Summary of Contents for Futuredesign controls UM100
- Page 1 User's Manual FDC 4100 / 7100 / 8100 / 9100 Auto-Tune Fuzzy / PID Process / Temperature Controller...
- Page 2 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. UM100 V2.0...
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Page 3: Table Of Contents
3-6 Ramp -------------------------49 3-7 Dwell Timer ------------------40 3-8 PV Shift -----------------------41 3-9 Digital Filter -------------------41 3-10 Failure Transfer -------------42 3-11 Auto-tuning ------------------43 3-12 Manual tuning -------------44 3-13 Manual Control -------------45 3-14 Data communication -----47 3-15 PV Retransmission----- -----47 UM100 V2.0... -
Page 4: Chapter 1 Overview
By using proprietary Fuzzy modified PID technology, the control loop will minimize the overshoot and undershoot in a shortest time. The following diagram is a comparison of results with and without Fuzzy technology. UM100 V2.0... - Page 5 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. UM100 V2.0...
- Page 6 The units have the flexibility for user to select those parameters which are most significant to him and put these parameters in the front of display sequence. There are at most 8 parameters can be selected to allow the user to build his own display sequence. UM100 V2.0...
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Page 7: Ordering Code
5: Isolated 0 - 10V 9: Isolated 5V/80mA 6: Triac output 1A / 240VAC,SSR transducer power supply C: Pulsed voltage to drive SSR, C: Pulsed voltage to drive SSR, 14V/40mA 14V/40mA 9: Special order A: Special order UM100 V2.0... -
Page 8: Programming Port
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. UM100 V2.0... -
Page 9: Keys And Displays
3. Enter auto-tuning mode during auto-tuning mode selected. 4. Perform calibration to a selected parameter during the calibration procedure. Press for 4.2 seconds to select manual control mode. Press for 5.4 seconds to select auto-tuning mode. Press for 6.6 seconds to select calibration mode. UM100 V2.0... - Page 10 2.5 seconds. The left diagram shows program no. 6 for FDC-9100 with version 12. The program no. for FDC-7100 is 13, for FDC-8100 is 11 and for FDC-4100 is 12. Figure 1.4 9100 Display of Initial Stage UM100 V2.0...
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Page 11: Menu Overview
NONE is selected for SEL5 ALFN. SP2 will be hidden if alarm function SEL6 is not selected for OUT2. The unused SEL7 parameter will be hidden even if it is SEL8 selected by SEL parameters. UM100 V2.0... -
Page 12: Parameter Descriptions
0 - 60 mV linear millivolt input of Linear (ma/VDC) 0 - 1V linear voltage input Require 0 - 5V linear voltage special order input 1 - 5V linear voltage only See Matrix input Page 8. 0 - 10V linear voltage input UM100 V2.0... - Page 13 0.5 second time constant 1 second time constant 2 seconds time constant Filter damping time FILT 5 seconds time constant of PV constant 10 seconds time constant 20 seconds time constant 30 seconds time constant 60 seconds time constant UM100 V2.0...
- Page 14 Low: 0.1 High: 90.0 sec. CYC1 18.0 High: 100.0 % OFST Offset value for P control Low: 0 25.0 : No Ramp Function : Use unit/minute as Ramp function selection RAMP Ramp Rate : Use unit/hour as Ramp Rate UM100 V2.0...
- Page 15 0.1 C value when output 2 High: 50.0 C Low: 0.1 O2HY (90.0 F) (0.2 F) performs alarm function Output 2 cycle time High: 90.0 sec. CYC2 Low: 0.1 18.0 Cooling proportional High: 300 % Low: 50 band value UM100 V2.0...
- Page 16 Communication COMM : Modbus RTU mode function protocol 4 - 20 mA PV Retransmission 0 - 20 mA PV retransmission 0 - 5 VDC PV Retransmission 1 - 5 VDC PV Retransmission 0 - 10 VDC PV Retransmission UM100 V2.0...
- Page 17 No parameter selected LOCK is put ahead INPT is put ahead UNIT is put ahead SEL1 Select 1'st parameter for user menu DP is put ahead SHIF is put ahead PB is put ahead TI is put ahead UM100 V2.0...
- Page 18 Select 5'th parameter SEL5 Same as SEL1 for user menu Select 6'th parameter SEL6 Same as SEL1 for user menu Select 7'th parameter SEL7 Same as SEL1 for user menu Select 8'th parameter SEL8 Same as SEL1 for user menu UM100 V2.0...
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Page 19: Chapter 2 Installation
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. UM100 V2.0... - Page 20 Figure 2.1 Mounting Dimensions Panel Cutout 3.62” FDC-4100 Panel 92 mm 53 mm 3.62” 2.08” Panel 3.62” FDC-8100 Cutout Panel 45 mm 1.77” 65 mm 2.55” 2.67” Panel Cutout FDC-7100 Panel 68 mm 2.67” 65 mm 2.55” UM100 V2.0...
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Page 21: Wiring Precautions
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. UM100 V2.0... - Page 22 Lead Termination for FDC-9100 3.0mm min. 90-250VAC 47-63 Hz 12VA TX1 TXD RS-485 /Retransmission Ma TX2 RXD RS-232 TC+, V+ PTB, mA+ TC-, V- PTB, mA- V mA RTD Figure 2.4 Rear Terminal Connection for FDC-4100 and FDC-8100 UM100 V2.0...
- Page 23 Figure 2.5 Rear Terminal Connection for FDC-7100 PV Retrans RS-232: RXD COM RS-485: TX1 TX2 13 14 15 90-250 VAC 47-63 Hz 12VA TC+, V+ PTB, mA+ TC-, V- PTB, mA- Figure 2.6 Rear Terminal Connection for FDC-9100 UM100 V2.0...
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Page 24: Power Wiring
In a liquid process, addition of a stirrer will help to eliminate thermal lag. Since the thermocouple is basically a point measuring device, placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes. UM100 V2.0... -
Page 25: Sensor Input Wiring
PTB, mA- PTB, mA- V mA RTD Figure 2.8 Sensor Input Wiring 2-7 Control Output 1 Wiring FDC-4100 FDC-7100 FDC-9100 FDC-8100 LOAD 120V/240VAC Mains Supply Figure 2.9 Output 1 Relay or Triac (SSR) to Drive Load External Device UM100 V2.0... - Page 26 0 - 1V, 0 - 5V 0 - 1V, 0 - 5V Load 1 - 5V, 0 - 10V 1 - 5V, 0 - 10V 1 - 5V, 0 - 10V Minimum Load 10 K ohms Figure 2.12 Output 1 Linear Voltage UM100 V2.0...
- Page 27 Figure 2.14 Output 2 Pulsed Voltage to Drive SSR FDC-4100 External device FDC-7100 FDC-9100 FDC-8100 0 - 20mA, 0 - 20mA, 0 - 20mA, Load 4 - 20mA 4 - 20mA 4 - 20mA Maximum Load 500 ohms Figure 2.15 Output 2 Linear Current UM100 V2.0...
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Page 28: Alarm Wiring
10 K ohms minimum ( for voltage output ) FDC-7100 Output to Recorder, 0-20/4-20ma, PLC, Etc. 0-5/1-5VDC, 0-10VDC Re - Load Resistance : 0 - 500 ohms ( for current output ) 10 K ohms minimum ( for voltage output ) Figure 2.18 Retransmission Output Wiring UM100 V2.0... -
Page 29: Data Communications
FDC-4100 RS-485 to RS-232 FDC-8100 network adaptor FDC-9100 FDC-7100 SNA10A or SNA10B RS-232 Twisted-Pair Wire FDC-4100 FDC-8100 FDC-9100 FDC-7100 Max. 247 units can be linked FDC-4100 FDC-8100 FDC-9100 FDC-7100 Terminator 220 ohms / 0.5W Figure 2.19 RS-485 Wiring UM100 V2.0... - Page 30 To DTE ( PC ) RS-232 Port FDC-4100 FDC-8100 FDC-9100 1 DCD 2 RD 3 TD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI Female DB-9 Figure 2.21 Configuration of RS-232 UM100 V2.0...
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Page 31: Chapter 3 Programming
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 : UM100 V2.0... -
Page 32: Control Outputs
Control OUT1 OUT2 O1HY O2HY Modes Heat only REVR Cool only DIRT Heat: PID REVR DE.HI Cool: ON-OFF Heat: PID REVR COOL Cool: PID :Required if ON-OFF control : Don't care is configured :Adjust to met process requirements UM100 V2.0... - Page 33 % with range 0 - 100.0 %. In the steady state ( ie. process has been stabilized ) if the process value is lower than the set point a definite value, say 5 LC, while 20 LC is used for PB, that is lower 25 %, UM100 V2.0...
- Page 34 O1TY ) & output 2 type ( O2TY ). Generally, selects 0.5 ~ 2 sec. for CYC1, if SSRD or SSR is used for O1TY; 10 ~ 20 sec. if relay is used for O1TY, and CYC1 is ignored if linear output is used. Similar condition is applied for CYC2 selection. UM100 V2.0...
- Page 35 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. UM100 V2.0...
- Page 36 OUT2=DE.HI SV+SP2 SV+SP2-O2HY Time OUT2 Action Figure 3.3 Output 2 Deviation Time High Alarm SP2+O2HY Time OUT2 Action Time Figure 3.4 Output 2 Process Low Alarm UM100 V2.0...
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Page 37: Alarm
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: UM100 V2.0... -
Page 38: Configure User Menu
When using the up-down key to select the parameters, you may not obtain all of the above parameters. The number of visible parameters is dependent on the setup condition. The hidden parameters for the specific application are also deleted from the SEL selection. UM100 V2.0... -
Page 39: Ramp
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. UM100 V2.0... -
Page 40: Dwell Timer
The timer stops to count during the manual control mode, failure mode, calibration period and auto-tuning period. Time power off or touch RESET key Time Timer starts Figure 3.6 Dwell Timer Function If alarm is configured as dwell timer, ALHY and ALMD are hidden. UM100 V2.0... -
Page 41: Pv Shift
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. UM100 V2.0... -
Page 42: Failure Transfer
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. UM100 V2.0... -
Page 43: Auto-Tuning
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. UM100 V2.0... -
Page 44: 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 UM100 V2.0... -
Page 45: Manual Control
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. UM100 V2.0... - Page 46 Set point P action PB too high Time TI too high Set point I action Ideal TI too low Time TD too low Ideal Set point D action TD too high Time Figure 3.9 Effects of PID Adjustment UM100 V2.0...
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Page 47: Data Communication
0/200 F unit would be setup as; RELO = 0 for 4 ma equals 0 F REHI = 200 for 20 ma equals 200 F This output would typically go to a recorder, PLC, indicator etc. UM100 V2.0... -
Page 48: Chapter 4 Calibration
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. UM100 V2.0... - Page 49 . 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 . UM100 V2.0...
- Page 50 RTDL is equal to -199.9 or 199.9 , then the calibration fails. Perform step 6 to calibrate offset of cold junction compensation, if required. Step 6. Setup the equipments according to the following diagram for calibrating the cold junction compensation. Note that a “K” type thermocouple must be used. UM100 V2.0...
- Page 51 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. UM100 V2.0...
- Page 52 60mV. The span signal is 1V for 0~1V input, 5V for 0~5V or 1~5V input, 10V for 0~10V input and 20mA for 0~20mA or 4~20mA input. Final step Step 8. Set the LOCK value to your desired function. UM100 V2.0...
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Page 53: Chapter 5 Specifications --53
1 mA for 4-20 mA input, below 0.25V for 1 - 5 V input, unavailable for other inputs. Sensor Break Responding Time: Within 4 seconds for TC, RTD and mV inputs. 0.1 second for 4-20 mA and 1 - 5 V inputs. UM100 V2.0... - Page 54 ( -346 F 1292 F ) PT100 -200 C 600 C +/-0.4 C 1.3 K ( JIS ) ( -328 F 1112 F ) -8mV 70mV +/-0.05 % 2.2 M -3mA 27mA +/-0.05 % 70.5 -1.3V 11.5V +/-0.05 % 650 K UM100 V2.0...
- Page 55 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 UM100 V2.0...
- Page 56 0 mA ( or 0V ) Saturation High : 22.2 mA ( or 5.55V, 11.1V min. ) Output Range : 0-22.2mA(0-20mA or 4-20mA) 0-5.55V ( 0 - 5V, 1 - 5V ) 0 - 11.1 V ( 0 - 10V ) UM100 V2.0...
- Page 57 A-D converter damage Ramping Control: 0 - 900.0 F/minute or 0 - 900.0 F/hour ramp rate Digital Filter Function: First order Time Constant: 0, 0.2, 0.5, 1, 2, 5, 10, 20, 30, 60 seconds programmable UM100 V2.0...
- Page 58 FDC-7100: 200 grams FDC-8100: 210 grams FDC-9100: 150 grams Agency Approvals Pending CSA Pending Protective Class: IP65 for panel with additional option IP50 for panel without additional option Ip20 for terminals and housing with protective cover. EMC: EN61326 UM100 V2.0...
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Page 59: Error Codes
Input sensor break, or input current below 1 mA if 4-20 mA is Replace input sensor. selected, or input voltage below 0.25V if 1 - 5V is selected A to D converter or related Return to factory for repair. component(s) malfunction UM100 V2.0... -
Page 60: Warranty
Warranty and Return Statement Warranty and Return Statement WARRANTY Future Design Controls products described in this manual are warranted to be free 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 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 Future Design Controls Facilities and to conform at that time to the specifications set...
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