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9300 User`s Manual - Environmental Test Chambers from Cincinnati

1. 9 9 9 9 9 A S 9 9 9 A 19 19 19 A A l9 19 ANNNNNNANNANNANANANAN DD PB PA PA LI PA PJ PJ D Py Ly D Py Dy Py D O O UU OU O U O G O O O G O O G G Sj 9 9 9 9 9j 9 A 19 A 13 09 a A 9 A A A Display Go Home The menu will revert to PV SV display after keyboard is kept untouched for 2 minutes except Display Mode Menu and Manual Mode Menu However the menu can revert to PV SV display at any time by pressing and PJ PA PA PA p Pj PJ PJ Dj PA DA PA D PJ o DJ PA PA D PA PA LI PI LI Ly PA LIL PA PJ Pj DI DJ DJ PA PA DJ PA Dy Dy D DJ Ly D 3 LO 19 19 L9 19 lA 09 A lA la A 19 l9 A A l9 lA 19 A LA LA lA 19 k9 LA lA LA LA LA LA LA A LA LA 19 LA lA 19 lA 9 A LA lA LA l9 LA LA LA 3 9 ko ta la a la Ea f9 f9 E l9 a la 9 ta a a a 9 9 9 a l9 al 9 9 9 9 9 a 9 la 9 9
2. nM 2 12 Event Input Wiring 2 13 Alarm 1 Wiring 2 14 Alarm 2 Wiring 2 15 RS 485 eo ren nnn en nn nn eT 2 16 Analog Retransmission 2 17 RS 232 eoo nnne nnne nnn nnn nnne nnn n Chapter 3 Programming Special Functions 3 1 Rearrange User Menu 3 2 Dwell Timer MM 3 3 Manual Control erue 3 4 Failure Transfer 3 5 Signal Conditioner DC Power Supply 3 6 Burnpless Transfer 3 7 Self Tuning ee n e 3 8 Auto Tuning ee ne e en nn n n 3 9 Manual Tuning nn nnnn nce nnnne 3 10 Pump Control ee nonno en e n enns 3 11 Sleep Mode reno roo 3 12 Remote LOCKOUT e rr rrr err 3 13 Hea
3. Figure 2 18 Analog Retransmission Wirlng Indicators Indicators PLC s PLC s Recorders Recorders Data loggers Inverters etc BE M Retransmlt Current Retransmit Voltage Do not exceed 500 ohms total load Minimum load must be greater than 10K ohms Data loggers Inverters etc UM9300 2 0 23 Y88G8Q0G PC E Figure 2 19 090909999 RS 232 Wiring TXT TX2 COM 9 pin RS 232 port E q LARA CC94 1 Note If the FDC 9300 is configured for RS 232 communication the El Event Input is disconnected internally The unit can no longer perform event input function EIFN When you insert a RS 232 module CM94 2 to the connectors on CPU board C930 the jumper JP22 on terminal board T930 must be modified as following J1 must be shorted and J2 must be cut and left open Location of JP22 is shown in the following diagram Figure 2 20 Location of Jumper JP22 If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable must be modified according to the following circuit diagram To DTE PC RS 232 Port 1 DCD FDC 9300 2 RD NG Dm a TX2 10 X2 E 5 GND nasan 6 DSR COM 7 RTS coM Q 14 8 CIS 9 RI Female DB 9 24 UM9300 2 0 Chapter 3 Programming Special Functions This unit provides an useful parameter FUNC which can be used to select the function complexity level befo
4. Yes Does the process oscillate Does the process oscillate Yes Y 1 gt Flag 0 PB1 PBu Oscillating period sTu ra Y 2PB1 gt PB1 o5PB1 PB1 PB1 E and Examine E Process Is steady state reached Yes the process oscillate Ves 1 6PB1 gt PB1 0 8PB1 PB1 The above procedure may take a long time before reaching a new steady state since the P band was changed This is particularly true for a slow process So the above manual tuning procedures will take from minutes to hours to obtain optimal PID values Load new PID values 1 7 PBu PB1 Tu TI1 0 3 Tu _ TD1 NOTE The final PID values can t be zero If PBu 0 then set PB 1 If Tu lt 1 sec then set Tll 1 sec 32 UM9300 2 0 The PBu is called the Ultimate P Band and the period of oscillation Tu is called the Ultimate Period in the flow chart of Figure 3 5 When this occurs the process is called in a critical steady state Figure 3 6 shows a critical steady state occasion If PB PBu PV the process sustains to oscillate Figure 3 6 Critical Steady Set point 77 State Time If the control performance by using above tuning is still unsatisfactory the following rules can be applied for further adjustment of PID values ADJUSTMENT SEQUENCE SYMPTOM SOLUTION
5. Benefits of Self tuning Benefits of Self tune 1 Unlike auto tuning Self tuning will produce less disturbance to the 1 Less disturbance to the process 2 process 2 Perform PID control during tuning Unlike auto tuning Self tuning doesn t change control mode during tuning period 3 period It always performs PID control 3 Available for ramping set point Changing set point during Self tuning is allowable Hence Self tuning can control and remote set point be used for ramping set point control as well as remote set point control control where the set point is changed from time to time n The parameter SELF is contained in setup menu Refer to Section 1 5 to obtain SELF for initiating a self tuning UM9300 2 0 29 3 8 Auto Tuning A 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 30 Operation Applicable Conditions 1 The system has been installed normally PB1 0 TM 30 if PB1 T11 TD1 2 Use the default values for PID before tuning assigned The default values are PB PB2 18 0 F T11 T 2 100 sec TD1 1D2 25 0 sec Of course you can
6. 5D oq PID Control ON OFF Control PID Control Warm Start ns If the auto tuning begins near the set point warm start the unit passes the warm up cycle and enters the waiting cycle Afterward the procedures are same as that described for cold start Auto Tuning Error If auto tuning fails an ATER message will appear on the upper display in cases of Auto Tuning Error e f PB exceeds 9000 9000 PU 900 0 F or 500 0 C e or if Tl exceeds 1000 seconds e or if set point is changed during auto tuning procedure e or if event input state is changed so that set point value is changed Solutions to 1 Try auto tuning once again 2 Don t change set point value during auto tuning procedure 3 Don t change event input state during auto tuning procedure 4 Use manual tuning instead of auto tuning See section 3 20 5 Touch any key to reset message UM9300 2 0 31 3 9 Manual Tuning In certain applications very few using both self tuning and auto tuning to tune a process may be inadequate for the control requirement then you can try manual tuning Connect the controller to the process and perform the procedures according to the flow chart shown in the following diagram Figure 3 5 Manual Tuning Procedure Use initial PID values to control the process Wait and Examine Wait and Examine the Process the Process Is steady state reached Is steady state reached
7. Within 4 seconds for TC RTD and mV inputs 0 1 second for 4 20 mA and 1 5 V inputs Input 2 Resolution 18 bits Sampling Rate 2 times second Maximum Rating 2 VDC minimum 12 VDC maximum Temperature Effect 0 005 of reading C Common Mode Rejection Ratio CMRR 120dB Sensor Break Detectlon Below 1 mA for 4 20 mA input below 0 25V for 1 5V input unavailable for other inputs sensor Break Responding Time 0 5 second Characteristics Accuracy Input R Type aio 25 C Impedance 2 Yo CT94 1 0 50 0A of Reading 302 KQ 0 2 A mA 3mA 27mA 0 05 70 50 a ue e 122 Input current V 1 3V 11 5V 0 05 96 302 Ko Characteristics Input 3 Event Input Accuracy npu HE f Type Range a Logic Low 10V minimum 0 8V maximum 5 a 25 C lmpasaka Logic High 2V minimum 10V maximum J 20 C 1000 C 2 0 2 2 MO Extemal pull down Resistance 400 Ko maximum 184 F 1832 F Extemal pull up Resistance 1 5 MA minimum y 200 C 1370 C 120 2 2Ma Functions Select second set point and or PID 328 F 2498 F reset alarm 1 and or alarm 2 250 C 400 C disable output 1 and or output 2 T 418 F 752 F t 2C 22M9 remote lockout 100 C 900 C E 1489 1652 20 22M9 Output 1 Output 2 F 4 2C Relay Rating 24 240 VAC life cycles 200 000 for B 0 C 1820 C 200 C 22 MO resi
8. 0 mA or OV Saturation High 22 2 mA or 5 55V 11 1V min Linear Output Range 0 22 2MA 0 20MA or 4 20MA 0 5 55V 0 5V 1 5V 0 11 1 V 0 10V User Interface Dual 4 digit LED Displays Upper 0 4 10 mm Lower 0 3 8 mm Keypad 3 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 1 255 of PB ON OFF 0 1 100 0 LF hysteresis control P band 0 P or PD O 100 0 96 offset adjustment PID Fuzzy logic modified Proportional band 0 1 900 0 F Integral time O 1000 seconds Derivative time O 360 0 seconds Cycle Time 0 1 100 0 seconds Manual Control Heat MV1 and Cool MV2 Auto tuning Cold start and warm start Self tuning Select None and YES Fallure Mode Auto transfer to manual mode while sensor break or A D converter damage Sleep Mode Enable or Disable Ramping Control 0 900 0 F minute or O 900 0 F hour ramp rate Power Limit O 100 96 output 1 and output 2 Pump Pressure Control Sophisticated functions provided Adaptive Heat Cool Dead Band Self adjustment Remote Set Point Programmable range for voltage or current input Differential Control Control PV1 PV2 at set point Digital Filter Function First order Time Constant 0 0 2 0 5 1 2 5 10 20 30 60 se
9. Etype thermocouple C mm re I rr Btype thermocouple 0 Rtype thermocouple non P ra un 1 rr S type thermocouple Table 1 6 Parameter Description continued 3 7 Contained Basic Parametef Display Parameter Range Default in Function Notation Format Description Value C type thermocouple P type thermocouple PT 100 ohms DIN curve PT 100 ohms JIS curve 4 20 mA linear current input 0 20 mA linear current input 0 1V linear Voltage input 0 5V linear Voltage input 1 5V linear Voltage input 0 10V linear Voltage input Special defined sensor curve dB r3 rr P 703 o 0 mr on Dr 3 Poke C3 un IN1 Sensor Type Selection Ny IC un un a C3 C3 C3 uy c3 Degree C unit IN1 Unit Selection Degree F unit Process unit nagi No decimal point 1 dP 1 decimal digit IN1 Decimal Point Selection E F 2 decimal digits Setup 3 3 dP 3 decimal digits Menu 1 IN1 Low Scale Value Low 19999 High B IN1 High Scale Value Low 19999 1000 0 nant N2 no function Current transformer input 1 Li 4 20 mA linear current input Li 0 20 mA linear current input IN2 Signal Type Selection 0 1V linear voltage input uang 0 5V linear voltage input 1 5V linear voltage input LI 0 10V linear voltage input BEN IN2 Unit Selection Same as IN1U 1 0 1 4 4 2 4 0 IN2 Decimal Point Selection Same
10. working PID values and compares the process behavior with previous cycle Selects If the new PID values achieve a better control then changing the next PID a values in the same direction otherwise changing the next PID values in Disable Self tuning reverse direction When an optimal condition is obtained the optimal PID or values will be stored in PB1 TI1 TD1 or PB2 TI2 TD2 which is determined by Event Input conditions When Self tuning is completed the value of SELF will Enable Self tuning be changed from YES to NONE to disable self tuning function When the Self tuning is enabled the control variables are tuned slowly so Default that the disturbance to the process is less than auto tuning Usually the Self SELF NONE tuning will perform successfully with no need to apply additional auto Exceptions The Self tuning will be disabled as soon as one of the following conditions occurs SELF is selected with NONE The controller is used for on off control that is PB 0 The controller is used for manual reset that is TI 0 The controller is under loop break condition The controller is under failure mode e g sensor break The controller is under manual control mode The controller is under sleep mode The controller is being calibrated 0 YO 01 0o ND If the self tuning is enabled the auto tuning can still be used any time The self tuning will use the auto tuning results for its initial values
11. Disable Output 1 coc Disable Output 2 LI p do io Disable Output 1 amp Output 2 Lock All Parameters Selects remote setpoint active Use PV1 as process value Use PV2 as process value EVMB PV Mode Selection Use PV1 PV2 difference as 0 process value Use PV2 PV1 difference as process value O second time constant lc 0 2 second time constant 5 0 5 second time constant 1 1 second time constant Filter Damping Time c 2 seconds time constant FILT Constant of PV c a 2 9 5 seconds time constant ig 10 seconds time constant et 20 seconds time constant 3 30 seconds time constant 51 60 seconds time constant Y Self Tuning Function aon E Self tune function disabled SELF A 0 Selection ES Self tune function enabled 0 nan E Sleep mode function disabled SLEP SLEP a Function A 0 1 YE 5 Sleep mode function enabled UM9300 2 0 Table 1 6 Parameter Description Contained Basic Parameter Display Range Default in Function Notation Format Description Value 0 op 2 Poetae SP2 depends on EIFN 1 ni ram Use minute ramp rate as set point 2 Hr Use hour ramp rate as set point SPMD 5P Ad Set point Mode Selection 0 3 B HL Use IN1 process value as set point 4 PUTI Use IN2 process value as set point 5 PLA Selected for pump control v spi SP IL Low 19999 High 45536 320 F 7 sPiH SP IH Low 19999 High 45536 1832 0 E 0 r set point 2 SP2 is an actual value iod Sue
12. UM9300 2 0 Table 1 6 Parameter Description continued 2 7 Contained Basic Parametef Display Parameter Range Default in Function Notation Format Description Value Low 1 Add Assi t of Digital Address ssignment of Digita High 255 0 3 Kbits s baud rate 0 6 Kbits s baud rate 1 2 Kbits s baud rate 2 4 Kbits s baud rate 4 8 Kbits s baud rate bA ud Baud Rate of Digital COMM i 9 6 Kbits s baud rate 5 14 4 Kbits s baud rate 19 2 Kbits s baud rate 28 8 Kbits s baud rate 38 4 Kbits s baud rate a A A JA A Data Bit count of Digital 7 data bits 4 COMM 8 data bits Even parity PA Parity Bit of Digital COMM Odd parity 0 No parity bit Stop Bit Count of Digital One stop bit STOP StoP comm 0 Setup Two stop bits Menu Retransmit IN1 process value Retransmit IN2 process value Retransmit IN1 IN2 difference process value Pp Retransmit IN2 IN1 difference process value AOFN RoFn Analog Output Function Retransmit set point value 0 Retransmit output 1 manipulation value Retransmit output 2 manipulation value Retransmit deviation PV SV Value 0C AOLO Bal s Analog Output Low Scale High 45536 32 0 F i igh 100 0 C AOHI Hat cee Output High Scale Low 19999 High 45536 120 E J type thermocouple NA IN1 IN1 Sensor Type Selection UM9300 2 0 9 rok K type thermocouple T type thermocouple n on Py Py Tr
13. bad function code 11 Communication error register address out of range Correct the communication software to meet the protocol requirements Don t issue an over range register address to the slave 12 Communication error access a non existent parameter Don t issue a non existent parameter to the slave 14 Communication error attempt to write a read only data Communication error write a value which is out of range to 15 a register 26 Fail to perform auto tuning function 29 EEPROM can t be written correctly Don t write a read only data or a protected data to the slave Don t write an over range data to the slave register 1 The PID values obtained after auto tuning procedure are out of range Retry auto tuning 2 Don t change set point value during auto tuning procedure 3 Don t change Event input state during auto tuning procedure 4 Use manual tuning instead of auto tuning Return to factory for repair Input 2 IN2 sensor break or input 2 current below 1 mA if 4 20 mA is selected or input 2 voltage below 0 25V if 1 5V is selected 38 Replace input 2 sensor Input 1 IN1 sensor break or input 1 current below 1 mA if 4 20 mA is selected or input 1 voltage below 0 25V if 1 5V is selected 39 40 A Er Ato D converter or related component s malfunction Replace input 1 sensor Return to factory for repair UM9300 2 0 43 Table 5 2 Common Fa
14. 0 Linear Current Q 12 SOO 13 14 15 1 Q ep 0 14 05V 1 5V 0 10V Minimum Load 10 K ohms Pulsed Voltage to Drive SSR Linear Voltage Max 1A 240V Load 120V 240V Mains Supply 1 2 3 4 5 6 7 8 SOOOOOOO Tri p i Figure 2 12 9 10 Output 1 Wiring Ak Triac SSR Output Direct Drive 20 99999999 UM9300 2 0 2 11 Output 2 Wiring Max 2A Resistive Load 120V 240V Mains Supply 66666666 Maximum Load 500 Ohm max 99999999 99999999 Figure 2 13 Relay Output Linear Current Output 2 Wiring 5VDC 30ma or O 1V 0 5V 14VDC 40ma Pulsed Voltage 1 6V 0 OV 66666666 66666666 Minimum Load 10 K ohm Pulsed Voltage to Drive SSR Linear Voltage Max 1A 240V gt 120V 240V Mains Supply Triac SSR Output UM9300 2 0 2 2 12 Event Input wiring 1 2 4 9 Qe Q Q Q d Q O Of Il e Q my A my IN oot EN D EV OT a ON j Open Collector Input 88089000 Figure 2
15. 14 Event Input Wiring 2889888989 Switch Input The event input can accept a switch signal as well as an open collector signal The event input function EIFN is activated as the switch is closed or an open collector or a logic signal is pulled down 2 13 Alarm 1 Wiring Load Mox 2A Resistive SYYY999O Hh 2999999 Relay Output n o 120V 240V Mains Supply Figure 2 15 Alarm 1 Wiring Note Both Form A and B contacts are available for alarm 1 relay 2 14 Alarm 2 Wiring Order a correct form for alarm 1 to suit for your application 20 Max 2A Resistive p SYYYY99O 9 10 11 EN 1 9999999 5 7 45 O 1 Io Relay Output Load 120V 240V Mains Supply Figure 2 16 Alarm 2 Wiring UM9300 2 0 2 15 RS 485 4 5 6 8 Figure 2 17 RS 485 to RS 232 RS 485 Wiring network adaptor SNAT0A or 99999999 c TX TX2 RS 485 RS 232 x Twisted Pair Wire 4 PC TO Em Q Q Qe O Qe Or Qe Qv Op Or Qs Oo O on Qe Mox 247 units can be linked Terminator 220 ohms 0 5W
16. E Integral Time 1 Value ow 0 High 1000 sec 100 Menu NA TD1 kd Derivative Time 1 Value Low 0 High 360 0 sec 25 0 ff CPB FRE Gooling Proportional Band wem 4 High 255 100 Heating Cooling Dead Band igh v DB Negative Values Overlap 36 0 High 36 0 0 SP2 GP Set point 2 See Table 1 5 1 8 100 0 PB2 Pg Proportional Band 2 Value Low 0 High 200 0 18 0 TI2 E Integral Time 2 Value Low 0 High 1000 sec 100 TD2 E d Derivative Time 2 Value Low 0 High 360 0 sec 25 0 Output 1 ON OFF Control 55 6 C s O1HY o IHY Hysteresis enkro ow 0 1 High 3000F 0 1 Y A1HY A HY Hysteresis Control of Alarm 1 Low 0 1 High 18 0 E 0 1 Y A2HY H2HY Hysteresis Control of Alarm 2 Low 0 1 High 13 0 A 0 1 PL1 PL Output 1 Power Limit Low 0 High 100 96 100 PL2 PL e Output 2 Power Limit Low 0 High 100 96 100 0 AGI Basic Function Mode FUNC Fisnf Function Complexity Level BSL 1 UNL Es 1 Full Full Function Mode 0 nan E No communication function 1 YEAS RS485 interface 2 gg RS232interface Af 4 20 mA analog retransmission 3 E cu output SRM COMM E ann Communication Interface 4 M FPF 0 20 mA analog retransmission 1 Type u Lf output 5 me ju 0 1V analog retransmission u 7 output n 1 0 5V analog retransmission Su 5 output 7 l 5 1 5V analog retransmission output St tft 0 10V analog retransmission BU a output PROT Pr ut COMM Protocol Selection O uy Modbus protocol RTU mode 0
17. PV1 or PV2 is used for SPMD Dependent Difference of PV1 and PV2 can t be used for PV while PV1 values used for PV and SV will create incorrect result of control or PV2 is used for SV Illegal setup values been used Before COOL is used for OUT2 DIRT cooling action has already been used for 4 OUT1 or PID mode is not used for OUT1 that is PB1 or PB2 0 and TI1 or TI22 0 Illegal setup values been used unequal IN1U and IN2U or 5 unequal DP1 and DP2 while P1 2 or P2 1 is used for PVMD or PV1 or PV2 is used for SPMD or P1 2 H P1 2 L D1 2 H or D1 2 L are used for A1FN or A2FN Check and correct setup values of OUT2 PB1 PB2 TI1 TI2 and OUT1 IF OUT2 is required for cooling control the control should use PID mode PB P TI 9 and OUT1 should use reverse mode heating action otherwise don t use OUT2 for cooling control Check and correct setup values of INTU IN2U DP1 DP2 PVMD SPMD A1FN or A2FN Same unit and decimal point should be used if both PV1 and PV2 are used for PV SV alarm 1 or alarm 2 6 Illegal setup values been used OUT2 select AL2 but A2FN select NONE 7 Illegal setup values been used Dwell timer TIMR is selected for both ATFN and A2FN Check and correct setup values of OUT2 and A2FN OUT2 will not perform alarm function if A2FN select NONE Check and correct setup values of A1FN and A2FN Dwell timer can only be properly used for single alarm output 10 Communication error
18. a pai 1 j gt set point 2 SP2 is a deviation a col value 0 nan E No parameter put ahead 1 E AE Parameter TIME put ahead 2 H GP Parameter A1SP put ahead 3 H IgH Parameter A1DV put ahead 4 Hg P Parameter A2SP put ahead 5 Hg 44 Parameter A2DV put ahead 6 ESE Parameter RAMP put ahead Setup 7 of SE Parameter OFST put ahead Menu Y SEL1 SEL Select 1 st Parameter 8 m EFL Parameter REFC put ahead 0 9 SH E Parameter SHIF put ahead 10 PE Parameter PB1 put ahead 11 E 4 Parameter TI1 put ahead 12 gg Parameter TD1 put ahead 13 PR Parameter CPB put ahead 14 gb Parameter DB put ahead 15 5PC Parameter SP2 put ahead 16 Phe Parameter PB2 put ahead 17 ti e Parameter TI2 put ahead 18 Edd Parameter TD2 put ahead Y SEL2 SEL Select 2 nd Parameter Same as SEL1 0 Y SEL3 SEL 3 Select 3 rd Parameter Same as SEL1 0 v sela SEL Same as SEL1 0 Y SEL5 SEL 5 Select 5 th Parameter Same as SEL1 0 Y ADO Ago Low 360 High 360 i ADG Ato D Gain Calibration Low 199 9 High 199 9 Mee v we On Coeffident Low 1999 High 1999 Menu Cold Junction Low NA CJTL EN ous Calibration Low 5 00C High 40 00C UM9300 2 0 13 Table 1 6 Parameter Description continued 7 7 Contained Basic Parameter Display Parameter in Function Notation Format Description Low 199 9 Range High 199 9 Default Value s Serial Resistance 1 Cold Junction Gain Y CJG L Jb Calibrati
19. be to display set point value 19999 will be displayed by Ll parameter value or control Output 1 iind output value etc N Program Code Indicator dada ee G A Vv 4 9999 naaoa e e e 3 Silicone Rubber Buttons a af af Wf f FDC 9300 for ease of control setup Figure 1 4 Front Panel Description end set point adjustment 15536 will be displayed by Program Version Program No Table 1 3 Display Form of Characters y F Date Code A R E E I N n S 5 X M J 6536 4 ors BlIbBl F FIJO p TIE YY MEN ILAN 9999 will be displayed by K Z Date 31 st Month December Year 1999 V Confused Character 6 UM9300 2 0 1 5 Menu Overview Piya JUser Sv vate Menu Setup ee m UN Control Q A Auto tuning AN Press for 3 seconds to enter Display E Mode Mode the auto tuning mode co rJ FILE Callbration 2 for 3 seconds To execute the default setting program 4 Hand Manual 2 for 3 seconds Press to enter Setup Mode Press to select parameter
20. or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform step 8 to calibrate voltage as well as CT function if required Step 8 for input 2 Press scroll key until the display shows 215 Simulate a 10 V signal to terminals 15 and 16 in correct polarity Press scroll key for at least 5 seconds and release the scroll key 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 equalto 199 9 or 199 9 then the calibration fails Perform step 9 to calibrate mA function if required for input 2 Step 9 Press scroll key until tne display shows Simulate a 20 mA signal to terminal 15 and 16 in correct polarity Press scroll key for at least 5 seconds and release the scroll key The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform step 10 to calibrate of n compensation if Step 10 40 required The DIP switch is set for T C input Setup the equipment according to the following diagram for calibrating the cold junction compensation Note that a K type thermocouple must be used The programming for the controller input DIP Switch Position and units can be any T C type and set for F or C Input type T F E TC Input programming does bot effect the cold junction calibra
21. or power service shorted Check and correct Check output wiring and output device Replace output device Replace output fuse Check and replace 9 Control abnormal or operation incorrect CPU or EEPROM non volatile memory defective Key switch defective Incorrect setup values Check and replace Read the setup procedure carefully 10 Display blinks entered values change by themselves 44 Electromagnetic interference EMI or Radio Frequency interference RFI EEPROM defective UM9300 2 0 Suppress arcing contacts in system to eliminate high voltage spike sources Separate sensor and controller wiring from dirty power lines ground heaters Replace EEPROM Chapter 6 Specifications Power 90 264 VAC 47 63 Hz 15VA 7W maximum 11 26 VAC VDC 15VA 7W maximum Input 1 Resolution 18 bits Sampling Rate 5 times second Maximum Rating 2 VDC minimum 12 VDC maximum 1 minute for mA input Temperature Effect 0 005 of reading C Sensor Lead Resistance Effect T C 0 2uV ohm 3 wire RTD 2 6 C ohm of resistance difference of two leads 2 wire RTD 2 6 C ohrn of resistance sum of two leads Burn out Current 200 nA Common Mode Rejection Ratio CMRR 120dB Sensor Break Detection Sensor open for TC RTD and mv inputs below 1 mA for 4 20 mA input below 0 25V for 1 5 V input unavailable for other inputs Sensor Break Responding Time
22. shock The enclosure must be connected to earth ground Local requirements regarding electrical installation should be rigidly observed Consideration should be given to preventfrom 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 resultsin most air heated processes Proper sensor type is also a very important factor to obtain precise measurements The sensor must have the correct temperature range to meet the process requirements In special processes the sensor might need to have different requirements such as leak proof anti vibration antiseptic etc Standard sensor limits of error are 4degrees F 2degrees C or 0 75 of sensed temperature half that for special plus drift caused by improper
23. the control is abnormal as the power is recovered and results in a large disturbance to the process During the sensor breaks the process loses power With Bumpless Transfer PV gt Power interrupted Sensor break A Set point p Load varies Small deviation Time After bumpless transfer configured the correct control variable is applied Warning After system fails immediately as the power is recovered the disturbance is small During the never depend on bumpless sensor breaks the controller continues to control by using its previous value If i transfer for a long time the load doesn t change the process will remain stable Thereafter once the iherwisati mlahi load changes the process may run away Therefore you should not rely on a pinasa gnt cause a bumpless transfer for a longer time For fail safe reason an additional alarm Problem to the system to run should be used to announce the operator when the system fails For example AWAY a Sensor Break Alarm if configured will switch to failure state and announces the operator fo use manual control or take a proper security action when the system enters failure mode 28 UM9300 2 0 3 7 Self Tuning The Self tuning which is designed by using an Innovative algorithm provides Self tune Menu an alternative option for tuning the controller It is activated as soon as SELF is selected with YES When Self tuning is working the controller will change its
24. to control fast processes such as pressure and flow Self tune is incorporated The self tune can be used to optimize the control parameters as soon as undesired control result is observed Unlike auto tune Self tune will produce less disturbance to the process during tuning and can be used any time The function of Fuzzy Logic is to adjust PID parameters internally in order to make manipulation output value MV more flexible and adaptive to various processes PID Fuzzy Control has been proven to be an efficient method to improve the control stability as shown by the comparison curves below PID control when properly tuned PID Fuzzy control Temperature Set point JD Figure 1 1 Fuzzy PID Enhances Control Warm Up Load Disturbance Stability UM9300 2 0 1 2 Ordering Code FDC 9300 4 Power Input 2 3 5 6 4 90 264 VAC 50 60 HZ 5 11 26 VAC or VDC 9 Special Order Signal Input Alarm 1 Communications 1 Standard Input a p T 0 None Input 1 Universal Input oA ANA a m Jr r E uw 2 DPA 3 Retransmit 4 20MA 0 20mAt RTD PT100 DIN PT100 JIS 9 Special order Al Retransmit 1 5V 0 5 Current 4 20mA O 20 mA 5 dicht 10V Voltage O 1V 0 5V 1 5V special order 0 10V Output 1 0 None Input 2 CT and Analog Input CT O 50 Amp AC Current Transformer Analog Input 4 20 mA O 20mA O 1V 0 5V 1 5V 0 10V Input 3 Event I
25. 12 13 14 15 16 L DIP Switch RTD RTD E Three wire RTD Two wire RTD 18 UM9300 2 0 2 8 Linear DC Input Wiring DC linear voltage and linear current connections for input 1 are shown in Figure 2 7 and Figure 2 8 DC linear voltage and linear current connections for input 2 are shown in Figure 2 9 and Figure 2 10 Figure 2 7 Input 1 Linear Voltage Wiring 0 1V O 5V 1 5V 0 10V Figure 2 9 Input 2 Linear Voltage Wiring 0 1V 0 5V 1 5V 0 10V Figure 2 8 Input 1 Linear Current Wiring DIP Switch 0 20mA or 4 20mA Figure 2 10 Input 2 Linear Current Wiring 9999999 Q AY Q 9600099 10 11 12 13 14 15 1 0 20mA or 4 20mA 7 Qt 2 9 CT Heater Current Input Wiring SOSSOOSS 10 11 12 13 e O O 0 la HG Figure 2 11 CT Input Wiring for Single Phase Heater CT Signal Input Total current CT94 1 not to exceed 50 A RMS UM9300 2 0 19 2 10 Output 1 Wiring Max 2A Resistive Load 120V 240V Mains Supply 1 2 4 YA 8 OOOO OQOOOOOQOCO 9 10 11 12 13 14 15 16 Relay Output 5VDC 30ma or 14VDC 40ma Pulsed Voltage IST Maximum Load 500 ohms SIS
26. 3 Reload Default Values 15 Heat Cool control 24 Isolated DC Power Supply 3 1 Rearrange User Menu The conventional controllers are designed with a fixed parameters scrolling If AE SEL1 you need a more friendly operation to suit your application the manufacturer will say sorry to you The FDC 9300 has the flexibility for you to select those LL parameters which are most significant to you and put these parameters in the SEL2 front of display sequence SELT Selects the most significant parameter for view and change SEL2 Selects the 2 nd significant parameter for view and change SEL3 SEL3 Selects the 3 rd significant parameter for view and change SELG SEL4 Selects the 4 th significant parameter for view and change SEL5 Selects the 5th significant parameter for view and change SEL4 Range NONE TIME A1 SP AT DV A2 SP A2 DV RAMP OFST REFC SHIF PB1 TI TD1 C PB SP2 PB2 TI2 TD2 When using the up down key to select the parameters you may not obtain S all of the above parameters The number of visible parameters is dependent on the setup condition The hidden parameters for the specific application are SELS also deleted from the SEL selection Example cei 1 selects TIME Now the upper display scrolling becomes SEL2 selects A2 DV SEL3 selects OFST E SELA selects PBI LE E ae Rede fof Se CPI SEL5 selects NONE UM9300 2 0 25 3 2 Dwell Timer Alarm 1 or alarm 2 can be configu
27. 400C 900C 1820C 1767 8C 1767 8 1832 F 2498 F 752 F 4652 F 3308 F 321 321 Input Type C_TC PT DN PT JS Lineage CV mA JD amp 5 a o I a gt 0C oc 210C 200 2810C 1395C 700C 600 4200 F 2543 F 1292 F 1112 F 90 Amp 45536 14 UM9300 2 0 Table 1 5 Input IN1 or IN2 Range Chapter 2 Installation AN 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 AN To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture AN 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 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 housin
28. 500 VAC 5V 0 15M 80MA 0 05 Vp p 500 VAC Alarm 1 Alarm 2 Alarm 1 Relay Form A or Form B Max Rating 2A 240VAC life cycles 100 000 for resistive load Alarm 2 Relay Form A Max rating 2A 240VAC life cycles 200 000 for resistive load Alarm Functions Dwell timer Deviation High Low Alarm Deviation Band High Low Alarm PV1 High Low Alarm PV2 High Low Alarm PV1 or PV2 High Low Alarm PV1 PV2 High Low Alarm Loop Break Alarm Sensor Break Alarm Alarm Mode Normal Latching Hold Latching Hold Dwell Timer 0 6553 5 minutes Data Communication Interface RS 232 1 unit RS 485 up to 247 units Protocol Modbus Protocol RTU mode Address 1 247 Baud Rate 0 3 38 4 Kbits sec Data Bis 7 or 8 bits Parity Bit None Even or Odd Stop Bit 1 or 2 bits Communication Buffer 50 bytes Analog Retransmission Functions PV1 PV2 PV1 PV2 PV2 PV1 Set Point MV1 MV2 PV SV deviation value Output Signal 4 20 MA 0 20 mA 0 1V O 5V 1 54 0 10Y 46 UM9300 2 0 Resolution 15 bits Accuracy 0 05 96 of span 0 0025 C Load Resistance O 500 ohms for current output 10 K ohms minimum for voltage output Output Regulation 0 01 for full load change Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC min Integral Linearity Error 0 005 of span Temperature Effect 0 0025 of span C Saturation Low
29. 9 a 9 9 ta 9 9 9 9 E 9 9 9 UUUUUUUUUUUUUUUUUuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuuu 4 The flow chart shows a complete listing of all parameters For actual application tne number of available parameters depends on setup conditions and should be less than that shown in the flow chart See Appendix A 1 for the existence conditions of each parameter 2 You can select at most 5 parameters put in front of the user menu by using SEL to SEL5 contained at the bottom ofsetup menu 7 1 6 Parameter Description Table 1 4 Parameter Description Contained Basic Parameter Display Parameter Range Default in Function Notation Format Description Value Y SP1 Set point 1 Low SP4L High SP1H IZOF Y TIME E AE Dwell Time Low 0 High 6553 5 minutes 0 0 Y ATSP A GP Alarm 1 Set point See Table 1 5 1 6 2120 a Y A1DV A ig Alarm 1 Deviation Value Low 380 0 E High 200 0 E 18 0 E Y A2SP Hg 5P Alarm 2 Set point See Table 1 5 1 7 2120 Pa 00 0 00 0 0 0 WA A2DV Heg l Alarm 2 Deviation Value Low 360 0F High 360 0F 18 0 F 00 0 RAMP AnP Ramp Rate Low 0 High 200 0 F 0 0 WA OFST oF5k Offset Value for P control Low 0 High 100 0 96 25 0 Reference Constant for igh REFC r EFL Specific Function Low 0 High 60 2 Y SHIF PV1 Shift offset Value 0 0 WA PB1 Pb Proportional Band 1 Value Low 0 High 200 0 E 180 User Y TM
30. ANTY Future Design Controls products described in this manual are warranted to be free from functional defects in materials and workmanship at the time the products leave Future Design Controls Facilities and to conform at that time to the specifications set forth in the relevant Future Design Controls manual sheet or sheets for a period of 3 years after delivery to the first purchaser for use There are no expressed or implied Warranties extending beyond the Warranties herein and above set forth Limitations Future Design Controls provides no warranty or representations of any sort regarding the fitness of use or application of its products by the purchaser Users are responsible for the selection suitability of the products for their application or use of Future Design Controls products Future Design Controls shall not be liable for any damages or losses whether direct indirect incidental special consequential or any damages costs or expenses excepting only the cost or expense of repair or replacement of Future Design Controls products as described below Future Design Controls sole responsibility under the warranty at Future Design Controls option is limited to replacement or repair free of charge or refund of purchase price within the warranty period specified The warranty does not apply to damage resulting from transportation alteration misuse or abuse Future Design Controls reserves the right to make changes witho
31. IFN If remote lockout is configured all parameters will be locked as the external switch is closed When the switch is left open the lockout condition is determined by internal DIP switch hardware lockout see Hardware Lockout Can be used only during initial setup Remote Lockout Can be used any time 36 UM9300 2 0 3 13 Heater Break Alarm A current transformer parts No CT94 1 should be installed to detect the Heater Break Alarm 1 heater current if a heater break alarm is required The CT signal is sent to Setup IN2 CT input 2 and the PV2 will indicate the heater current in 0 1 Amp resolution ATEN PV2 L The range of current transformer is 0 to 50 0 Amp AIMD NORM A1HY 0 1 Adjust ATSP Trigger levels ATSP A1 2 ATHY Heater Break Alam 2 Example Setup IN2 CT A furnace uses two 2KW heaters connected in parallel to warm up the process A2FN PV2 L The line voltage is 220V and the rating current for each heater is 9 09A If we A2MD NORM want to detect any one heater break set ATSP 13 0A AIHY 0 1 A2HY 0 1 A1FN PV2 L AIMD NORM then Adjust A2SP Trigger levels A2SP A1 2 A2HY Limitations 1 Linear output can t use heater break alarm No heater breaks 1 heater breaks 2 heaters breaks 2 CYC1 should use 1 second or 3 de Neal 3 de Alarm longer to detect heater current reliably 20 30 20 30 20 30 Figure 3 9 m ii m Heater Break Alarm 0 50 0 50 0 50 3 14 Reload Default Values
32. Isolated 500 ohm load Max 1 5V 0 5V Isolated Min impedance 10K 0 10V Isolated Min impedance 10K Triac Output 1A 240VAC SSR 20V 25mA DC Isolated Output Power Supply 12V 40 mA DC Isolated Output Power Supply BV 80mA DC Isolated Output Power Supply C Pulsed voltage to drive SSR 14VDC 2 40ma A Special order Range set by front keyboard xx Alternative between RS 232 and El x x Need to order an accessory CT94 1 if Heater Break detection is required Related Products SNA10A Smart Network Adaptor for Third Party Software Converts 255 channels of RS 485 or RS 422 to RS 232 Network 1 3 Programming Port and DIP Switch Access Hole Rear Terminal Control Chassis Bottom View The programming port is used to connect to P10A hand held programmer for automatic programming also can be connected to ATE system for automatic testing amp calibration DIP Switch Eon OFF 1 2 3 4 TC RTD mV B Input 1 0 1V 0 5V 1 5V 0 10V O Select 0 20 mA 4 20 mA E E All parameters are Unlocked L1 LI Only SP1 SEL1 SEL5 are unlocked Bi Lockout Only SP1 is unlocked DE All Parameters are locked gm mH Factory Default Setting eooo 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 purpos
33. Slow Response Decrease PB1 or PB2 1 Proportional Band P PB and or PB2 High overshoot OF mcrease PBI or PB2 Oscillations Slow Response Decrease TI or TI2 2 Integral Time I TI1 and or TI2 ese at Increase TI1 or T12 Table 3 2 PID Adjustment Gulde Oscillations Slow Response or 3 Derivative Time D Oscillations TD1 and or TD2 Decrease TD1 or TD2 High Overshoot Increase TD1 or TD2 CPB Programming The cooling proportional band is measured by 96 of PB with range 1 2595 Initially set 100 for CPB and examine the cooling effect If cooling action should be enhanced then decrease CPB if cooling action is too strong then Increase CPB The value of CPB is related to PB and its value remains unchanged throughout the self tuning and auto tuning procedures Adjustment of CPB is related to the cooling media used For air is used as cooling media adjust CPB at 100 96 For oil is used as cooling media adjust CPB at 125 96 For water is used as cooling media adjust CPB at 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 rnore negative value of DB greater overlap is used an excessive overshoot over the set point can be minimized but an unwanted cooling action will occur It is adjustable in the range 36 0 to 36 0 of Pb1 o
34. The default values listed in Table 1 4 are stored in the memory as the product leaves the factory In certain occasions it is desirable to retain these values after the parameter values have been changed Here is a convenient tool to reload the default values Operation Press several times until Then press The upper FILE O display will show Use up down key to select O to 1 If C unit is C Default File required select O for FILE and if F unit is required select 1 for FILE Then Press f for at least 3 seconds The display will flash a moment and the default FILE 1 values are reloaded F Default File CAUTION The procedures mentioned above will change the previous setup data Before doing so make sure that if it is really required UM9300 2 0 37 Chapter 4 Calibration AN 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 Equipment needed before calibration 1 A high accuracy calibrator Fluke 5520A Calibrator recommended with following functio
35. The upper display indicates the parameter symbol and the lower display indicates the selection or the value of parameter 2 seconds Menu 1 PVH 3 a LO l9 LO 19 a l9 LO A l9 lA l0 3 a a 9 9 9 la a Ea o THO O r u v v Sislold 18 s 221 s md jo ANQNNNNanananana VU U U U UUU UO U O U a LO 19 LO 19 A A A A l9 lA A gt Pj PJ D PA PA PA PA PA PA PJ PI o 9 a LO 19 A LO l9 l9 l0 PA PA PA LP PJ PB Apply these modes will break the control loop and change some of the previous setting data Make sure that If the system is allowable to use these modes UM9300 2 0 SEL1 SEL2 SEL3 SEL4 SEL5 A for 3 d m A ID R N U 9
36. User s Manual FDC 9300 Self Tune Fuzzy PID Process Temperature Controller C O N T R O L S CONTENTS Chapter 1 Overview 1 1 Features en ren rer rr nr 1 2 Ordering Code 1 3 Programming Port and DIP Switch 1 4 Keys and Displays 1 5 Menu Overview eoo er 1 6 Parameters Description Chapter 2 Installation 2 1 Unpacking m o 2 2 Mounting e ee eee e ee e 2 3 Wiring Precautions 2 4 Power Wiring e e nnn e nn 2 5 Sensor Installation Guidelines 2 6 Thermocouple Input Wiring 2 7 RTD Input Wiring 2 8 Linear DC Input Wiring 2 9 CT Heater Current Input Wiring 2 10 Output 1 Wiring 2 11 Output 2 Wiring
37. amp EN50082 2 Approvals UR CSA CE RHOS Compliant Front panel sealed to NEMA 4X amp IP65 FDC 9300 Fuzzy Logic plus PID microprocessor based controller incorporates a bright easy to read 4 digit LED display indicating process value The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time with the minimum of overshoot during power up or external load disturbance The units are housed in a 1 16 DIN case measuring 48 mm x 48 mm with 75 mm behind panel depth The units feature three touch keys to select the various control and input parameters Using a unique function you can put at most 5 parameters in front of user menu by using SELT to SEL5 contained in the setup menu This is particularly useful to OEM s asit is easy to configure menu to suit the specific application FDC 9300 is powered by 11 28 or 90 264 VDC AC supply incorporating a 2 amp control relay as standard Up 1o two additional optional relay outputs can be supported Output two can be a cooling relay or alarm or dwell timer The third relay performs as a programmable alarm Alternative output options include SSR Drive Triac 0 4 20 mA and O 10 volts FDC 9300 is fully programmable for PT100 thermocouple types J K T E B R S C B 0 20mA 4 20mA and voltage signal input with no need to modify the unit The input signals are digitized by using a 18 bit Ato D converter Its fast sampling rate allows the FDC 9300
38. as DP1 IN2 Low Scale Value Low 19999 High 45536 IN2 High Scale Value Low 19999 High 45536 1000 or E ue Reverse heating control action Output 1 Function 0 1 fi rk Direct cooling control action Relay output Solid state relay drive output Solid state relay output Output 1 Signal Type 4 20 mA current module 10 UM9300 2 0 Table 1 6 Parameter Description continued 4 7 Contained Basic in Functio Notation Format Description Value 0 20 mA current module 0 1V voltage module Output 1 Signal Type 0 5V voltage module 0 1 5V voltage module 0 10V voltage module a iES CYC1 Y Output 1 Cycle Time l High 100 0 sec 18 0 o IFE 7 Select BPLS bumpless transfer or 0 0 100 0 O1FT Output 1 Failure Transfer to continue output 1 control function as the unit BPLS l Mode fails power starts or manual mode starts Output 2 no function PID cooling control Output 2 Function 2 Perform alarm 2 function DC power supply module installed Output 2 Signal Type Same as O1TY 0 Output 2 Cycle Time Low 0 1 High 100 0 sec 18 0 Select BPLS bumpless transfer or 0 0 100 0 aie 2 Failure Transfer to continue output 2 control function as the unit BPLS ode fails power starts or manual mode starts v Y v v Y v v nant No alarm function Es Air Dwell timer action JEH Deviation high alarm JEL mc Deviation low alarm dhami Devia
39. conds programmable Environmental amp Physical Operating Temperature 10 C to 50 C Storage Temperature 40 C to 60 C Humidity 0 to 90 RH non condensing Insulation Resistance 20 Mohms min at 500 VDC Dielectric Strength 2000 VAC 50 60 Hz for 1 minute Vibration Resistance 10 55 Hz 10 m for 2 hours Shock Resistance 200 m s 20 g Moldings Flame retardant polycarbonate Dimensions 50 7mm W X 50 7mm H X 88 0mmY D 75 0 mm depth behind panel Weight 150 grams Approval Standards UR File E197216 CSA File 209463 GE RHoS Compliant The color code typically used on the thermocouple extension leads are shown in below Thermocouple Cable Color Codes Thermocouple Cable British American German French Type Material BS ASTM DIN NFE Copper Cu white 4 blue red yellow L Constantan blue red brown blue Cu Ni blue blue brown blue Iron Fe t yellow t white red t yellow J Constantan blue red blue black Cu Ni black black blue black sar 4 brown yellow red yellow K E blue red green purple Nee ld red yellow green yellow Ni Al white black red yellow de eA blue red white green Kaka x green x green x white x green Pt 30 Rh Use baat ped Use Pt 6 Rh Copper Wire grey grey Copper Wire Color of overall sheath UM9300 2 0 47 A 1 Menu Existence Condit
40. e When the unit leaves the factory the DIP switch is set so that TC amp RTD are selected for input 1 and all parameters are unlocked Lockout function is used to disable the adjustment of parameters as well as operation of calibration mode However the menu can still be viewed even under lockout SEL1 SEL5 represent those parameters which are selected by using SEL1 SEL2 SEL5 parameters contained in Setup menu Parameters been selected are then allocated at The beginning of the user menu UM9300 2 0 Figure 1 2 Access Hole Overview Table 1 1 DIP Switch Configuration 1 4 Keys and Displays The unit is programmed by using three keys on the front panel The available key functions are listed in following table Table 1 2 Keypad Operation TOUCHKEYS FUNCTION DESCRIPTION K Up K Press and release quickly to increase the value of parameter A piney Press and hold to accelerate increment speed SZ D wi Ke Press and release quickly to decrease the value of parameter Y y Press and hold to accelerate decrement speed Scroll Key Select the parameter in a direct sequence P Allow access to more parameters on user menu also used to Enter manual 1635 Enter Key mode auto tune mode default setting mode and to save calibration data for at least 3 seconds during calibration procedure Press Start Record Key Reset historical values of PVHI and PVLO and start to record the peak process for at least 6 seconds val
41. e is equal to 199 9 or 199 9 then the calibration fails Perform both steps 5 and 6 to calibrate RTD function if required for input 1 Step 5 Change the DIP switch for the RTD input Press scroll key until the DIP Switch Position display shows F Send a 100 ohms signal to terminals 11 12 FY nd JF I I RTD input uU o s ci and 13 according to the connection shown below 11 TANE v FDC 9300 Figure 4 1 RTD Calibration Press the scroll key for at least 5 seconds then release scroll key The display will blink a moment otherwise the calibration fails UM9300 2 0 39 Step 6 Step 7 Press the scroll key and the display will show 5r Change the simulated ohm s value to 300 ohms Press scroll key for at least 5 seconds and release scroll key The display will blink a moment and two values are obtained for SR1 and REF 1 last step Otherwise if the display didn t blink or if any value obtained for SRI and REFI is equal to 199 9 or 199 9 then the calibration fails Perform step 7 to calibrate mA function if required for input 1 Change the DIP switch for mA input Press the scroll key until the DIP Switch Position display shows Simulate a 20 MA signal to terminals 12 and ON 13 in correct polarity Press scroll key for at least 5 seconds and E i a mA Input release scroll key The display will blink a moment and a new value is aemm obtained Otherwise if the display didn t blink
42. g of control 2 2 Mounting Make panel cutout to dimension shown in Figure 2 1 Take both mounting clamps away and insert the controller into panel cutout Install the mounting clamps back Gently tighten the screws in the clamp till the controller front panels is fitted snugly in the cutout MOUNTING k 177 gt 1 77 Panel cutout Flgure 2 1 Mounting Dimenslons 43 Z UM9300 2 0 15 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 t is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools All wiring must conform to appropriate standards of good practice and local codes and regulations Wiring must be suitable for voltage current and temperature rating of the system The stripped leads as specified in Figure 2 2 below are used for power and sensor connections Beware not to over tighten the terminal screws Unused control terminals should not be used as jumper points as they may be internally connected causing damage to the unit Verify that the ratings of the output devices and the inp
43. he scroll key to advance to the calibration required NOTE Outputs now transfer to there failure transfer mode values Perform step 2 to calibrate Zero of Ato D converter and step 3 to calibrate gain of A to D converter The DIP switch is set for T C input Step 2 With on the display short terminals 2 and 13 then press scroll key for at least 5 seconds and release scroll key The display will blink a moment and a new value is obtained Otherwise if the display didn t DIP Switch Position blink or if the obtained value is equal to 360 or 360 then the ON calibration fails B B A A T C input Step 3 Press scroll key until the display shows Simulate a 60MV signal to terminals 12 and 13 in correct polarity Press scroll key for at least 5 seconds then release scroll key The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform step 4to calibrate voltage function if required for input 1 Step 4 Change the DIP switch for the Voltage input Press scroll key until DIP Switch Position the display shows _ Y 15 Send a 10 V signal to terminals 12 and ON mead odds AI 0 10v input 13 in correct polarity Press scroll key for at least 5 seconds then tig all release scroll key The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained valu
44. hut off the pump each time when all the valves are closed A typical value for REFC is between 3 and 5 An ordinary pump may slowly lose the pressure even if the valves are completely closed Adjust SP2 according to the rule that a more negative value of SP2 will allow the pump to be shut off for a longer time as the valves are closed A typical value for SP2 is about 0 50 Kg crn 3 11 Sleep Mode c I al To Enter Sleep Mode Sleep Mode Features FUNC selects FULL to provide full function Shut off display SLEP selects YES to enable the sleep mode Shut off outputs Press for 3 seconds the unit will enter its sleep mode Green Power During sleep mode Replace Power Switch 1 Shut off all display except a decimal point which is lit periodically 2 Shut off all outputs and alarms Setup Menu To Extt Sleep Mode FUNC FULL 1 Press to leave the sleep mode SLEP YES 2 Disconnect the power Default SLEP NONE Sleep Function can be used to replace a power switch to reduce the system cost Sleep mode is disabled Note If the Sleep mode is not required by your system the SLEP should select NONE to disable sleep mode against undesirable occurrence 3 12 Remote Lockout The parameters can be locked to prevent from being changed by using Remote Lockout you need the parameters to be locked by using an external switch and 2 remote lockout function then connect a switch to terminals 13 and 14 5 Set LOCK for E
45. ide control Defective solid state relays Defective line switches Burned out contactor Defective circuit breakers 3 If the points listed on the above chart have been checked and the controller does not function properly it is suggested that the Instrument be returned to the factory for Inspection Do not attempt to make repairs without qualified engineer and proper technical information It may create costly damage Also It is advisable to use adequate packing materials to prevent damage in transportation 4 Dismantle the controller according to Flgure 5 1 Refer to Table 5 2 for some probable causes and actions CD Press both sides of the latch located on rear terminal block Hold tightly and remove the terminal block from the housing 2 Expand the rear edge of the housing by using a tool Pull out the PCB from the housing Figure 5 1 Dismantling the Controller 42 UM9300 2 0 Table 5 1 Error Codes and Corrective Actions ae cranes Error Description Corrective Action 4 Illegal setup values been used PV1 is used for both PVMD Check and correct setup values of PVMD and SPMD PV and SPMD It is meaningless for control and SV can t use the same value for normal control Illegal setup values been used PV2 is used for both PVMD 2 and SPMD It is meaningless for control Same as error code 1 Illegal setup values been used P1 2 or P2 1 is used for Check and correct setup values of PVMD and SPMD 3 PVMD while
46. ilure Causes and Corrective Actions Symptom 1 Keypad no function 2 LED s will not light Probable Causes Bad connection between PCB amp keypads No power to instrument Power supply defective Corrective Actions Clean contact area on PCB Replace keypads Check power line connections Replace power supply board 3 Some segments of the display or LED lamps not lit or lit erroneously LED display or LED lamp defective Related LED driver defective Replace LED display or LED lamp Replace the related transistor or IC chip 4 Display Unstable 5 Considerable error in temperature indication Analog portion or A D converter defective Thermocouple RTD or sensor defective Intermittent connection of sensor wiring Wrong sensor or thermocouple type wrong input mode selected Analog portion of A D converter defective Replace related components or board Check thermocouple RTD or sensor Check sensor wiring connections Check sensor or thermocouple type and if proper input mode was selected Replace related components or board 6 Display goes in reverse direction counts down scale as process warms 7 No heat or output 8 Heat or output stays on but indicator reads normal Reversed input wiring of sensor No heater power output incorrect output device used Output device defective Open fuse outside of the instrument Output device shorted
47. ions Menu Existence Conditions Table 1 3 Parameter m Your Existence Conditions Exists unconditionally TIME Exists if ATFN selects TIMR or A2FN selects TIMR ATSP Exists if ATFN selects PV1H PVIL PV2H PV2L P12H P12L D12H or D12L ATDV Exists if ATFN selects DEHI DELO DBHI or DBLO A2SP Exists if A2FN selects PV1H PVIL PV2H PV2L P12H P12L D12H or D12L A2DV Exists if A2FN selects DEHI DELO DBHI or DBLO Exists if SPMD selects MINR or HRR Exists if TI is used for control depends on Event input and EIFN selection but Tll 0 and OFST PB1 40 or if TI2 is used for control depends on Event input and EIFN selection but TI2 0 and PB2z0 REFC Exists if SPMD selects PUMP SHIF Exists unconditionally T T a EN T T Exists if PB1 0 Exists if EIFN selects SP2 or SPP2 or if SPMD selects PUMP Exists if EIFN selects PID2 or SPP2 Exists if EIFN selects PID2 or SPP2 provided that PB2 0 D CO OC E O1HY If PID2 or SPP2 is selected for EIFN then O1HY exists if PB O or PB2 O If PID2 or SPP2 is not selected for EIFN then O1HY exists if PB1 O ATHY Exists if AIFN selects DEHI DELO PV1H PVIL PV2H PV2L P12H P12L D12H or D12L EN A2HY Exists if A2FN selects DEHI DELO PV1H PVIL PV2H PV2L P12H P12L D12H or D12L EN B1 PB b 2 B2 2 2 If PID2 or SPP2 is selected for EIFN then PL1 exists if PB or PB2 Q If PID2 or SPP2 is not selected for EIFN then PL1 ex
48. ists if PB 0 PL2 Exists if OUT2 selects COOL 48 UM9300 2 0 Menu Existence Conditions Table continued 2 3 Parameter Your FUNC Exists unconditionally COMM Exists if FUNC selects FULL EE Exists if COMM selects 485 or 232 AOFN Exists if COMM selects 4 20 0 20 0 1V O 5V 1 5V or 0 10 EHE AOLO Exists if COMM selects 4 20 0 20 0 1V 0 5V 1 5V or 0 10 and AOFN is not MV1 and MV2 AOHI INT INTU Exists unconditionally Setup DPI o i gt INTL Exists if INTselects 4 20 0 20 O 1V 0 5V 1 5V or 0 10 INTH Exists if FUNC selects FULL Exists if IN2 selects 4 20 0 20 0 1V 0 5V 1 5V or 0 10 Exists unconditionally Exists if OUT2 selects COOL UM9300 2 0 49 Menu Existence Conditions Table continued 3 3 Parameter zl Your Existence Conditions ATFN Exists unconditionally Exists if ATFN selects DEHI DELO DBHI DBLO PV1H PVIL PV2H PV2L P12H P12L D12H D12L LB or SENB AlFT Exists if ATFN is not NONE A2FN Exists unconditionally Exists if A2FN selects DEHI DELO DBHI DBLO PV1H PVIL PV2H PV2L P12H P12L D12H D12L LB or SENB A2FT Exists if A2FN is not NONE A AMD A2MD PVMD Exists if FUNC selects FULL Setup Menu FILT SELF Exists unconditionally SLEP Exists if FUNC selects FULL SPMD SPIL Exists unconditionally SP1H SP2F Exists if EIFN selects SP2 or SPP2 or if SPMD selects PUMP Exists unconditionally E 50 UM9300 2 0 A 2 Warranty WARR
49. lications Caution YOO Q SOO Don t use the DC power supply beyond its rating current to 9 10 1112 13 14 15 16 avoid damage Purchase a correct voltage to suit your external devices See ordering code in section 1 2 4 20mA UM9300 2 0 27 3 6 Bumpless Transfer The bumpless transfer function is available for output 1 and output 2 provided Bumpless Transfer Setup that OUT2 is configured as COOL 1 O1FT BPLS 2 O2FT BPLS Bumpless Transfer is enabled by selecting BPLS for OTFT and or O2FT and activated as one of the following cases occurs 1 Power starts within 2 5 seconds 2 The controller enters the failure mode See section 3 4 for failure mode Burnpless Transfer Occurs as 1 Power Starts within 2 5 seconds 2 Failure mode is activated descriptions 3 Manual mode is activated 3 The controller enters the manual mode See section 3 3 for manual mode A ka l M descriptions 4 Calibration mode is activated A The controller enters the calibration mode See Chapter 4 for calibration mode descriptions As the bumpless transfer is activated the controller will transfer to open loop control and uses the previous averaging value of MV1 and MV2 to continue control Without Bumpless Transfer PV F Power interrupted a break Set point Figure 3 3 Benefits of Bumpless Transfer Large deviation Time Since the hardware and software need time to be initialized
50. nput EI 9 Special Order 2 Pulsed voltage to 3 4 Min impedance 10K 5 0 10V Isolated Min Impedance 10K Example 6 Triac Output Standard Model 1A 240VAC SSR FDC 9300 411111 C Pulsed voltage to e 90 264 operating voltage e nput Standard Input e Output 1 Relay Output 2 Relay Alarm 1 Form A Relay eRS 485 Communication Interface 9 Special order Accessories CT94 1 0 50 Amp AC Current Transformer OM95 3 Isolated 4 20 mA O 20 mA Analog Output Module OM95 4 Isolated 1 5V O 5V Analog Output Module OM95 5 Isolated O 10V Analog Output Module OM94 6 Isolated 1A 240VAC Triac Output Module SSR DC94 Isolated 20V 25mA DC Output Power Supply DC94 2 Isolated 12V 40mA DC Output Power Supply DC94 3 Isolated 5V 80mA DC Output Power Supply CM94 1 Isolated RS 485 Interface Module CM94 2 Isolated RS 232 Interface Module CM94 3 Isolated 4 20 mA O 20 mA Retransmission Module CM94 4 Isolated 1 5V O 5V Retransmission Module CM94 5 Isolated O 10V Retransmission Module CC94 1 RS 232 Interface Cable 2M UM9300 2 0 FDC 9300 User s Manual UM9300 2 0 4 5 drive SSR 14VDC 40ma 7 8 9 3 1 Relay rated 2A 240vAc Output 2 Alarm 2 O drive SSR 5VDCO30MA 1 4 20MA 0 20mA 2 Isolated 500 ohm load max 1 5V 0 5V Isolated None Form A Relay 2A 240VAC Pulsed voltage to drive SSR 5V 30mA 4 20mA 0 20mA
51. ns 0 100 mV millivolt source with 0 005 accuracy 0 10 V voltage source with 0 005 96 accuracy 0 20 mA current source with 0 005 accuracy O 300 ohm resistant source with 0 005 96 accuracy 2 A test chamber providing 25 C 50 C temperature range 3 A switching network SW6400 optional for automatic calibration 4 A calibration fixture equipped with programming units optional for automatic calibration 5 A PC installed with calibration software FD 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 ATTENTION A unit requires a 20 minute warm up BEFORE Calibration can be 38 Initiated UM9300 2 0 Manual Calibration Procedures Perform step 1 to ENTER calibration mode Step 1 Set the lockout DIP switch to the unlocked condition both switches 3 and 4 are off Dip switches must be set correctly for calibration performed Press both the scroll key and down keys simultaneously and release them quickly Will appear on the top display In the bottom display Continue to press the scroll and down arrow keys simultaneously until appears on the top display Then press and hold the scroll key only for at least 5 seconds and release the key The top Display should now show You have now entered into the calibration mode You can now begin with ADO calibration routine or use t
52. o the fast sampling rate owned by FDC 9300 can realize such application To achieve this set the following parameters in the setup menu FUNC FULL Key menu EIEN NONE SPMD PVMD PV1 SP2F FILT 0 5 SELF NONE iis SPMD PUMP SP2F DEVI and program the following parameters in the user menu REFC Reference constant SP2 A negative value is added to SP1 to obtain the set point for idle state Since the pump can t produce any more pressure at lower speed the Pump Control Features pump may not stop running even if the pressure has reached the set point 1 Minimum oscillation of pressure If this happens the pump will be over worn out and waste additional 2 Rapidly stabilized power To avoid this the FDC 9300 provides a Reference Constant REFC in 3 Guaranteed pump stop the user menu If PUMP is selected for SPMD the controller will periodically 4 Programmable pump stopping test the process by using this reference constant after the pressure has interval reached its set point If the test shows that the pressure is still consumed by The process the controller will continue to supply appropriate power to the pump If the test shows that the pressure is not consumed by the process The controller will gradually decrease the power to the pump until the pump stops running As this happens the controller enters Idle state The idle state will use a lower set point which is obtained by adding SP2 to SP1 until the pressure falls below
53. on Coefficient Reference Voltage 1 REF1 r EF Calibration Coefficient for RTD 1 5 199 9 High 199 9 Temperature Current Derivative Time TD Value 1440 sec CJCT Cold Junction Compensation 90 00 C Current Process Rate Value Maximum Process Rate Value PVRL PU Minimum Process Rate Value 16383 16383 High 16383 Calibration Mode Y SR1 r Calibration Coefficient for Low 199 9 High 199 9 Menu RTD 1 v MAIG 5A IG MA input Gain Calibration oy 199 9 High 199 9 war Voltage Input 2 Gain TM Y Calibration Coefficient Low 199 9 High 199 9 a Y MA2G AA2b hae a Gain Calibration Low 1999 High 199 9 us Y PVH PYH Historical Maximum Value of Low 19999 High 45536 Y PVLO pur a pu iga Minimum Value of Low 19999 High 45536 _ Y MV1 H_ __ Current Output 1 Value Low 0 High 100 00 Y MV2 C___ Current Output 2 Value Low 0 High 100 00 Y DV ge ORE Deviation PV SV ome 12600 High 12600 Y PV1 PU IN1 Process Value Low 19999 High 45536 Display Mode Y PV2 PYF 1N2 Process Value Low 19999 High 45536 Menu Current Proportional Band ap 500 0 C Y PB Pb Value p Low 0 High 9000F CN Y Tl Current Integral Time Value 4000 sec WEN Y Y Y Y Y 16383 1200 200C 2500 100C oc oc C Range Low 184 F C328 F 418 F 148 F 321 32F 32F 1000C 13700
54. plications it is desirable to supply a process with a constant demand Operation Press until Hand Control appears on the display H33 4 Means Press ce for 3 seconds then the upper display will begin to flash and the lower MV1 38 4 96 display will show The controller now enters the manual control mode for OUTI or Heating Pressing ce the lower display will show andH___ alternately where H indicates output 1 or heating control variable value MV1 and _ _ _ Means indicates output 2 or cooling control variable value MV2 Now you can use MV2 7 63 up down key to adjust the percentage values for H or C for OUT2 or Cooling Exception The controller performs open loop control as long as it stays in manual control it OUTI is configured as ON OFF mode The H value is exported to output 1 OUTI and C value is exported to control ie PB1 0 if PB is output 2 provided that OUT2 is performing cooling function ie OUT2 selects assigned or PB2 0 if PB2 is COOL assigned by event input UM9300 2 0 the controller will never perform Exif Manual Control manual control mode To press keys the controller will revert to its previous operating mode may be a failure mode or normal control mode 26 UM9300 2 0 3 4 Failure Transfer Fallure Mode Occurs as The controller will enter failure mode as one of the following conditions occurs 1 SBIE 1 SBIE occurs due to the input 1 sen
55. protection or an over temperature occurrence This error is far greater than controller error and cannot be corrected on the sensor except by proper UM9300 2 0 2 6 Thermocouple Input Wiring IThermocouple input connections are shown in Figure 2 5 The correct type of thermocouple extension lead wire MUST be used for the entire distance from thermocouple sensor to connection to the controller Splices and joints should be avoided if at all possible POLARITY MUST be observed when connecting thermocouples If the length of thermocouple plus the extension wire is too long it may affect the temperature measurement A 400 ohms K type or a 500 ohms J type thermocouple lead resistance will produce 1 degree C temperature error approximately Nm rM A Figure 2 5 gt HN Thermocouple Input Wiring DIP Switch 2 7 RTD Input Wiring RTD connection are shown in Figure 2 6 with the compensating lead connected to terminal 12 For two wire RTD inputs terminals 12 and 13 should be linked The three wire RTD offers the capability of lead resistance compensation provided that Two wire RTD should be avoided if possible for the purpose of accuracy A 0 4 ohm lead resistance of a two wire RTD will produce 1 degree C temperature error N ul Figure 2 6 A T RTD Input Wiring 940000000 00000000 gt 10 11 12 13 14 15 16 10 n
56. r PB2 if PB2 is selected A negative DB value shows an overlap area over which both outputs are active A positive DB value shows a dead band area over which neither output is active UM9300 2 0 33 Figure 3 25 shows the effects of PID adjustment on process response P action PV PB too narrow Perfect Set point Figure 3 7 Effects of PID Adjustment PB too wide Time action Tl too high PV Set point Perfect TI too low Time D action PV TD too low Perfect Figure 3 8 Continued Effects of PID Adjustment Set point TD too high Time 34 UM9300 2 0 3 10 Pump Control Pump Control function is one of the unique features of FDC 9300 Using this PUMP A Cost Effective function the pressure in a process can be controlled excellently The yet Perfect Solution pressure in a process is commonly generated by a pump driven by a variable speed motor The complete system has the following characteristics which affects the control behavior 1 The system is very noisy 2 The pressure is changed very rapidly 3 The pump characteristics is ultra nonlinear with respect to its speed 4 The pump can t generate any rnore pressure as its speed is lower than half of its rating speed 5 An ordinary pump may slowly lose the pressure even if the valves are Obviously a conventional controller can t fulfill the conditions mentioned above Only the superior noise rejection capability in addition t
57. re setup If the Basic Mode FUNC BASC is selected for a simple application then the following functions are ignored and deleted from the full function menu RAMP SP2 PB2 TI2 TD2 PL1 PL2 COMM PROT ADDR BAUD DATA PARI STOP AOFN AOLO AOHI IN2 IN2U DP2 IN2L IN2H EIFN PVMD FILT SLEP SPMD and SP2F Basic Mode capabilities If you don t need 1 Input 1 Thermocouple RTD Volt mA 1 Second setpoint 2 Input 2 CT for heater break detection 2 Second PID 3 Output 1 Heating or Cooling Relay SSR SSRD Volt mA 3 Event input 4 Output 2 Cooling Relay SSR SSRD Volt mA DC Power supply 4 Soft start RAMP 5 Alarm 1 Relay for Deviation Deviation Band Process Heater Break Loop 5 Remote set point Break Sensor Break Latch Hold or Normal Alarm 6 Complex process value 6 Alarm 2 Relay for Deviation Deviation Band Process Heater Break Loop 7 Output power limit Break Sensor Break Latch Hold or Normal Alarm 8 Digital communication 7 Dwell Timer 16 Hardware Lockout 9 Analog retransmission 8 Heater Break Alarm 17 Self Tune 10 Power shut off Sleep Mode 9 Loop Break Alarm 18 Auto Tune 11 Digital filter 10 Sensor Break Alarm 19 ON OFF P PD PI PID Control 12 Pump control 11 Failure Transfer 20 User Defined Menu SEL 13 Remote lockout 12 Bumpless Transfer 21 Manual Control then n Basic M 13 PV1 Shift 22 Display Mode 14 Programmable SP1 Range 2
58. red as a dwell timer by selecting TIMR for ATFN or A2FN but not BOTH Otherwise ErO7 will appear As the dwell timer is configured the parameter TIME is used for the dwell time adjustment The dwell time is measured in minutes ranging from O to 6553 5 minutes Once the process reaches the setpoint the dwell timer begins to count from zero until time out The timer relay output will remain unchanged until the dwell time has timed out Then output will change state The dwell timer operation is shown in the example below ES Er 1 Eror Code If alarm 1 is configured as dwell timer A1SP ATDV ATHY and ATMD are hidden Same case is for alarm 2 Example Set A1FN TIMR or A2FN TIMR but not both Adjust TIME in minutes ON ll oo ATMD if ATFN TIMR or A2MD if A2FN TIMR is ignored in this case OFF If a form B relay is required for dwell timer then order form B alarm 1 and configure ATFN Form B relay is not available for alarm 2 Timer starts Figure 3 1 Dwell Timer Function 3 3 Manual Control The manual control may be used for the following purposes 1 To test the process characteristics to obtain a step response as well as an impulse response and use these data for tuning a controller 2 To use manual control instead of a close loop control as the sensor fails or The controllers A D converter fails NOTE that a bumpless transfer can not be used for a longer time See section 3 6 3 In certain ap
59. rol Learning cycle is used to test the characteristics of the process The data are measured and used to determine the optimal PID values At the end of the two successive ON OFF cycles the PID values are obtained and automatically stored in the nonvolatile memory After the auto tuning procedures are completed the process display will cease to flash and the unit revert to PID control by using its new PID values During pre tune stage the PID values will be modified if any unstable phenomenon which is caused by incorrect PID values is detected Without pre tune stage like other conventional controller the tuning result will be strongly related to the time when the auto tuning is applied Hence different values will be obtained every time as auto tuning is completed without pre tune It is particularly true when the auto tuning are applied by using cold start and warm start UM9300 2 0 Auto tuning Auto tuning Begins Complete Cycle Cycle Learning Cycle New PID Cycle e a a 2 Integral Time Pre tune Stage PV Figure 3 4 Auto tuning Procedure Set Point Post tune Stage PID Control ON OFF Control PID Control bg UA n Cold Start ul Auto tuning Auto tuning Begins Complete Pre tune Stage py Waiting Cycle Learning Cycle New PID Cycle ba 9 Bl 2 Integral Time Set Point Pre tune Stage Post tune Stage i lt _ 75 e_Ho q_ c
60. s and release scroll key 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 an automated test fixture to perform Final step Step 12 Set the DIP switch to your desired position refer to section 1 3 after performing any or all require calibrations UM9300 2 0 Chapter 5 Error Codes amp Troubleshooting This procedure requires access to the circuitry of a live power unit Dangerous accidental contact with line voltage is possible Only qualified personnel are allowable to perform these procedures Potentially lethal voltages are present Troubleshooting Procedures 1 If an error message is displayed refer to Table 5 1 to see what cause it is and apply a corrective action to the failure unit 2 Check each point listed below Experience has proven that many control problems are caused by a defective instrument Line wires are improperly connected No voltage between line terminals Incorrect voltage between line terminals Connections to terminals are open missing or loose Thermocouple is open at tip Thermocouple lead is broken Shorted thermocouple leads Short across terminals Open or shorted heater circuit Open coil in external contactor Burned out line fuses Burned out relay ins
61. sor break or input 1 current below 1mA gt SB2E if 4 20 mA is selected or input 1 voltage below 0 25V if 1 5 V is selected if 3 ADER PV1 P1 2 or P2 1 is selected for PVMD or PV1 is selected for SPMD i 2 SB2E occurs due to the input 2 sensor break or input 2 current below IMA Fallure Transfer of outout 1 and output 2 if 4 20 mA is selected or input 2 voltage below 0 25V if 1 5 Vis selected if occurs as PV2 P1 2 or P2 1 is selected for PVMD or PV2 is selected for SPMD 1 Power start within 2 5 seconds 3 ADER occurs due to the A D converter of the controller fails 2 Failure mode is activated 3 Manual mode is activated Output 1 Fallure Transfer if activated will perform 4 Calibration mode Is activated 1 If output 1 is configured as proportional control PB1 O and BPLS is selected for OTFT then output 1 will perform bumpless transfer Thereafter 7 Failure Transfer of alarm 1 and alarm 2 the previous averaging value of MV1 will be used for controlling output 1 occurs as 2 If output 1 is configured as proportional control PB1 0 and a value Of 1 Failure mode is activated O to 100 0 is set for OTFT then output 1 will perform failure transfer Thereafter the value of OTFT will be used for controlling output 1 Fallure Transfer Setup 3 If output 1 is configured as ON OFF control PB1 0 then output 1 will be 1 OTFT driven OFF if O1FN selects REVR and be driven ON if OTFN selects DIRT 2 O2FT 3 ATFT Outp
62. stive load 32 F 3308 F 1820 C Pulsed Voltage Source Voltage 5V current limiting resistance 66 0 C 1767 8 C R B A 2C 2 2 Mo 32 F 3214 F Linear Output Characteristics 0 C 1767 8 C S eB o 2C 2 2 MQ Zero Span Load eet Type tolerance Tolerance Capacity C lisa P 4200 p 2C 22Mo 4 20 mA 3 8 4mA 20 21 mA 5000 max p O C 1395 C 126G 22 MQ 0 20 mA 0 MA 20 21 mA 5009 max 32 P 2543 F 0 5V OV 5 5 25V 10Ko min DIN 346 F 1292 F 41040 13Ko 1 5V 0 95 1V 5 5 25V 10KQ min PT100 200 C 600 C 0 10V OV 10 10 5V 10KQ min 16 sosee 111 F 5949 Ten mV 8mV 70mV 0 05 2 2 Mo mA 3MA 27MA 0 05 70 50 V 1 3V 11 5V 0 05 302 KO UM9300 2 0 45 Linear Output Resolution 15 bits Output Regulation 0 01 for full load change Output Settling Time 0 1 sec stable to 99 9 Isolation Breakdown Voltage 1000 VAC Temperature Effect 0 0025 96 of SPAN LC Trlac 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 DC Voltage Supply Characteristics Installed at Output 2 Max Output Ripple Isolation Type Tolerance Current Voltage Barrier 20V 0 5V 25MA 0 2 Vp p 500 VAC 12V 0 3V 40mA 0 1 Vp p
63. ter Break e M 3 14 Reload Default Parameters Chapter 4 Calibration Chapter 5 Error Codes and Troubleshooting Chapter 6 Specifications Appendix A 1 Menu Existence Your Settings A 2 Warranty ns 2 UM9300 2 0 Chapter 1 Overview Unique 1 1 Features cis Two function complexity levels ek User menu configurable Soft start ramp and dwell timer Programmable inputs thermocouple RTD mA VDC Adaptive heat cool High accuracy 18 bit input A PAnalog input for remote set point and CT High accuracy 15 bit output D Fast input sample rate 5 times dead band Pump control A Event input for changing function amp set point second Programmable digital filter Hardware lockout remote lockout protection Loop break alarm Fuzzy PID microprocessor based control Heater break alarm x Automatic programming Differential control x Auto tune function Self tune function Sleep mode function Sensor break alarm Bumpless transfer RS 485 RS 232 communication Analog retransmission Signal conditioner DC power supply A wide variety of output modules available EMC CE EN50081 1
64. this set point The idle state is provided for the purpose of preventing the pump from been restarted too frequently The value of SP2 should be negative to ensure a correct function The pump functions are summarized as follows 1 If the process is demanding material ie lose pressure the controller will precisely control the pressure at set point 2 If the process no longer consumes material the controller will shut off the pump as long as possible 3 The controller will restart the pump to control the pressure at set point as soon as the material is demanded again while the pressure falls below a predetermined value ie SP1 SP2 UM9300 2 0 35 Programming Gulde 1 Perform auto tuning to the system under such condition that the material ie pressure is exhausted at typical rate A typical value for PB1 is about 10 Kg cm Ill is about 1 second TD1 is about 0 2 second 2 If the process oscillates around set point after auto tuning then increase PB1 until the process can be stabilized at set point The typical value of PB1 is about half to two times of the range of pressure sensor Increase FILT Filter can further reduce oscillation amplitude But a value of FILT higher than 5 seconds is not recommended A typical value for FILT is0 5o0r 1 Close the valves and examine that if the controller can shut off the pump each time The value of REFC is adjusted as small as possible so that the controller can s
65. tion band out of band alarm dhL g Deviation band in band alarm py iH IN1 process value high alarm iL 11 N1 process value low alarm ATFN A En Alarm 1 Function Natt E 2 pusa IN2 process value high alarm pugil IN2 process value low alarm 10 f IN1 or IN2 process value high P CH alarm E 3 11 IN1 or IN2 process value low Ms alarm 12 N1 IN2 difference process value s high alarm 13 N1 IN2 difference process value pia low alarm 14 Loop break alarm Sensor break or A D fails nor n Normal alarm action tech Latching alarm action 0 Hal d Hold alarm action L Eg Latching amp Hold action UM9300 2 0 11 Table 1 6 Parameter Description continued 5 7 Contained in Setup Menu 12 Basic Parameter Display Parameter Range Default Function Notation Format Description Value ZE A tput OFF it fail v AIFT Alarm 1 Failure Transfer 9 al P RES TRES 4 Mode 1 grm Alarm output ON as unit fails Y A2FN Alarm 2 Function Same as A1FN 2 WA A2MD Alarm 2 Operation Mode Same as A1MD 0 Alarm 2 Failure Transfer WA A2FT Moda Same as A1FT 1 0 nan E Event input no function 1 ope SP2 activated to replace SP1 PB2 TI2 TD2 activated to replace P de PB1 T11 TD1 k 5 PPe SP2 PB2 TI2 TD2 activated to replace SP1 PB1 TI1 TD1 r 5H Reset alarm 1 output EIFN Event Input Function r SAZ Reset alarm 2 output 1 rA Lo Reset alarm 1 amp alarm 2 cdo d
66. tion procedure glial Calibrator KTC Figure 4 2 Lg Cold Junction ALLOW at least 20 minutes warm up Callbration Setup in still air at a room temperature of 25 C o The calibrator MUST be set for K type thermocouple output with internal compensation Simulate a 0 00 C signal to unit under calibration UM9300 2 0 Perform step 1 as stated to enter into calibration mode Press the scroll key until With on the display and simulator simulating the K t c 0 00 C degree input signal use the up down keys until value 0 00 is obtained Then press and hold scroll key at least 5 seconds and release the scroll key 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 x Perform step 11 to calibrate High temp gain of cold junction compensation if required otherwise perform step 11N to use a nominal value for the cold junction gain if a test chamber for calibration is not avallable Step 11 Setup the equipments same as step 10 The unit under calibration is powered in a still air room with temperature 50 C Allow at least 20 minutes for warming up at the 50 C ambient The calibrator source is set at 0 00 C with internal compensation mode Perform step 1 stated above then press scroll key until the display shows 7 15 Apply up down key until value 0 0 is obtained Press scroll key for at least 5 second
67. ue Press A Reverse Scroll Key Select the parameter in a reverse sequence during menu scrolling Press Y Mode Key Select the operation Mode in sequence Reset the front panel display to a normal display mode also used to leave Press Y Reset Key the specific Mode execution to end up the auto tune and manual control execution and to quit the sleep mode A Press Sleep Key lu e enters the sleep mode if the sleep function SLEP is enabled for at least 3 seconds select By entering correct security code to allow execution of engineering programs Press Factory Key This function is used only at the factory to manage the diagnostic reports The user should never attempt to operate this function Alarm 1 Indicator How to display a 5 digit number Alarm 2 Output 2 Indicator For a number with decimal point the Power On Sequence Process Value Indicator display will be shifted one digit right pper Dacos 4553 6 will be displayed by 4553 l Display segments OFF for 0 5 secs E a ic fo display process value 2 Display segments ON for 2 0 secs ici ct ee Setpoint y pu II II Value ame Amo ame aAA code etc the display will be divided into two 4 Display Date Code for 1 25 secs menu symbol and eror For a number without decimal point 3 Display Program Code for 2 5 secs alternating phases naa 5 Display S N for 1 25 secs r Lower Display Indicator AE
68. use other PB2 O TI2 70 if PB2 TI2 TD2 reasonable values for PID before tuning according to your previous assigned experiences But don t use a zero value for PB1 and TI1 or PB2 and TI2 otherwise the auto tuning program will be disabled 3 Set the set point to a normal operating value or a lower value if overshooting beyond the normal process value is likely to cause damage 4 Press until appears on the display 5 Press for at least 3 seconds The upper display will begin to flash and the auto tuning procedure is beginning NOTE Any of the ramping function remote set point or pump function if used will be disabled once auto tuning is proceeding Procedures The auto tuning can be applied either as the process is warming up Cold Start or as the process has been in steady state Warrn Start See Figure 3 4 If the auto tuning begins apart from the set point Cold Start the Pre tune Function Advantage unit enters Warm up cycle As the process reaches the set point Consistent tuning results can be value the unit enters walting cycle The waiting cycle elapses a obtained double integral time TI1 or TI2 dependent on the selection then it enters a leaming cycle The double integral time is introduced to allow the process to reach a stable state Before learning cycle the unit performs pre tune function with a PID control While in learning cycle the unit performs post tune function with an ON OFF cont
69. ut notification to purchaser to materials or processing that does not effect the compliance with any applicable specifications Return Material Authorization Contact Future Design Controls for a Return Authorization Number prior to returning any product to our facility UM9300 2 0 5 fd FuTUREDESIGN Future Design Controls 7524 West 98th Place PO Box 1196 Bridgeview IL 60455 USA 888 751 5444 Office 888 307 8014 Fax 866 342 5332 Technical Support E mail csr futuredesigncontrols com Website http futuredesigncontrols com Um9300 2 0 Version2 0 Dated 4 2008 DNUDIA S Jesf JO OILUOD einjpjeduue sse2old 0086 2474 NDIS3O3UNINI s 104 L N O D 0 2 OO 6WN
70. ut 2 Fallure Transfer if activated will perform 4 AQFT 1 If OUT2 selects COOL and BPLS is selected for OTFT then output 2 will perform bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 Exception If Loop Break LB alarm or 2 If OUT2 selects COOL and a value of 0 to 100 0 is set for O2FT then sensor Break SENB alarm is output 2 will perform failure transfer Thereafter the value of OTFT will be configured forA1FN or A2FN the alarm1 2 used for controlling output 2 will be switched to ON state independent Alarm 1 Fallure Transfer is activated as the controller enters failure mode of the setting of ATFT A2FT If Dwell Timer Thereafter the alarm 1 will transfer to the ON or OFF state preset by ATFT TIMR is configured for ATFN A2FN The alarm 1 alarm2 Alarm 2 Fallure Transfer is activated as the controller enters failure mode will not perform failure transfer Thereafter the alarm 2 will transfer to the ON or OFF state preset by A2FT 3 5 Signal Conditioner DC Power Supply Three types of isolated DC power supply are available to supply an external transmitter or sensor These are 20V rated at 25mA 12V rated at 40 mA and 5V rated at 80 mA The DC voltage is delivered to the output 2 terminals Two line Transmitter Set Oum DC Power Supply T 4 5 6 8 Figure 3 2 DC Power Supply App
71. uts as specified in Chapter 6 are not exceeded Electric power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes This electrical noise can enter and adversely affect the operation of microprocessor based controls For this reason we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the controller This wire is a twisted pair construction with foil wrap and drain wire The drain wire is to be attached to ground at one end only 2 0mm 0 08 max q oo Ss Figure 2 2 Lead Termination ml 4 5 7 0 mm 0 18 0 27 Se _OUT1 ALM1 2o o0 p 90 264VAC 2A 240VAC 2A 240VAC JB 5 47 63HZ 20VA E 2A 1240 VAC TG TC Eh Al Alt PTA PTB PIB COM CT cr Figure 2 3 Rear Terminal Connectlon Diagram CT Al E cari 16 UM9300 2 0 2 4 Power Wiring The controller is supplied to operate at 11 28 VAC VDC or 90 264VAC Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller Fuse 90 264 VAC or amp 11 28 VAC VDC Figure 2 4 Power Supply Connectlons Q Qv Qe Qe Qe Qe On Qe QOQOQO 9 10 11 12 13 14 15 16 A This equipment is designed for installation in an enclosure which provides adequate protection against electric

9300 User`s Manual - Environmental Test Chambers from Cincinnati

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