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Future Design C22 User Manual

High performance process & temperature controllers
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C-SERIES USER MANUAL
VERSION UM0C621-H
January 2021

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Summary of Contents for Future Design C22

  • Page 1 C-SERIES USER MANUAL VERSION UM0C621-H January 2021...
  • Page 2 Revision History Version Description Date  Updated for firmware o C62/C22 / R22: V15 o C42 / C82 / C83: V08 UM0C621H  User Security information updated January, 2021  RS485 Signed Integer Data type added  Communication chapter added with mode and command details.

  • Page 3: Table Of Contents

    1.1 Introduction ------------------------------------------------------------------------------------------------------------------------------------------- 9 1.2 Features ------------------------------------------------------------------------------------------------------------------------------------------------ 9 1.3 Specifications ---------------------------------------------------------------------------------------------------------------------------------------- 13 1.4 Ordering Code --------------------------------------------------------------------------------------------------------------------------------------- 17 1.4.1 C22 Ordering Code --------------------------------------------------------------------------------------------------------------------------- 17 1.4.2 C62 Ordering Code --------------------------------------------------------------------------------------------------------------------------- 18 1.4.3 C82, C83, C42 Ordering Code -------------------------------------------------------------------------------------------------------------- 19 1.4.4 R22 Ordering Code --------------------------------------------------------------------------------------------------------------------------- 20 1.4.5 Accessories ------------------------------------------------------------------------------------------------------------------------------------- 20...
  • Page 4 2.8 Alarm Wiring ----------------------------------------------------------------------------------------------------------------------------------------- 77 2.8.1 Alarm 1 ------------------------------------------------------------------------------------------------------------------------------------------ 77 2.8.2 Alarm 2 ------------------------------------------------------------------------------------------------------------------------------------------ 77 2.8.3 Alarm 3 ------------------------------------------------------------------------------------------------------------------------------------------ 78 2.8.4 Alarm 4 ------------------------------------------------------------------------------------------------------------------------------------------ 78 2.9 Event Input Wiring --------------------------------------------------------------------------------------------------------------------------------- 78 2.10 CT Input Wiring ------------------------------------------------------------------------------------------------------------------------------------ 79 2.11 RS-485 Data Communication ------------------------------------------------------------------------------------------------------------------ 79 2.12 Retransmission Wiring -------------------------------------------------------------------------------------------------------------------------- 80 2.13 Remote Setpoint Wiring ------------------------------------------------------------------------------------------------------------------------ 80 3 PROGRAMMING -------------------------------------------------------------------------------------------- 81...
  • Page 5 3.15 Default Setting ----------------------------------------------------------------------------------------------------------------------------------- 103 3.15.1 Factory Default Setting ------------------------------------------------------------------------------------------------------------------ 103 3.15.2 User Default Setting ---------------------------------------------------------------------------------------------------------------------- 103 3.15.2.1 Store User Default Setting ------------------------------------------------------------------------------------------------------- 103 3.15.2.2 Load User Default Setting -------------------------------------------------------------------------------------------------------- 103 3.16 Data Communication -------------------------------------------------------------------------------------------------------------------------- 103 3.16.1 RS-485 Setup ------------------------------------------------------------------------------------------------------------------------------- 103 3.17 Retransmission ---------------------------------------------------------------------------------------------------------------------------------- 104 3.18 Heater Current Monitoring ------------------------------------------------------------------------------------------------------------------ 104 3.19 Event Input --------------------------------------------------------------------------------------------------------------------------------------- 105...
  • Page 6 5 CALIBRATION --------------------------------------------------------------------------------------------- 121 5.1 Equipment Required Before Calibration --------------------------------------------------------------------------------------------------- 121 5.1.1 Manual Calibration Procedure ---------------------------------------------------------------------------------------------------------- 121 5.1.1.1 Calibrate Zero of A to D Converter ---------------------------------------------------------------------------------------------- 121 5.1.1.2 Calibrate Gain of A to D Converter ---------------------------------------------------------------------------------------------- 121 5.1.1.3 Calibrate Offset of Cold Junction Compensation ---------------------------------------------------------------------------- 122 5.1.1.4 Calibrate Gain of Cold Junction Compensation ------------------------------------------------------------------------------ 122 5.1.1.5 Calibrate RTD Input ------------------------------------------------------------------------------------------------------------------ 122 5.1.1.6 Calibrate Linear Input --------------------------------------------------------------------------------------------------------------- 123...
  • Page 7 C42 DIMENSION WITHOUT CLAMP ----------------------------------------------------------------------------------------------------------------- 65 R22 DIMENSION ------------------------------------------------------------------------------------------------------------------------------------------ 66 CT98-1 DIMENSION -------------------------------------------------------------------------------------------------------------------------------------- 67 CT98-1 APPEARANCE ------------------------------------------------------------------------------------------------------------------------------------ 67 LEAD TERMINAL FOR ALL MODELS EXCEPT C22 ------------------------------------------------------------------------------------------------- 68 LEAD TERMINAL FOR C22 ------------------------------------------------------------------------------------------------------------------------------ 68 C22 REAR TERMINAL CONNECTION ----------------------------------------------------------------------------------------------------------------- 68 C62 REAR TERMINAL CONNECTION ----------------------------------------------------------------------------------------------------------------- 69 C82 &...
  • Page 8 DEVIATION IN-BAND ALARM (DB.LO) --------------------------------------------------------------------------------------------------------------- 89 PROCESS VALUE HIGH (PV.HI) ------------------------------------------------------------------------------------------------------------------------ 90 PROCESS VALUE LOW (PV.LO) ------------------------------------------------------------------------------------------------------------------------ 90 HEATER BREAK(H.BK) ----------------------------------------------------------------------------------------------------------------------------------- 91 HEATER SHORT (H.ST) ----------------------------------------------------------------------------------------------------------------------------------- 91 EVENT INPUT CONTROLLED OUTPUT (E1.C.O OR E2.C.O.) ------------------------------------------------------------------------------------ 92 RANGE HIGH (RG.HI) ------------------------------------------------------------------------------------------------------------------------------------ 92 RANGE LOW (RG.LO) ------------------------------------------------------------------------------------------------------------------------------------ 93 RANGE HIGH LOW (RG.H.L) ---------------------------------------------------------------------------------------------------------------------------- 93 PROCESS VALUE HIGH- NORMAL ALARM ---------------------------------------------------------------------------------------------------------- 94...

  • Page 9: Introduction

    1 Introduction 1.1 Introduction The new generation low-cost PID microprocessor-based Fuzzy logic controller series incorporate two bright easy to read LCD Displays which indicate Process Value (PV) and Setpoint (SP). The Fuzzy Logic technology incorporated on these series controllers enables a process to reach a predetermined set point in the shortest time with a minimum of overshoot during startup (Power ON) or external load disturbances (example: an oven door being opened).

  • Page 10: Fuzzy Pid Control

    LCD Display All the controllers in this series will be equipped with high brightness LCD Display. Digital Communication RS-485 Digital communication is available as an additional option. These options allow the units to be integrated with supervisory control systems and software. A Micro USB programming port is available for automatic configuration, calibration and testing without the need to access the keys on the front panel.

  • Page 11: Programming Port

    Programming Port A Micro USB programming port is available for automatic configuration, calibration and firmware upgrades without the need to access the keys on the front panel. 1-2.Programming Port Auto-tuning The auto-tuning function allows the user to simplify the initial setup for a new system. A clever algorithm is provided to obtain an optimal set of control parameters for the process.
  • Page 12 These controllers have the option for Ramp and Soak Profiles with 16 segments. These segments can be used as 4 Profiles with each 4 segments or 2 Profiles with each 8 segments or one profile with 16 segments. This option is not available with the C22, C62 and R22 models. Bidirectional Menu Navigation The C series controllers have bidirectional menu navigation.

  • Page 13: Specifications

    Power Supply 90 to 250VAC, 47 to63Hz, 20 to 28 VAC,47-63Hz / 11 to 40 VDC Power Consumption C22 / R22: 8VA, 4W Maximum., C62: 10VA, 5W Maximum., C82 / C83 / C42: 12VA,6W Maximum Over Voltage Category Signal Input...
  • Page 14 Specification Event Input Number of Event Inputs Logic Low -10VDC minimum, 0.8VDC maximum. Logic High 2VDC minimum, 10VDC maximum Functions See the availability table CT Input CT Type CT98-1 Accuracy ±5%of Full-scale Reading ±1 Digit. Input Impedance 294Ω Measurement Range 0 to 50AAC Output of CT 0 to 5VDC...
  • Page 15 Analog Retransmission Output Signal 4-20mA, 0-20 mA,0 - 10VDC Resolution 15 Bits Accuracy ±0.05% of Span ± 0.0025% / °C Load Resistance 0 to 500Ω for current output, 10KΩ minimum for Voltage Output Output Regulation 0.01% for full load change Output Setting Time 0.1Second (stable to 99.9%) Isolation Breakdown...
  • Page 16 Environmental and Physical Specifications Operating Temperature -10°C to 50°C Storage Temperature -40°C to 60°C Humidity 0 to 90 % RH (Non-Condensing) Altitude 2000 Meters Maximum Pollution Degree II Insulation Resistance 20MΩ Minimum (@500V DC) Dielectric Strength 2000VAC,50/60 Hz for 1 Minute Vibration Resistance 10 to 55 Hz, 10m/s for 2 Hours...

  • Page 17: Ordering Code

    1.4 Ordering Code 1.4.1 C22 Ordering Code C22 – Power Input 4: 90 to 250 VAC, 47-63Hz 5: 20 to 28 VAC, 47-63Hz / 11 to 40 VDC Output 1 1: Form A Relay (2A, 250V) 2: SSRD, 5VDC/30mA (33Ω, ¼W *2)

  • Page 18: C62 Ordering Code

    1.4.2 C62 Ordering Code C62- Power Input 4: 90 to 250 VAC, 47-63Hz 5: 20 to 28 VAC, 47-63Hz / 11 to 40 VDC Output 1 1: Form A Relay (2A, 250V) 2: SSRD, 5VDC/30mA (33Ω, ¼W *2) 3: Isolated 4-20mA/0-20mA (OM98-3) 5: Isolated 0-10VDC (OM98-5) C: SSRD, 14VDC/40mA (OM94-7) Output 2 / Alarm 1...

  • Page 19: C82, C83, C42 Ordering Code

    1.4.3 C82, C83, C42 Ordering Code C82- C83- C42- Power Input 4: 90 to 250 VAC, 47-63Hz 5: 20 to 28 VAC, 47-63Hz / 11 to 40 VDC Output 1 1: Form A Relay (2A, 250V) 2: SSRD, 5VDC/30mA (33Ω, ¼W *2) 3: Isolated 4–20mA/0–20mA (OM98-3) 5: Isolated 0–10VDC (OM98-5) C: SSRD, 14VDC/40mA (OM94-7)

  • Page 20: R22 Ordering Code

    OM98-3 = Isolated 4-20mA/0-20mA Analog Output Module OM98-5 = Isolated 0-10VDC Analog Output Module CM98-3 = Isolated 4-20mA/0-20mA Retransmission Module for all models except C22 & R22 CM98-5 = Isolated 0-10VDC Retransmission Module for all models except C22 & R22 PA98-1 = USB Programming Adaptor CC98-1 = Programming Port Cable (1.5m)

  • Page 21: Related Products

    1.4.6 Related Products SNA10A = Smart Network Adaptor for third party software, which converts up to 255 channels of RS-485 or RS-422 to be usable on an RS-232 network. FDC-Set = Configuration Software 1.5 Programming Port A Micro USB Port provided on the controller can be used to connect to a PC by using a programming port cable (CC98-1) and a programming adapter ( for firmware upgrades.

  • Page 22: Keys And Displays

    8.6 seconds, then let go to select calibration mode. During power-up, the upper display will show PROG and the lower display will show the Firmware version for 6 seconds. 1-5. C22 Front Panel Keys and Display Page 22 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 23: C62 Front Panel Keys And Display

    1-6.C62 Front Panel Keys and Display 1-7.C82 Front Panel Keys and Display Page 23 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 24: C83 Front Panel Keys And Display

    1-8.C83 Front Panel Keys and Display 1-9.C42 Front Panel Keys and Display Page 24 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 25: R22 Front Panel Keys And Display

    1-10.R22 Front Panel Keys and Display 1-11.How Characters are Displayed on the LCD screen Page 25 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 26: Menu Flowchart

    1.7 Menu Flowchart The Menu has been divided into 5 groups. They are as follows: User Menu Setup Menu Manual Mode Menu Auto-Tuning Mode Menu Calibration Mode Menu Auto-Tuning Calibration Manual Mode Setup User Menu Menu Mode Mode 5 Sec 6.2 Sec 7.4 Sec 8.6 Sec...

  • Page 27: User Menu

    1.7.1 User Menu The below user menu parameters are available depends on the user selection. PV,SV SFtR CT1R CT2R DTMR PASS CYCR STEP TIMR SEL1 SEL2 SEL3 SEL4 SEL5 SEL6 SEL7 SEL8 1.7.2 Setup Menu The setup menu has been categorized into eight categories. They are listed as below.

  • Page 28: Basic Menu (Base)

    1.7.2.1 Basic Menu (bASE) key to get bASE in the lower display then use key to enter to basic menu parameters. bASE OFS1 OFS2 OFS3 INPT UNIT INLO INHI SP1L SP1H FILT DISP RAMP RETY RELO REHI RMSP RINL RINH CODE OFTL OFTH...

  • Page 29: Output Menu (Out)

    1.7.2.2 Output Menu (oUT) key to get oUT in the lower display then use key to enter to output menu parameters. OUT1 O1TY O1FT O1HY CYC1 OFST OUT2 O2TY O2FT CYC2 PL1L PL1H PL2L PL2H 1.7.2.3 Event Input Menu (EI) key to get EI in the lower display then use key to enter to event input menu parameters.

  • Page 30: Alarm Menu (Alrm)

    1.7.2.4 Alarm Menu (ALRM) key to get ALRM in the lower display then use key to enter to alarm menu parameters. ALRM A1FN A1MD A1HY A1FT A1SP A1DV A1DL A2OT A2FN A2MD A2HY A2FT A2SP A2DV A2DL A3OT A3FN A3MD A3HY A3FT A3SP...

  • Page 31: User Select Menu (Sel)

    1.7.2.5 User Select Menu (SEL) key to get SEL in the lower display then use key to enter to select the user menu parameters. SEL1 SEL2 SEL3 SEL4 SEL5 SEL6 SEL7 SEL8 1.7.2.6 Communication Menu (CoMM) key to get CoMM in the lower display then use key to enter into communication menu parameters.

  • Page 32: Profile Menu (Prof)

    1.7.2.8 Profile Menu (PRoF) key to get PRoF in the lower display then use key to enter into Profile menu parameters. PRoF PROF TSP7 RMPU RPT7 STAR SKT7 TSP8 RPT8 HBLO SKT8 HBHI TSP9 RPT9 CYCL SKT9 CYCR TSPA STEP RPTA TIMR SKTA...

  • Page 33: Manual Mode Menu

    1.7.3 Manual Mode Menu HANd 5 Sec FILE Press key 5 Sec To execute the selected default program 1.7.4 Auto-Tuning Mode Press key 5 seconds to activate Auto-Tuning Mode 1.7.5 Calibration Mode CALI 2 sec minimum,3 sec maximum ADLO ADHI RTDL RTDH CJLO...

  • Page 34: Parameter Availability Table

    Notation Exists unconditionally C42 / C82 / C83: Exists if E1FN selects SP2 C62/C22 / R22: Exists if E1FN exists and E1FN selects SP2 C42 / C82 / C83: Exists if E2FN selects SP3 C62/R22: Exists if E2FN exists and E2FN...
  • Page 35 PVLO, H. BK, H.ST, RG.HI, RG. LO, RG.H.L, PFHB, PFED, E1.C.O, or E2.C.O A2MD C22 / R22: Exists if OFS2 selects AL2 and A2FN selects DTMR, DEHI, DELO, DBHI, DBLO, PVHI, PVLO, H. BK, H.ST, RG.HI, RG. LO, RG.H.L, E1.C.O or E2.C.O...
  • Page 36 Register Parameter Existence Conditions Address Notation C82 / C83 / C42: Exists if A3FN is set to PVHI, PVLO, RG.HI, RG. LO, RG.H.L, A3SP C62: Exists if OFS3 is set to ALM3, or if A3FN is set, PVHI, PVLO, RG.HI, RG. LO, RG.H.L, C82 / C83 / C42: Exists if A3FN is set to DEHI, DELO, DBHI, DBLO, RG.HI, RG.
  • Page 37 20, 0-5V, 1-5V, 0-10, A.4.20, A.0.20, A.0.5V, RELO A.1.5V, or A.0.10 C62: Exists if OFS3 selects 4-20, 0-20, 0-5V, 1- 5V, 0-10 REHI C22 / R22: Exists if OFS2 selects 4-20, 0-20, 0- 5V, 1-5V, 0-10 ADDR BAUD DATA Exists if OFS1 selects RS-485...
  • Page 38 Exists unconditionally C42 / C82 / C83: Exists unconditionally E1FN C62: Exists if OFS2 selects EI12 or EICT C22 / R22: Exists if OFS1 selects EI1 C42 / C82 / C83: Exists unconditionally E2FN C62: Exists if OFS2 selects EI12...

  • Page 39: Parameter Availability

    TSP5 RPT5 SKT5 C42 / C82 / C83: Exists if PROF selects 2 or 3 TSP6 or 7 C62/C22 / R22: Not exist RPT6 SKT6 TSP7 RPT7 SKT7 C42 / C82 / C83: Exists if PROF selects 2 or 3...

  • Page 40: Parameters Description

    1.9 Parameters Description Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High Low: SP1L 25.0°C Set Point 1 -19999 45536 High: SP1H (77.0°F) Low: SP1L 100.0°C Set Point 2 -19999 45536 High: SP1H (212.0°F)
  • Page 41 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High 0 0: 0 second time constant 1 0.2: 0.2 second time constant 2 0.5: 0.5 second time constant 3 1: 1 second time constant Filter damping 4 2: 2 second time constant FILT...
  • Page 42 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High 0 NoNE: Output2 turned off 1 COOL: Cooling PID Function 2 AL1: Alarm 1 Function Output 2 OUT2 3 rAL1: Reverse Alarm 1 65535 function Function...
  • Page 43 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High 0 OFF: Alarm output OFF if the Alarm 1 failure sensor fails A1FT 65535 transfer mode 1 ON: Alarm output ON if the sensor fails Alarm 1 set Low: -19999...
  • Page 44 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High 0 NoNE: No alarm function 1 dtMR: Dwell timer action 2 dE.HI: Deviation high alarm 3 dE.Lo: Deviation low alarm 4 db.HI: Deviation band out of band alarm 5 db.Lo: Deviation band in band alarm...
  • Page 45 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High 0 NoNE: No alarm function 1 dtMR: Dwell timer action 2 dE.HI: Deviation high alarm 3 dE.Lo: Deviation low alarm 4 db.HI: Deviation band out of band alarm 5 db.Lo: Deviation band in band alarm...
  • Page 46 Error code ------ 65535 High: 65535 Operation Low: 0 MODE mode & alarm ------ 65535 High: 65535 status C22:22. XX C62:62. XX C82:82. XX PROG71 Program code ------ 65535 C83:83. XX C42:42. XX R22:23. XX Low: 0 CMND Command code...
  • Page 47 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High Power limit Low: 0 PL1L 65535 Output1 low High:PL1H or 50% Power limit Low: PL1L PL1H 65535 Output1 high High: 100 % Power limit Low: 0 PL2L...
  • Page 48 Option 1 integer data on Modbus 65535 2 S16b: RS485 with signed integer data on Modbus C22 / R22: 0 NoNE: Not selected 1 R485: RS-485 with unsigned integer data on Modbus 2 EI1: Event 1 input 3 CT1: CT 1 input...
  • Page 49 (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High C22: 0. NoNE: No selected 1. 4-20: 4-20mA retransmission output 2. 0-20: 0-20mA retransmission output 3. 0-5V: 0-5V retransmission output 4. 1-5V: 1-5V retransmission output 5. 0-10: 0-10 retransmission output 6.
  • Page 50 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High C62: 0 NoNE: Not selected 1 4-20: 4-20mA retransmission output 2 0-20: 0-20mA retransmission output 3 0-5V: 0-5VDC retransmission output 4 1-5V: 1-5VDC retransmission output 5 0-10: 0-10VDC retransmission output...
  • Page 51 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High Triple point Low: 0.0 HB2T current for 65535 High: 120.0 heater break 2 Enable Heater 0 oFF: Off HSEN short 65535 oN: On detection Heater short...
  • Page 52 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High Input signal value during Low: CALO+1 CAHI 1000 -19999 45536 high point High: 45536 calibration … Reserved … … … … …...
  • Page 53 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High 1 SP5: SP5 activated to Event input 4 E4FN replace SP1 65535 function Others: Same as E3FN 0 NoNE: none 1 SP6: SP6 activated to replace SP1 2 rS.A1: Reset alarm 1 output 3 rS.A2: Reset alarm 2 output...
  • Page 54 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High 0 NoNE: Not uses. 1 1--4: Uses steps 1 to 4 2 5--8: Uses steps 5 to 8 3 1--8: Uses steps 1 to 8 PROF Profile selection 65535...
  • Page 55 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High Target setpoint Low: SP1L 100.0°C TSP1 -19999 45536 for segment 1 High: SP1H (212.0°F) Ramp time of Low: 00.00 RPT1 00.00 65535 segment 1 High: 99.59...
  • Page 56 Scale Modbus Data Parameter Parameter Default (Unsigned 16 Bit Register Range Access Data) Notation Description Value Address Type High Ramp time of Low: 00.00 RPTA 00.00 65535 segment 10 High: 99.59 Soak time of Low: 00.00 SKTA 00.00 65535 segment 10 High: 99.59 Target setpoint Low: SP1L...

  • Page 57: Installation And Wiring

    2 Installation and Wiring Sometimes dangerous voltages capable of causing death are present in this instrument. Before doing the installation or any troubleshooting procedures, the power to the 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.

  • Page 58: C22 Dimension

    2.2.1 C22 Dimension 2-1.C22 Dimensions with clamp Page 58 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 59: C22 Dimension Without Clamp

    2-2.C22 Dimension without Clamp Page 59 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 60: C62 Dimension

    2.2.2 C62 Dimension 2-3. C62 Dimension with clamp Page 60 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 61: C62 Dimension Without Clamp

    2-4. C62 Dimension without Clamp Page 61 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 62: C82 Dimension

    2.2.3 C82 Dimension 2-5.C82 Dimension with Clamp 2-6.C82 Dimension without Clamps Page 62 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 63: C83 Dimension

    2.2.4 C83 Dimension 2-7.C83 Dimension with Clamps 2-8.C83 Dimension without Clamp Page 63 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 64: C42 Dimension

    2.2.5 C42 Dimension 2-9. C42 Dimension with Clamps Page 64 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 65: C42 Dimension Without Clamp

    2-10. C42 Dimension without Clamp Page 65 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 66: R22 Dimension

    2.2.6 R22 Dimension 2-11.R22 Dimension 2.2.7 CT98-1 Dimension Page 66 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 67: Wiring

    2-12.CT98-1 Dimension 2-13.CT98-1 Appearance 2.3 Wiring Sometimes dangerous voltages capable of causing death are present in this instrument. Before doing the installation or any troubleshooting procedures, the power to the 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.

  • Page 68: C22 Terminal Connection

    2-14.Lead Terminal for all models except C22 2mm max 4.5 to 7mm max 2-15.Lead Terminal for C22 2.3.1 C22 Terminal Connection 2-16.C22 Rear Terminal Connection Page 68 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 69: C62 Terminal Connection

    2.3.2 C62 Terminal Connection 2-17. C62 Rear Terminal Connection 2.3.3 C82 & C42 Terminal Connection 2-18. C82 & C42 Rear Terminal Connection Page 69 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 70: C83 Terminal Connection

    2.3.4 C83 Terminal Connection 2-19.C83 Rear Terminal Connection Page 70 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 71: R22 Terminal Connection

    2.3.5 R22 Terminal Connection 2-20.R22 Terminal Connection Page 71 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 72: Power Wiring

    2.4 Power Wiring The controller is designed to operate at either 11-26VAC/VDC or 90-250VAC depending on power input option ordered. Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller. Near the controller, a fuse and a switch rated at 2A/250VAC should be equipped as shown below.

  • Page 73: Sensor Input Wiring

    2.6 Sensor Input Wiring 2-22.Sensor Input Wiring 2.7 Control Output Wiring 2.7.1 Output 1 2-23. Output 1 Relay to Drive Load Page 73 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 74: Output 1 Relay To Drive Contactor

    2-24. Output 1 Relay to Drive Contactor 2-25. Output 1 Pulsed voltage to Drive SSR 2-26. Output 1 Linear Current Control Page 74 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 75: Output

    2-27. Output 1 Linear Voltage Control 2.7.2 Output 2 2-28. Output 2 Relay to Drive Load 2-29. Output 2 Relay to Drive Contactor Page 75 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 76: Output 2 Pulsed Voltage To Drive Ssr

    2-30. Output 2 Pulsed Voltage to Drive SSR 2-31. Output 2 Linear Current Control 2-32. Output 2 Linear Voltage Control Page 76 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 77: Alarm Wiring

    2.8 Alarm Wiring 2.8.1 Alarm 1 2-33. Alarm 1 Output to Drive Load 2.8.2 Alarm 2 2-34. Alarm 2 Output to Drive Load Page 77 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 78: Alarm

    2.8.3 Alarm 3 2-35. Alarm 3 Output to Drive Load 2.8.4 Alarm 4 2-36. Alarm 4 Output to Drive Load 2.9 Event Input Wiring The event input can accept a switch (dry contact) or an open collector signal. The event input function (EIFN) is activated as the switch is closed or an open collector (or a logic signal) is pulled down.

  • Page 79: Ct Input Wiring

    2.10 CT Input Wiring 2-38. CT Input Wiring for Single Phase Heater 2.11 RS-485 Data Communication 2-39.RS-485 Wiring Page 79 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 80: Retransmission Wiring

    2.12 Retransmission Wiring 2-40. Retransmission Wiring 2.13 Remote Setpoint Wiring 2-41.Remote SetPoint Page 80 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 81: Programming

    3 Programming Press for 5 seconds and release to enter the setup menu. Press and release to select the desired parameter. The upper display indicates the parameter symbol, and the lower display indicates the value of the selected parameter. 3.1 User Security There are two parameters PASS (password) and CODE (security code) which will control the data security function.

  • Page 82: Control Output

    3.3 Control Output There are 4 kinds of control modes can be configured as shown below. Control Mode OUT 1 OUT 2 O1HY Heat Only REVR ∆ Cool Only DIRT ∆ Heat PID, Cool ON-OFF REVR COOL Heat PID, Cool PID REVR COOL 3-2.Control Mode...

  • Page 83: Heat Only P Or Pd Control

    3.3.2 Heat only P or PD Control Select REVR for OUT1 set TI = 0, OFST is used to adjust the controlled offset (manual reset). If PB ≠0 then O1HY will be hidden. OFST Function: OFST is measured in % with a range of 0 - 100.0 %. When the process is stable, let’s say the process value is lower than the setpoint by 5°C.

  • Page 84: Db Programming

    3.3.7 DB Programming Adjustment of DB (Dead band) is dependent on system requirements. If a greater dead band is used, then an unwanted cooling action can be avoided, but an excessive overshoot of the setpoint will occur. If a smaller dead band (DB) is used, then an excessive overshoot can be minimized, but an overlapping of the heating and cooling action will occur.

  • Page 85: Alarm

    3.5 Alarm The controller has up to four alarm outputs depending on the controller model. There are 16 types of alarm functions and one dwell timer that can be selected. There are 4 kinds of alarm modes (A1MD, A2MD, A3MD, and A4MD) available for each alarm function (A1FN, A2FN, A3FN, and A4FN). In addition to the alarm output, output 2 can also be configured as an alarm.
  • Page 86 Heater break detection is enabled by setting A1FN to HBEN. A Heater break alarm (H. bK) alerts the user when the current measured by CT1 in CT1R is lower than HB1T, or CT2 in CT2R is lower than HB2T. When the current measured by CT1 in CT1R is higher than HB1T+HBHY and CT2 in CT2R is lower than HB2T+HBHY, the heater break alarm will be off.

  • Page 87: Dwell Timer (Dtmr)

    3-4 Dwell Timer (dtMR) 3-5 Deviation High Alarm (dE.HI) Page 87 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 88: Deviation Low Alarm (De.lo)

    3-6 Deviation Low Alarm (dE.Lo) 3-7 Deviation out of Band Alarm (db.HI) Page 88 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 89: Deviation In-Band Alarm (Db.lo)

    3-8 Deviation In-Band Alarm (db.Lo) Page 89 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 90: Process Value High (Pv.hi)

    3-9 Process Value High (PV.HI) 3-10 Process Value Low (PV.Lo) Page 90 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 91: Heater Break(H.bk)

    3-11 Heater Break(H.bk) 3-12 Heater Short (H.St) Page 91 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 92: Event Input Controlled Output (E1.C.o Or E2.C.o.)

    3-13 Event Input Controlled Output (E1.C.o or E2.C.o.) 3-14 Range High (RG.HI) Page 92 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 93: Range Low (Rg.lo)

    3-15 Range Low (RG.Lo) 3-16 Range High Low (RG.H.L) Page 93 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 94: Alarm Modes

    3.5.2 Alarm Modes There are six types of alarm modes available for each alarm function. 1. Normal alarm 2. Latching alarm 3. Holding alarm 4. Latching/ Holding alarm 5. Setpoint Holding Alarm 6. Latching None Reset Alarm 3.5.2.1 Normal Alarm: ALMD = NORM When a normal alarm is selected, the alarm output is de-energized in the non-alarm condition and energized in an alarm condition.

  • Page 95: Process Value High- Latching Alarm

    3-18 Process Value High- Latching Alarm 3-19 Process Value High- Holding Alarm Page 95 of 131 FDC_C-Series_User_Manual_UM0C62H_January-2021.docx...

  • Page 96: Alarm Delay

    3-20 Process Value High- Latching & Holding Alarm 3.5.3 Alarm Delay In certain applications during startup, nuisance alarms will be generated before the process value reaches the set point. To avoid these kinds of nuisance alarms, a time delay for alarms is available. To enable the time delay for alarms, set the delay time using the A1DL, A2DL, A3DL, and A4DL parameters.

  • Page 97: User Select Menu Configuration

    3.6 User Select Menu Configuration Conventional controllers are designed with parameters in a fixed order. If the user needs a friendlier menu operation to suit their application, most conventional controllers do not offer a solution. The C series controllers have the flexibility for the user to select those parameters which are most significant and put these parameters in an easy access USER menu.

  • Page 98: Ramp

    3.7 Ramp The ramping function is performed during power up as well as any time the setpoint is changed. Choose MINR or HRR for the RAMP setting, and the controller will perform the ramping function. The ramp rate is programmed by adjusting the RR setting. The ramping function is disabled as soon as the Failure mode, the Manual control mode, the Auto-Tuning mode or the Calibration mode occur.

  • Page 99: User Calibration

    After the timer has finished, the dwell timer can be restarted by pressing the RESET key. The timer stops counting during manual control mode, failure mode, calibration and Auto-Tuning. If alarm1 is configured as a dwell timer, A1HY and A1MD are hidden. It is similar for other alarms as well. 3.9 User Calibration Each unit is calibrated in the factory before shipment.

  • Page 100: Digital Filter

    3.10 Digital Filter In certain applications, 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 a time constant specified by the FILT parameter. A value of 0.5 seconds is used as a factory default. Adjust FILT to change the time constant from 0 to 60 seconds.

  • Page 101: Alarm Failure Transfer

    3.11.3 Alarm Failure Transfer An alarm failure transfer is activated as the controller enters failure mode. After that, the alarm output will transfer to the ON or OFF state which is determined by the set value of A1FT, A2FT, A3FT, and A4FT. 3.12 Auto-Tuning The Auto-Tuning process will be performed at the setpoint (SP1).

  • Page 102: Manual Tuning

    3.13 Manual Tuning In certain applications (very few), using Auto-Tuning to tune a process may be inadequate for the control requirement. In this case, the user can try manual tuning. If the control performance by using Auto- Tuning is still unsatisfactory, the following guidelines can be applied for further adjustment of PID values.

  • Page 103: Default Setting

    3.15 Default Setting 3.15.1 Factory Default Setting The controller’s parameters can be loaded with default values listed in the parameter description table. In certain situation, it is desirable to retain these values after the values of the parameters have been changed.

  • Page 104: Retransmission

    3.17 Retransmission The controller can output (retransmit) PV or SP via its retransmission terminals RE+ and RE- provided that the retransmission option is ordered. A correct signal type should be selected for the option board to meet the retransmission option installed. RELO and REHI are adjusted to specify the low scale and high scale values of retransmission.

  • Page 105: Event Input

    3.19 Event Input There are 6 or 2 or 1 Event Inputs that are available in this series of controllers depending on the size of the controller. Refer section 2.8 for wiring an event input. The Event input accepts a digital (on/off) type signal.

  • Page 106: Remote Setpoint

    LOCK: All parameters are locked and unable to be changed (Read-only) in communication. AU.MA: Switch between Auto-Tuning and manual tuning control mode. F.tra: Switch to Failure Transfer Mode AL. oN: If Alarm 2 or Alarm 3 set to E1.c.o or E2.c.o then EI1 or EI2 will activate Alarm Output Alarm 2 or Alarm 3.

  • Page 107: Run

    3.21.2 RUN Select the profile rune mode. There are 5 modes available in the controller. 1. StAR: Start to run profile 2. CoNt: Continue run profile 3. PV: Continue run profile from current PV 4. Hold: Hold profile 5. SToP: Stop profile 3.21.2.1 StAR The Profile starts to run from the first segment in the selected profile.

  • Page 108: Pfr

    3.21.6 PFR If power is lost and then restored, while a profile is running, the behaviour of the profile is determined by the setting of the parameter “PFR “power fail recovery in the profile configuration. The options available for PFR are CONT, PV, SP1. 3.21.6.1 CONT If CONTis selected, then when power is restored the profile continues from where it was interrupted when power was lost.

  • Page 109: Sp1

    3-30.Power failure recovery from PV at Ramp Segment 3.21.6.3 SP1 If SP1 If is selected, then when power is restored the profiler is disabled and it enters static mode, and SP1 is selected for control set point. 3.21.7 Holdback As the set point ramps up or down (or dwells), the measured value may lag or deviate from the setpoint by an undesirable amount.

  • Page 110: Profile Segment Parameters

    3.21.11.1 Profile Segment Parameters Each profile segments have the following parameters. 1. Target Set Point (TSP) 2. Ramp Time (RPT) 3. Soak Time (SKT) 3.21.11.1.1 Target Set point The target Setpoint of the segment can be configured by the parameters TSP1, TSP2, TSP3, TSP4, TSP5, TSP6, TSP7, TSP8, TSP9, TSPA, TSPB, TSPC, TSPD, TSPE, TSPF, and TSPG.

  • Page 111: Applications

    4 Applications 4.1 Heat Only Control with Dwell Timer An oven is designed to dry the products at 150°C for 30 minutes, and then stay unpowered for another batch. A C Series controller equipped with a dwell timer is used for this purpose. The system diagram is shown as below.

  • Page 112: Cool Only Control

    4.2 Cool Only Control A C Series Controller is used to control a refrigerator at a temperature below 0°C. Since the required temperature is lower than the ambient temperature, a cooling action is required. Hence, select DIRT for OUT1. Since output 1 is used to drive a magnetic contactor, O1TY is set to RELY. A small temperature oscillation is tolerable;...

  • Page 113: Heat And Cool Control

    4.3 Heat and Cool Control An injection mold is required to be controlled at 120°C to ensure a consistent quality of the parts. An oil pipe is buried in the mold. Since plastic is injected at a higher temperature (e.g. 250°C), the circulation oil needs to be cooled as its temperature rises.

  • Page 114: Ramp & Dwell

    4.4 Ramp & Dwell 4.4.1 Temperature Cycling Chamber A chamber is used to test the temperature cycling effect on personal Computers. An external cycle timer is used to control the event input for switching the set point. The products under test are required to stay at 60°C for 1 hour and -10°C for 1 hour. The transition interval between high-low temperatures is required to be 5 minutes.

  • Page 115: Programmable Bread Baking Oven

    4.4.2 Programmable Bread Baking Oven Bread is baked in batches. A ramp is incorporated to control the thermal gradient to suit for making the bread. A dwell timer is used to shut off the oven power and announce to the baker. The system is configured as shown in the following diagram and configuration.

  • Page 116: Remote Setpoint

    4.5 Remote Setpoint An on-line multiple zone oven is used to dry paint. Since heat demand varies at different positions in the production line, multiple zones with individual controls should be used to ensure a consistent temperature profile. If the user uses a C Series Controller with a retransmission output for the master controller and retransmits its setpoint to the remote Setpoint input of the slave controllers, each zone will be synchronized with the same temperature.

  • Page 117: Rs 485 Communication In Controller

    4.6 RS 485 Communication in Controller A Tile making plant has 5 production lines. Each production line is equipped with 16 Controllers to control the temperature for the Kiln. The foreman wants to be able to program the controllers and monitor the process in the control room to improve quality and productivity.

  • Page 118: Retransmission Application

    4.7 Retransmission Application An air-conditioned room uses controllers to control its temperature and humidity. The temperature and humidity are required to be recorded on a recorder. The ranges of interest for these two quantities are 20°C to 30°C and 40% RH to 60% RH. The recorder inputs accept 0 - 5 V signal. To achieve this, set the following parameters in the Setup menu.

  • Page 119: Ramp & Soak Profile In Heat Treatment Chamber

    4.8 Ramp & Soak Profile in Heat Treatment Chamber A heat treatment chamber needs to vary temperature as a function of time. Because the process requires a rapid increase in temperature as it is heated and a rapid decrease in temperature as it is cooled.
  • Page 120 The temperature profile shown in the above figure can be achieved by using the following parameters. PROF=1-4 RUN=StAR RMPU=MM: SS STAR=PV END=OFF PFR=CONT CYCL=1 TSP1=400°C RPT1=25:00 SKT1=00:00 TSP2=400°C RPT2=00:00 SKT2=21:00 TSP3=1000°C RPT3=09:00 SKT3=00:00 TSP4=1000°C RPT4=00:00 SKT4=18:00 INPT=K_TC UNIT=°C DP=No dP OUT1=REVR O1FT=BPLS CYC1=18...

  • Page 121: Calibration

    5 Calibration Do not proceed through this section unless there is a definite need to re-calibrate the controller. All previous calibration data will be lost. Do not attempt recalibration unless you have appropriate calibration equipment. If calibration data is lost, you will need to return the controller to your supplier who may charge you a service fee to re-calibrate the controller.

  • Page 122: Calibrate Offset Of Cold Junction Compensation

    5.1.1.3 Calibrate Offset of Cold Junction Compensation Setup the equipment according to the following diagram for calibrating the cold junction compensation. Note that a K type thermocouple must be used. 5-1.Cold Junction calibration Setup Let controller sit at least 20 minutes in a room temperature of 25±3°C. The 5520A calibrator is to be configured as a K type thermocouple output with internal compensation.

  • Page 123: Calibrate Linear Input

    5.1.1.6 Calibrate Linear Input Select the input type as 0 to 10V in the INPT parameter in bASE menu configuration. Press and hold the scroll key until appears on the display, then release the scroll key. Press the scroll key for 2-3 seconds then release, the display will show and the unit will enter the calibration mode.

  • Page 124: Communication

    6 Communication This chapter explains the Modbus Communication protocol of the controller using RS-485 communication. This supports only RTU mode. Data is transmitted as 8-bit binary bytes with 1 start bit,1 stop bit and optional parity checking (None, Odd, Even). Baud rate may be set to 2400, 4800, 9600, 14400, 19200, 28800, 38400, 57600 and 115200 BPS.

  • Page 125: Function Code 06: Pre-Set Single Register

    6.1.2 Function Code 06: Pre-set Single Register Slave Address (1~247) Slave Address (1~247) Function Code (06) Function Code (06) Starting Address of Register Hi (00) Starting Address of Register Hi (00) Starting Starting Starting Starting Address of Address of Address of Address of Query (From Response...

  • Page 126: Exception Responses

    6.2 Exception Responses If the controller receives a message which contains a corrupted character (parity check error, framing error etc.), or if the CRC16 check fails, the controller ignores the message. However, if the controller receives a syntactically correct message which contains an illegal value, it will send an exception response, consisting of five bytes as follows: Slave address +offset function code + exception code + CRC16 Hi +CRC16 Lo Where the offset function code is obtained by adding the function code with 128 (i.e.

  • Page 127: Mode

    6-5.Error Code 6.5 Mode The Value of the Mode Register is as below. Mode Value Mode H'000X Normal mode H'010X Calibration mode H'020X Auto-Tuning mode H'030X Manual control mode H'040X Failure mode H'0X00 Alarm status is off H'0x01 Alarm status is on 6-6.Operation Mode Bit wise description of Mode register value as below.

  • Page 128: Command Mode

    6.6 Command Mode The Value of the Command Mode and job registers are as below. Command Function Job1 Value Mode Value Mode Description Code Set Date Low:0 High:3719 Date =(Y*12+M) *31+D 26680 6838 Write Date [DATE] [DATE] [DATE]  Year=0…9Y=0…9 Month=1…12M=0…11 Day=1…31D=0…30 Calibrate ADLO...

  • Page 129: Scaling

    32767. This option is available from firmware version 15 in C62, C22 & R22 and firmware version 8 in C42, C82 & C83. Page 129 of 131...

  • Page 130: Communication Examples

    6.10 Communication Examples 6.10.1 Read PV, SV, MV1 and MV2 Send the following command to the controller via the communication port H’40 H’80 Slave Address Function Code Starting Address No of Words CRC16 6.10.2 Perform Reset Function (same effect as pressing R key) Query H’48 H’68...

  • Page 131: Warranty

    Warranty: Future Design Controls C-Series Process Controls are warranted to be free from functional defects in materials and workmanship at the time the products leave Future Design Controls facilities and to conform at that time to the specifications set forth in the relevant Future Design Controls manual, sheet or sheets for a period of Three years after delivery to the first purchaser for use.

This manual is also suitable for:

C62C82C83C42R22

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