communication Buffer : 160 bytes
UM91001A 63
User Interface
Dual 4-digit LED Displays
Keypad : 4 keys
Programming Port : For automatic setup, calibration
and testing
Communication Port : Connection to PC for
supervisory control
Control Mode
Output 1 : Reverse ( heating ) or direct ( cooling )
action
Output 2 : PID cooling control, cooling P band 50~300%
of PB, dead band -36.0 ~ 36.0 % of PB
ON-OFF : 0.1 - 90.0 ( LF ) hysteresis control
( P band = 0 )
P or PD : 0 - 100.0 % offset adjustment
PID : Fuzzy logic modified
Proportional band 0.1 ~ 900.0 LF.
Integral time 0 - 1000 seconds
Derivative time 0 - 360.0 seconds
Cycle Time : 0.1 - 90.0 seconds
Manual Control : Heat (MV1) and Cool (MV2)
Auto-tuning : Cold start and warm start
Failure Mode : Auto-transfer to manual mode while
sensor break or A-D converter damage
Ramping Control : 0 - 900.0 LF/minute or
0 - 900.0 LF/hour ramp rate
Digital Filter
Function : First order
Time Constant : 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60
seconds programmable
64 UM91001A
Environmental & Physical
Operating Temperature : -10 BC to 50 BC
Storage Temperature : -40 BC to 60 BC
Humidity : 0 to 90 % RH ( non-condensing )
Insulation Resistance : 20 Mohms min. ( at 500 VDC )
Dielectric Strength : 2000 VAC, 50/60 Hz for 1 minute
2
Vibration Resistance : 10 - 55 Hz, 10 m/s for 2 hours
Shock Resistance : 200 m/s 2 ( 20 g )
Moldings : Flame retardant polycarbonate
Dimensions :
BTC-4100-----96mm(W) X 96mm(H) X 65mm(D),
53 mm depth behind panel
BTC-7100-----72mm(W) X 72mm(H) X 78.2mm(D),
BTC-8100-----48mm(W) X 96mm(H) X 80mm(D),
BTC-9100-----48mm(W) X 48mm(H) X 116mm(D),
Weight : BTC-4100----- 250 grams

BTC-7100----- 200 grams
BTC-8100----- 210 grams
BTC-9100----- 150 grams
Approval Standards
Safety : UL61010C-1
CSA C22.2 No. 24-93
EN61010-1 ( IEC1010-1 )
Protective Class :
IP65 for panel with additional option
IP50 for panel without additional option
IP20 for terminals and housing with protective cover.
EMC: EN61326
UM91001A 65
Chapter 7 Modbus Communications
This chapter specifies the Modbus Communications protocol as
RS-232 or RS-485 interface module is installed. Only RTU mode is
supported. Data is transmitted as eight-bit binary bytes with 1 start bit,
1 stop bit and optional parity checking (None, Even or Odd). Baud
rate may be set to 2400, 4800, 9600, 14400, 19200, 28800 and 38400.
7-1 Functions Supported

Only function 03, 06 and 16 are available for this series of controllers.
The message formats for each function are described as follows:
Function 03: Read Holding Registers

Query ( from master ) Response ( from slave )
Slave address (0-255)
Function code (3)
Starting address of register Hi (0) Byte count
Starting address of register Lo (0-79) Data 1 Hi
No. of words Hi (0) Data 1 Lo
No. of words Lo (1-79) Data 2 Hi
CRC16 Hi Data 2 Lo
CRC16 Lo
CRC16 Hi
CRC16 Lo
Function 06: Preset single Register

Function code (6)
Register address Hi (0)
Register address Lo (0-79)
Data Hi
Data Lo
CRC16 Hi
CRC16 Lo
66 UM91001A
Function 16: Preset Multiple Registers
Function code (16)
Starting address of register Hi (0)
Starting address of register Lo (0-79)
No. of words Hi (0)
No. of words Lo (1-79)
Byte count (2-158) CRC16 Hi
Data 1 Hi CRC16 Lo
Data 1 Lo
Data 2 Hi
Data 2 Lo
CRC16 Hi
CRC16 Lo
UM91001A 67
7-2 Exception Responses
If the controller receives a message which contains a corrupted
character (parity check error, framing error etc.), or if the CRC16 check
fails, the controller ignores the message.
However, if the controller receives a syntactically correct message
which contains an illegal value, it will send an exception response,
consisting of five bytes as follows:
slave address +offset function code + exception code + CRC16 Hi +
CRC16 Lo
Where the offset function code is obtained by adding the function
code with 128 (ie. function 3 becomes H'83), and the exception code
is equal to the value contained in the following table:
Exception Code Name Cause

Function code is not supported
1 Bad function code by the controller
2 Illegal data address Register address out of range
Data value out of range or
3 Illegal data value attempt to write a read-only or
protected data
68 UM91001A
7-3 Parameter Table
Register Parameter Scale Scale
Parameter Notes
Address Notation Low High
0 SP1 Set point 1 *4 *4 R/W
3 LOCK Lock code 0 65535 R/W
4 INPT Input sensor selection 0 65535 R/W
5 UNIT Measuring unit 0 65535 R/W
6 DP Decimal point position 0 65535 R/W
7 INLO Low scale value for linear input *4 *4 R/W
8 INHI High scale value for linear input *4 *4 R/W
9 SP1L Low limit of SP1 *4 *4 R/W
10 SP1H High limit of SP1 *4 *4 R/W
11 SHIF PV shift value *4 *4 R/W
12 FILT Filter time constant 0 65535 R/W
13 DISP Display form ( for C21 ) 0 65535 R/W
14 PB P ( proportional ) band *5 *5 R/W
15 TI Integral time 0 65535 R/W
16 TD Derivative time 0.0 6553.5 R/W
17 OUT1 Output 1 function 0 65535 R/W
18 O1TY Output 1 signal type 0 65535 R/W
19 O1FT Output 1 failure transfer -1999.9 4553.6 R/W
20 O1HY Output 1 ON-OFF hysteresis *5 *5 R/W
21 CYC1 Output 1 cycle time 0.0 6553.5 R/W
22 OFST Offset value for P control 0.0 6553.5 R/W
23 RAMP Ramp function 0 65535 R/W
24 RR Ramp rate *5 *5 R/W
25 OUT2 Output 2 function 0 65535 R/W
26 Reserved 0 65535 R/W
27 O2TY Output 2 signal type 0 65535 R/W
28 O2FT Output 2 failure transfer -1999.9 4553.6 R/W
29 O2HY Output 2 ON-OFF hysteresis *5 *5 R/W
UM91001A 69
Parameter Notes
30 CYC2 Output 2 cycle time 0.0 6553.5 R/W
31 CPB Cooling P band 0 65535 R/W
32 DB Heating-cooling dead band -1999.9 4553.6 R/W
33 ALFN Alarm function 0 65535 R/W
35 ALMD Alarm opertion mode 0 65535 R/W
36 ALHY Alarm hysteresis *5 *5 R/W
37 ALFT Alarm failure transfer 0 65535 R/W
38 COMM Communication function 0 65535 R/W
39 ADDR Address 0 65535 R/W
40 BAUD Baud rate 0 65535 R/W
41 DATA Data bit count 0 65535 R/W
42 PARI Parity bit 0 65535 R/W
43 STOP Stop bit count 0 65535 R/W
44 SEL1 Selection 1 0 65535 R/W
52 ADLO mV calibration low coefficient -1999.9 4553.6 R/W
53 ADHI mV calibration high coefficient -1999.9 4553.6 R/W
54 RTDL RTD calibration low coefficient -1999.9 4553.6 R/W
55 RTDH RTD calibration high coefficient -1999.9 4553.6 R/W
56 CJLO Cold junction calibration low coefficient -199.99 455.36 R/W
57 CJHI Cold junction calibration high coefficient -1999.9 4553.6 R/W
60 HOUR Working hours of the controller 0 65535 R/W
70 UM91001A
Parameter Notes
61 BPL1 Bumpless transfer of OP1 0.00 655.35 R
62 BPL2 Bumpless transfer of OP2 0.00 655.35 R
63 CJCL Cold junction signal low 0.000 65.535 R
64 PV Process value *4 *4 R
65 SV Current set point value *4 *4 R
Read only,
OP1 control output value unless in
66 MV1 0.00 655.35
manual
control
Read only,
OP2 control output value unless in
67 MV2 0.00 655.35
manual
control
68 TIMER Remaining time of dwell timer -1999.9 4553.6 R
69 EROR Error code *1 0 65535 R
70 MODE Operation mode & alarm status *2 0 65535 R
71 PROG Program code *3 0.00 655.35 R
72 CMND Command code 0 65535 R/W
73 JOB1 Job code 0 65535 R/W
76 Reserved 0 65535 R
*1: The error code is show in the first column of Table A.1.
*2: Definition for the value of MODE register
H'000X = Normal mode H'0X00 = Alarm status is off
H'010X = Calibration mode H'0x01 = Alarm status is on
H'020X = Auto-tuning mode
H'030X = Manual control mode The alarm status is shown in
H'040X = Failure mode MV2 instead of MODE for
models C21, C91 and C92.
UM91001A 71
*3: The PROG Code is defined in the following table:
Model No. BTC-9100 BTC-8100 BTC-4100 BTC-7100 C21 C91 C92
PROG Code 6.XX 11.XX 12.XX 13.XX 33.XX 34.XX 35.XX
Where XX denotes the software version number. For example:
PROG=34.18 means that the controller is C91 with software version
18.
*4: The scale high/low values are defined in the following table for SP1,
INLO, INHI, SP1L, SP1H, SHIF, PV and SV:
Non-linear Linear input Linear input Linear input Linear input
Conditions input DP = 0 DP = 1 DP = 2 DP = 3
Scale low -1999.9 -19999 -1999.9 -199.99 -19.999
Scale high 4553.6 45536 4553.6 455.36 45.536
*5: The scale high/low values are defined in the following table for PB,
O1HY, RR, O2HY and ALHY:
Scale low 0.0 0 0.0 0.00 0.000
Scale high 6553.5 65535 6553.5 655.35 65.535
*6: The scale high/low values are defined in the following table for SP3:
ALFN=1 Non-linear Linear input Linear input Linear input Linear input
Conditions (TIMR) input DP = 0 DP = 1 DP = 2 DP = 3
Scale low -1999.9 -1999.9 -19999 -1999.9 -199.99 -19.999
Scale high 4553.6 4553.6 45536 4553.6 455.36 45.536
*7: The scale high/low values are defined in the following table for SP2:
For C21, C91and C92
OUT2=1 Non-linear Linear input Linear input Linear input Linear input
Conditions (TIMR) input DP = 0 DP = 1 DP = 2 DP = 3
Scale low -1999.9 -1999.9 -19999 -1999.9 -199.99 -19.999
Scale high 4553.6 4553.6 45536 4553.6 455.36 45.536
72 UM91001A
For BTC-9100, BTC-8100, BTC-7100 and BTC-4100
Scale low -1999.9 -19999 -1999.9 -199.99 -19.999
Scale high 4553.6 45536 4553.6 455.36 45.536
7-4 Data Conversion

The word data are regarded as unsigned ( positive ) data in the
Modbus message. However, the actual value of the parameter may
be negative value with decimal point. The high/low scale values for
each parameter are used for the purpose of such conversion.
Let M = Value of Modbus message
A = Actual value of the parameter
SL = Scale low value of the parameter
SH = Scale high value of the parameter
The conversion formulas are as follows:
65535 ( A SL)
M=
SH-SL
SH-SL
A= M + SL
65535
7-5 Communication Examples :

Example 1: Down load the default values via the programming port
The programming port can perform Modbus communications
regardless of the incorrect setup values of address, baud, parity, stop
bit etc. It is especially useful during the first time configuration for the
controller. The host must be set with 9600 baud rate, 8 data bits, even
parity and 1 stop bit.
The Modbus message frame with hexadecimal values is shown as
follows:
UM91001A 73
01 10 00 00 00 34 68 4F 19 4E 83 4E 83
Addr. Func. Starting Addr. No. of words Bytes SP1=25.0 SP2=10.0 SP3=10.0
00 00 00 01 00 00 00 01 4D 6D 51 C4
LOCK=0 INPT=1 UNIT=0 DP=1 INLO=-17.8 INHI=93.3
4D 6D 63 21 4E 1F 00 02 00 00 00 64
SP1L=-17.8 SP1H=537.8 SHIF=0.0 FILT=2 DISP=0 PB=10.0
00 64 00 FA 00 00 00 00 4E 1F 00 01
TI=100 TD=25.0 OUT1=0 O1TY=0 O1FT=0 O1HY=0.1
00 B4 00 FA 00 00 00 00 00 02 00 00
CYC1=18.0 OFST=25.0 RAMP=0 RR=0.0 OUT2=2
00 00 4E 1F 00 01 00 B4 00 64 4E 1F
O2TY=0 O2FT=0 O2HY=0.1 CYC2=18.0 CPB=100 DB=0
00 02 00 00 00 00 00 01 00 00 00 01
ALFN=2 ALMD=0 ALHY=0.1 ALFT=0 COMM=1
00 01 00 02 00 01 00 00 00 00 00 02
ADDR=1 BAUD=2 DATA=1 PARI=0 STOP=0 SEL1=2
00 03 00 04 00 06 00 07 00 08 00 0A
SEL2=3 SEL3=4 SEL4=6 SEL5=7 SEL6=8 SEL7=10
00 11 Hi Lo
SEL8=17 CRC16
74 UM91001A
Example 2: Read PV, SV, MV1, MV2, TIMER, EROR and MODE
Send the following message to the controller via the COMM port or
programming port:
03 00 H'40 00 07 Hi Lo
Addr. Func. Starting Addr. No. of words CRC16
Example 3: Perform Reset Function (same effect as pressing R key)

Query
06 00 H'48 H'68 H'25 Hi Lo
Addr. Func. Register Addr. Data Hi/Lo CRC16
Example 4: Enter Auto-tuning Mode

Query
06 00 H'48 H'68 H'28 Hi Lo
Example 5: Enter Manual Control Mode

Query
06 00 H'48 H'68 H'27 Hi Lo
Example 6: Read All Parameters

Query
03 00 00 00 H'50 Hi Lo
Addr. Func. Starting Addr. No. of words CRC16
UM91001A 75
Table A.1 Error Codes and Corrective Actions
Error Display Error Description
Code Symbol Corrective Action
Illegal setup values been used: Check and correct setup values of
Before COOL is used for OUT2, OUT2, PB, TI and OUT1. IF OUT2
DIRT ( cooling action ) has already is required for cooling control, the
been used for OUT1, or PID mode control should use PID mode ( PB
4 is not used for OUT1 ( that is PB = 0, TI = 0 ) and OUT1 should
= 0, and / or TI = 0 ) use reverse mode (heating action)
, otherwise, don't use OUT2 for
cooling control.
Communication error: bad function Correct the communication
10 code software to meet the protocol
requirements.
Communication error: register Don't issue an over-range
11 address out of range register address to the slave.
Communication error: attempt Don't write a read-only data or a
14 to write a read-only data or a protected data to the slave.
protected data
Communication error: write a Don't write an over-range data
15 value which is out of range to a to the slave register.
register
1.The PID values obtained after
auto-tuning procedure are out
of range. Retry auto-tuning.
2.Don't change set point value
Fail to perform auto-tuning during auto-tuning procedure.
26 3.Use manual tuning instead of
function
auto-tuning.
4. Don't set a zero value for PB.
5. Don't set a zero value for TI.
6. Touch RESET key
29 EEPROM can't be written correctly Return to factory for repair.
30 Cold junction compensation for

Return to factory for repair.
thermocouple malfunction
Input sensor break, or input
current below 1 mA if 4-20 mA is Replace input sensor.
39
selected, or input voltage below
0.25V if 1 - 5V is selected
A to D converter or related
40 Return to factory for repair.
component(s) malfunction
76 UM91001A
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.
UM91001A 77
BRAINCHILD Electronic Co., Ltd.
6F., No.209, Chung Yang Rd., Nan Kang Dist.,
Taipei, Taiwan, R.O.C.
Tel: 886-2-27861299
Fax: 886-2-27861395
web site: http://www.brainchild.com.tw

02 - Rad-Rac-A Recirculating Air Cond Trainer Exp Man LT 10002 - Politeknik

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02 - Rad-Rac-A Recirculating Air Cond Trainer Exp Man LT 10002 - Politeknik

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RECIRCULATING AIR CONDITIONING

2. ABOUT THE TRAINER 3

Labtech Recirculating Air Conditioning Trainer is a self-contained training system for

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2.1. LIST OF ITEMS THAT COME WITH THE TRAINER

Figure 2.1. Recirculating Air Conditioning Trainer

2.2. SETTING UP THE TRAINER

2.3. PARTS IDENTIFICATION

Figure 2.4. Recirculating Air Conditioning Components

2.3.1.2. Steam Generator

Figure 2.5. Steam Generator Tank

2.3.1.4. Sensors and Control

Figure 2.6. Temperature Sensor

➢ Humidity sensor (hygrometer)

Figure 2.7. Humidity Sensor

➢ Air velocity sensor

Figure 2.8. Air Flow Sensor

➢ Refrigerant flow meter sensor

Figure 2.9. Refrigerant flow meter Sensor

2.3.1.5. Circuit Breakers Panel

Figure 2.10. Circuit Breakers Panel

2.3.1.6. Instrument and Control Panel

Figure 2.11. Instrument and Control Panel

Table 2.1 Manual/Auto Control

➢ Relative Humidity (RH)/Temperature Selector and Display.

➢ Refrigerant Flowmeter Switch and Display.

Figure 2.11. Steam Generator Thermostat and Solenoid Valve Switch

➢ Steam Generator Thermostat

2.3.2. Data Acquisition Hardware and Software (RAD-RAC-01)

2.4. SAFETY CARE AND MAINTENANCE

For long life and better trainer performance:

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3.1. DEFINITION OF AIR CONDITIONING

3.2. COMFORT AND THE BODY

3.3. PSYCHROMETRIC PROPERTIES OF AIR

Figure 3.3-1. A Psychrometer

3.3.2. Dry-Bulb and Wet-Bulb Temperature

3.3.3. Dew-Point Temperature

3.3.4. Superheat Gases in Air

3.4. THE PSYCHROMETRIC CHART

Figure 3.4-1A. Psychrometric Chart. Reproduced courtesy of Carrier Corporation.

0.75 0.80 DRY BULB TEMPERATURE C 0.85 0.90

Figure 3.4-1B. Constant Property Lines Psychrometric Chart

3.4.1. Plotting on the Psychrometric Chart

WHEN AIR IS CONDITIONED AND THE PLOT MOVES IN THE

Figure 3.4-14. A summation of sensible and latent heat

3.5. REFRIGERATION PROCESSES

3.5.1. Refrigeration Cycle

Most refrigerants undergo a series of evaporation, compression, condensation, throttling, and

Figure 3.5-2. Skeleton of Pressure-Enthalpy

3.5.2. Representation of Vapor Compression Cycle on Pressure-Enthalpy Diagram

Figure 3.5-3. Refrigerant Cycle on Pressure–Enthalpy (P–H) Diagram

• Coefficient Of Performance or Energy for Heating ( E H )

Water Pan Signal Light

3.7. AIR VELOCITY MEASUREMENT

STATIC PRESSURE TOTAL PRESSURE 3

FLOW ps FLOW FLOW ps hv FLOW

ps = STATIC PRESSURE pt = TOTAL PRESSURE hv = VELOCITY PRESSURE

VELOCITY PRESS. = TOTAL PRESS. − STATIC PRESS.

Fig. 3.7-1. Types of Pressure Measurement

The air velocity can be calculated using the basic formula:

To determine dry air density, use the formula:

Electronics Air Flow Sensor