User`s Manual - Future Design Controls
Contents
1. Scroll Key Down Key Return Key Up Key fd FDC 8130 4 INPUT RANGE amp ACCURACY IN Sensor Input Type Range C Accuracy 0 J ron Constantan 50 to 999 C 2 CT 1 K Chromel Alumel 50 to 1370 C 2 C 2 m Copper Constantan 270 to 400 C 2 C 3 E Chromel Constantan 50 to 750 C 2 CT 4 B Pt30 RH Pt6 RH 300 to 1800 C 3 C 5 R Pt13 RH Pt 0 to 1750 C 2 C 6 S Pt10 RH Pt 0 to 1750 C 2 C F N Nicrosil Nisil 50 to 1300 C 2 C 8 RTD PT100 ohms DIN 200 to 400 C 0 4 C 9 RTD PT100 ohms JIS 200 to 400 C 0 4 C 10 Linear TOmV to 60mV 1999 to 9999 0 05 5 SPECIFICATIONS INPUT Thermocouple T C RTD Linear Range Accuracy Cold Junction Compensation Sensor Break Protection External Resistance Normal Mode Rejection Common Mode Rejection Sample Rate CONTROL Proportion Band Reset Integral Rate Derivative Ramp Rate Dwell ON OFF Cycle Time Control Action POWER Rating Consumption ENVIRONMENTAL amp PHYSICAL Operating Temperature Humidity Insulation Breakdown Vibration Shock Net Weight Housing Materials Safety Page 1 type J K T E B R S N PT100 ohm RTD DIN 43760 BS1904 or JIS 10 to 60mV configurable input attenuation User configurable refer to Table above Refer to Table above 0 1 C ambient typical Protection mode configurable 100 ohms max 60dB2. Manual Mode Execution DESCRIPTION Advance the index display to the desired position Indexs advanced continuously and cyclically by pressing this keypad Increases the parameter Decreases the parameter Resets the controller to its normal status Also stops auto tuning output percentage monitoring and manual mode operation Allows more parameters to be inspected or changed 1 2 Executes auto tuning function Calibrates control when in calibration level Allows the set point display to indicate the control output value Allows the controller to enter the manual mode Page 2 8 2 FLOW CHART PROCESS VALUE DISPLAY SETPOINT VALUE DISPLAY Long ASP rr oF 5 ASP SH F Add Pb CPb db E b kd Long 6 seconds Loll 5 SEL Ek CCE rumo fo E oe 4 Level 1 g a Q 3 fa ALA ALA RHY AHY CF rESo Level 2 PU gl 9 9 9 2 Conf fe Er Pr o HYSE LLIE HLI E 2 Long 6 seconds LEAL co v HCAL Level 3 co The return key can be pressed at any time This vvill prompt the display to return to the Process value Setpoint value Povver Applied 1 130 Di
3. PF User s Manual FDC 8130 Self Tune Fuzzy PID Process Temperature Controller c O N T R O L S Model FDC 8130 4 Instruction Manual CONTENTS 1 INTRODUCTION 2 NUMBERING SYSTEM 3 FRONT PANEL DESCRIPTION 4 INPUT RANGE amp ACCURACY 5 SPECIFICATIONS 6 INSTALLATION 7 CALIBRATION 8 OPERATION 9 ERROR MESSAGES 10 COMMON FAILURES 11 T C COLOR CODES 1 INTRODUCTION This manual contains information for the installation and operation of the Future Design model FDC 8130 Fuzzy Logic micro processor based controller The Fuzzy Logic is an essential feature of this versatile controller Although PID control has been widely accepted by industries yet it is difficult for PID control to work with some sophistic systems efficiently for examples systems of second order long time lag various setpoints various loads etc Because of disadvantage of controlling principles and fixed values of PID control it is inefficient to control the systems with plenty of varieties and the result is obviously frustrating for some systems The Fuzzy Logic control can overcome the disadvantage of PID control it controls the system in a efficient way by experiences it had before The function of Fuzzy Logic is to adjust the PID values indirectly in order to making the manipulation output value MV adjusts flexibly and quickly adapt to various processes By this way it enables a process to reach its predetermined setpoint in the sho
4. 120dB 3 times second 0 200 0 360 F 0 3600 seconds 0 1000 seconds 0 200 0 C minute 0 360 0 F minute 0 3600 minutes With adjustable hysteresis 0 20 of SPAN 0 120 seconds Direct for cooling and reverse for heating 90 264VAC 50 60Hz Less than 5VA 10 to 50 C 0 to 90 RH non codensing 20M ohms min 500 VDC AC2000V 50 60Hz 1 minute 10 55Hz amplitude 1mm 200 m s 20g 260 grams Poly Carbonate Plastic UL CSA CE 6 INSTALLATION 6 1 DIMENSIONS amp PANEL CUTOUT 3 62 177 Panel Panel Cutout f f Figure 6 1 Mounting Dimensions 6 2 WIRING DIAGRAM FDC 8130 Alarm 1 HNO 141 Interface Alarm1 Com 2 EA Tx2 12 Vo N O Control 3 o 13 2 414 EA of 114 Alarm2 Com N O 421 5 Alarm2 N O ouT fg c b 16 7 N C 17 zt B V g0 264 VAC 8 1 181 7 B Power Input 9 AC 19 RTD po A 10 20 8 OPERATION 8 1 KEYPAD OPERATION 7 CALIBRATION Note Do not proceed through this section unless their is a genuine need to re calibrate the controller All previous calibration data will be lost Do not attempt recalibration unless you have available appropriate calibration equipment If calibration data is lost you willneed to return the controlle
5. 9 Control abnormal or operation incorrect 10 Display blinks entered values change by themselves Analog portion or A D converter defective Thermocouple RTD or sensor defective ntermittent connection of sensor vviring VVrong sensor or thermocouple type vvrong input mode selected Analog portion of A D converter defective No heater povver output incorrect output device used Output device defective Open fuse outside of the instrument CPU or EEPROM non volatile memory defective Key svvitch defective ncorrect setup values Electromagnetic interference EMI or Radio Frequency interference RFI EEPROM defective 11 0 T C COLOR CODES Thermocouple Cable Color Codes Check sensor or thermocouple type and if proper input mode was selected Replace related components or board Reversed input wiring of sensor Check and correct Check output wiring and output device Replace output device Replace output fuse Output device shorted or power service Check and replace shorted Check and replace Read the setup procedure carefully Suppress arcing contacts in system to eliminate high voltage spike sources Separate sensor and controller wiring from dirty power lines ground heaters Replace EEPROM Thermocouple Cable British American German French Type Material BS ASTM DIN NFE Copper Cu white blu
6. setpoint is set to close to the process temperature or if there is insufficient capacity in the system to reach setpoint e g inadequate heating power available Upon completion of Auto tune the new PID settings are automatically entered into the controller s non volatile memory 8 5 MANUAL P I D ADJUSTMENT VVhilst the auto tuning function selects control settings which should prove satisfactory for the majority of processes you may find it necessary to make adjustments to these arbitrary settings from time to time This may be the case if some changes are made to the process or if you wish to fine tune the control settings t is important that prior to making changes to the control settings that you record the current settings for future reference Make slight changes to only one setting at a time and observe the results on the process Because each of the settings interact with each other itis easy to become confused with the results if you are not familiar with process control procedures TUNING GUIDE Proportional Band Symptom Slow Response High Overshoot or Oscillations Integral Time Reset Sympton Slow Response Instability or Oscillations Derivative Time Rate Symptom Slow Response or Oscillations High Overshoot Solution Decrease PB Value Increase PB Value Solution Decrease Integral Time Increase Integral Time Solution Decrease Deriv Time Increase Deriv Time 8 6 M
7. ANUAL TUNING PROCEDURE Step 1 Adjust the integral and derivative values to 0 This inhibits the rate and reset action Step 2 Set an arbitrary value of proportional band and monitor the control results Step 3 If the original setting introduces a large process oscillation then gradually increase the proportional band until steady cycling occurs Record this proportional band value Pc Step 4 Measure the period of steady cycling PV PV Process value 4 TIME Record this value Tc in seconds Step 5 The Control Settings are determined as follows Proportional Band PB 1 7 Pc Integral Time TI 0 5 Tc Derivative Time TD 0 125 Tc 8 7 RAMP amp DWELL The FDC 8130 controller can be configured to act as either a fixed setpoint controller or as a single ramp controller on power up This function enables the user to set a pre determined ramp rate to allow the process to gradually reach setpoint temperature thus producing a Soft Start function A dwell timer is incorporated within the FDC 8120 and the alarm relay can be configured to provide either a dwell function to be used in conjunction with the ramp function The ramp rate is determined by the Fr parameter which can be adjusted in the range to 200 0 C minute The ramp rate function is disabled when the r r parameter is set to o The soak function is enabled by configuring the alarm output to act as a dwell timer The parameter FL A needs t
8. FF OFF ON ON ON OFF ON ON OFF ON ON ON ON ON ON s l ONO Hysteresis for ON OFF Control 0 to 20 of SPAN Low Limit of Range HE High Limit of Range Low Calibration Figure HEAL Calibration Figure NOTES Adjusting Range of the Parameter Factory settings Process alarms are at fixed temperature points Deviation alarms move with the setpoints value Page 3 DEFAULT SETTING Undefined 0 C min 0 0 0 C a s l 3 Relay Pulsed Voltage Linear Volt mA 1 nm o T C RTD Linear 1000 C 800 C 8 T 4 3 8 4 AUTOMATIC TUNING 1 Ensure that controller is correctly configured and installed 2 Ensure Proportional Band Pb is not set at 3 Press Return Key for at least 6 seconds maximum 16 seconds This initialises the Auto tune function procedure press Return Key and release 4 The Decimal point in lovver right hand corner of PV display flashes to indicate Auto tune is in progress Auto tune is complete when the flashing stops 5 Depending on the particular process automatic tuning may take up to two hours Processes with long time lags will take the longest to tune Remember while the display point flashes the controller is auto tuning To abort auto tuning NOTE If an AT error RE Er occurs the automatic tuning process is aborted due to the system operating in ON OFF control PB 0 The process will also be aborted if the
9. e red yellow T Constantan blue red brown blue Cu Ni blue blue brown blue Iron Fe yellow white red yellow J Constantan blue red blue black Cu Ni black black blue black brown yellow red yellow K blue red green purple red yellow green yellow Ni Al white black red yellow 1277 blue red white green ar tea green green white green R Pt 30 Rh Use 77 Use Pt 6 Rh Copper Wire grey grey Copper Wire Colour of overall sheath Page 5 c ON T R OL S d ruTuReDEsIGN 7524 West 98th Place Bridgeview IL 60455 Phone 888 751 5444 Fax 888 307 8014 jenuew sasn 4 llonuo2 SSS901d 0 L9 IAA
10. e setpoint HL l k valle Replace module Check for A H E cr Analog hybrid module damage outside source of damage such as transient voltage spikes Incorrect operation of auto tune Repeat procedure Increase Prop r procedure Prop Band set to 0 Band to a number larger than 0 Manual mode is not allowable for N PE r an ON OFF control system Increase proportional band Check sum error values in r 5 E memory may have changed L r accidentally Check and reconfigure the control parameters Page 4 10 0 COMMON FAILURE CAUSES Common Fallure Causes and Corrective Actlons Symptom Probable Causes Corrective Actions Bad tion bet PCB amp k d Clean contact area on PCB 1 Keypad no function Bad connection between eypads Replace keypads No power to instrument Check power line connections Power supply defective Replace power supply board 3 Some segments of the display or LED display or LED lamp defective Replace LED display or LED lamp ir lamps not lit or lit erroneously Related LED driver defective Replace the related transistor or IC chip Replace related components or board Check thermocouple RTD or sensor Check sensor wiring connections 2 LED s will not light 4 Display Unstable 5 Considerable error in temperature indication 6 Display goes in reverse direction counts dovvn scale as process vvarms 7 No heat or output 8 Heat or output stays on but indicator reads normal
11. o be set to the value 12 The alarm contact vvill novv operate as a timer contact vvith the contact being closed at power up and opening after the elapsed time set at parameter ASP f the controller power supply or output is wired through the alarm contact the controller will operate as a guaranteed soak controller In the example below the Ramp Rate is setto 5 C minute AL A 12 and ASP 15 minutes Power is applied at zero time and the process climbs at 5 C minute to the setpoint of 125 C Upon reaching setpoint the dwell timer is activated and after the soak time of 15 minutes the alarm contact will open switching off the output The process temperature will eventually fall at an undetermined rate C 150 125 100 Process Value 75 i 15 minutes 50 gt pe 1 Alarm Output 25 l lo t minutes 0 10 20 30 40 50 60 70 80 90 The dwell function may be used to operate an external device such as a siren to alert when a soak time has been reached ALA need to be set to the value 13 The alarm contact will now operate as a timer contact with the contact being open on the initial start up The timer begins to count down once the setpoint temperature is reached After the setting at ASP has elapsed the alarm contact closes 9 ERROR MESSAGES l Replace RTD or sensor AL Nn 1 Sensor break error Use manual mode operation q Process display beyond the lovv l Process display beyond the high oA rang
12. r to your supplier who may apply a charge for re calibration Prior to calibration ensure that all parameter settings are correct input type C F resolution low range high range 1 Tum power off the unit Remove sensor input wiring and connect a standard input simulator of the correct type to the controller input Verify correct polarity Set simulated signal to coincide with low process signal e g zero degrees Use the Scroll Key until the CAL appears on the PV Display Refer to 8 2 Use the Up and Down Keys until the SV Display represents the simulated input Press the Return Key for at least 6 seconds maximum 16 seconds then release This enters the low calibration figure into the controller s non volatile memory Press and release the Scroll Key HERL appears on the PV Display This indicates the high calibration point Increase the simulated input signal to coincide with high process signal e g 100 degrees Use the Up and Down Keys until the SV Display represents the simulated high input Press the Return Key for at least 6 seconds maximum 16 seconds then release This enters the high calibration figure into the controller s non volatile memory remove all test wiring and replace sensor wiring observing polarity With power on it has to wait for 12 seconds to memorize the new values of parameters once it been changed Output Percentage Monitor
13. rr oFSk 10 ASPR rr ASPo 11 A5P2 oF5k Proportional Cycle Time of Output 1 0 to 120 seconds a A a 8 ASP oF St 9 A5P I ASP ASPlsrr ASP 1 5 Proportional Cycle Time of Output 2 20 seconds Input Mode Selection 0 J type T C 6 S type T C K type T C 7 N type T C ype T C 8 PT100DIN ype T C 9 PT100JIS ype T C 10 Linear Voltage or Current R type T C Note T C Close solder gap J3 RTD open J3 larm Mode Selection Process High Alarm Process Low Alarm Deviation High Alarm 8 Outband Alarm 9 Inband Alarm 10 Inhibit Outband Alarm Deviation Low Alarm 11 Inhibit Inband Alarm Inhibit Process High Alam 12 Alarm Relay OFF as Dwell Inhibit Process Low Alarm Time Out Inhibit Deviation High Alarm 13 Alarm Relay ON as Dwell Inhibit Deviation Low Alarm Time Out 12813 only available with alarm 1 Hysteresis of Alarm 1 O to 20 of SPAN C F Selection 0 F 1 C Resolution Selection 0 No Decimal Point 2 2 Digit Decimal 1 1 Digit Decimal 3 3 Digit Decimal 2 amp 3 may only be used for linear voltage or current M Control Action 0 Direct Cooling Action 1 Reverse Heat Action Error Protection Output 1 Output 2 Alarm 1 Alarm 2 Output 1 Output 2 Alarm 1 Alarm 2 OFF OFF OFF OFF 8 OFF ON OFF OFF OFF OFF ON OFF 9 OFF ON ON OFF ON OFF OFF OFF 10 ON ON OFF OFF ON OFF ON OFF 11 ON ON ON OFF OFF OFF OFF ON OFF ON OFF ON OFF OFF ON ON OFF ON ON ON ON O
14. rtest time with minimum overshooting during tuning or external disturbance Different from PID control with digital information the Fuzzy Logic is a control with language information PID control when properly tuned PID Fuzzy control PID FUZZY CONTROL Temperature Setpoint Warm Load Disturbance Time In addition this instrument has functions of single stage ramp and dwell auto tuning and manual mode execution Ease of use is also an essential feature with it 2 NUMBERING SYSTEM Model No 1 2 3 4 5 6 7 8 L L L L L L L L 1 Power Input 4 90 264VAC 5 20 32VAC VDC 9 Other 2 Signal Input Configurable 9 Universal Other 3 Range Code 1 Configurable 9 Other 4 Control Mode 3 PID ON OFF Control 5 amp 6 Output 1 amp Output 2 Option Relay rated 3A 240VAC Resitive SSR Drive rated 20mA 24V 0 20mA linear max load 500 ohms Module OM93 2 0 10V linear min impedance 500K ohms Module OM93 3 None RS 485 4 20mA 0 20mA Other retransmission retransmission 3 FRONT PANEL DESCRIPTION Process Value Display 0 4 red LED Setpoint Value Display 0 3 green LED Control Outputs i A M PV F o E F __ a OUT1 OUT2 ALM1 ALM2 F Indicator c D Indicator DO Alarm Outputs
15. splayed for 4 seconds Software Version 3 4 or higher 2 BBBB LED test All LED segments must be lit for 4 seconds 3 Process value and setpoint indicated 8 3 PARAMETER DESCRIPTION INDEX DESCRIPTION ADJUSTMENT RANGE SV Setpoint Value of Control Low Limit to High Limit Value Alarm Setpoint Value Low Limit to High Limit Value if Al A 0 1 40r5 0 to 3600 minutes if ALA 120r13 Low Limit minus set point to High Limit minus set point value if ALA or ALA 2 3 61011 Ramp Rate for the process value to limit an abrupt change of process Soft Start 010 200 0 C 360 0 F minute iff M 0109 Oto 3600 unit minute if M 10 Offset Value for Manual Reset if Er 0 0 to 100 Offset shift for process value 111 C to 111 C Address Code for Digital Transmission 0 31 For Digital Transmission Proportional Band of Output 1 0 to 200 C set to O for on off control Proportional Band of Output 2 0 to 4 0 of PB Dead Band 100 to 100 of PB Integral Reset Time 0 to 3600 seconds Derivative Rate Time O to 1000 seconds Local Mode 0 No control parameters can be changed 1 Control parameters can be changed Parameter Selection allovvs selection of additional parameters to be accessible at level 0 security None err oFSE 12 ASP brr ASP ASP I 7 A5Pl rr oF5E 13 ASP 1 oF SE ASP 14 A5Po rr oFSE 15 ASP b
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