NSC Versatile Brix Manual

CONTENTS
INTRODUCTION ______________________________________________________ 3
Optional - Level request from Slave Level Transmitter ____________________________ 5
External Keys with Label – ___________________________________________________ 5
SPECIFICATIONS _____________________________________________________ 6
MOUNTING DETAILS DRAWING________________________________________ 7
TERMINAL CONNECTIONS ____________________________________________ 8
TERMINAL CONNECTIONS & LINKS ____________________________________ 9
Relay Contact Links – _______________________________________________________ 9
Communication Links – ______________________________________________________ 9
Low/High Range Selection Switch – ____________________________________________ 9
OPERATING ELEMENTS ______________________________________________ 10
Keypad ___________________________________________________________________ 10
LEDs_____________________________________________________________________ 10
Display ___________________________________________________________________ 11
DISPLAY MODES AND KEY OPERATION _______________________________ 12
Normal Mode of Display during RUN – ________________________________________ 12
PROFILE parameter display – _______________________________________________ 12
PID parameter display - _____________________________________________________ 13
Control Valve o/p in Manual - _______________________________________________ 14
Non-linearised output display - _______________________________________________ 14
Temperature output display - ________________________________________________ 14
Changing timer function - __________________________________________________ 14
Starting timer function in manual mode - ______________________________________ 14
Changing System mode - ____________________________________________________ 14
Changing to parameter set-up mode - _________________________________________ 14
Changing PID remote or local mode selection - _________________________________ 15
Changing PID auto or manual mode selection - _________________________________ 15
MENU FUNCTIONS __________________________________________________ 16
Menu Operation ___________________________________________________________ 16
Data Entry (General) _______________________________________________________ 19
Data Entry (Linearisation table) ______________________________________________ 21
Page 1
OPERATION MANUAL FOR BRIX TRANSMITTER for MOLASSES & MELTER (BTM)
Data Entry (Calibration) ____________________________________________________ 21

Input Resistance (Brix) Calibration ___________________________________________ 21
Temperature Input Calibration_______________________________________________ 22
Output Calibration _________________________________________________________ 22
PARAMETER DETAILS _______________________________________________ 24
Default Settings of parameters _______________________________________________ 32
PID CONTROL _______________________________________________________ 34
SELF CLEANING TIMER (CLEAN RELAY) ______________________________ 35
MODBUS COMMUNICATION __________________________________________ 36
PREPARING INSTRUMENT FOR BRIX INDICATION _ ERROR! BOOKMARK NOT
DEFINED.
DETAILED CALIBRATION PROCEDURE ________________________________ 40
Input Resistance (Brix) Calibration _____________________ Error! Bookmark not defined.
Temperature Input Calibration_______________________________________________ 42
Brix Output calibration _____________________________________________________ 42
Control Output calibration __________________________________________________ 43
REVISION HISTORY __________________________________________________ 43
WARRANTY CERTIFICATE ____________________________________________ 44
Ver-btm3.x.xx / bmm3.x.xx Page 2

INTRODUCTION
BRIX TRANSMITTER is an electronic instrument specifically developed for batch pan
in sugar industry for Melter or Molasses unit. This instrument is two-card system (Main
or microcontroller card and analog - power card) housed in an Aluminium enclosure. It
also has junction PCB for field connections in the power compartment of the instrument.
Power compartment also has optional SMPS (Switched Mode power supply) for 230V
operation.
It has a keypad having 8 keys and few bi-color led indications, which gives system status
of the mode or sensor. Unit also has Label having 3 or 4 external keys, for easy operation
of unit without opening front. Additionally, 12 nos. of seven-segment display is present
for data and message indication. Main & Analog-power cards are connected with each
other using 26-core flat cable. Analog-power card is also connected to junction PCB
using 26-core flat cable.
This instrument operates on 24V DC source. This instrument operates on 230V AC
source (optional). Instrument has built-in 24V DC power source suitable for the operation
and is located on junction box PCB.
The instrument is connected to Brix sensor, which is mounted in a pan at suitable

locations.
This instrument has a timer based relay outputs, which is called ‘Cleaning’. Cleaning
relay reciprocates the probe in guide bush.. Parameters for & cleaning relay timer can be
set by the operator. Timer function can be ‘Enabled’ or ‘Disabled’ through keyboard.
When any of these timing functions are carried out, Process Value and Control Output
are fixed to previous readings and are not updated. Also this relay contacts are with
potential as input supply voltage, so that it can be directly connected to solenoid valves.
Brix sensor is excited by a radio frequency signal of the order of 2 mA (peak to peak) by
the instrument. Instrument measures AC resistivity of the massecuite and gives output
proportional to the brix of massecuite. However, the direct output of instrument varies in
non-linear proportion with respect to brix. The non-linearity in the output is removed by
finding a polynomial relation between brix readings and direct output of transmitter. This
polynomial equation is calculated in the instrument as explained later in the manual.
Two such polynomial equations, one for Material 1 and another for Material 2 are
generated in the instrument. Operator can easily select any one, depending on the system
operation using few keystrokes and selection is indicated on the instrument using led.

Brix transmitter unit can also be connected to PLC or SCADA using RS-485
communication. Instrument communicates data using standard MODBUS protocol.
Equipment can handle RTU as well as ASCII communication protocol. Optionally.
Instrument can communicate through TCP-IP using MODBUS-TCPIP protocol
(optional). Different parameters such as type, baud rate, parity, no. of data bits for
MODBUS can be set in equipment. Using MODBUS communication instrument
parameters such as PID settings, Local/Remote mode of PID etc. can be changed..
Equipment sends brix data, system mode (Material 1 or Material 2) etc. using MODBUS.
This equipment also has built-in PID control algorithm.
Equipment has two 4-20 mA current outputs.
One output is proportional to the linearised brix output, which is isolated type. This
output can be connected to indicator or any other instrument. Output should be connected
in 4-wire mode.
Another current output is connected to activate control valve, which is in turn controls,
the flow of the massecuite in the pan. The percentage opening of the control valve is
received from PLC or SCADA on the RS-485 using MODBUS protocol (REMOTE) or
from built-in PID (LOCAL).

Optional - Level request from Slave Level Transmitter
This Brix transmitter (MIX) unit is connected to Level Transmitter using RS-485
communication (ASCII only). Brix Transmitter Instrument should be selected as Master
and communicates with a slave Level transmitter (MIX) (having fixed address 32) using
standard MODBUS protocol, with ASCII communication protocol..
Equipment requests Level from Level Transmitter (having fixed address 32) and
calculates set-point using a PROFILE parameters, for built-in PID, to control the flow of
massecuite in the pan. The profile table having relation between level & setpoint is of
maximum 6 steps and can be easily edited by operator. Two different profiles are stored
in the equipment (one for BOILING selection & another for GRAINING selection).
For this master application, software version will be different. E.g. Ver bmmx.x.xx
instead of Ver btmx.x.xx
When Instrument is selected as a slave unit, it can send brix data, selected sensor (inside
or outside sensor), system mode (boiling or graining) etc. using MODBUS to PLC or
SCADA. Different parameters such as type, baud rate, parity, no. of data bits for
MODBUS can be set in equipment
Always select PID as LOCAL.
External Keys with Label –
For easy operation of unit, external keys are provided on Serial no. Label. Without
opening front of the unit, using these keys, operator can select Material 1 or Material 2
mode, Auto or Manual operation of PID and increment or decrement of control output in
Manual mode of PID operation can be changed using these keys.

SPECIFICATIONS
Enclosure Cylindrical Aluminium casting

Dimensions Max diameter 190 mm, length 150 mm
Mounting 2” pipe / mounting plate
AC Input Power 230V AC (150V~270V)

Fuse 2A/20mm
DC Input Power 24V DC (18V-30V)
Display 5 + 7 (seven segment LED)

Status Indication 4 bi-color LEDs
Keys 8 (Internal) + 4 External keys on Label
Input Sensor minimum 1 no. & maximum 2 no.s

Input Sensor type RF sensor
Optional Sensor RTD PT-100

Purpose Temperature Compensation
Relay output 1 No. Potential free for Material 1 / Material 2

1 No. Potential same as Input Power to the equipment used
for cleaning solenoid valve
Control type Proportional, Integral, Derivative

Control type selection Local / Remote as well as AUTO / MANUAL
Analog Outputs 2 nos. 4-20mA DC of which one is isolated (4-wire)

Output Calibration Software
Communication RS-485(built-in) or TCPIP(optional)

Communication Protocol MODBUS (ASCII or RTU)
Communication rate 1200/2400/4800/9600/19200/38400 software selectable
Communication parity None/Even/Odd software selectable
No. of samples 3 to 120 samples software selectable
Default Indication Brix in %, Control Valve opening in %, PID set-point in %
Optional Indication Non-linearised count in mA

Temperature in ºC

MOUNTING DETAILS DRAWING

TERMINAL CONNECTIONS
Terminal Terminal Terminal Details Terminal Description
No. Label
X3-1 L This is AC power input to the
AC POWER INPUT
X3-2 E instrument. (Input range 150V-
optional. 270V), which is connected to J2
X3-3 N through SMPS

No. Label
J3-1 GND This is DC power input to the
DC POWER INPUT
instrument either through SMPS
J3-2 24V
or directly.

No. Label
X2-1 D- RS-485 connections for
MODBUS
X2-2 D+ MODBUS protocol.
COMMUNICATION
X2-3 GND
X2-4 BRIX - BRIX O/P 4-20 mA DC current output proportional
X2-5 BRIX + to linearised brix output.
X2-6 CV - CONTROL O/P 4-20 mA DC current output proportional
X2-7 CV + to opening of flow control valve.
X2-8 RTD COM PT-100 temperature connection
TEMPERATURE
X2-9 RTD - for temperature compensation
X2-10 RTD + (optional)
X2-11 SPARE For Future use.
NOT USED
X2-12 SPARE
X2-13 SPARE For Future use.
NOT USED
X2-14 SPARE
X2-15 SI - This is the sensor connected
SENSOR INSIDE
X2-16 SI +

No. Label
X4-1 CLEAN - This relay o/p should be connected
CLEANING RELAY
X4-2 CLEAN + for cleaning SV engergised with
WITH POTENTIAL
24V (same as input voltage)
X4-3 B/G - Potential free relay contacts for
RELAY OUTPUT
X4-4 B/G + Material 1 / Material 2

TERMINAL CONNECTIONS & LINKS

On the rear side of the instrument, analog-power PCB is fitted. On this PCB, group of
connectors are available as per requirement of the system.
X1 group contains DC POWER INPUT connections.
X2 group contains all other field connections for sensor, communication, current output.
X4 group contains all connections for Material1 / Material2 selection output.
Relay Contact Links –
Note that if for L9 & L10, links are connected between A-B then relay are with 24V
potential.. If links are connected between L9/A – L10A, then relay contacts are potential
free. As per the applications, these links can be changed.
Note that if for L11 & L12, links are connected between A-B then relay are with 24V
potential.. If links are connected between L11/A – L12A, then relay contacts are potential
free. As per the applications, these links can be changed.
Communication Links –
Terminating resistor of 120 ohms for MODBUS (via RS-485) can be selected by making
switch 3 of DIP switch S1 to ON, located on ANALOG PCB.
Active pull-ups and pull-downs can be selected by making switch 1 & 2 of DIP switch S1
to ON, located on ANALOG PCB. When Brix Transmitter is selected as a MASTER
& is connected to SLAVE level transmitter (in MIX version) always connect these.
Low/High Range Selection Switch –
Switch 4 of DIP switch S1 is used to select High/Low range of sensor input. If this switch
4 is OFF, then high hardware range is selected for 100E-2000E of input resistance. If this
switch 4 of S1 is ON, then low hardware range is selected for 10E-600E of Input
resistance. (For Molasses and Melter, usually low range is selected).
Note that, when this switch position is changed, software calibration (i.e. Input
Resistance calibration) has to be done.

OPERATING ELEMENTS
Keypad
The layout of various keys is as shown below –
Menu function & Data Entry keys –

Data Entry keys -  (UP),
 (DOWN),
→ (RIGHT or MENU),
 (ENTER)
1/2 C A/M L/R
Hot keys - 1 / 2 (Material 1 or Material 2 selection),

C (Cleaning Cycle selection),
A / M (PID Auto or Manual),
L / R (PID Local or Remote)
LEDs
The description of LEDs are as follows –
LED 1 (green) indicates system is selected for “Material 1”

LED 2 (red) indicates system is selected for “Material 2”
LED C (green) indicates Cleaning cycle is in OFF delay
LED C (red) indicates Cleaning cycle is in ON delay
LED A (green) indicates “control valve o/p from Auto” is selected
LED M (red) indicates “control valve o/p from Manual” is selected
LED L (green) indicates “control valve o/p from Local” is selected
LED R (red) indicates “control valve o/p from Remote” is selected

Display
Display is standard 7-segment and has 2 lines –
Line1 (5 digits (0.56”) - Used to edit numbers, display brix etc.

Line2 (7 digits (0.3”) - Used to show menu titles, messages, pid set-point (SP),
control valve opening (OP) percentage (00%- 100%)
The seven-segment display is generally used to show numbers. Unit uses the same
display to show alphanumeric characters as well. Most of the characters (A to Z) can be
shown at least in upper or lower case, while others (such as m, w) are shown differently.
Initially, such a text looks quite awkward but after couple of weeks operator will get used
to it. The character will be displayed as in the following table –
! “ # $ % & ‘ (
) * + - / 0 1 2
3 4 5 6 7 8 9 :
; < = > ? @ A B
C D E F G H I J
K L M N O P Q R
S T U V W X Y Z
[ \ ] ^ _ ‘ a b
c d e f g h I j
k l m n o p q r
s t u v w x y z

DISPLAY MODES AND KEY OPERATION

Brix transmitter instrument has two main modes of operation – RUN /AUTO mode and
PARAMETER SET-UP mode. System can be changed easily from one to another.
Normal Mode of Display during RUN –

Brix transmitter instrument normally displays linearised Brix value in % on Line1 and
set-point & control valve opening on Line2.
PROFILE parameter display –

This feature is available only in Mix model.
If ENTER key is pressed, Line 1 displays “-Pro-“ and Line 2 displays “Par” and now
operator can view/change Profile parameters i.e. relation between level and set-point
option.
UP or DOWN key is used to switch between different parameters, in the following
sequence. Line 1 displays parameter value and Line 2 displays parameter name.
Line 1 Line 2
-Pro- Par indicating now Profile parameters can be changed, using
UP or DOWN key. ENTER key brings back to Normal
mode of display
Level 1 O.L1 Indicates Level 1 parameter value, if operator wants to edit
XXX this parameter, press RIGHT key. If operator wants to view
next or previous parameter, press DOWN or UP key
Brix 1 O.b1 Indicates brix set-point corresponding to Level 1 set above
XXX.XX parameter value, if operator wants to edit this parameter,
press RIGHT key. If operator wants to view next or
previous parameter, press DOWN or UP key
------ similarly for level 2, brix 2, level 3, brix 3
level 4, brix 4, level 5, brix 5 -------
Level 6 O.L6 Indicates Level 6 parameter value, if operator wants to edit
XXX this parameter, press RIGHT key. If operator wants to view
next or previous parameter, press DOWN or UP key
Brix 6 O.b6 Indicates brix setpoint corresponding to Level 6 set above
XXX.XX parameter value, if operator wants to edit this parameter,
press RIGHT key. If operator wants to view next or
previous parameter, press DOWN or UP key
-Pro- Par ENTER key returns back to normal mode of display
RIGHT key is used to edit viewed parameter value & digit starts flashing.
Once digit starts flashing, RIGHT key is used to change position of flashing digit.
UP key increments flashing digit
DOWN key decrements flashing digit
ENTER key accepts the entered parameter value if it is within the acceptable range, and
Line 1 becomes steady. If it is out side the valid limits, Line 1, displays “H Err” or “ L
Err”, and ENTER key clears this error and operator can change viewed parameter value.

This profile generates a set-point as per level received from slave Level Transmitter and a
selected profile as per BOILING or GRAINING selection. and controls PID algorithm as
per this setpoint.
When actual level increases above set Level X, corresponding set-point Brix X is
calculated in Master BTMMIX. When actual level decreases below (Level X –
hysteresis), set-point corresponding to Brix (X-1) is calculated.
Hysteresis value can be changed by operator.
PID parameter display -

If ENTER key is pressed, Line 1 displays “-PId-“ and Line 2 displays “Par” and now
operator can view/change PID parameters.
UP or DOWN key is used to switch between different parameters, in the following
sequence. Line 1 displays parameter value and Line 2 displays parameter name.
Line 1 Line 2
-PId- Par indicating now PID parameters can be changed, using UP or
DOWN key. ENTER key brings back to Normal mode of
display
Kp value O.Kp Indicates Proportional Gain parameter value, if operator
XXX.XX wants to edit this parameter, press RIGHT key. If operator
wants to view next or previous parameter, press DOWN or
UP key
Ti value O.ti Indicates Integral time constant parameter value, if operator
XXX.XX wants to edit this parameter, press RIGHT key. If operator
wants to view next or previous parameter, press DOWN or
UP key
Td value O.td Indicates Derivative time constant parameter value, if
XXX.XX operator wants to edit this parameter, press RIGHT key. If
operator wants to view next or previous parameter, press
DOWN or UP key
SP value O.SP Indicates Set-point parameter value, if operator wants to
XXX.XX edit this parameter, press RIGHT key. If operator wants to
view next or previous parameter, press DOWN or UP key
-PId- Par ENTER key returns back to normal mode of display
RIGHT key is used to edit viewed parameter value & digit starts flashing.
Once digit starts flashing, RIGHT key is used to change position of flashing digit.
UP key increments flashing digit
DOWN key decrements flashing digit
ENTER key accepts the entered parameter value if it is within the acceptable range, and
Line 1 becomes steady. If it is out side the valid limits, Line 1, displays “H Err” or “ L
Err”, and ENTER key clears this error and operator can change viewed parameter value.

Control Valve o/p in Manual -

If Manual mode is selected, UP or DOWN keys are used to increment or decrement
control valve output. In REMOTE as well as LOCAL mode of control, o/p can be
changed in Manual mode.
Non-linearised output display -

If UP key is pressed, Line 1 displays non-linearised o/p proportional to AC resistivity (in
the range of 4.00 to 20.00). After 3 seconds, display automatically shows linearised brix
value as in Normal mode of display.
Temperature output display -

If RIGHT key is pressed, Line 1 displays temperature (in the range of 20 ºC to 150 ºC).
After 3 seconds, display automatically shows linearised brix value as in Normal mode of
display.
Changing timer function -

If DOWN and RIGHT keys are pressed simultaneously, operator can enable or disable
timer function. If disabled, relay will be OFF continuously, otherwise relay will be ON as
per selected timing.
Now system is ready to change clean timer function. Line1 display changes to “C.Enb?”
or “C.dSb” asking whether operator wants to change timer function (i.e. enable timer
function or disable timer function). If operator presses ENTER key, change will be done.
If after message display, operator doesn’t want to change timer function, please press any
other key than ENTER.
Starting timer function in manual mode -

If C key is pressed, operator can start clean timer function. This manual cycle will be
started only if clean timer is not in manual mode or clean timer is in auto start delay
cycle. And now the timer function will start similar auto cycle except start delay. Note
that C led will be red for ON cycle & green for OFF cycle.
Changing System mode -

After pressing 1 / 2 key, Line2 display changes to “M1 2?” asking whether operator
wants to change system mode either from “Material 1” to “Material 2” or line1 display
changes to “M2 1?” asking whether operator wants to change system mode either from
“Material 2” to “Material 1”. If operator presses 1 / 2 key again, change will be done. If
after message display, operator doesn’t want to change sensor, please do not press any
key and message disappears. Corresponding material no. led will show the system mode
status.
Changing to parameter set-up mode -

If DOWN and ENTER keys are pressed simultaneously (DOWN key should be pressed
first), system is changed into parameter set-up mode. In this mode, different parameters
can be seen and changed, if required. After all changes are done and system can be exited
from set-up mode (Fn. 8.0) and then display automatically shows linearised brix value as

in Normal mode of display. (Details of this parameter set-up mode are using MENU
functions and are explained later).
Changing PID remote or local mode selection -

If operator presses L / R key, PID mode change will be done. Corresponding Local or
Remote led will show the PID source status.
Changing PID auto or manual mode selection -

If operator presses A / M key, PID mode change will be done. Corresponding Auto or
Manual led will show the PID o/p status.

MENU FUNCTIONS
BRIX TRANSMITTER instrument has different parameters, which are set in parameter
set-up mode. During normal run mode, when DOWN and ENTER keys are pressed
simultaneously, equipment goes into parameter set-up mode.
Complete operation of BRIX TRANSMITTER parameter set-up is organised under menu

functions. These functions are numbered & may be grouped under submenus for operator
convenience, e.g. most of the system parameters are grouped under menu SYS PAr.
Menu Operation
Menu of BRIX TRANSMITTER is organised in a tree structure as follows –
TOP MENU KEY SUB MENU KEY ACTUAL PARAMETER KEY

LEVEL LEVEL
Fn. 1.0 / SYStem → Fn. 1.1 / → No. of samples 
Parameters no.SAmp

Fn. 1.2 / → Communication Address 
address


Fn. 1.13 / → Repeat cycle count for clean timer 
Clean rEPeats
Fn. 2.0 / → Fn. 2.1 / Brix → Brix low enginnering units in % 
Engineering Units Low
& PID parameters

Fn. 2.2 / Brix → Brix high engineering units in % 
High


Fn. 2.6 / Set- → Set-point in % 
point
Fn. 3.0 / Material 1 → Fn. 3.1 / m1 → Material 1 Offset 
Linearisation table offset

Fn. 3.2 / m1 → Material 1 No. of samples 
Samp


Fn. 3.14 / m1 → Material 1 6th Brix reading 
br 6


LEVEL LEVEL
Fn. 4.0 / Material 2 → Fn. 4.1 / m2 → Material 2 Offset 
Linearisation table offset

Fn. 3.2 / m2 → Material 2 No. of samples 
Samp


Fn. 3.14 / m2 → Material 2 6th Brix reading 
br 6
Fn. 9.0 / Material1 → Fn. 9.1 / → Material1 profile 1st Level 
Profile table m1.SP L1

Fn. 9.2 / → Material1 profile 1st brix 
m1.SP b1 corresponding to 1st Level


Fn. 9.12 / → Material1 profile 6th brix 
m1.SP b6 corresponding to 6th Level
Fn. 10.0 / Material2 → Fn. 10.1 / → Material2 profile 1st Level 
Profile table m2.SP L1

Fn. 9.2 / → Material2 profile 1st brix 
m2.SP b1 corresponding to 1st Level


Fn. 9.12 / → Material2 profile 6th brix 
m2.SP b6 corresponding to 6th Level


LEVEL LEVEL
Fn. 5.0 / Calibration → Fn. 5.1 / resi → Calibrate Low Resistance of i/p 
I/p Low sensor

Fn. 5.2 / resi → Calibrate High Resistance of i/p 
I/p High sensor


Fn. 5.8/ → Calibrate 20mA of Control valve 
control o/p current o/p
High
Fn. 6.0 / tests → Fn. 6.1 / → Test sensor input resistance 
resistance i/p

Fn. 6.2 / temp → Test temperature input 
i/p


Fn. 6.6 / → Display test 
display
Fn. 7.0 / Set ALL → 1. ALL → Initialize memory with Calibration data
with confirmation yes/no
2. noCL → Initialize memory without Calibration
data with confirmation yes/no
Fn. 8.0 / Exit → 1. YES → Exit or not from parameter set-up

2. no with confirmation yes/no
As indicated above –
• Use → MENU key to go from top menu to submenu or from sub menu to actual
function.
• Use  ENTER key to return from sub menu to top menu for e.g. Fn. 4.4 to Fn.4.0
• Use  DOWN or  UP key to select the desired top menu or sub menu.

Data Entry (General)

All the data entries in BRIX TRANSMITTER are of the two basic types –
• Numeric entry – For example no. of samples, linearisation constants, exponents
etc.
• Selecting an option – such as “Parity None” or “Parity Odd” or “Parity
Even”
This section describes the procedure of each type of data entry
• Numeric entry – Most of the time operator is required to enter numbers in to

equipment. Bottom line display shows prompt string for the number & top line
display shows existing number. The digit position flashes. In general, use UP or
DOWN keys to enter desired number at flashing position and RIGHT key to change
editing position and after setting correct numeric data, press ENTER key. If the
number you entered is OK, i.e. within limits, it is accepted else the message tells you
what went wrong.
Function of keys when editing a number –
Key Function
 UP Increment number
 DOWN Decrement number
→ RIGHT Changes editing position
 ENTER Completes editing
Let us take an example of entry of code number under Fn.1.1 (No. of samples) to change
from 60 to 120 –
Display Key Notes

060 → Goes to edit ‘No. of samples’
no.SAmp
060  or  Flashing digit is changed to 1 from 0 using UP or DOWN keys
no.SAmp
160 → Flashing digit is changed to next right digit i.e. 6 from 1
no.SAmp
160  or  Flashing digit is changed to 2 from 6 using UP or DOWN keys
no.SAmp
120 → Flashing digit is changed to next right digit i.e. 0 from 2
no.SAmp
120 → Flashing digit is changed to next right digit i.e. 0 from 2. As we want this
no.SAmp digit to be 0, we can finish editing
120  This completes editing and as this data is valid data, it is accepted and
no.SAmp

• Selecting an option – At times functions of the instrument will ask to select one of
the 2 or more options. Many functions under Fn.1.0 Sys require entries of this
type. Options are numbered 1. 2. 3. etc. and shown in top line as number followed
by its text. Use  or  key see them one by one and select by pressing  when the
desired option is present on display.
Function of keys when selecting an option –
Key Function
 UP see next option (or first if already at the end)
 DOWN see previous (or last if already at the first)
ENTER choose the option shown on display
Let us take an example of selection of parity under Fn.1.4 –
Display Key Notes

1.none → go to edit parity function, which is presently
Parity none i.e. no parity
2.EvEn  Displays next i.e. even parity
Parity
3. odd  ENTER key to accept parity as odd parity.
Parity

Data Entry (Linearisation table)

Linearisation between brix readings and output is done using a polynomial equation
up to 4th order. This equation is calculated into the instrument as per table feed in
parameter set-up mode Maximum 6 such brix & equivalent 4-20 counts should be
fed. Less no. of samples will generate equation of lower order. Two separate
equations can be calculated in it, one for Material 1 and another for Material 2.
Appropriate equation is selected for Material 1 and for Material 2.
Entered offset (+/-) can be added to equation.
Note : while entering table please be sure that no two same ma entries be done.
Note : In case display is required in terms of “ % Resistivity”, following values

should be entered
Offset = 0, Samples = 6,
ma 1 = 4, brix 1 = 0.0,
ma 2 = 8, brix 2 = 25.0,
ma 3 = 12, brix 3 = 50.0,
ma 4 = 14, brix 4 = 62.5,
ma 5 = 16, brix 5 = 75.0,
ma 6 = 20, brix 6 = 100.0,
Instrument can generate equation up to the 5th order similar to

Brix = A + B (mA) + C (mA)2 + D (mA)3 + E (mA)4 + F (mA)5
Please note following points during editing of linearisation parameters
Sign of Offset entry can be changed with A / M key.

No. of samples in the table should be entered properly otherwise equation can be
wrong. No two same mA values should be entered in table.
Table should be entered as ma and corresponding brix.
Data Entry (Calibration)
Input Resistance (Brix) Calibration
Fn. 5.1 Input resistance (Brix) Low calibration –
In this operator first enters at what resistance, low should be calibrated. E.g. 100 Ohms.
Then operator connects 100 ohms resistance at inside sensor terminals SI & SI(G).
Display line1 shows ADC data. Adjust readings using proper trim-pots on Analog card.
After display reading is steady (within 4-5 counts), press ENTER key. (Note that after
pressing operator should wait for few seconds until it comes of display ADC mode). Now
this reading is stored inside the instrument for set low resistance.

Fn. 5.2 Input resistance (Brix) High calibration –
In this operator first enters at what resistance, high should be calibrated. E.g. 1000 Ohms.
Then operator connects 1000 ohms resistance at inside sensor terminals SI & SI(G).
Display line1 shows ADC data. Adjust readings using proper trim-pots on Analog card.
After display reading is steady (within 4-5 counts), press ENTER key. (Note that after
pressing operator should wait for few seconds until it comes of display ADC mode). Now
this reading is stored inside the instrument for set high resistance.
Temperature Input Calibration
Fn. 5.3 Temperature Input Low calibration –
In this operator first enters at what resistance, low should be calibrated. E.g. 110 Ohms
(26 ºC). Then operator connects 110 ohms resistance (i.e. at temperature RTD sensor
terminals RTD COM, RTD + & RTD -. Display line1 shows ADC data. After display
reading is steady (within 2 counts), press ENTER key. Now this reading is stored inside
the instrument for set low temperature.
Fn. 5.4 Temperature Input High calibration –
In this operator first enters at what resistance, high should be calibrated. E.g. 140 Ohms
(104 ºC). Then operator connects 140 ohms resistance at inside sensor terminals 13 & 14.
Display line1 shows ADC data. After display reading is steady (within 2 counts), press
ENTER key. Now this reading is stored inside the instrument for set high temperature.
(note that temperature compensation is done between 20 ºC to 150 ºC).
Output Calibration
Fn. 5.5 Brix Output Low calibration –
Connect the current meter at the BRIX + & BRIX - terminals.

Display shows “Adj 4”; At this point observe the reading on the meter. Press UP key to
increase the current value & DOWN key to decrease the current value. Once 4 mA is
achieved on the meter, press ENTER key to come out of it.
Fn. 5.6 Brix Output High calibration –
Connect the current meter at the BRIX + & BRIX - terminals.

Display shows “Adj 20”; At this point observe the reading on the meter. Press UP key to

Fn. 5.7 Control Output Low calibration –
Connect the current meter at the CV+ & CV - terminals.

Display shows “Adj 4”; At this point observe the reading at the meter. Press UP key to
Fn. 5.8 Control Output High calibration –
Connect the current meter at the CV + & CV - terminals.

Display shows “Adj 20”; At this point observe the reading at the meter. Press UP key to

PARAMETER DETAILS
Function Parameter Type Purpose
Title
Fn. 1.0 System parameters Edit System parameters
SyS Par
Fn. 1.1 No. of Samples Numeric. Each sample is taken at 100ms. More the
No.SAmp Limit: 3 - 120 samples, more averaging
Fn. 1.2 Communication Slave Numeric. Slave address of this Brix transmitter
address Address Limit: 1 - 64 unit
Fn. 1.3 MODBUS Option selection Selects communication speed
baud rt Communication speed i.e. 1. 1200
Baud rate 2. 2400
3. 4800
4. 9600
5. 19.2K
6. 38.4K
7. 56.0K
8. 57.6K
Fn. 1.4 MODBUS Option selection Selects communication parity bit
parity Communication Parity bit 1. none
2. EvEn
3. Odd
Fn. 1.5 MODBUS Option selection Selects communication type
mod tyP Communication Type 1. Rtu
2. ASCII
Fn. 1.6 PID Sampling Time Numeric. Selects Sampling time in msec
Samp tm Limit: 100 - 9000
Fn. 1.7 Temperature Option selection If enabled, temperature compensation is
temp co compensation in ºC 1. dISL done. If disabled, temperature
2. enbL compensation. is neglected.
Fn. 1.8 Reference Temperature Numeric. this is the reference temperature wrt
temp.ref for compensation in ºC Limit: 30 - 120 which compensation is done, if enabled.
Fn. 1.9 Enable / Disable clean Option selection Disabling will make clean relay OFF
CL En.Ds timer 1. diSb continuously and Enabling will select
2. Enab auto function of clean relay
Fn. 1.10 Start delay for clean timer Numeric. Start delay for clean relay logic, at start
CL Strt Limit: 0 – 250 and after repeat cycles in auto
Minutes
Fn. 1.11 Off time for clean timer Numeric. Off time for clean relay
CL OFFt Limit: 1 – 60
Seconds
Fn. 1.12 On time for clean timer Numeric. On time for clean relay
CL Ont Limit: 1 – 60
Seconds
Fn. 1.13 No. of repeats of On-Off Numeric. No. of On-Off cycles to be repeated for
CL rPts cycle for clean relay Limit: 1 – 10 clean relay


Title
Fn. 2.0 Engineering limits for View Brix Engineering units and edit
Eng Par Brix Display & PID local PID parameters
parameters
Fn. 2.1 Brix Engineering Unit Display Only Can not edit this value, it shows brix low
brix Lo Low limit limit display value. It is calculated in
RUN mode
Fn. 2.2 Brix Engineering Unit Display Only Can not edit this value, it shows brix
brix Hi High limit high limit display value. It is calculated
in RUN mode
Fn. 2.3 Proportional gain in % Numeric. Proportional gain in %op / %error
Kp % Limit: 0 – 999.99
Fn. 2.4 Integral time constant in Numeric. Integral time constant in repeats / minute
Ti S seconds Limit: 0 – 999.99
Fn. 2.5 Derivative time constant Numeric. Derivative time constant in minutes
Td S in seconds Limit: 0 – 9999.9
Fn. 2.6 Set-point for PID control Numeric. PID set-point and this should be kept
SP % in % Limit: 0 – 140.00 between Brix-Low limit and Brix-High
limit set by equipment.


Title
Fn. 3.0 Linearisation table for Edit Linearisation table for Material 1
Ln Mat1 Material 1 system mode linearisation polynomial equation
Fn. 3.1 Offset Numeric. With Offset to be added or subtracted after
m1 OffS sign linearisation
Limit: 0-05.00
A / M key for
sign
Fn. 3.2 No. of samples Numeric. With No. of samples in the following table
m1 Samp sign
Limit: 3-6
Fn. 3.3 ma reading for 1st sample Numeric. Current in mA for 1st sample
m1 ma 1 Limit: 4.00-20.00
Fn. 3.4 brix reading for 1st Numeric. brix reading for 1st sample
m1 br 1 sample) Limit: 0-200.00
Fn. 3.5 ma reading for 2nd sample Numeric. Current in mA for 2nd sample
m1 ma 2 Limit: 4.00-20.00
Fn. 3.6 brix reading for 2nd Numeric. brix reading for 2nd sample
Fn. 3.7 ma reading for 3rd Numeric. Current in mA for 3rd sample
m1 ma 3 sample Limit: 4.00-20.00
Fn. 3.8 brix reading for 3rd Numeric. brix reading for 3rd sample
Fn. 3.9 ma reading for 4th Numeric. Current in mA for 4th sample
Fn. 3.10 brix reading for 4th Numeric. brix reading for 4th sample


Title
Fn. 4.0 Linearisation table for Edit Linearisation table for Material 2
Ln Mat2 Material 2 system mode linearisation polynomial equation
Fn. 4.1 Offset Numeric. With Offset to be added or subtracted after
m2 OffS sign linearisation
Limit: 0-05.00
A / M key for
sign
Fn. 4.2 No. of samples Numeric. With No. of samples in the following table
m2 Samp sign
Limit: 3-6
Fn. 4.3 ma reading for 1st sample Numeric. Current in mA for 1st sample
m2 ma 1 Limit: 4.00-20.00
Fn. 4.4 brix reading for 1st Numeric. brix reading for 1st sample
Fn. 4.5 ma reading for 2nd sample Numeric. Current in mA for 2nd sample
m2 ma 2 Limit: 4.00-20.00
Fn. 4.6 brix reading for 2nd Numeric. brix reading for 2nd sample
Fn. 4.7 ma reading for 3rd Numeric. Current in mA for 3rd sample
Fn. 4.8 brix reading for 3rd Numeric. brix reading for 3rd sample


Title
Fn. 9.0 Profile between level & MIX model only
m1 Prof brix set-point for
Material1
Fn. 9.1 Level 1 in % Numeric. Lowest value of level in % for which
m1.SP L1 Limit: 0 - 100 brix 1 set-point should be send
Fn. 9.2 Brix 1 in % Numeric. Lowest brix value corresponding to
m1.SP b1 Limit: 0 - 20000 Level 1 in % (0 % to 200.00 %)
Fn. 9.3 Level 2 in % Numeric. value of level in % for which brix 2
m1.SP L2 Limit: 0 - 100 set-point should be send (should be
more than or equal to Level 1 value)
Fn. 9.4 Brix 2 in % Numeric. brix value corresponding to Level 2 in
m1.SP b2 Limit: 0 - 20000 % (0 % to 200.00 %)
m1.SP b3 Limit: 0 - 20000 % (0 % to 200.00 %)
m1.SP b4 Limit: 0 - 20000 % (0 % to 200.00 %)
m1.SP b5 Limit: 0 - 20000 % (0 % to 200.00 %)
m1.SP b6 Limit: 0 - 20000 % (0 % to 200.00 %)


Title
Fn. 10. Profile between level & MIX model only
m2 Prof brix set-point for
Material2
Fn. 10.1 Level 1 in % Numeric. Lowest value of level in % for which
m2.SP L1 Limit: 0 - 100 brix 1 set-point should be send
Fn. 10.2 Brix 1 in % Numeric. Lowest brix value corresponding to
m2.SP b1 Limit: 0 - 20000 Level 1 in % (0 % to 200.00 %)
m2.SP b2 Limit: 0 - 20000 % (0 % to 200.00 %)
m2.SP b3 Limit: 0 - 20000 % (0 % to 200.00 %)
m2.SP b4 Limit: 0 - 20000 % (0 % to 200.00 %)
m2.SP b5 Limit: 0 - 20000 % (0 % to 200.00 %)
m2.SP b6 Limit: 0 - 20000 % (0 % to 200.00 %)


Title
Fn. 5.0 Calibration Mode
CALibr
Fn. 5.1 Resistance Low (Brix) Numeric. Low value of resistance in Ohms for
resi.I.Lo calibration Limit: 0-1500 which brix transmitter is to be calibrated
Fn. 5.2 Resistance High (Brix) Numeric. High value of resistance in Ohms for
resi.I.Hi calibration Limit: 0-3500 which brix transmitter is to be calibrated
Fn. 5.3 Temperature Low Fixed to 110 Low value of resistance in Ohms for
temp.I.Lo calibration ohms which RTD is to be calibrated
Fn. 5.4 Temperature High Fixed to 140 High value of resistance in Ohms for
temp.I.Hi calibration ohms which RTD is to be calibrated
Fn. 5.5 Brix current output Low Fixed to 4mA Low value of current for which brix
brix.O.Lo calibration current output is to be calibrated
Fn. 5.6 Brix current output High Fixed to 20mA High value of current for which brix
brix.O.Hi calibration current output is to be calibrated
Fn. 5.7 Control valve current Fixed to 4mA Low value of current for which Control
cntr.O.Lo output Low calibration valve current output is to be calibrated
Fn. 5.8 Control valve current Fixed to 20mA High value of current for which Control
cntr.O.Hi output High calibration valve current output is to be calibrated
Fn. 6.0 Test Mode Note that, during test mode, MODBUS
teStS communication is stopped
Fn. 6.1 Resistance input (Brix) None Displays ADC readings of resistance
reSi in test mode which is connected to SI, SI(G)
Fn. 6.2 temperature input (Brix) None Displays ADC readings of resistance
temp in test mode which is connected to RTDCOM, RTD+
& RTD-
Fn. 6.3 Brix output test mode UP or DOWN key Check brix current output on multimeter
brix oP to change output which is connected to BRIX+, BRIX -
Fn. 6.4 Control valve output test UP or DOWN key Check control valve current output on
cntr oP mode to change output multimeter which is connected to CV+,
CV -
Fn. 6.5 Cleaning relay test UP or DOWN or Check relay contacts on multimeter
relay RIGHT key to which is connected to power 24V DC
change
Material 1 / Material 2 UP or DOWN or Check relay contacts on multimeter
relay test RIGHT key to which is connected to B/G- & B/G+
change
Fn. 6.6 Display test mode All seven-segment displays and leds are
display tested


Title
Fn. 7.0 Set memory to default Option selection For each option confirmation is required
Set All values as per given 1. ALL i.e. Yes or No option should be selected.
2. noCL When ALL is selected, all system and
other parameters including Calibration
data is set to default. Hence re-
calibration is must.
When noCL is selected, all system and
other parameters excluding Calibration
data is set to default.
Fn. 8.0 Exit from parameter set Option selection Select yes to Exit from Parameter set-up
Exit mode 1. yES mode and no for not to Exit
2. no

Default Settings of parameters
Default Settings of Parameters all selecting Fn.7.0 i.e. Set
Parameter Parameter Description Default Value

Fn. 1.1 No. of Samples 5
Fn. 1.2 Communication Slave Address 1
Fn. 1.3 MODBUS communication Speed 19200 baud
Fn. 1.4 MODBUS communication Parity NONE
Fn. 1.5 MODBUS communication Type RTU
Fn. 1.6 PID Sampling Time 500 msec
Fn. 1.7 Temp. Compensation disabled
Fn. 1.8 Temp. Reference 60 deg C
Fn. 1.9 Enable / Disable Clean timer Enable
Fn. 1.10 Start delay for Clean timer 1 minute
Fn. 1.11 Off time for Clean timer 5 seconds
Fn. 1.12 On time for Clean timer 10 seconds
Fn. 1.13 No. of repeats of on-off cycle for Clean 3
timer
Fn. 1.9 Master Slave selection Master - Available only in Mix
model
Fn. 1.10 Hysteresis 5% - Available only in Mix model
Fn. 2.1 Brix Low Limit 85.00% (for Material 1) & 84.00%
(for Material 2)
Fn. 2.2 Brix High Limit 104.30% (for Material 1) & 100.00%
(for Material 2)
Fn. 2.3 Proportional Gain 000.10
Fn. 2.4 Integral time constant 000.00 repeats / minute
Fn. 2.5 Derivative time constant 0000.0 minute
Fn. 2.6 Set-point for PID control 91.00 %
Fn. 3.0 Linearisation equation for Material 1 y = 86.29 - 1.78x + 0.4714 x^2 –
0.0299 x^3 + 0.0006515 x^4
Fn. 4.0 Linearisation equation for Material 2 y = 80 + x
Fn. 9.0 Profile for Material1 Available only in Mix model

Level1 = 0%, Brix1 = 80.00%
Level2 = 20%, Brix2 = 82.00%
Level3 = 40%, Brix3 = 85.00%
Level4 = 60%, Brix4 = 88.00%
Level5 = 80%, Brix5 = 91.00%
Level6 = 100%, Brix6 = 95.00%

Parameter Parameter Description Default Value

Fn. 10.0 Profile for Material2 Available only in Mix model
Level1 = 0%, Brix1 = 80.00%
Level2 = 20%, Brix2 = 85.00%
Level3 = 40%, Brix3 = 87.00%
Level4 = 60%, Brix4 = 95.00%
Level5 = 80%, Brix5 = 101.00%
Level6 = 100%, Brix6 = 105.00%
Fn. 5.1 Resistance Low (Brix) calibration 50 counts for 100 ohms
Fn. 5.2 Resistance High (Brix) calibration 4000 counts for 1500 ohms
Fn. 5.3 Temperature Low calibration 100 counts for 110 ohms
Fn. 5.4 Temperature High calibration 1500 counts for 140 ohms
Fn. 5.3 Brix current output Low calibration 200 counts for 4 mA
Fn. 5.4 Brix current output High calibration 20 counts for 20 mA
Fn. 5.5 Control valve current output Low 200 counts for 4 mA
calibration
Fn. 5.6 Control valve current output High 20 counts for 20 mA
calibration
System Mode Material 1

PID source Remote (Local for Mix model )
PID o/p Auto
PID Manual o/p 0

PID CONTROL
This equipment has built-in PID control algorithm. When equipment is selected in
LOCAL mode, this controls control valve output. When control is selected in REMOTE
mode, PLC or SCADA controls the control valve output and PID parameters as well as
its set-point can be changed easily in LOCAL mode. Also equipment also has facility to
manipulate output in MANUAL mode of operation; both in LOCAL as well as REMOTE
mode of operation.
This equipment has built-in PID control algorithm for controlling control valve in
LOCAL mode (L / R hot key) of operation. Algorithm can be used as P-control or PI
control or PD control or PID control. In AUTO, output is controlled by algorithm and
operator can change this output, if MANUAL is selected (A / M hot key).
Proportional (P), Integral (I) and Derivative (D) control algorithm:
CV = Kp { E + Ti Edt + Td [(E – En-1) / dt]}
Where
CV = Output
Kp = Proportional gain i.e. 100 / Proportional Band
Ti = Integral time constant (repeat per minute)
Td = Derivative time constant (minutes)
dt = Time between samples
E = Error = SP – PV
PV = Process variable
SP = Set-point
En-1 = Error value from last sample
Control action in AUTO mode is “direct acting” i.e. as PV increases CV also increases.
If no derivative action is wanted, Td (derivative time constant) has to be set to zero.

If no integral action is wanted, Ti (integral time constant) has to be set to zero.
If no proportional action is wanted, Kp (proportional gain) has to be set to zero.
P-control is the principle method of control and should do most of the work.
I-control is added carefully just to remove the offset left behind by P-control.
D-control is there for stability only. It should be set up so that its stabilizing effect is
larger than the destabilizing effect of I-control.

SELF CLEANING TIMER (CLEAN RELAY)

This equipment has a built-in self cleaning timer operated relay, which is used for auto
cleaning of the sensor. This are labeled as ‘CLEANING’. Cleaning relay is used to
reciprocate the probe in the guide bush. Timer function can be ‘Enabled’ or ‘Disabled’ by
operator using keypad. If deselected i.e. disabled, then relay will be continuously OFF
and if enabled, clean relay will be operated as per following parameter settings. Also
operator can select the manual cycle (excluding Start delay time by pressing the
respective hot key. Manual cycle can be started only if Auto cycle is in auto start time
delay cycle (i.e. not in ON or OFF time cycle).
For this relay following parameters are settable –
Start time delay - This is start time at power-on or after timer function is selected or
after repeat cycle is over, during which relay is Off. This delay
time is in minutes.
Off time - This is Off time for relay, which is in seconds.
On time - This is On time for relay, which is in seconds.
No. of repeats - No. of times for which On & Off cycle will be repeated. After this
is over, again start time starts and cycle repeats forever or until
timer function is deselected.
e.g. if no. of repeats set to 4, relay will be ON as per following timing diagram. When
CLEAN RELAY is ON, it is indicated on LED labeled as ‘C’.
AUTO CYCLE
1 2 3 4 1 2 3 4
O O O O O O O O
N F N F N F N F
F F F F
START START
DELAY DELAY
NOTE : DURING CLEANING CYCLE, BRIX READINGS ARE NOT UPDATED

AND BRIX READING SHOWS PREVIOUS READING BEFORE CYCLE
STARTS.

MODBUS COMMUNICATION
MODBUS communication is done using RS-485 standard. Brix Transmitter is a slave

device. Brix transmitter can handle both RTU as well as ASCII communication. Note
that, first five registers are read only & rest 11 registers are read/write type.
Address can be set to 1 to 64.
MODBUS communication type can be selected as ASCII or RTU.
Please note that for ASCII communication, no. of data bits should be set to 7 (in the
master device) and for RTU communication, no. of data bits should be set to 8 (in the
master device).
Parity can be set to none or even or odd. Note that, if parity is selected as even or odd,
then no. of stop bits should be set to 1; but if parity is selected as none, then no. of stop
bits should be set to 2 (in the master device).
Please note that, when any of the communication parameter is changed, please switch the
equipment OFF and ON.
When optional MODBUS on TCPIP (with RJ-45 connector) is used, parameter settings
should be
Address-1, Baud-19200, type-RTU, Parity-None.
TCPIP address can be set on DIP switch (SW1-8) on JBTCP card.

Switches should ON for ‘1’ & OFF for ‘0’, SW1 is MSB & SW8 is LSB. E.g. to set TCP
address as 208 (i.e. D0 Hex i.e. 1101 0000 Binary). 1 means switch should be ON & 0
means switch should be OFF. Therefore switch setting from 1 to 8 will be “ON, ON,
OFF, ON, OFF, OFF, OFF, OFF”.
Also this IP address is displayed after power-on (if changed then in next power-on) and
in Fn.1 as 192.3168.0.208. If not used , then it is displayed as 192.168.0.0. If not used,
then this IP address is not displayed after power-on.

PLC Comm Register Rear/ Register Details

register addr Write
0 HR40001 Brix R Brix display * 100 in %
1 HR40002 Temperature R Temperature display in C
2 HR40003 Clean Relay Status R 0/1 for OFF/ON for BTM
(BTM)
3 HR40004 Auto/Manual Status R 0/1 for AUTO/MANUAL
4 HR40005 R
5 HR40006 Local/Remote R/W 0/1 for Local / Remote Selection of PID
6 HR40007 Control Valve o/p R/W 40 - 200 for 0 - 100 % for Remote PID
7 HR40008 SP R/W PID SP 0-20000 for 0.00 –200.00%
8 HR40009 P-Band R/W PID P-gain 0-65535 for 0.00-655.35
9 HR40010 I-Time R/W PID I-time 0-65535 for 0.00-655.35 min.
10 HR40011 D-Time R/W PID D-time 0-65535 for 0.00-655.35 min.
11 HR40012 Mode Selection R/W 0/1 for Material 1 /Material 2
12 HR40013 Start Clean Cycle R/W Any non-zero value to Start Clean Cycle
13 HR40014 Level R/W for Mix Model, for Local PID SP using profile
14 HR40015
15 HR40016 TCP Address R/W 0-255
NOTE : For PLC registers 6 (Control Valve o/p) to be written, unit must be in REMOTE
mode of operation, otherwise exceptional error “ILLEGAL DATA VALUE (03)” will
be send from slave unit.
If PLC register 7, 8, 9, 10 is out of limits, then master will get response but new value
will not be updated (which can be confirmed after reading the register).
NOTE: Do not forget to connect terminating resistance (120 ohms) on the bus, at both
end nodes, which can be connected externally or by making ‘ON’ switch 3 of DIP switch
S1 on ANALOG PCB.
Active pull-ups and pull-downs can be selected by making ‘ON” switch 1 & 2 of DIP
switch S1 on ANALOG PCB.
This should be exercised as per site requirements.

NOTE ON CALIBRATION (BTM)
After connecting the sensor to respective instruments, following things to be ensured on sensor
side, before beginning the calibration procedure
• Sensor Location: Sensor probe should be well dipped into flowing

massecuite. (If sensor is mounted in stagnant zone or above the massecuite
level, will continuously show wax reading)
• Electrical connections on the sensor/Transmitter side are firm.
• No hard material like Light massecuite is accumulated on the sensor rod.
(To ensure this, operate the cleaning and washing cycle manually for
number of times from the instruments).
• There is no leakage past the sensor rod through the gland nut. (If any
leakage is observed tighten the gland nut).
Once the sensor side is checked for above points and found satisfactory, start the calibration and
sampling procedure of Transmitter as described below:
Calibration Of Transmitter:
Selection of proper calibration range is of utmost importance to get correct brix readings.
Instrument is factory calibrated for-
b) Software Calibration Range Of (This range can be checked using Fn. 5.1(low) & Fn.
5.2(Hi).
Static Resistance 10 Ω --------- 500 Ω

Display reading (obtained by 4 ------------- 20
pressing  key)
PLEASE NOTE THAT, FOR GIVEN TYPE OF MATERIAL OR FOR GIVEN

CONTINUOUS PAN, ALL THE RELATED INSTRUNENTS SHOULD BE
CALIBRATED FOR THE SAME HARDWARE AND SOFTWARE RANGE.

Step 1: Fixing The Correct Range:

Power up all the instrument for given pan, please make sure the conditioner is running with full
capacity
and boiling/circulation is proper inside the pan/conditioner
Let ‘Z’ indicate impedance of the massecuite / molasses
Now, if 10 Ω ≤ Z ≤ 500, for conditioner, instruments are ready for sampling as

described in step ‘2’.
If ‘Z’< 10 Ω, display (as observed by pressing  key) will show ‘4’ (minimum
reading) continuously. In this case, lower limit of calibration range should be less than 10 Ω. This
can be achieved by connecting the fixed resistance less than 10 Ω to the sensor terminals of the
transmitter.
If ‘Z’ for any compartment is greater than 500 Ω instrument will display a value of ‘20’ (as
obtained by pressing  key). This indicates that, the impedance of molasses is beyond the
maximum calibration range.
Here we have to stretch the Software range from the preset HI limit of
500 Ω to the required value. This can be achieved by connecting the higher value of fixed
resistance from resistance box and carrying out Software calibration as described on page 18 &
19 of Operation Manual.
This value of resistance is required to be selected experimentally, in such a way that the displayed
reading, corresponding to ‘Z’ lies below ‘20’.
Minimum range (Ω) ≤ Z (any compartment) ≤maximum range.
Once the readings for all the instruments after re-calibration, fall between 4-20
(Reading displayed by pressing  key), we can start the sampling procedure.
Step 2: Sampling: (Preparing the instruments for brix readings)

Brix Transmitter instrument measures AC resistivity of the molasses. However relation

between brix & resistivity being a non-linear, the non-linearity in output is removed by
finding a polynomial relation between brix readings and direct output of transmitter. This
relation is fed in the instrument as Linearisation Table for Material 1 & Material 2
separately.
Hence follow the following instructions -

Assuming that instrument is ready & calibrated for the required range of the Pan type
(A/B/C). Instrument has already a set of sample readings.
Set the sampling time to 5 (Fn 1.1)
GENERATE RELATION BETWEEN BRIX AND NON-LINEAR COUNTS BY

TAKING SAMPLES:
Allow pan to boil for the dropping strike (Material 1).
Collect a sample of the Material 1, simultaneously measure ma corresponding to non-
linear counts (henceforth called as ma or nlc reading) by pressing UP key. Note down
this ma reading (which is in the range of 4.0 to 20.0 mA) & measure hydrostatic brix of
the sample in a laboratory. This ma reading & brix of the sample contributes 1st set of
reading.
Similarly take 5 more samples and note down its brix in % and mA reading.
5-6 such sample readings are needed to prepare instrument for brix indication.
Note: while preparing set of samples, please be sure that no two same ma entries be done.
Suppose 6 readings for Material 1 & Material 2 are as follows:
MATERIAL 1 MATERIAL 2
nlc/ma Brix reading in a nlc/ma Brix reading in
reading Laboratory reading a Laboratory
1 6.30 83.49 6.30 78.50
2 20.00 96.10 4.00 75.00
3 4.00 80.00 20.00 92.90
4 14.32 92.50 15.30 85.50
5 10.80 87.60 17.50 88.50
6 17.32 93.60 8.80 80.10
From these set of readings, it is clear that, during Material 1 brix readings will be in the
range of 80.00 %; called as Brix Low Engineering unit to 96.10 %; called as Brix High
Engineering unit (corresponding to 4 & 20 respectively).
And during Material 2 brix readings will be in the range of 75.00 %; called as Brix Low
Engineering unit to 92.90 %; called as Brix High Engineering unit (corresponding to 4
& 20 respectively).

LINEARISATION TABLE Entry :

Now enter those Material 1 readings in Fn 3.0 & Material 2 readings in Fn 4.0
Let’s take an example for Material 1 readings.
Fn 3.1 is OFFSET (enter this as 0, we will explain its purpose little later)
Fn 3.2 is NO OF SAMPLES (in this case, we are entering 6 sample readings, so set this
to 6).
Fn 3.3 is ma reading corresponding to first sample, which is 6.30
Fn 3.4 is brix reading corresponding to first sample, which is 83.49
Fn 3.5 is ma reading corresponding to second sample, which is 20.00
Fn 3.6 is brix reading corresponding to second sample, which is 96.10
Fn 3.7 is ma reading corresponding to third sample, which is 4.00
Fn 3.8 is brix reading corresponding to third sample, which is 80.00
Fn 3.9 is ma reading corresponding to fourth sample, which is 14.32
Fn 3.10 is brix reading corresponding to fourth sample, which is 92.50
Fn 3.11 is ma reading corresponding to fifth sample, which is 10.80
Fn 3.12 is brix reading corresponding to fifth sample, which is 87.60
Fn 3.13 is ma reading corresponding to sixth sample, which is 17.32
Fn 3.14 is brix reading corresponding to sixth sample, which is 93.60
Please note that, if only 5 samples are taken, then enter NO OF SAMPLES as 5, and 6th
sample readings for ma & brix should be entered as 0.00
After Linearisation table entries for both Material 1 & Material 2 are done, Exit (Fn. 8.0)
programming mode and brix readings will be displayed as per entered table.
OFFSET Entry:
Now check readings during normal operation. If it is found out that all the readings are
shown are deviated up or down by few brix, then OFFSET (Fn. 3.1 or Fn. 4.1) should be
entered. E.g. if all readings displayed up by 0.5 % then enter OFFSET as -0.50. & if all
reading are displayed down by say 1.5 %, then enter OFFSET as 1.50. (Sign +/- is
toggled using A/M key).
Maximum offset of +/-5% can be entered.
Note: readings corresponding 4.00 ma & 20.00 ma are not deviated due to addition
of OFFSET and only intermediate brix readings are changed due to addition of
offset.

Temperature Input Calibration

To calibrate temperature input channel, technician should calibrate both high & low
range using standard resistance of 110 ohms and 140 ohms respectively.
To calibrate temperature input channel, no hardware adjustments are required.
Now do software calibration using Fn. 5.3 & 5.4.

• First select Fn. 5.3 i.e. Temperature Input Low calibration. Connect 110 ohms
(equivalent of 26 ºC) at RTD sensor terminals RTD COM, RTD + & RTD -.
Display line1 shows ADC counts within range of 500 to 1000. After display
reading is stable (within 10 counts will do), press ENTER key. Now this reading
is received inside the instrument as low temperature.
• Now select Fn. 5.4 i.e. Temperature Input High calibration. Connect 140 ohms
(equivalent of 104 ºC) at RTD sensor terminals RTD COM, RTD + & RTD -.
Display line1 shows ADC data. After display reading is stable (within 10 counts
will do), press ENTER key. Now this reading is received inside the instrument for
high temperature.
Please note that although calibrated temperature input at 26 ºC & 104 ºC, instrument does
temperature compensation in the range of 20 ºC to 150 ºC.
Brix Output calibration

To calibrate Brix output (4-20 mA), technician should calibrate both high & low using a
Digital Multimeter in DC current input measurement mode.
To calibrate Brix output, no hardware adjustments are required.

• First select Fn. 5.5 i.e. Brix Output Low calibration. Connect the current meter at
the BRIX + & BRIX - terminals. Display shows “Adj 4”; At this point observe
the reading on the meter. Press UP key to increase the displayed current value on
the meter & DOWN key to decrease the displayed current value on the meter.
Once 4 mA is achieved on the meter, press ENTER key.
• Now select Fn. 5.6 i.e. Brix Output High calibration. Connect the current meter at
the BRIX + & BRIX - terminals. Display shows “Adj 20”; At this point observe
the reading on the meter. Press UP key to increase the displayed current value on
the meter & DOWN key to decrease the displayed current value on the meter.
Once 20 mA is achieved on the meter, press ENTER key.

Control Output calibration

To calibrate Control output (4-20 mA), technician should calibrate both high & low using
a Digital Multimeter in DC current input measurement mode.
To calibrate Control output, no hardware adjustments are required.

• First select Fn. 5.7 i.e. Control Output Low calibration. Connect the current meter
at the CV + & CV - terminals. Display shows “Adj 4”; At this point observe the
reading on the meter. Press UP key to increase the displayed current value on the
meter & DOWN key to decrease the displayed current value on the meter. Once 4
mA is achieved on the meter, press ENTER key.
• Now select Fn. 5.8 i.e. Control Output High calibration. Connect the current
meter at the CV + & CV - terminals. Display shows “Adj 20”; At this point
observe the reading on the meter. Press UP key to increase the displayed current
value on the meter & DOWN key to decrease the displayed current value on the
meter. Once 20 mA is achieved on the meter, press ENTER key.
REVISION HISTORY
Normal Model -
Rev. No. Modifications

btm 1.6.09 Nov 2009 –
Mix model –
Mix model –
Rev. No. Modifications

bmm3.4.12. August 2012 - Communication parameters changed. Hardware
changed for Junction Box. Optional SMPS added. Facility to
communicate through MODBUS TCPIP.

WARRANTY CERTIFICATE
This instrument is warranted against any manufacturing defects for its design, material,
workmanship and trouble free performance for a minimum period of two crushing
seasons (one crushing season to be of more than 90 days) or performance of plant,
whichever is earlier.
Kindly note the following:

1. The warranty will be void if the instrument is opened or tampered within anyway.
2. In case of any defect reported during this warranty period we will be replace /
repair the same free of cost at your site immediately.
Instrument : BRIX TRANSMITTER (MELTER / MOLASSES)

Serial No. :
Client :
P.O. No. :
Date of Despatch:
Authorised Signatory :
Company Seal :

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CONTENTS

Data Entry (Calibration) ____________________________________________________ 21

Ver-btm3.x.xx / bmm3.x.xx Page 2

The instrument is connected to Brix sensor, which is mounted in a pan at suitable

Ver-btm3.x.xx / bmm3.x.xx Page 3

This equipment also has built-in PID control algorithm.

Equipment has two 4-20 mA current outputs.

Ver-btm3.x.xx / bmm3.x.xx Page 4

Optional - Level request from Slave Level Transmitter

Always select PID as LOCAL.

External Keys with Label –

Ver-btm3.x.xx / bmm3.x.xx Page 5

Enclosure Cylindrical Aluminium casting

Mounting 2” pipe / mounting plate

AC Input Power 230V AC (150V~270V)

DC Input Power 24V DC (18V-30V)

Display 5 + 7 (seven segment LED)

Input Sensor minimum 1 no. & maximum 2 no.s

Optional Sensor RTD PT-100

Relay output 1 No. Potential free for Material 1 / Material 2

Control type Proportional, Integral, Derivative

Analog Outputs 2 nos. 4-20mA DC of which one is isolated (4-wire)

Communication RS-485(built-in) or TCPIP(optional)

No. of samples 3 to 120 samples software selectable

Default Indication Brix in %, Control Valve opening in %, PID set-point in %

Optional Indication Non-linearised count in mA

Ver-btm3.x.xx / bmm3.x.xx Page 6

MOUNTING DETAILS DRAWING

Ver-btm3.x.xx / bmm3.x.xx Page 7

Terminal Terminal Terminal Details Terminal Description

Terminal Terminal Terminal Details Terminal Description

Terminal Terminal Terminal Details Terminal Description

Ver-btm3.x.xx / bmm3.x.xx Page 8

TERMINAL CONNECTIONS & LINKS

X1 group contains DC POWER INPUT connections.

X4 group contains all connections for Material1 / Material2 selection output.

Relay Contact Links –

Low/High Range Selection Switch –

Ver-btm3.x.xx / bmm3.x.xx Page 9

Menu function & Data Entry keys –

1/2 C A/M L/R

Hot keys - 1 / 2 (Material 1 or Material 2 selection),

The description of LEDs are as follows –

LED 1 (green) indicates system is selected for “Material 1”

Ver-btm3.x.xx / bmm3.x.xx Page 10

Display is standard 7-segment and has 2 lines –

Line1 (5 digits (0.56”) - Used to edit numbers, display brix etc.

Ver-btm3.x.xx / bmm3.x.xx Page 11

DISPLAY MODES AND KEY OPERATION

Normal Mode of Display during RUN –

PROFILE parameter display –

Ver-btm3.x.xx / bmm3.x.xx Page 12

PID parameter display -

Ver-btm3.x.xx / bmm3.x.xx Page 13

Control Valve o/p in Manual -

Non-linearised output display -

Temperature output display -

Changing timer function -

Starting timer function in manual mode -

Changing System mode -