100 Series Manual - Future Design Controls
Contents
1. 19 2 2 Mounting 19 2 3 Wiring precautions 21 2 4 Power Wiring 24 2 5 Sensor Installatio Guidelines 24 2 6 Sensor Input Wiring 25 2 7 Control Output Wiring 25 2 8 Alarm Wiring 28 2 9 Process Retransmission 28 2 10 Data Communications 29 Chapter 3 Programming 3 1 Lockout l 3 2 Signal Input 3 3 3 Control Outputs 32 3 4 Alarm 97 3 5 Configure User Menu 48 3 6 Ramp 49 3 7 Dwell Timer 40 3 8 PV Shift 4 3 9 Digital Filter 4 3 10 Failure Transfer 42 3 11 Auto tuning 43 3 12 Manual funing 44 3 13 Manual Control 45 3 14 Data communication 47 3 15 PV Retransmission 47 UM91001D Page No Chapter 4 Calibration Chapter 5 Specifications 53 Appendix A Error Codes 59 A 2 Warranty 60 Chapter 1 Overview 1 1 General The Fuzzy Logic plus PID microprocessor based controller series incorporate two bright easy to read 4 digit LED displays indicating process value and set point value The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time with the minimum2. gl a Release 3 22 then press cL for 3 seconds ee CF NPT E to start C UNT auto tunin C RIDH da End ie mode CJLO C PB c cu c TI C Press C for 3 seconds P f r CADDR to start K 3 seconds to perform calibration manual control A Apply these modes will break the control loop and change sorne of the previous setting data Make sure that if the system is allowable to apply these modes The flow chart shows a complete listing of all parameters For actual application the number of available parameters depends on setup conditions and should be less than that shown in the flow chart 2 You can select at most 8 parameters put in the user menu by using SEL SEL8 contained at the bottom of setup menu 3 Release press co again for 2 seconds or longer but not longer than 3 seconds then release to enter the calibration menu The user menu shown in the flow chart is corresponding to the default setting for the SEL parameters SEL to SEL8 SP3 will be hidden if NONE is selected for ALFN SP2 will be hidden if alarm function is not selected for OUT2 The unused parameter will be hidden even if it is selected by SEL parameters UM91001D 11 1 6 Parameter Descriptions Parameter Notation SP1 Parameter Description Set point for output 1 Set point for output 2 when output 2 performs alarm function Set point for alarm or d
3. 32 Heat Only ON OFF Control Select REVR for OUT1 Set PB to O1HY is used to adjust dead band for ON OFF control The output 1 hysteresis OTHY is enabled in case of PB 0 The heat only on off control function is shown in the following diagram PV SP1 Dead band O1HY SP O1HY OUTI Action Time Time Figure 3 2 Heat Only ON OFF Control The ON OFF control may introduce excessive process oscillation even if hysteresis is minimized to the smallest If ON OFF control is set ie PB 0 TI TD CYC1 OFST CYC2 CPB DB will be hidden and have no function to the system The auto tuning mode and bumpless transfer will be disabled too Heat only P or PD control Select REVR for OUT1 set TI to O OFST is used to adjust the control offset manual reset OTHY is hidden if PB is not equal to 0 OFST Function OFST is measured by with range 0 100 0 n the steady state ie process has been stabilized if the process value is lower than the set point a definite value say 5 LC while 20 LC is used for PB that is lower 25 96 UM91001D 33 then increase OFST 25 96 and vice versa After adjusting OFST value the process value will be varied and eventually coincide with set point Using the P control TI set to O the auto tuning is disabled Refer to section 3 12 manual tuning for the adjustment of PB and TD Manual reset adjust OFST is not practical because the load may change
4. gt gt are 6 0mm max T 3 0mm min m 3 Figure 2 2 Lead Termination for FDC 4100 FDC 8100 and FDC 7100 Figure 2 3 Lead Termination for FDC 9100 90 250VAC 47 63 Hz 12VA E TX TAD RE RS 485 B 1X2 RXD RE Retransmission Ma i COM RS 232 OP2 ALM PTA E TC V PTB MA POO B PT mA 2777 PE IC V mA RID Figure 2 4 Rear Terminal Connection for FDC 4100 and FDC 8100 22 UM91001D 90 250VAC 8 F 47 63 Hz OP1 12VA 019 Xl ms 485 ALM 1X2 PV Retransmission A PTA 16 V OP2 PTB mA tht B 16M pws IC V mA RID Figure 2 5 Rear Terminal Connection for FDC 7100 PV Retrans 158 232 RXD COM 158 485 1 TX2 IE V PTB mA TC V PTB mA Figure 2 6 Rear Terminal Connection for FDC 9100 UM91001D 23 2 4 Power Wiring The controller is supplied to operate at 11 26 VAC VDC or 90 250 VAC Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller FDC 4100 FDC 7100 FDC 8100 90 250VAC or FDC 9100 99 250 VAC or 11 26VAC VDC 11 26VAC VDC 7 Figure 2 7 Power Supply Connections N This equipment is designed for installation in an enclosure which provides adequate protection against electric shock The enclosure must be connected to earth ground Local requirements regarding electrical installation should be rigidly observ
5. 7 High limit of set point TM 537 8 C W SHIF PV shift offset value Low 360 0 E High 207 E 0 0 0 1 0 second time constant 0 2 second time constant Ca m R 0 5 secondi fime constant second time constant 2 seconds time Filter damping time constant constant of PV 5 seconds time constant 10 seconds time constant 20 seconds time constant 30 seconds time constant Li 60 seconds time constant Co NO C un Kw FILT Lh O Pu Lo Co Lb Lo o n UM91001D 13 Parameter inti Notation Parameter Description Proportional bond value Integral time value Low O High 1000 sec Derivative time value Low 0 High 360 0 sec 77 Dong Output 1 function control action Direct Peon control action re uc Relay output Solid state relay drive output Solid state relay output 7 un nm un un nm Lt 3 4 20 mA current module 0 20 mA current module 0 IV voltage module 5V voltage module 1 5V voltage module iy QO 10V voltage module a Select BPLS bumpless transfer or 0 0 100 0 to Output 1 failure transfer continue output 1 control mode function as the unit fails or select OFF 0 or ON 1 for ON OFF control m Output 1 signal type 8
6. Linear Output Resolution Output Regulation Output Settling Time Isolation Breakdown Voltage Temperature Effect Triac SSR Output Rating Inrush Current Min Load Current Max Off state Leakage Max On state Voltage Insulation Resistance Dielectric Strength 15Bits 0 02 for full load change 0 1 sec stable to 99 9 1000 VAC 0 01 of SPAN LC 1A 240 VAC 20A for 1 cycle 50 mA rms 3 mA rms 1 5 V rms 1000 Mohrns min at 500 VDC 2500 VAC for 1 minute UM91001D 55 DC Voltage Supply Characteristics Installed at Output 2 Max Output Ripple Isolation Alarm Alarm Relay Alarm Functions Alarm Mode Dwell Timer Form C Rating 2A 240VAC 200 000 cycles for resistive load Dwell timer PV High Low Alarm Deviation High Low Alarm Deviation Band High Low Alarm Normal Latching Hold Latching Hold 0 1 4553 6 minutes Data Communications Interface RS 232 1 unit RS 485 up to 247 units Protocol Modbus Protocol RTU mode Address 1 247 Baud Rate 2 4 38 4 Kbits sec Data Bits or 8 bits Parity Bit None Even or Odd Stop Bit 1 or 2 bits Comm Buffer 160 bytes Analog Retransmission Functions Process Variable Output Signal 4 20 mA 0 20 mA 0 SV 1 5V O 10V Resolution 15 bits Accuracy 0 05 96 of span 0 0025 C Load Resistance Regulation settling Time Breakdown Volts Linearity Error Temp E
7. 12VA 5W maximum npuf Resolufion 18 bits Sampling Rate 5 Times second Maximum Rating 2 VDC minimum 12 VDC maximum 1 minute for mA input Temperature Effect 1 5uV C for all inputs except mA input 3 0uV C for mA input 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 ohm of resistance sum of two leads Burn ouf Current 200 mA Common Mode Rej 120dB Normal Mode Rej o5ciB Sensor Break Detection Sensor open for TC RTD and mv inputs Sensor short for RTD input below 1 mA for 4 20 mA input below 0 25V for 1 5 V input unavailable for other inputs Sensor Break Responding Time Within 4 seconds for TC RTD and mV inputs 0 1 second for 4 20 mA and 1 5V inputs UM91001D 53 Characteristics F E s ri E Era C 1767 8 C L 328E 3214F C 1300 a 770 328 F 1652 2 22MQO mm 210 C 700 C 346 F 1292 F HAC take STO ES C 600 C Ru xr me F 1112 F 404C 13Kn 8mV 7OmV 70mV 0 05 A 22MQ 2 UM91001D 54 Output 1 Output 2 Relay Rating Pulsed Voltage 2A 240 VAC life cycles 200 000 for resistive load Source Voltage 5V current limiting resistance 66 Q Linear Output Characteristics vee Zero span Load yp Tolerance Tolerance Capacity 4 20 mA 3 8 4 mA 20 21 mA 500 max 0 20 mA 20 21 mA 500 max 0 95 1V 10 min 0 10V 10 10 5V 10K min
8. 30 ma 6l Pulsed Voltage Pulsed Voltage 120V 240V Moins Supply m q 30mA 5V 5V Pulsed l Voltage 33 T 33 LA MI l a 4 Figure 2 14 Output 2 Pulsed Voltage to Drive SSR FDC 4100 External device FDC 8100 FDC 7100 FDC 9100 5 0 20mA E 0 20mA i 5 4 20mA 4 20mA Moximum Load 900 ohms Figure 2 15 Output 2 Linear Current UM91001D 27 Control Output 2 Wiring Cont d FDC 4100 External device FDC 8100 FDC 7100 FDC 9100 R 558 o peel fut EX NR i 0 1V 0 5V 6 0 1V 0 5V 0 1V 0 5V 1 5V 0 10V 7 1 5V 0 10V 1 5V 0 10V 6l EA Minimum l Load Figure 2 16 Output 2 Linear Voltage 10Kohms 2 0 Alaih Wiring FDC 4100 FDC 8100 FDC 7100 FDC 9100 8 1 20V 240VAC Figure 2 17 Alarm Output to Drive Load Mains Supply External device 2 9 Process Retransmission FDC 9100 8100 4100 Output to Re 13 zz Recorder 0 5 1 5VDC 0 10vbc PLC Etc Re Load Resistance 500 ohms for current output 10 K ohms minimum for voltage output FDC 7100 Output to Re 10 0 20 4 20ma Recorder 0 5 1 5VDC 0 10VDC PLC Etc Re Load Resistance 500 ohms for current output 10 K ohms minimum for voltage output Figure 2 18 Retransmission Output Wiring UM91001D 2 10 Data Communication FDC 4100 FDC 8100 RS 485 to RS 232 FDC 9100 FDC 7100 network adaptor x 13 ES SNATOA o
9. 0 Output 1 ON OFF control nm hysteresis Low 0 1 High 50 0 C 90 0 F Output 1 cycle time Low 0 1 High 90 0 sec Offset value for P control Low 0 High 100 0 nonE NoRamp Function Ramp function selection mr 77v 7 os 2 Hr r Use unit hour as Ramp Rate 14 UM91001D Poromefer eH Default Notefion Parameter Description Range Value RR Ramp rate Low 0 High 900 0 S 0 0 Output 2 function Output 2 signal type Output 2 No Function Deviation High Alarm Deviation Low Alarm Process High Alarm Process Low Alarm Cooling PID Function Relay output Solid state relay drive output Solid state relay output 4 20 mA current module O 20 mA current module 1V voltage module 5V voltage module 5V voltage module 10V voltage module CPB Output 2 failure transfer mode Output 2 hysteresis value when output 2 performs alarm function Cooling proportional band value Select BPLS bumpless transfer or 0 0 100 0 to continue output 2 control function as the unit fails or select ON 0 or OFF 1 for alarm function Low 0 1 Low 50 90 0C High ooo Fy High 300 100 UM91001D Parameter inti Default Notation Parameter Description Range Value Heating cooling dead l DB band negative value Low 36 0 High 36 0 0 overlap Onun E No alarm function 1 E mr Dwell timer
10. C Pulsed voltage to drive SSR AR Bb 14V AOmA ODS ie A Special order UM91001D 7 1 3 Programming Port 4 Front Terminal Panel Figure 1 2 Programming Port Overview Access Hole A special connector can be used to touch the programming port which is connected to a PC for automatic configuration also can be connected to an ATE system for automatic calibration and testing The programming port is used for off line automatic setup and testing procedures only Do NOT attempt to make any connection to these pins when the unit is in normal operation 8 UM91001D 1 4 Keys and Disploys KEYPAD OPERATION SCROLL KEY This key is used to select a parameter to be viewed or adjusted UP KEY 4 This key is used to increase the value of selected parameter DOWN KEY Y This key is used to decrease the value of selected parameter RESET KEY This key is used to 1 Revert the display to display the process value 2 Reset the latching alarm once the alarm condition is removed 3 Stop the manual control mode auto tuning mode and calibration mode 4 Clear the message of communication error and auto tuning error 5 Restart the dwell timer when the dwell timer has been time out 6 Enter the manual control menu during failure mode occurs ENTER KEY Press for 3 seconds or longer Press for 3 seconds to 1 Ener setup menu The display shows 2 Enter manual control mode during manual control
11. L RTD PT DN PT JS linear 4 20 0 20 0 60 O 1V 0 5V 1 5V 0 10 UNIT Selects the process unit Range C F PU process unit If the unit is neither C nor F then selects PU DP Selects the resolution of process value Range for T C and RTD NO DP 1 DP for linear NO DP 1 DP 2 3 DP INLO Selects the low scale value for the linear type input INHI Selects the high scale value for the linear type input How to use INLO and INHI IA unit ordered with 4 20 mA is setup as INPT 4 20 then if SL specifies the input signal low ie 4 mA SH specifies the input signal high ie 20 mA S specifies the current input signal value the conversion curve of the process value is shown as follows UM91001D 31 process value Figure 3 1 Conversion Curve for Linear Type Process Value input signal Formula PV INLO INHI ANLO B oe Example A 4 20 mA current loop pressure transducer with range 0 15 kg cmt is connected to input then perform the following setup INPT 4 20 INLO 0 00 INHI 15 00 DP 2 DP Of course you may select other value for DP to alter the resolution 3 3 Control Outputs There are 4 kinds of control modes can be configured as shown in Table 3 1 Table 3 1 Heat Cool Control Setup Value 2377 Fm x x REVR DEHI Heat PID Cool pp REVR COOL X Don t care if ON OFF control O Adjust to met process is configured requirements UM91001D
12. above parameters The number of visible parameters is dependent on the setup condition The hidden parameters for the specific application are also deleted from the SEL selection 38 UM91001D Example OUT2 selects DE LO PB 100 0 SEL T selects INPT SEL2 selects UNIT SEL3 selects PB SELA selects TI SEL5 SEL8 selects NONE Now the upper display scrolling becomes Run e HE FB 3 6 Ramp The ramping function is performed during power up as well as any time the set point is changed Choose MINR or HRR for RAMP the unit will perform the ramping function The ramp rate is programmed by adjusting RR The ramping function is disabled as soon as the failure mode the manual control mode the auto tuning mode or the calibration mode occurs Example without Dwell Timer select MINR for RAMP selects C for UNIT selects 1 DP for DP Set RR 10 0 SV is set to 200 C initially and changed to 100 C after 30 minutes since power up The starting temperature is 30 C After power up the process is running like the curve shown below Figure 3 5 RAMP Function 0 17 30 40 anaes Note When the ramp function is used the lower display will show the current ramping value However it will revert to show the set point value as soon as the up or down key is touched for adjustment The ramping value is initiated to process value either as power up or RR and or set point are changed Setting RR to zero means no ramp function at all UM91001D 39
13. and depress Press for 3 seconds then the MAN indicator will begin to flash and the lower display will show The controller now enters the manual control mode indicates output control variable for output 1 and indicates control variable for output 2 Now you can use up down key to adjust the percentage values for the heating or cooling output The controller performs open loop control as long as it stays in manual control mode Exit Manual Control press key the controller will revert to its normal display mode UM91001D 45 PV PB too lovv Ideal Set point P action PB too high Time TI too high PV Set point l action Ideal TI too low Time PV TD too low Set point D action TD too high Time Figure 3 9 Effects of PID Adjustment 46 UM91001D 3 14 Data Communication The controllers support RTU mode of Modbus protocol for the data communication Other protocols are not available for the series Two types of interface are available for Data Communication These are RS 485 and RS 232 interface Since RS 485 uses a differential architecture to drive and sense signal instead of a single ended architecture which is used for RS 232 RS 485 is less sensitive to the noise and suitable for a longer distance communication RS 485 can communicate without error over 1 km distance while RS 232 is not recommended for a distance over 20 meters Using a PC for data communication is the most economic way The si
14. equipment must be switched off and isolated Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair Component replacement and internal adjustments must be made by a qualified maintenance person only N To minimize the possibility of fire or shock hazards do not expose this instrument to rain or excessive moisture N Do not use this instrument in areas under hazardous conditions such as excessive shock vibration dirt moisture corrosive gases or oil The ambient temperature of the areas should not exceed the maximum rating specified in Chapter 5 2 1 Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage If any damage due to transit report and claim with the carrier Write down the model number serial number and date code for future reference when corresponding with our service center The serial number S N and date code D C are labeled on the box and the housing of control 2 2 Mounting Make panel cutout to dimension shown in Figure 2 1 Take both mounting clamps away and insert the controller into panel cutout Install the mounting clamps back Gently tighten the screws in the clamp till the controller front panels is fitted snugly in the cutout UM91001D 19 20 k 2 1 Mounfing Dimensions 3 62 Panel Cutout mm Le 3 62 Panel 9 02 g Cutout 2 67 wo l 68
15. 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 96 of PB A negative DB value shows an overlap area over which both outputs are active A positive DB value shows a dead band area over which neither output is active Output 2 ON OFF Control Alarm function The output 2 can also be configured as alarm function There are 4 kinds of alarm functions can be selected for output 2 these are DE HI deviation high alarm DE LO deviation low alarm PV HI process high alarm and PV LO process low alarm Refer to Figure 3 3 and Figure 3 4 for the description of deviation alarm and process alarm UM91001D 35 PV OUT2 DE HI OV 9P2 SV SP2 O2HY OUT2 Action Figure 3 3 Output 2 Deviation Time High Alarm SP2 0O2HY SP2 OUT2 Action Figure 3 4 Output 2 Process ine Low Alarm 36 UM91001D 3 4 Alarm The controller has one alarm output There are types of alarm functions and one dwell timer can be selected and four kinds of alarm modes ALMD are available for each alarm function ALFN Besides the alarm output the output 2 can also be configured as another alarm But output 2 only provides 4 kinds of alarm functions and only normal alarm mode is avaiable for this alarm A process alarm sets two absolute trigger levels When the process is higher than SP3 a process high alarm PV HI occurs and
16. mm 45 1 77 Panel Cutout mm 2 67 ASSY 53 mm gt NA A A S K KAK S O UM91001D 2 08 Panel 65 mm 2 55 FDC 4100 FDC 8100 FDC 7100 1 77 Ponel lt 45 mm Panel Cutout FDC 9100 1 77 lt 45 mm 4 12 2 3 Wiring Precautions x Before wiring verify the label for correct model number and options Switch off the power while checking x Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded x t is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible x All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools All wiring must conform to appropriate standards of good practice and local codes and regulations Wiring must be suitable for voltage Current and temperature rating of the system Beware not to over tighten the terminal screws Unused control terminals should not be used as jumper points as they may be internally connected causing damage to the unit Verify that the ratings of the output devices and the inputs as specified in Chapter 5 are not exceeded UM91001D 21 3 2mm min 0MM mox
17. mode is selected 3 Enter auto tuning mode during auto tuning mode is selected 4 Perform calibration to a selected parameter during the calibration procedure Press c lfor 4 2 seconds to select manual control mode Press co for 5 4 seconds to select auto tuning mode Press c for 6 6 seconds to select calibration mode UM91001D 9 Alarm Indicator Upper Display to display process value menu symbol and error code etc Output 2 Process Unit Indicator Indicator Output 1 Indicator Manual Lower Display Mode to display set point value Indicator parameter value or Auto tuning control output value etc Indicator A v 4 Buttons for ease of control setup and 9100 set point adjustment Figure 1 3 Front Panel Description Table 1 1 Display Form of Characters A R E E T N n S S X B b F F u J O o T E Y C F G G K E P P u uz c c H H L L S vie D d h R M A R V 1 1 1 7 Confused Character OP1 OP2 ALM Display program code of the product for 2 5 seconds The left diagram shows program no 6 for FDC 9100 with version 12 The program no for FDC 7 100 is 13 for FDC 8100 is 11 and for FDC 4100 is 12 a Y Figure 1 4 9100 J Display of Initial Stage 10 UM91001D 1 5 Menu Overvievv User Setup Manual uu tuning Calibration menu menu Mode Mode AN 4 2 sec 5 4 sec 6 6 sec 7 8 sec Cary CgEE ed era
18. of overshoot during power up or external load disturbance FDC 9100 is a 1 16 DIN size panel mount controller FDC 7100 is a 72X72 DIN size panel mount controller FDC 8100 is a 1 8 DIN size panel mount controller and FDC 4100 is a 1 4 DIN size panel mount controller These units are powered by 11 26VAC VDC or 90 250 VAC supply incorporating a 2 amp control relay output as standard The second output can be used as cooling control or an alarm Both outputs can select triac 5V logic output linear curent or linear voltage to drive external device There are six types of alarm plus a dwell timer can be configured for the third output The units are fully programmable for 1 00 and thermocouple types J K T E B R S N L with no need to modify the unit The input signal is digitized by using a 18 bit A to D converter Its fast sampling rate 5 scans second allows the unit to control fast processes Digital communications RS 485 or RS 232 excluding FDC 7100 are available as an additional option These options allow the units to be integrated with supervisory control system and software A programming port is available for automatic configuration calibration and testing without the need to access the keys on front panel By using proprietary Fuzzy modified PID technology the control loop will minimize the overshoot and undershoot in a shortest time The following diagram is a comparison of results with and without Fuzzy technolog
19. the alarm is off as the process is lower than SP3 ALHY When the process is lower than SP3 a process low alarm PV LO occurs and the alarm is off as the process is higher than SP3 ALHY A process alarm is independent of set point A deviation alarm alerts the user when the process deviates too far from set point When the process is higher than SV SP3 a deviation high alarm DE H occurs and the alarm is off as the process is lower than SV SP3 ALHY When the process is lower than SV SP3 a deviation low alarm DE LO occurs and the alarm is off as the process is higher than SV SP3 ALHY Trigger level of deviation alarm is moving with set point A deviation band alarm presets two trigger levels relative to set point The two trigger levels are SV SP3 and SV SP3 for alarm When the process is higher than SV SP3 or lower than SV SP3 a deviation band high alarm DB HI occurs When the process is within the trigger levels a deviation band low alarm DB LO occurs In the above descriptions SV denotes the current set point value for control which is different from SP1 as the ramp function is performed There are four types of alarm modes available for each alarm function these are Normal alarm Latching alarm Holding alarm and Latching Holding alarm They are described as follows UM91001D 37 Normal Alarm ALMD NORM When a normal alarm is selected the alarm output is de energized in the non alarm cond
20. 0 E vt r1 Even parity Parity bit of digital 41 4 j PARI 1 communication 1 od Odd pariy 0 2 n n E No parity bit s sop Stop bit count of digital 0 fi E One stop bit communication 126 E Two stop bits PV Retranmission M ici 17 8 C RELO kow Val Low 19999 High 45486 OF REHI PV Retranmission High 93 3 C High Value Low 19999 igh 45486 200 0 F monte No parameter selected 2 11 LOCK is put ahead 2 nFE PT is put ahead SELI Select parameter for 3 wor E UNITis put ahead 5 4 gP DP is put ahead 5 GH F SHIF is put ahead 6 PL PB is put ahead y LE Tisput ahead UM91001D 17 dise Parameter Description Range 8 LE d TD is put ahead 90 OTHY s put ahead 102 Yf CYC1 is put ahead 11 2F SE OFST is put ahead 12 RR is put ahead SEL 7 C O 7 ui o CH H O2HY is put ahead 2 14L YE CYC2 is put ahead 15 CPB is put ahead 16 gb DB is put ahead 17 Addr ADDR is put ahead 18 HL H H ALHY is put ahead Select 2nd parameter for user menu same as SELI Select 3 rd parameter for user menu Same as SELT SELS SEL6 SEL7 SEL8 Select 4 th parameter for user Menu Some as SEL zr nalan i ni 7 7 sere i 7 UM91001D Chapter2 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
21. 1 type OTTY amp output 2 type O2TY Generally selects 0 5 2 sec for CYC 1 if SSRD or SSR is used for O1TY 10 20 sec if relay is used for OTIY and CYC I is ignored if linear output is used Similar condition is applied for CYC2 selection 34 UM91001D You can use the auto tuning program for the new process or directly set the appropriate values for PB Tl amp TD according to the historical records for the repeated systems If the control behavior is still inadequate then use manual tuning to improve the control See section 3 12 for manual tuning CPB Programming The cooling proportional band is measured by 96 of PB with range 50 3090 Initially set 10096 for CPB and examine the cooling effect If cooling action should be enhanced then decrease CPB if cooling action is too strong then increase CPB The value of CPB is related to PB and its value remains unchanged throughout the auto tuning procedures Adjustment of CPB is related to the cooling media used For air is used as cooling media adjust CPB at 100 96 For oil is used as cooling media adjust CPB at 125 96 For water is used as cooling media adjust CPB at 250 96 DB Programming Adjustment of DB is dependent on the system requirements If more positive value of DB greater dead band is used an unwanted cooling action can be avoided but an excessive overshoot over the set point will occur If more negative value of DB greater overlap is used an
22. 3 7 Dvvell Timer Alarm output can be configured as dwell timer by selecting TIMR for ALFN As the dwell timer is configured the parameter SP3 is used for dwell time adjustment The dwell time is measured in minute ranging from 0 1 to 4553 6 minutes Once the process reaches the set point the dwell timer starts to count down until zero time out The timer relay will remain unchanged until time out The dwell timer operation is shown as following diagram After time out the dwell timer will be restarted by pressing the RESET key The timer stops to count during the manual control mode failure mode calibration period and auto tuning period Time ALM SP3 power off or H4 touch RESET key Timer starts Figure 3 6 Dwell Timer Function If alarm is configured as dwell timer ALHY and ALMD are hidden 40 UM91001D 3 8 PV Shift In certain applications it is desirable to shift the controller display value from its actual value This can be easily accomplished by using the PV shift function The SHIF function will alter PV only Example If process variable is reading a value of 195 degrees and needs to match another indicator reading 200 The value of 5 can be installed in the SHIFT parameter This will now ADD a 5 degree value to current reading allowing controller to read 200 degrees A negative value can also be used to subtract from controller current reading 3 9 Digital Filter In c
23. Thereafter the previous averaging value of MV1 will be used for controlling output 1 2 If output 1 is configured as proportional control PB 0 and a value of 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 3 If output 1 is configured as ON OFF control PB 0 then output 1 will transfer to off state if OFF is set for O1FT and transfer to on state if ON is set for OTFT Output 2 Failure Transfer if activated will perform 1 If OUT2 is configured as COOL and BPLS is selected for O2FT then output 2 will perform bumpless transfer Thereafter the previous averaging value of MV2 will be used for controlling output 2 2 If OUT2 is configured as COOL and a value of O to 100 0 is set for O2FT then output 2 will perform failure transfer Thereafter the value of O2FT will be used for controlling output 2 3 If OUT2 is configured as alarm function and OFF is set for O2FT then output 2 will transfer to off state otherwise output 2 will transfer to on state if ON is set for O2FT Alarm Failure Transfer is activated as the controller enters failure mode Thereafter the alarm will transfer to the ON or OFF state which is determined by the set value of ALFT 42 UM91001D 3 11 Auto tuning The auto tuning process is performed of set point The process will oscillate around the set point during tuning process Set a set point to a lowe
24. Users Manual FDC 41001 710081009100 Auto Tune Fuzzy PID Process Temperature Controller Warning Symbol N This Symbol calls attention to an operating procedure practice or the like which if not correctly performed or adhered to could result in personal injury or damage to or destruction of part or all of the product and system Do not proceed beyond a warning symbol until the indicated conditions are fully understood and met Use the Manual e Installers Read Chapter 1 2 e System Designer Read All Chapters e User Read Page 12 NOTE It is strongly recommended that a process should incorporate a LIMIT CONTROL like the FDC L91 which will shut down the equipment at a preset process condition in order to preclude possible damage to products or system Information in this users manual is subject to change without notice Copyright November 2003 Future Design Controls all rights reserved No part of this publication may be reproduced transmitted transcribed or stored in a retrieval system or translated into any language in any form by any means without the written permission of Future Design Controls 2 UM91001D Contents Page No Chapter 1 Overview 1 1 General 4 1 2 Ordering Code 7 1 3 Programming Port 8 1 4 Keys and Displays 9 1 5 Menu Overview 11 1 6 Parameter Descriptions 12 Chapter 2 Installation 2 1 Unpacking
25. action 2 JEH Deviation high alarm 3 dEL p Deviation low alarm ALFN alarm output band alarm 2 5 dbhLla Deviation band in band alarm 6 PUL Process value high x alarm 7 pu Lo Process value low alarm morn Normal alam action 1 LEch Latching alarm ALMD Alarm operation mode action 0 2 d Hold alarm action 3 LE Ha Latching amp Hold action Hysteresis control of 5000C 0 1 C ALHY Alarh Low 0 1 High 90 0 F 0 2 F 0 r Alarm output ON as ALFT Alarm failure transfer unit fails 0 mode 1 p EE Alarm output OFF as unit fails 2 nun E No communicofion COMM Communication 1 function 1 r t LI Modbus RTU mode protocol 2 Uu 23 4 20mA 1 c PV Retransmission 3 m am 0 20mA PV retransmission n cu 0 5VDC 0 PV Retransmission 5 1 5VDC eurem PV Retransmission rs r O 10 VDC du PV Retransmission 16 UM91001D Parameter inti Default Notation Parameter Description Range Value Address assignment of k ADDR digital communication Low High 255 H 2 4 Kbits s baud rate 1 UB 4 8 Kbits s baud rate 2 9 6 Kbits s baud rate paip Poe orig 3 4M 14 4 Kbits s baud rate 2 communication 4 18g 19 2 Kbits s baud rate 5 098 28 8 Kbits s baud rate 6 FAY 38 4 Kbits s baud rate 1 para Data bit count of digital 0 ibi E 7 data bits i communication 1 Bb amp 8 data bits
26. d on the sensor except by proper selection and replacement 2 6 Sensor Input Wiring FDC 4100 FDC 8100 FDC 7100 FDC 9100 PTA PTA TC V 19 TC V 13 PTB MA PTB MA TC V TC V PTB mA PTB mA Figure 2 8 Sensor Input Wiring 2 7 Control Output 1 Wiring FDC 4100 FDC 8100 FDC 7100 FDC 9100 H8l p h a 120V 240VAC Mains Supply Figure 2 9 Output 1 Relay or Triac SSR to Drive Load External Device UM91001D 25 2 7 Control Output 1 Wiring Cont d External device FDC 4100 120 240 8100 FDC 100 FDC 9100 Mains Supply Output El Output Ee Internal Circuit nunu A 7 30mA 5V 5 sx v Pulsed Voltage i 33 La 33 Figure 2 10 Output 1 Pulsed 5 VDC Voltage to Drive SSR FDC 4100 ulu FDC 8100 FDC 7100 FDC 9100 3 0 20mA 0 20mA 4 20mA ghee Moximum Load 500 ohms Figure 2 11 Output 1 Linear Current FDC 4100 FDC 8100 FDC 7100 FDC 9100 a n Dea 5 EZ 0 1V 0 5V 1 5V 0 10V 1 5V 0 10V 1 5V 0 10V Figure 2 12 Output 1 Linear Voltage m Minimum Load 1OK ohms 26 UM91001D Control Output 2 Wiring FDC 4100 FDC 8100 FDC 7100 FDC 9100 re 6 He D 120V 240VAC Mains Supply Figure 2 13 deindi device Output 2 Relay or Triac SSR to Drive Load 41 00 External device FDC 8100 FDC 7100 FDC 9100 MERE SSR 5 VDC 30 ma 6 5 VDC
27. ed Consideration should be given to prevent from unauthorized person access to the power terminals 2 5 Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a control system The probe should be placed so that it can detect any temperature change with minimal thermal lag In a process that requires fairly constant heat output the probe should be placed closed to the heater In a process where the heat demand is variable the probe should be closed to the work area Some experiments with probe location are often required to find this optimum position In a liquid process addition of a sfirrer will help to eliminate thermal lag Since the thermocouple is basically a point measuring device placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes 24 UM91001D 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 4 degrees F 2 degrees C or 0 75 of sensed temperature half that for special plus drift caused by improper protection or an over temperature occurrence This error is far greater than controller error and cannot be correcte
28. ertain application the process value is too unstable to be read To improve this a programmable low pass filter incorporated in the controller can be used This is a first order filter with time constant specified by FILT parameter The default value of FILT is 0 5 sec before shipping Adjust FILT to change the time constant from to 60 seconds 0 second represents no filter is applied to the input signal The filter is characterized by the following diagram PV FILT 0 1 sec P FILT 30 1 sec Time Figure 3 8 Filter Characteristics Note The Filter is available only for PV and is performed for the displayed value only The controller is designed to use unfiltered signal for control even if Filter is applied A lagged filtered signal if used for control may produce an unstable process UM91001D 41 3 10 Failure Transfer The controller will enter failure mode as one of the following conditions OCCUIS 1 SBER occurs due to the input sensor break or input current below TmA if 4 20 mA is selected or input voltage below 0 25V if 1 5 V is selected 2 ADER occurs due to the A D converter of the controller fails The output 1 and output 2 will perform the failure transfer function as the controller enters failure mode Output 1 Failure Transfer if activated will perform 1 If output 1 is configured as proportional control PBZO and BPLS is selected for OTFT then output 1 will perform bumpless transfer
29. ffect saturation Low saturation High Output Range 56 O 500 ohms for current output 10 Kohms minimum for voltage output 0 01 for full load change 0 1 sec stable to 99 9 1000 VAC min 0 005 of span 0 0025 96 of soan C mA or OV 22 2 mA or 5 55V 11 1V min 0 22 2mA 0 20mA or 4 20mA 0 5 55V 0 5V 1 5V 0 111V 0 10V UM91001D User Interface Display Keypad Programming Port Communication Port Control Mode Output 1 Output 2 ON OFF P or PD PID Cycle Time Manual Control Auto tuning Failure Mode Ramping Control Digital Filter Function Time Constant Dual 4 digif LED Displays 4 keys For autornatic setup calibration and testing Connection to PC for supervisory control Reverse heating or direct cooling action PID cooling control cooling P band 50 3002976 of PB dead band 36 0 36 0 of PB 0 1 90 0 F hysteresis control P band 0 O 100 0 offset adjustment Fuzzy logic modified Proportional band 0 1 900 0 F Integral time 1000 seconds Derivative time 360 0 seconds 0 1 90 0 seconds Heat MV1 and Cool MV2 Cold start and warrn start Auto transfer to manual mode while sensor break or A D converter damage O 900 0 F minufe or O 900 0 F hour ramp rate First order O 0 2 0 5 1 2 5 10 20 30 60 seconds programmable UM91001D 57 Environmental amp Physical Operati
30. for cooling control Communication error bad Correct the communication 10 function code software to meet the protocol requirements Communication error register Don t issue an over range 11 address out of range register address to the slave Communication error attempt Don t write a read only data or a 14 to write a read only data or a protected data to the slave protected data Communication error write a Don t write an over range data 15 value which is out of range toa to the slave register register The PID values obtained after auto tuning procedure are out of range Retry auto tuning 2 Don t change set point value 22 Fail to perform auto tuning during auto tuning procedure function 3 Use manual tuning instead of auto tuning 4 Don t set a zero value for PB 5 Dont set a zero value for Tl 6 Touch RESET key EE PE EEPROM can t be written correctly Return to factory for repair Cold junction compensation for BSR IG TOO thermocouple malfunction npuf sensor breok or inpuf current below 1 mA if 4 20 mA is 39 selected or input voltage below Ree STP 0 25V if 1 5V is selected A to D converter or related 40 RaE component s malfunction Return to factory for repair UM91001D 59 Warranty Future Design Controls warranties or representations of any sort regarding the fitness for use or the application of its products by the Purchaser The selection application or use of Future Desig
31. frorn time to time and often need to adjust OFST repeatealy The PID control can avoid this situation Heat only PID control Selecting REVR for OUTI PB and TI should not be zero Operate auto tuning for the new process or set PB TI and TD with historical values See section 3 11 for auto tuning operation If the control result is still unsatisfactory then use manual tuning to improve the control See section 3 12 for manual tuning The unit contains a very clever PID and Fuzzy algorithm to achieve a very small overshoot and very quick response to the process if it is properly tuned Cool only control ON OFF control P PD control and PID control can be used for cool control Set OUTI to DIRT direct action The other functions for cool only ON OFF control cool only P PD control and cool only PID control are same as descriptions for heat only control except that the output variable and action for the cool control is inverse to the heat control NOTE The ON OFF control may result excessive overshoot and undershoot problems in the process The P or PD control will result in a deviation process value from the set point It is recommended to use PID control for the Heat Cool control to produce a stable and zero Offset process value Other Setup Required OTTY CYC1 O2TY CYC2 OTFT O2FT OTTY amp O2TY are set in accordance with the types of OUT amp OUT2 installed CYCI amp CYC2 are selected according to the output
32. gnal is transmitted and received through the PC communication Port generally RS 232 Since a standard PC can t support RS 485 port a network adaptor such as SNA10A has to be used to convert RS 485 to RS 232 for a PC if RS 485 is required for the data communication Multiple RS 485 units up to 247 units can be connected to one RS 232 port Setup Enters the setup menu Select RTU for COMM Set individual address as for those units which are connected to the same port Sef the Baud Rate BAUD Data Bit DATA Parity Bit PARI and Stop Bit STOP such that these values are accordant with PC setup conditions 3 15 Process Retransmission The controllers support a optional ma VDC output retransmit of the process variable The program parameters to scale the ma VDC signal are RELO and REHI respectively for low and high scale For example using a 4 20 ma retransmission option to represent a temperature of 0 200 F unit would be setup as RELO for 4 ma equals F REHI 200 for 20 ma equals 200 F This output would typically go to a recorder PLC indicator etc UM91001D 47 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 retum the controller to your
33. ition and energized in an alarm condition Latching Alarm ALMD LTCH If a latching alarm is selected once the alarm output is energized it will remain unchanged even if the alarm condition is cleared The latching alarm is reset when the RESET key is pressed once the alarm condition is removed Holding Alarm ALMD HOLD A holding alarm prevents an alarm from power up The alarm is enabled only when the process reaches the set point value Afterwards the alarm performs same function as normal alarm Latching Holding Alarm ALMD LT HO A latching holding alarm performs both holding and latching function The latching alarm is reset when the RESET key is pressed once the alarm condition is removed Alarm Failure Transfer is activated as the unit enters failure mode Alarm will go on if ON is set for ALFT and go off if OFF is set for ALFT The unit will enter failure mode when sensor break occurs Or if the A D converter of the unit fails 3 5 Configure User Menu This series has the flexibility for you to select those parameters which are most significant to your application These parameters are able to be put in the front of display sequence for ease of access SEL1 SEL8 Selects the parameter for view and change in the user menu Range LOCK INPT UNIT DP SHIF PB TI TD OTHY CYC1 OFST RR O2HY CYC2 CPB DB ADDR ALHY When using the up down key to select the parameters you may not obtain all of the
34. message will appear on the upper display in cases of 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 Solutions to E E 1 Try auto tuning once again 2 Don t change set point value during auto tuning procedure 3 Don t set zero value for PB and TI 4 Use manual tuning instead of auto tuning See section 3 12 5 Touch RESET key to reset message 3 12 Manual Tuning In certain applications very few using auto tuning to tune a process may be inadequate for the control requirement then you can try manual tuning If the control performance by using auto tuning is still unsatisfactory the following rules can be applied for further adjustment of PID values 44 UM91001D ADJUSTMENT SEQUENCE SYMPTOM SOLUTION 1 Proportional Band PB Increase PB Slow Response High overshoot or Oscillations 2 Integral Time TI Slow Response Instability or Decrease Tl Oscillations Increase TI Decrease TD Increase TD Table 3 2 PID Adjustment Guide Slow Response or Oscillations 3 Derivative Time TD High Overshoot Figure 3 9 shows the effects of PID adjustment on process response 3 13 Manual Control Operation To enable manual control the LOCK parameter should be set with NONE then press for 4 2 seconds H HA d Hand Control will appear on the display Release key
35. n products is the Purchasers responsibility No claims will be allowed for any damages or losses whether direct indirect incidental special or consequential Specifications are subject to change without notice In addition Future Design reserves the right to make changes without notification to Purchaser to materials or processing that do not affect compliance with any applicable specification Future Design products are warranted to be free from defects in material and workmanship for two years after delivery to the first purchaser for use An extended period is available with extra cost upon request Future Design s sole responsibility under this warranty at Future Design s option is limited to replacement or repair free of charge or refund of purchase price within the warranty period specified This warranty does not apply to damage resulting from transportation alteration misuse or abuse RETURN MATERIAL AUTHORIZATION Please contact Future Design Controls for Return Material Authorization Number prior to returning to factory Future Design Controls 7524 West 98th Place Bridgeview IL 60455 Main Office Phone 888 751 5444 Fox 888 245 2883 Technical Support Phone 866 342 5332 Www futuredesigncontrols com E mail csr futuredesigncontrols com 60 UM91001D
36. ng Temperature 10 C to 50 C Storage Temperature 40 C to 60 C Humidity O to 90 RH non condensing Insulation Resistance 20 Mohms min at 500 VDC Dielectric Strengt 2000 VAC 50 60 Hz for 1 minute Vibration Resistance 10 55 Hz 10 m s for 2 hours Shock Resistance 200 m s 20g Moldings Flame retardant polycarbonate Dimensions FDC 4100 X 96mm H X 65mm D 53 mm depth behind panel FDC 7100 72mm W X 72mm H X 78 2mm D 65 mm depth behind panel FDC 8100 48mm W X 96mm H X 80mm D 65 mm depth behind panel FDC 9100 8mm W X 48mm H X 116mmY D 105 mm depth behind panel Weight FDC 4100 250 grams FDC 7 100 200 grams FDC 8 100 210 grams FDC 9 100 150 grams Agency Approvals UL Pending CSA Pending Protective Class IP65 for panel with additional option IP50 for panel without additional option ID20 for terminals and housing with protective cover EMC EN61326 58 UM91001D Table A 1 Error Codes and Corrective Actions Displa Error Descripfion Corrective Action Illegal setup values been used Check and correct setup values of Before COOL is used for OUT2 OUT2 PB TI and OUTI IF OUT2 DIRT cooling action has is required for cooling control the alreadybeen used for OUTI control should use PID mode PB 4 or PID mode is not used for OUTI Tl 70 and OUTI should that is PB and orTl use reverse mode heating action otherwise don t use OUT2
37. nt to him and put these parameters in the front of display sequence There are at most 8 parameters can be selected to allow the user to build his own display sequence 6 UM91001D 1 2 Ordering Code 4100 TTLTL L L L L BTC 7100 L i BTC 8100 bilons BTC 9 100 0 Panel mount IPSO standard 1 Panel mount IP65 water Power Input resistant rubber installed 4 90 250 VAC 2 DIN Rail mount with IP50 50 60 HZ for 9100 only 5 11 26 VAC or 3 DIN Rail mount with IP65 VD for 9100 only 9 Special Order Communications Signal Input 0 None 9 E 1 RS 485 interface 1 Standard Input 2 RS 232 interface not Thermocouple available for 7100 J K T E B R 3 Retransmit 4 20mA 0 20mA SNL 4 Retransmit 1 5 V 0 5V RTD PT100 DIN 5 Retransmit 0 10V PT100 JIS 9 Special order 2 60 mV Alarm 3 0 1V 0 None 4 0 5V 1 Form C relay 2A 240VAC 2 A 9 Special order 4 20m 7 0 20 mA 5007 57 To A relay A AQUAE Form A relay 2 Pulsed voltage to drive SSR 5V 307mmA 3 Isolated 4 20mA 0 20mA 4 Isolated 1 5V 5V None 5 Isolated 10V 1 Relay rated 2A 240VAC 6 Triac output 1A 240VAC 2 Pulsed voltage to drive SSR SSR 5V 30mA 7 Isolated 20V 25mA 3 Isolated 4 20mA 0 20mA transducer power supply A Isolated 1 5V O 5V 8 Isolated 12V 40mA 5 Isolated O 10V transducer power supply Triac output 1A 240VAC SSR 20077 PMPENE xc 7 7 lo GIVE S218
38. ort A programming port is used fo connect the unit to a hand held programmer or a PC for quick configuration also can be connected to an ATE system for automatic testing amp calibration Auto tune The auto tune function allows the user to simplify initial setup for a new system A clever algorithrn is provided to obtain an optimal set of control parameters for the process and it can be applied either as the process is warming up cold start or as the process has been in steady state warr start Lockout Protection According to actual security requirement one of four lockout levels can be selected to prevent the unit from being changed abnormally Bumpless Transfer Bumpless transfer allows the controller to continue to control by using its previous value as the sensor breaks Hence the process can be well controlled temporarily as if the sensor is normal Soft start Ramp The ramping function is performed during power up as well as any time the set point is changed It can be ramping up or ramping down The process value will reach the set point with a predetermined constant rate Digital Filter A first order low pass filter with a programmable time constant is used to improve the stability of process value This is particularly useful in certain application where the process value is too unstable to be read SEL Function The units have the flexibility for user to select those parameters which are most significa
39. r Twisted Pair Wire FDC 4100 FDC 8100 FDC 9100 FDC 7100 t 13 A 1X2 Max 247 units can be linked FDC 4100 FDC 8100 FDC 9100 FDC 7100 na 113 Ul 1X2 Figure 2 19 RS 485 Wiring Terminator 220 ohms 0 5W UM91001D 29 RS 232 FDC 4100 FDC 8100 FDC 9 100 x 113 RXD 14 f com 15 94 1 Figure 2 20 RS 232 Wiring If you use a conventional 9 pin RS 232 cable instead of CC94 1 the cable must be modified according to the following circuit To DTE PC RS 232 Port FDC 4100 FDC 8100 FDC 9100 Female DB 9 9 RI Figure 2 21 Configuration of RS 232 30 UM91001D Chapter 3 Programming Press for 3 seconds and release to enter setup menu Press to select the desired parameter The upper display indicates the parameter symbol and the lower display indicates the selected value of parameter 3 1 Lockout There are four security levels can be selected by using LOCK parameter If NONE is selected for LOCK then no pararneter is locked If SET is selected for LOCK then all setup data are locked If USER is selected for LOCK then all setup data as well as user data refer to section 1 5 except set point are locked to prevent from being changed If ALL is selected for LOCK then all parameters are locked to prevent from being changed 3 2 Signal Input INPT Selects the sensor type or signal type for signal input Range thermocouple J K LE B R S N
40. r value if overshooting beyond the normal process value is likely to cause damage The auto tuning is applied in cases of x Initial setup for a new process he set point is changed substantially from the previous auto tuning value he control result is unsatisfactory Operation The system has been installed normally 2 Set the correct values for the setup menu of the unit But don t use a zero value for PB and TI otherwise the auto tuning program will be disabled The LOCK parameter should be set at NONE 3 Set the set point to a normal operating value or a lower value if overshooting beyond the normal process value is likely to cause damage 4 Press and hold until appears on the display 5 Press for at least 3 seconds The AT indicator will begin to flash and the auto tuning procedure is beginning NOTE The ramping function if used will be disabled once auto tuning is proceeding The auto tuning mode is disabled as soon as either failure mode or manual control mode occurs UM 1001D 43 Procedures The auto tuning can be applied either as the process is warming up Cold Start or as the process has been in steady state Warm Start After the auto tuning procedures are completed the AT indicator will cease to flash and the unit revert to PID control by using its new PID values The PID values obtained are stored in the nonvolatile memory Auto Tuning Error If auto tuning fails an ATER
41. required setup the equipments same as step 6 The unit under calibration is powered in a still air room with temperature 50 3 C Stay at least 20 minutes for warming up The calibrator source is set at 0 00 C with internal compensation mode UM91001D 51 Perform step 1 stated above then press scroll key until the display shows Press scroll key for at least 3 seconds The display will blink a mornent and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails This setup is performed in a high temperature chamber hence it is recommended to use a computer to perform the procedures x Input modification and recalibration procedures for a linear voltage or a linear current input 1 Remove R60 3 3K and install two 1 4 W resistors RA and RB on the control board with the recommended values specified in the following table The low temperature coefficient resistors should be used for RA and RB 2 Perform Step 1 and Step 2 to calibrate the linear input zero 3 Perform Step 3 but send a span signal to the input terminals instead of 60mV The span signal is 1V for O 1V input 5V for O 5V or 1 5V input 10V for 0 10V input and 20mA for 0 20mA or 4 20mA input Final step Step 8 Set the LOCK value to your desired function 52 UM91001D Chapter 5 Specifications Power 90 250 VAC 47 63 Hz 12VA 5W maximum 11 26 VAC VDC
42. ress scroll key for at least 3 seconds The display will blink a moment and two values are obtained for RTDH and RTDL step 4 Otherwise if the display didn t blink or if any value obtained for RTDH and RIDL is equal to 199 9 or 199 9 then the calibration fails x Perform step 6 to calibrate offset of cold junction compensation if required Step Setup the equipments according to the following diagram for calibrating the cold junction compensation Note that a K type thermocouple must be used 50 UM91001D Temperature Calibrator K IC Le FDC 4100 FDC 8100 FDC 7100 FDC 9100 v K 13 K 5 20 K m K E pe at least 20 minutes in sfill air room room temperature 25 3 C Figure 4 2 Cold Junction Calibration Setup The temperature calibrator is configured as K type thermocouple output with internal compensation Send a 0 00 C signal to the unit under calibration Step 7 The unit under calibration is powered in a still air room with temperature 25 3 C Stay at least 20 minutes for warming up Perform step 1 stated above then press scroll key until the display shows Press up down key to obtain 40 00 Press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didnt blink or if the obtained value is equal to 5 00 or 40 00 then the calibration fails x Perform step 7 to calibrate gain of cold junction compensation if
43. supplier who may charge you a service fee to re calibrate the controller A Entering calibration mode will break the control loop Verify that the system is acceptable to apply calibration mode Equipments needed before calibration 1 2 3 4 5 A high accuracy calibrator Fluke 5520A Calibrator recommended with following functions O 100 mV millivolf source with 0 005 accuracy O 10 V voltage source with 0 005 accuracy O 20 mA current source with 0 005 96 accuracy O 300 ohm resistant source with 0 005 96 accuracy A test chamber providing 25 C 50 C temperature range A switching network SWU16K optional for automatic calibration A calibration fixture equipped with programming units optional for automatic calibration A PC installed with calibration software FDC Net and Smart Network Adaptor SNATOB optional for automatic calibration The calibration procedures described in the following section are a step by step manual procedures since it needs 30 minutes to warm up an unit before calibration calibrating the unit one by one is quite inefficient An automatic calibration system for small quantity as well as for unlimited quantity is available Consult factory 48 UM91001D Manual Calibration Procedures x Perform step 1 to enter calibration mode Step 1 Set the Lock parameter to the unlocked condition LOCK NONE Press and hold the scroll key until appears on
44. the display then release the scroll key Press the scroll key for 2 seconds then release the display will show and the unit enters calibration mode Perform step 2 to calibrate Zero of Ato D converter and step 3 to calibrate gain of A to D converter Step 2 Short the thermocouple inpt terminals then press scroll key for at least 3 seconds The display will blink a moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Step 3 Press scroll key until the display shows Ad H Send a 60 mv signal to the thermocouple input terminals in correct polarity Press scroll key for at least 3 seconds The display will blink o moment and a new value is obtained Otherwise if the display didn t blink or if the obtained value is equal to 199 9 or 199 9 then the calibration fails Perform both steps 4 and 5 to calibrate RTD function if required for input UM91001D 49 Step A Press scroll key until the display shows Send a 100 ohms signal to the RTD input terminals according to the connection shown below FDC 4100 FDC 8100 FDC 7100 FDC 9100 18 12 100 ohms 100 ohms 100 ohms s Ve Figure 4 1 RTD Calibration Press scroll key for at least 3 seconds The display will blink a moment otherwise the calibration fails Step 5Press scroll key and the display will show c EdH Change the ohmis value to 300 ohms P
45. well fimer output SP2 SP3 Select parameters to be FOGR locked Input sensor selection INPT NOTE Input Selection 11 17 of Linear ma VDC Require Range Low SPIL High SP1H Low 19999 High 45536 Low 19999 High 45536 No parameter is locked Setup data are locked Setup data and User data except Set point are locked All data are locked J type thermocouple Ktype thermocouple T type thermocouple E type thermocouple B type thermocouple R type thermocouple S type thermocouple N type thermocouple 8L EL L type thermocouple 9 PE gn PT 100 ohms DIN Curve 10 PE JS PT 100 ohms JIS Curve 11 4 20 4 20 mA linear current input 12 G 2G 0 20 mA linear current input 13 8 58 0 60 mv linear millivolf input 14 Q 1 O IV linear voltage input 15 0 5 0 5V linear voltage special order input i 16 4 Y 1 5V linear voltage only See Matrix 9 Page 8 17 B 10 0 10V linear voltage input Default Value 25 0 C 77 0F 0 UM91001D Parameter inti Notation Parameter Description Range Degree C unit Input unit selection Degree F unit Process unit No decimal i point l l 1 decimal digit DP Decimal point selection 1 2 decimal digits 5 3 decimal digits INLO Input low sale value Low 19999 High 45486 OE T M 93 3 C INHI Input high scale value Low INLO 50 High 45536 200 0 F Low limit of set point cdi 17 8 C
46. y 4 UM91001D PID control with properly tuned PID Fuzzy control Temperofure set et T 2 DUN ne Figure 1 1 Fuzzy Control Advantage Warm Up Load Disturbance Time High Accuracy This Series controllers are manufactured with custom designed ASIC Application Specific Integrated Circuit technology which contains a 18 bit A to D converter for high resolution measurement true 0 1 F resolution for thermocouple and PT100 and a 15 bit D to A converter for linear current or voltage control output The ASIC technology provides improved operating performance low cost enhanced reliability and higher density Fast Sampling Rate The sampling rate of the input A to D converter reaches 5 times second The fast sampling rate allows this series to control fast processes Fuzzy Control The function of Fuzzy control is to adjust PID parameters from time to time in order to make manipulation output value more flexible and adaptive to various processes The results is to enable a process to reach a predetermined set point in the shortest time with the minimum of overshoot and undershoot during power up or extemal load disturbance Digital Communication The units are equipped with RS 485 or RS 232 interface card to provide digital communication By using the twisted pair wires there are at most 247 units can be connected together via RS 485 interface to a host computer UM91001D 5 Programming P
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