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Future Design MCT-CM User Manual

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MCT-CM User Manual
MCT-CM User Manual Rev C
August 2022 (V1.2eCM30/V1.3eCM22)
Supersedes: May 2021

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  • Page 1 MCT-CM User Manual MCT-CM User Manual Rev C August 2022 (V1.2eCM30/V1.3eCM22) Supersedes: May 2021...
  • Page 2 Your comments or suggestions on this manual are welcome. Please send them to: Future Design Controls, P.O. Box 1196, Bridgeview, Illinois, 60455 Telephone: +1 (888) 751-5444; fax: +1 (888) 307-8014 csr@futuredesigncontrols.com The MCT-CM User Manual is copyrighted by Future Design Controls, Inc., © 2012, all rights reserved (http://www.futuredesigncontrols.com/MCT.htm).

  • Page 3: Table Of Contents

    MCT-CM What is the MCT-CM? ....................8 1.1 Features ..........................8 Installation ........................10 2.1 Enclosure Guidelines ......................10 2.1.1 Locating the MCT Touch Screen Interface ..................10 2.2 Environmental Considerations .................... 11 2.3 Mounting Dimensions ......................11 MCT 4.3” Touch Screen Interface ....................12 2.3.1...
  • Page 4 MCT-CM 4.1.3 Setting the Number of System Events ................... 50 4.1.4 Setting the Number of Loop/Monitor Alarms .................. 50 4.1.4.1 Protected Loop/Monitor Alarms Example ....................50 4.1.5 Setting the Number of Digital Inputs ....................51 4.1.5.1 Protected Digital Input Example ......................51 4.1.6...
  • Page 5 MCT-CM 5.5.1.2 Manual Operation ........................... 89 5.5.1.3 Program Operation ..........................90 5.5.2 Overview Screen ..........................90 5.5.3 Alarm Set Points ..........................91 5.6 Process Monitoring ......................92 5.6.1 Charts ............................. 92 5.6.1.1 Chart Setup ............................92 5.6.2 Digital IO Monitor ..........................94 5.7 System Alarms ........................
  • Page 6 MCT-CM 9.1 Defrost ..........................137 9.1.1 Defrost Description of Operation ....................138 9.2 Redundancy ........................138 9.2.1 Concurrent Redundancy Switching ....................141 9.2.2 Alternating Redundancy Switching ....................141 9.2.3 Equal Run Time Switching ......................141 9.2.3.1 Before Defrost Switching ........................141 9.2.3.2...
  • Page 7 MCT-CM 10.13 Configuration ......................178 10.13.1 Cloud Server Settings ........................181 10.13.2 Importing an OEM Default Configuration ..................182 10.14 About MCT ......................... 183 10.15 Exit Application ......................183 11 Communications ...................... 184 11.1 Ethernet Communications ....................184 11.1.1 Guide to Smart Networking Practices ..................184 11.1.1.1 The MCT and Network Security......................

  • Page 8: What Is The Mct-Cm

    In addition to a maximum of ten loops of control, the MCT-CM can also provide up to an additional 15 inputs for process monitoring for a total of 25 process inputs. The system is provided with eight digital inputs and 8 digital outputs standard.
  • Page 9 MCT-CM The MCT-CM controller includes the following features: ALARMS ACCESSIBILITY • • Touch screen, “Smart Device” user interface (UI) with Maximum of 30 alarms configurable to any loop/monitor 30,000-hour LED display in the system. • • Built in configuration software; no external software or...

  • Page 10: Installation

    MCT-CM 2 Installation All MCT components are pre-loaded with all operating software and firmware before leaving the factory so they are ready to install when you receive them. Before beginning installation, completely read through this section as well as the following section (3 Wiring) to gain an understanding of the entire installation process. Consider the installation carefully.

  • Page 11: Environmental Considerations

    MCT-CM Proper clearance must also be maintained above, below and on both sides of the interface to allow for heat dissipation and to facilitate mounting. A minimum of 2” is recommended. Note that additional space may be required below and to the right of the interface (looking from rear of unit) to accommodate the communications wiring depending upon the type of communication cables used.

  • Page 12: Mct 4.3" Touch Screen Interface

    MCT-CM MCT 4.3” Touch Screen Interface 2.3.1 All dimensions are in mm. Tolerance +/- 1 mm. Panel cutout: 123 x 99 DB9, Male Not Used LAN, Ethernet (RJ45) SD slot DB25, Female USB port Power supply NOTE: The MCT will not operate properly without the SD card installed into the SD card slot on the back of the unit.

  • Page 13: Mct 7" Touch Screen Interface

    MCT-CM MCT 7” Touch Screen Interface 2.3.2 All dimensions are in mm. Tolerance +/- 1 mm. Panel cutout: 197 x 141 DB9, Male Not Used LAN, Ethernet (RJ45) SD slot DB25, Female USB port Power supply NOTE: The MCT will not operate properly without the SD card installed into the SD card slot on the back of the unit.

  • Page 14: Mct Process Loop Controls

    2.3.3 MCT Process Loop Controls The MCT-CM requires one PID loop control for each process control loop required in the system. Refer to the operating manual for the model loop control being used for dimensions, appropriate mounting and operating conditions.

  • Page 15: Mct Control Module

    MCT-CM 2.3.5 MCT Control Module The basic MCT control module consists of the main CPU (FC6A-D16R1CEE) and the dual RS232/485 serial communication card (FC6A-SIF52) if used, which connects to the right side of the CPU. NOTE: The US2000B communication module (see section 2.5 US2000B Communication Module Option) may be used in place of the FC6A-SIF52 communication card.

  • Page 16: Installing The Fc6A-Sif52 Dual Rs232/485 Serial Communication Card

    MCT-CM 2.3.5.1 Installing the FC6A-SIF52 Dual RS232/485 Serial Communication Card When the FC6A-SIF52 communications card is used, it must be installed as the first card to the right of the CPU. It is recommended that the communications card and any additional analog or digital IO cards be installed prior to mounting the control module to a DIN rail.

  • Page 17: Installing The Control Module In An Enclosure

    MCT-CM 2.3.5.2 Installing the Control Module in an Enclosure The control module must be mounted horizontally on a vertical plane as shown below. All other mounting directions are not permitted. Be sure to leave adequate spacing between the sides of the enclosure and/or...

  • Page 18: Mct Analog And Digital I/O Cards

    MCT-CM 2.3.6 MCT Analog and Digital I/O Cards The MCT analog and digital I/O cards provide connections for additional digital inputs and outputs and analog remote set point input and retransmit outputs. The I/O cards attach to the right side of the main CPU following the FC6A-SIF52 dual RS232/485 serial communication card (if used).

  • Page 19: Digital Output Card

    Optional Communications Module for Barcode Reader and/or Remote Display The MCT-CM provides the ability to connect a barcode reader to the system which can be used to automatically select a ramp/soak program or be used to automatically add operator events (annotations) to a currently operating data file.
  • Page 20 MCT-CM...

  • Page 21: Control Module Assembly Example

    6. FC6A-R081 Digital Output Cards IMPORTANT: The MCT-CM can only support up to seven expansion cards connected directly to the right of the CPU. If more than seven expansion cards are required for the application, contact Future Design Controls for information regarding the use of the F6A-EXM2 expansion interface...

  • Page 22: Us2000B Communication Module Option

    MCT-CM 2.5 US2000B Communication Module Option The US2000B is a replacement communication module for the FC6A-SIF52 communications card used on the FC6A control module. It incorporates an aluminum housing with screw mounting holes which is ideal for most industrial environments.

  • Page 23: Us2000B Configuration Settings

    MCT-CM 2.5.1 US2000B Configuration Settings The US2000B provides a web-paged based configuration interface in order to allow the unit to be configured for use. FDC provides the US2000B preconfigured for proper operation with your system. The following information is provided for informational/troubleshooting purposes only. You do not have to configure your unit prior to use.
  • Page 24 MCT-CM...

  • Page 25: Wiring

    MCT-CM 3 Wiring This section describes the methods and precautions for wiring the MCT system components. Before beginning wiring, be sure to read “Safety Precautions” in the beginning of this manual. • Turn off power to the MCT before starting installation, removal, wiring, WARNING: maintenance and inspection of the controller.

  • Page 26: Installing The Power-On Delay Relay

    MCT-CM 3.1.1 Installing the Power-On Delay Relay Due to the rate at which AC/DC power supplies reach their nominal supply voltage after application of power, the relay contact of the timer should be installed between the output of the power supply and the power input of the MCT control system components.

  • Page 27: Grounding Requirements

    MCT-CM 3.2 Grounding Requirements Proper grounding is critical to the performance and reliability of the MCT. Most of the problems in electrical systems can be attributed to poor or improper grounding techniques, as well as poor earth grounds at the installation site.

  • Page 28: Connecting To The Mct Interface

    MCT-CM 3.3 Connecting to the MCT Interface Power wiring lengths should be kept to a minimum, and it is preferable to have the power wiring run using a minimum of 18/2 twisted shielded cable. This keeps the “hot” and “common” wires paired to minimize the effects of external noise.

  • Page 29: Serial Communications To Control Module

    (connected to COM1), and pig tail leads at the CPU end (connected to the upper side port of the dual RS232/485 communication card). Future Design Controls offers this cable as an option (p/n CA-232-8A). A cable can also be fashioned and connected according to the following diagram: 3.3.1.2...

  • Page 30: User Serial Communications

    MCT-CM 3.3.2 User Serial Communications The MCT touch screen provides a user communications port with both RS232 and RS485 interfaces for connecting the MCT to a PC running software such as FDC’s Envision. In order to connect the MCT to a PC...
  • Page 31 MCT-CM If more than one MCT controller is to be placed on the serial communication link with a PC, use the RS485 interface to connect multiple MCT units together on the PC serial communications link. Note that an RS232/485 converter will be required at the PC to convert the standard RS232 serial port to an RS485 interface, or a USB to RS485 serial adapter can be used.

  • Page 32: Connecting To The Mct Process Loop Controls

    3.4 Connecting to the MCT Process Loop Controls The MCT-CM can support up to 10 individual control loops. The controls communicate with the MCT control module using RS485 serial communications. This allows all loop controls to be connected using one 2-wire link.

  • Page 33: Us2000B Communication Module To Loop Controls

    Assigning the Proper Communications Settings The MCT-CM can support up to ten C-Series R22 controls or up to ten FDC 300 Series controls depending upon the firmware version installed in the CM. Each loop control must have its own communication address.
  • Page 34 MCT-CM In addition to the communication parameters, the function level of the control must be set to ‘FuLL’. This permits the MCT control module to access the necessary data values within the loop control. If the function level is left in the basic (bASC) mode, communication errors will result.

  • Page 35: Connecting To The Mct Process Monitor Modules

    3.5 Connecting to the MCT Process Monitor Modules The MCT-CM can connect with four different versions of monitor modules. Each version of module provides a different input type so that it can be tailored to match the application. The IO-8TCS provides up to eight thermocouples, the IO-8AIIS or IO-8AIVS provide up to eight current or voltage inputs and the IO-6RTD provides up to 6 RTD inputs.

  • Page 36: Thermocouple Module (Io-8Tcs) Input Wiring

    MCT-CM 3.5.1 Thermocouple Module (IO-8TCS) Input Wiring The IO-8TCS is an 8 isolated thermocouple input module. The module uses differential inputs to reduce effects of electrical noise. The thermocouple inputs are isolated from the internal logic and from each other. The module has built in cold junction compensation.
  • Page 37 MCT-CM The following diagram shows how the analog inputs are connected to a 0(4)-20mA source. Note that all of the common terminals are isolated from each other. The following diagram shows how the analog inputs are connected to a 0(2)-10Vdc source. Note that all of the...

  • Page 38: Rtd Module (Io-6Rtd) Input Wiring

    MCT-CM 3.5.3 RTD Module (IO-6RTD) Input Wiring The IO-6RTD module is a 6 RTD input module. The module can accommodate either 2 or 3 wire RTD sensors. The RTD inputs are isolated from the internal logic. DIP-switch 9 is used to select the upscale or downscale value for sensor break detection.

  • Page 39: Connecting To The Mct Control Module

    MCT-CM 3.6 Connecting to the MCT Control Module If output relays or transistors in the control module should fail, outputs may CAUTION: remain on or off. For outputs that may cause malfunction of equipment that could lead to property damage or injury, monitoring and/or safety circuits MUST be provided outside of the control module.

  • Page 40: Main Cpu Wiring

    MCT-CM 3.6.1 Main CPU Wiring The following information covers basic input/output connection information for the MCT control module. Since the MCT is a fully configurable control system, the use of each input and output is dependent upon the application; therefore, the input and output control devices and ‘real world’ connections are determined by the...

  • Page 41: Optional Remote Display Wiring

    3.6.3 Optional Barcode Scanner Wiring Future Design Controls recommends and supports the use of the Unitech MS-120-2 barcode scanner with an RS232 interface and built in decoder. The barcode scanner also requires a separate 5Vdc power supply which attaches to the decoder module (Unitech model 101000-0150 110V power adapter).
  • Page 42 MCT-CM In order to connect the barcode scanner to the MCT, the optional cartridge adapter (FC6A-HPH1) and RS232 communication cartridge (FC6A-PC1) are required. The upper cartridge slot supports the communications interface for the barcode scanner. To connect to the RS232 interface of the barcode scanner, a DB9 male connector must be wired as shown.

  • Page 43: Optional Digital Input Expansion Card Wiring

    MCT-CM 3.6.4 Optional Digital Input Expansion Card Wiring The following information covers basic input connection information for the MCT digital input expansion cards. Since the MCT is a fully configurable control system, the use of each input is dependent upon the application;...

  • Page 44: Optional Digital Output Expansion Card Wiring

    MCT-CM 3.6.5 Optional Digital Output Expansion Card Wiring The following information covers basic output connection information for the MCT digital output expansion cards. Since the MCT is a fully configurable control system, the use of each output is dependent upon the application;...
  • Page 45 MCT-CM...

  • Page 46: Optional Analog I/O Expansion Card Wiring

    ‘real world’ connections are determined by the system designer. The number of analog expansion cards in the system will also vary depending upon the application. The MCT-CM can support up to 14 analog inputs and 7 analog outputs for a total of 7 analog expansion cards. NOTE: The analog inputs and outputs are added sequentially as each card is added to the system.

  • Page 47: Configuring The Mct-Cm

    MCT-CM 4 Configuring the MCT-CM The MCT Configurator is a powerful tool that is built in to the system and allows the OEM or user to set up control system options for the MCT runtime application. This allows for on-the-spot setup of the MCT without the need for external hardware and software.
  • Page 48 MCT-CM The configurator menu is accessed by pressing the “Monitor” icon at the top left of the screen. The File menu provides the exit function for the configurator. After selecting this menu item and exiting the configurator, the controller runtime software will run after the unit is re-powered.

  • Page 49: Io Settings

    Upon exiting the Configurator application and cycling power to the MCT, the runtime application will be automatically started on the next boot sequence. To assist in setup and documentation of the MCT, see the “MCT-CM Configuration Worksheet” Excel file provided on the Future Design Controls website. This document provides setup and configuration forms and templates for all of the MCT-CM configuration parameters.

  • Page 50: Setting The Number Of Monitor Points

    The # of Alarms field sets the number of loop/monitor alarms that will be accessible under the MCT runtime application Setup menu. The alarms provide various alarming and output control functions for indicating out- of-tolerance conditions for the various loop and monitors configured in the system. The MCT-CM provides up to 30 loop/monitor alarms.

  • Page 51: Setting The Number Of Digital Inputs

    MCT-CM Once the system has been configured and tested, prior to shipment, the OEM can then access the configurator once more and change the “# of Alarms” field to a value of two. Since the field is now set to two, only the first two alarms will be accessible from the Setup menu, i.e., alarms 1 and 2, the alarms for the end user.

  • Page 52: Protected Digital Output Example

    MCT-CM If the maximum number of digital outputs is set to zero, the Digital Outputs selection under the Offline\Setup\IO menu in the runtime application will be hidden, regardless of the number of digital outputs physically attached to the system. This provides the OEM with a means of protecting the outputs from accidental changes that may occur if the end user accesses them.

  • Page 53: Setting The Number Of Analog Outputs

    MCT application. It is intended for use on equipment that does not use a local MCT display, or that contains multiple MCT systems linked together and operated from a single computer and software interface such as Future Design Control’s EnVision software package.

  • Page 54: Loop Setup

    Design Control products and software is the sole responsibility of the OEM and/or end user. Future Design Control will not be held responsible for any damages or losses, whether direct, indirect, incidental, special or consequential, resulting from the use of Future Design Control products or software.

  • Page 55: Loop Settings

    MCT-CM 4.2.1 Loop Settings The Loop Settings screen is accessed by pressing the Setup button on the Loop Setup screen. The Loop Settings screen provides all settings related to the loop input configuration for the MCT. When all settings have been made, press the “Done”...

  • Page 56: Loop Options

    MCT-CM The Low Setpoint and High Setpoint fields are used to set the minimum and maximum allowable set points for the control loop. These settings allow the OEM to enter an absolute minimum and maximum range for the operation of the control loop regardless of the end user’s desired range. The set point “Limits” screen in the runtime application (see section 9.4 Limits) will be limited to the loop input low and high set point limits as set...

  • Page 57: Cascade Control Mode Settings

    MCT-CM The SP permissive is used to allow the user to change the set point at the loop control. However, if the loop is currently under automatic program operation through the MCT, any set point change made at the loop control by an operator will be overridden by the program generated set point in the MCT.
  • Page 58 MCT-CM The maximum oil temperature is limited to a safe operating range since it is now controlled directly. The product temperature control generates a set point of 0 to 400°C based on a 0 to 100% output. Thus, the oil temperature will not exceed 400°C.

  • Page 59: Monitor Setup

    MCT-CM Thus, if the source loop output range is 0 to 100%, at 0% output, the loop set point will be 40, at 50% output the set point for the loop will be 55 and at 100% output the loop set point will be 70.

  • Page 60: Monitor Point Settings

    MCT-CM The Source is a display only field that allows the user to view the current input source for the monitor point. In order to change the input source and access other settings for the monitor point, press the “Setup” button. This will provide access to the “Monitor Point Settings”...

  • Page 61: Important Settings For Using Loop Input 2 As Monitor Points

    MCT-CM The Low Scale and High Scale fields are shown for analog input types only. They are used to set the display range for the input in order to scale the 0(2)-10Vdc or 0(4)-20mA signal. The display value is then a linear representation of the input signal from the low to high scale value.

  • Page 62: Monitor Card Configuration

    MCT-CM 4.3.2 Monitor Card Configuration In order for the MCT to properly interface with the optional monitor input modules, the MCT must be given the proper configuration settings for the type of monitor input modules used. These settings are accessed by pressing the “Monitor Card Configuration”...

  • Page 63: Event Setup

    MCT-CM Connecting to the MCT Process Monitor Modules for more information on the proper DIP switch settings pertaining to the type of monitor card used. The card type drop-down menu is used to select the type of monitor module connected to the MCT. Available selections are Not Used, Analog, RTD and Thermocouple.

  • Page 64: Defrost Setup

    MCT-CM When the screen is first displayed, each event will be checked to determine which outputs are assigned. This process can be cancelled at any time as it can take upwards of 30 seconds if all 32 possible events are enabled.
  • Page 65 MCT-CM The Defrost Type selection is used to choose the defrost mode. Available selections are Disabled, Timed Defrost and Timed Process. When Timed Defrost is selected, defrost occurs on regular intervals based on the interval time entered on the defrost screen in the MCT runtime application. When Timed Process is selected, defrost also occurs on regular intervals based on the interval time entered on the defrost screen in the MCT runtime application;...

  • Page 66: Setting The Defrost Enable Outputs

    MCT-CM 4.5.1 Setting the Defrost Enable Outputs In order for defrost to operate, timed or timed process, an output must be selected as an enable for the defrost logic. When the output is on, the defrost interval timer will begin operation. Note that if timed process is selected, the enable loop/monitor point must also be below the enable setpoint.

  • Page 67: Redundancy Setup

    MCT-CM For example, if digital output 2 is used as the control output for the system fans when a system event is turned on, then select digital output 2 from the list. This will turn off the fans during defrost and precool whenever the defrost cycle is active.

  • Page 68: Setting The System 1/2 Alarm Inputs

    MCT-CM If defrost is disabled in the MCT configuration and redundancy is enabled, you must select ‘After NOTE: Defrost’ in order to activate equal run time switching. Alternating time settings will not be activated in the MCT runtime application unless it is selected.

  • Page 69: Functions

    MCT-CM For example, if digital output 1 is used as a control output to turn on a circulating fan that are common to both system 1 and system 2 when a system event is turned on, then select digital output 1 from the list. This will enable the redundancy logic whenever the circulating fans are on.
  • Page 70 MCT-CM MCT Function Runtime Menu Location Description Loop View View\Loop View loop PV, %Out, set loop manual output mode and loop set point NOTE: Without access to the loop view screen, the user will be unable to set loop in manual mode and adjust its output.
  • Page 71 MCT-CM MCT Function Runtime Menu Location Description Automatic Program Jump Program\Entry ability to view/program jump steps in an automatic Entry program NOTE: If a program is loaded that has jump steps programmed, the operator will be unable to view or change the jump step settings.
  • Page 72 MCT-CM MCT Function Runtime Menu Location Description Alarm Settings Device\Settings\Set\Alarm access loop/monitor alarm settings NOTE: Alarms can be configured in the runtime and then the menu removed by disabling this function. The alarms will operate as configured in the background removing all access by the operator.

  • Page 73: Startup View

    MCT-CM MCT Function Runtime Menu Location Description Digital Output Setup Device\Settings\Offline\Hardware\ access digital output settings Digital Output NOTE: Once digital outputs are set in the runtime application, this menu item can be disabled and hidden from the operator so that OEM configuration is preserved and cannot be accessed or altered.

  • Page 74: Digital Input Names

    MCT-CM 4.9.1 Digital Input Names The Digital Input Names screen is accessed from the “Tagnames” menu and allows the OEM to edit the names of the digital inputs. These names will be displayed in the runtime application under the Digital IO Monitor screens and used as the alarm description on the Alarm Monitor screen if the input is configured as an alarm input.

  • Page 75: Custom Name\Address

    MCT-CM 4.10 Custom Name\Address The Custom Name\Address screen is accessed from the Tagnames menu and is typically used by the OEM to configure the main splash screen when the MCT runtime application starts. It allows the company name and contact information to be entered and shown each time the MCT controller is powered up. It also allows the name of the controller to be changed in order to adapt it to a specific product or market.

  • Page 76: Basic Operation

    MCT-CM 5 Basic Operation This section is designed to help guide the user through the MCT touch screen interface and menu structure in order to navigate through the various operation, monitor and setup screens and gain an understanding of how to use them.

  • Page 77: Touch Screen Interface

    MCT-CM 5.2 Touch Screen Interface The MCT display is split into two sections; the icon bar and main display area. Icon Bar Main Display Loop View Screen The menu icon will open the main menu for navigating to the different control and monitoring screens.

  • Page 78: Menu Navigation

    MCT-CM 5.3 Menu Navigation The MCT provides the user with the ability to select text-based menu navigation, much like the typical file menu system of a PC, as well as an icon-based navigation system like that of a “smart” device. The user can switch back and forth between the two from the Setup menu.

  • Page 79: Home Menu

    MCT-CM 5.3.1 Home Menu The home menu is the top level, default menu provided when the MCT first powers on. Pressing the menu (monitor) icon will display the main menu offering the selections shown below. 5.3.1.1 Text Based Home Menu The View menu provides navigation to all standard view screens.

  • Page 80: Icon/Slide Page Based Home Menu

    MCT-CM 5.3.1.2 Icon/Slide Page Based Home Menu Slide page 1 provides navigation to all standard view screens. These include the Loop, Overview, Chart, Digital I/O monitor, Alarms monitor, and Alarm File. It also provides quick access to the MCT Settings and Data file functions...

  • Page 81: Device Settings Menu

    MCT-CM 5.3.2 Device Settings Menu The device settings menu is provided when the user selects “Settings” from the main “Device” menu. See section 9 Device Settings for detailed information on these settings and their use. 5.3.2.1 Text Based System Setup Menu The View menu provides navigation to the Defrost and Redundancy operation/setup screens as well as the loop Tuning screen.

  • Page 82: Icon/Slide Page Based Device Settings Menu

    MCT-CM 5.3.2.2 Icon/Slide Page Based Device Settings Menu Slide page 1 provides access to the primary MCT setup screens. These include options for Navigation type, control loop setpoint Limits, Alarm setup, Event tagname entry, power Recovery, Defrost operation/setup and email server settings and messaging.

  • Page 83: Offline Menu

    MCT-CM 5.3.3 Offline Menu The offline menu is provided when the user selects “Offline” from the device settings “Offline” menu. See section 10 Offline for information on these settings and their use. NOTE: Offline settings can only be accessed when an automatic ramp/soak program is not running and data logging is turned off.

  • Page 84: Icon/Slide Page Based Offline Menu

    MCT-CM 5.3.3.2 Icon/Slide Page Based Offline Menu Slide page 1 provides navigation back device settings menu, temperature units selection, Clock, Service items and Options, touch screen calibration and language settings. It also provides access to the About and Exit application screens.

  • Page 85: Data Menu

    MCT-CM 5.3.4 Data Menu The data log menu is provided when the user selects “Data” from the main “Data” menu. See section 8 Data Logging for information on these settings and their use. 5.3.4.1 Text Based Data Logging Menu The View menu provides access to the data file Annotation and digital Signature screens.

  • Page 86: Icon/Slide Page Based Log Menu

    MCT-CM 5.3.4.2 Icon/Slide Page Based Log Menu Slide page 1 provides access to the main Data log screen and to the log point Assignment screen where the user can select which items are to be logged. Historical data file functions...

  • Page 87: Notifications

    MCT-CM 5.4 Notifications The notification window is a feature that can be accessed by pressing the date/time field in the icon bar. This window provides a snapshot of current MCT activity. The notification window can be closed by pressing the date/time field again, or is automatically closed if the Menu, Home or a navigation arrow icon is pressed.

  • Page 88: Control Loops (Single Set Point Operation)

    MCT-CM 5.5 Control Loops (Single Set point Operation) The loop view screens provide direct viewing options for the control and monitoring of the MCT control loops and process monitor inputs. The loop screens allow the user to adjust the current loop set points (SP) and view the process variables (PV) and percentages of output (%) for each loop.

  • Page 89: Historical Minimum And Maximum

    MCT-CM The loop name and loop units, shown at the bottom of each loop (or monitor point), will display the tagname and units as entered in the Configurator. 5.5.1.1 Historical Minimum and Maximum The MCT monitors and stores the minimum and maximum process value reached during operation for each loop and monitor in the system.

  • Page 90: Program Operation

    MCT-CM 5.5.1.3 Program Operation The Program Operation button displays a “slide out” window with all automated program operations included. Press the desired icon for quick access to any program operation. The “Select” icon can be used to select any program stored for quick run operations.

  • Page 91: Alarm Set Points

    MCT-CM The Overview screen contains two scrolling lists. The list on the left contains all loop and monitor information. To change the set point of a loop, touch the row of the desired loop. The numeric keypad will then be shown allowing a new set point to be entered.

  • Page 92: Process Monitoring

    MCT-CM 5.6 Process Monitoring The Loop and Overview screens provide the current process values of the MCT. In order to view the process inputs over time, the MCT provides real-time charts. Eight user configurable trends are provided with up to eight plot points per trend.
  • Page 93 MCT-CM them. Select the left or right vertical axis for each item by selecting the item in the list and press the button for the desired “Left” or “Right” axis. The left axis is the default axis selection. If none of the channels are assigned to the right axis, the axis will not be shown on the chart.

  • Page 94: Digital Io Monitor

    MCT-CM 5.6.2 Digital IO Monitor The Digital IO monitor screen is accessed from the home “View”’ menu. It provides simple, at a glance status monitoring of all digital inputs and outputs configured on the MCT control module. To view input status, press the Input button.

  • Page 95: Alarm File

    MCT-CM 5.7.2 Alarm File The Alarm File screen is accessed from the home “View” menu. It displays all alarms for any given day. The MCT can store daily alarm files for a period of a year or longer (time based on storage usage for data history).

  • Page 96: Automatic Ramp/Soak Program Operation

    MCT-CM 6 Automatic Ramp/Soak Program Operation A ramp/soak program is a set of instructions (set points and events) programmed as a timed sequence of steps. When a program is run, the MCT executes each step of the program automatically, in sequence, based on the time duration and settings for each step.

  • Page 97: Entering A Ramp/Soak Program

    MCT-CM The pop-up “Edit” icon menu provides the following functions: Copy Copies all current step data including events. Paste Pastes all previously copied step data to the current step. Clone Copies and pastes current step events only to all following steps.

  • Page 98: Entering Step Time And Set Points

    MCT-CM 6.1.1 Entering Step Time and Set Points The length of the step, loop set points and jump steps are entered by touching the corresponding row for the desired entry in the list on the left side of the program entry screen. For example, to enter the time for the step, press the first row in the step data list view that contains the time entry.

  • Page 99: Setting Step And Soak Events

    MCT-CM 6.1.2 Setting Step and Soak Events The Event selections are used to select which system events (and corresponding digital outputs) are to be on during the step. To edit step events, press the “Event”’ button on the program Entry screen. This will display the list of all events configured in the system.

  • Page 100: Setting Wait Conditions

    MCT-CM NOTE: Guaranteed soak is typically not used during set point ramping steps as the ramp rate will be affected if any process variable deviates from its soak band because the program will be placed into hold. When the program is in hold, the step length will be extended and all set points will no longer ramp at the desired rate.

  • Page 101: Delta Control Setting

    MCT-CM NOTE: The set point entry is critical in order for the step to operate correctly when Edge is selected as the wait type. During the wait state, each selected loop and/or monitor input must arrive at or cross the wait set point in order for the program to resume operation.
  • Page 102 MCT-CM NOTE: Delta control is only active during the wait condition of the step. Once the wait conditions have been met, delta control will be terminated. The loop(s) selected for delta control will then use the set point programmed in the step. Therefore, you must make sure you program the loop set point(s) of the step properly to maintain proper control of the process once the wait condition is met and delta control is no longer active.

  • Page 103: Setting Jump Steps

    MCT-CM Step 2 Loop 1 set point = 400 Time = 1 hour This step is the soak step at 400 degrees for one hour since the set point is the same as the previous step 1. No wait or delta is programmed on this step.

  • Page 104: Setting Program Auto Start

    MCT-CM Cycle Count: Sets the number of jumps that will be made from the step. Once all jumps have been made, the program will continue on to the next step in sequential order. Jumps are disabled on the step when the cycle count is zero. MCT will ignore the jump step so it does not have to be set.

  • Page 105: Setting Guaranteed Soak Limits

    MCT-CM NOTE: The time is entered in a 24-hour format. To convert time from a 12-hour format (AM/PM) into 24-hour format, add 12 to the hours for PM time. For example, 2pm will be a value of 14 (2 + 12) for hours.
  • Page 106 MCT-CM The program operation allows an operator to run, hold, stop, edit and select automatic programs. The Program Operation window will display the program loaded in the MCT which is ready for operation by pressing the Run, Hold Stop or Off buttons. If a program is already loaded, the user can start the program without entering a start step.

  • Page 107: Hold/Resume Ramp/Soak Program Operation

    MCT-CM 6.2.1 Hold/Resume Ramp/Soak Program Operation At any time during the operation of a program, it can be manually placed into hold. This stops the program timer; however, MCT continues operation under the current step settings at the time the program was put into hold.

  • Page 108: Monitoring Automated Ramp/Soak Program Operation

    MCT-CM 6.3 Monitoring Automated Ramp/Soak Program Operation The program Status view provides all information regarding the operation of the current program. Status indicates the current operating mode of the program, i.e., active, hold, ramp, steady, waiting, etc. Start indicates the date and time at which the program was started.

  • Page 109: Common Questions About Ramp/Soak Program Operation

    MCT-CM 6.4 Common Questions About Ramp/Soak Program Operation 1. How do I start or run a ramp/soak program? To select and start a program, use the Program Operation window which can be accessed from the Loop, Overview or program Entry screens. All start, stop, hold, edit and program select operations are available from this window.

  • Page 110: Security

    MCT-CM 7 Security The MCT security model provides an administrator with the tools to add up to 30 users to the system. Each user must have a unique ID, full name and password. Four user levels are provided which include system, user, supervisor and administrator levels.

  • Page 111: Adding Users

    MCT-CM 7.1 Adding Users The “New” user tab provides the ability to add up to 30 users to the system. Select the type of user from the drop-down list (System, User, Supervisor or Administrator). Press each field to add the user ID, full name and password (no spaces allowed, 5 characters minimum and 16 characters maximum).

  • Page 112: Setting User Access

    MCT-CM 7.3 Setting User Access The “Access” tab provides the administrator the ability to assign rights to each user level (System, User, Supervisor and Administrator). To enable or disable specific program functions (user rights) for each user level, select the user right from the list and press the corresponding on/off button for the user level you want to change access rights for.
  • Page 113 MCT-CM User Right Menu Location Description Tuning Device/Settings/Tuning enable or disable loop control AT (auto tune) button and manual edit of loop tuning (PID) parameters Program Operate Program/Start, Hold, Halt, Off actions applies to all program control menu selections; does not...

  • Page 114: Setting Security Options

    MCT-CM User Right Menu Location Description Offset Calibration Device/Settings/Offline/Calibrate/Offset enter bias for monitor points Analog Inputs Device/Settings/Offline/Hardware/ configure Analog Input(s) to act as remote set points for Analog Inputs specific loop controls Analog Outputs Device/Settings/Offline/Hardware/ configuration of PV, SP or %out retransmission from...

  • Page 115: Audit Trail

    MCT-CM NOTE: When using password aging and the password expires for a user, the user will be required to change their password before access to the system is permitted. A user can change their password at any time (even if aging is not used) by selecting “Password” from the main security menu.

  • Page 116: Data Logging

    MCT-CM 8 Data Logging The MCT data logging features are accessed via the home “Data” menu item. The system data logging provides the ability to select individual points for logging, view data log files and start/stop logging operations. The logging ability of MCT provides an easy-to-use, convenient method to obtain electronic data without the need for additional data acquisition equipment.

  • Page 117: Selecting Points For Logging

    MCT-CM 8.1 Selecting Points for Logging In order for the data logging function of the MCT to operate, the user must first select what variables are to be logged to the data file. To choose which points are to be logged, select “Assign” from the Data menu.
  • Page 118 MCT-CM If more than one MCT utilizes the same entries, the data from all units with the same ID’s will be combined under the one ID in the database. This will render the data unusable as there will be no way to split the data between the different units and know which data points are from each unit.

  • Page 119: Calculating Log File Size

    MCT-CM 8.2.1 Calculating Log File Size The MCT saves the log file in a text-based format (.csv), so the amount of memory consumed for each reading is dependent upon the number of digits required to accurately display the value (1 byte per character). This optimizes memory usage but also makes calculating an exact file size difficult.

  • Page 120: Plotting Historical Data

    MCT-CM Any point from the data file can be selected along with the vertical axis to be used for each channel to be plotted. Select channels from the list by turning them on or off and use the “Left” and “Right” axis buttons to assign the selected item to the left or right axis for the plot range.
  • Page 121 MCT-CM Pressing the “Legend” button will provide the user with channel information by displaying the names of the selected plot channels, which axis they are associated with and the color used to display the plot channel. Pressing the button again will toggle the display back to the historical chart.

  • Page 122: Usb File Transfer

    MCT-CM 8.4 USB File Transfer The “Utilities” section of the MCT interface provides all the functionality required for retrieving files and maintaining the internal SD memory card. The internal SD card should not be removed from the MCT interface. Any change to SD directory structure (moving or deleting files with a PC) may cause the MCT interface to stop operating and a new SD card will need to be ordered.

  • Page 123: Recommended File Maintenance

    NOTE: The USB memory stick must be inserted into the USB port for any of the file utility operations to function. It is recommended to only use memory sticks certified by Future Design Controls for use with the MCT. Future Design Controls has tested and validated these memory devices for proper operation and performance.

  • Page 124: Ftp/Fileweb/Dataweb Interface

    MCT-CM If a file name is specified or logging on Program operation is enabled, each file will begin with the same prefix. Thus, multiple files can begin with the same 8 characters this limiting the maximum number of files that can be stored.
  • Page 125 MCT-CM The Type drop down is used to select the FTP/WAN interface. Choices are FTP, FileWeb and DataWeb. The IP Add field is used to enter the IP address of the FTP/FileWeb/DataWeb site that MCT is to interface with. The User field allows you to enter a user name for site access.

  • Page 126: More About Ftp, Fileweb And Dataweb Interfaces

    MCT-CM 8.5.1 More About FTP, FileWeb and DataWeb Interfaces FTP servers (File Transfer Protocol) have been around for many years and can be installed on local or network machines. The FTP server allows a client (MCT) to transfer files to the FTP server once installed. This allows for manual and automatic backup of data from the MCT.
  • Page 127 MCT’s that connect to the same server database. (see section 8.2 Starting/Stopping Data Logging) NOTE: An IT professional with experience is required for DataWeb server setup. Future Design Controls does not support server-side programming or setup but can offer 3 party resources to assist with or handle complete server-side projects.

  • Page 128: Fileweb/Dataweb Server Components And Requirements

    8.6 FDCUtil.com Web site for FTP, FileWeb and DataWeb Testing The FDCUtil web site is a Future Design Controls http/https site that allows customers to create a free account and test the FTP, FileWeb and DataWeb interfaces offered on the MCT. The site automatically deletes files every hour since this is a test site only and cannot be used for permanent web storage of files or data.
  • Page 129 MCT-CM Once you have created and verified your account, you can log in to the website. Once logged in, the main FDCUtil website will be displayed with tabs for Data (DataWeb), Files (FileWeb), FTP Files (FTP) and Configurations. These tabs can be clicked on and will display data after transfer from the MCT device. Every hour, the data will be deleted from each section (except for Configurations) or the data can be manually deleted using the “Delete”...
  • Page 130 To setup the MCT for use with the FDCutil.com FTP server, go to the FTP/WAN screen on the MCT and contact Future Design Controls technical support for FTP access. The FTP section of FDCutil.com is used for tech support (pass/fail) testing only when validation if required at a customer site (customer site not working for some reason).
  • Page 131 MCT-CM Data Files Page (FileWeb): The data files page, accessible from the “Files” menu item, lists the files in the customer’s data directory. These are only the files in the customer’s directory, not all uploads. The user can delete the files from this page.
  • Page 132 MCT-CM Database Data Page (DataWeb): Once logged in, the customer will be shown the Data page. If data has been uploaded to the database, the “Device ID” drop-down menu will contain the list of units (according to the ID#1 and/or ID#2 entries as made on the Data logging screen).
  • Page 133 MCT-CM The available data can also be viewed in graph format. Hover the mouse over the Data tab and selections for Trend and Table will be provided. Once Trend is selected, choose the desired unit from the Device ID menu. Place a check next to each available point you want to plot and click the Update Chart button.

  • Page 134: Annotation

    MCT-CM DataWeb sample setup using FDCutil.com: To setup the MCT for use with the FDCutil.com DataWeb server, go to the FTP/WAN screen on the MCT and enter the following data into the screen fields. Make sure to replace the “custName” and “custPassword” text below with the actual user name/password entered during the FDCutil.com signup process.

  • Page 135: Add\View Digital Signatures

    MCT-CM To add an annotation to the running log file, touch the “Entry” field at the bottom of the screen and enter the message (up to 16 characters maximum). Press the “Add” button and the message will be added to the current log file.

  • Page 136: Device Settings

    MCT-CM 9 Device Settings This section covers the use of extended controller features that enhance the functionality of the system. To gain access to the MCT setup options, select “Settings” from the home Device menu. To assist in setup and documentation of the MCT, see the “MCT Configuration and Worksheets” Excel file provided on the Future Design Controls website (http://www.futuredesigncontrols.com/MCT.htm).

  • Page 137: Defrost

    MCT-CM 9.1 Defrost The MCT defrost function was designed for use with refrigeration or other types of cooling systems that may accumulate ice on cooling surfaces such as finned coils, and provide a means of pausing operation at preset intervals in order to remove the build-up of ice to restore efficient operation.

  • Page 138: Defrost Description Of Operation

    MCT-CM minutes in order to activate defrost. Setting the field to zero allows the user to disable defrost operation for testing purposes or to prevent it from operating if its use is not required. The Fan Delay field is used to adjust the fan delay. The time can be set from 0-999 seconds.
  • Page 139 MCT-CM The redundancy settings are accessed by selecting ‘Redundancy’ from the device settings ‘View’ menu. They allow the user to set the redundancy mode of operation, select the primary system and adjust the concurrent minimum runtime and/or alternating times. The user can also activate the product Load Timer which enables the alarm inhibit of the OEM configured redundancy alarm.
  • Page 140 MCT-CM Alarms). By activating the product load timer, the alarm will be reset and the alarm start delay will become active. Once the start delay expires, if the alarm condition is present, the alarm delay will become active and once expired, the redundancy alarm will be activated.

  • Page 141: Concurrent Redundancy Switching

    MCT-CM 9.2.1 Concurrent Redundancy Switching When redundancy is active (OEM configured enable output(s) on), any digital outputs configured for “Redundant System 1’ or ‘Redundant System 2’ that correspond with the selected primary system will be turned on. The opposing system then becomes the ‘backup’ system by default.

  • Page 142: After Defrost Switching

    MCT-CM 9.2.3.2 After Defrost Switching After defrost operation provides equal run time switching based on the user defined alternating switch interval. When OEM configured for ‘After Defrost’ and no redundancy alarm condition exists, a defrost cycle will be forced at each system switch time when ‘timed defrost’ is configured. If defrost is configured for timed process, a defrost cycle will be forced at system switch only if required based on the condition of the loop or monitor point configured.

  • Page 143: Alarms

    MCT-CM 9.3 Alarms The Alarm screen provides access to the MCT alarm module which contains up to 30 user configurable alarms. These alarms can be assigned to any loop or monitor input in the system. After any and all changes made to any of the following alarm settings, you MUST press the ‘Save’...

  • Page 144: Set Points And Alarm Message

    MCT-CM Latch: When latching is enabled, the alarm will remain active even after the alarm condition has passed until acknowledged by the user. Latched alarms are acknowledged by the user when pressing the ‘Reset’ button on the Alarm screen or by activating a digital input configured for ‘Remote Alarm Reset’.
  • Page 145 MCT-CM NOTE: The low and high alarm set point fields are shown for Absolute, Deviation & %Out alarm types. Although both set point fields are shown, only the high SP is used for ‘high’ alarms, low for all ‘low’ alarms and both fields are used for Absolute, Deviation & %Out ‘both’ alarm types.

  • Page 146: Output Defeat

    MCT-CM its normal operating mode. The process will operate indefinitely in an alarm condition unless an operator notices it, because the alarm will not activate since it never entered the normal range. By setting the start delay, the alarm inhibit will be disabled once this time period is exceeded from the start-up of the system.

  • Page 147: Event Names

    MCT-CM Enter the desired set point limits by touching the “Lower Limit” and “Upper Limit” entry fields and enter the desired values using the numeric keypad. IMPORTANT: The minimum and maximum values for the set point limits are defined by the OEM or equipment installer limits set in the MCT configuration.

  • Page 148: Recovery

    MCT-CM The Number of Loops to View field allows the user to set the number of loops that are to appear on the main Loop view screen. The range is from one to five loops. If less than a total of five loops and monitor points is configured for the system, the maximum value will be equal to the total loops and monitor points.

  • Page 149: Communication Settings

    MCT-CM Select Off to have the MCT default to the off state on power-up. If a program was running when power was lost, the program will be stopped. In addition, all system events will be turned off. Note that loop controls will maintain the last set point value prior to power loss with loop control outputs active (ON).

  • Page 150: Ethernet Settings

    MCT-CM IMPORTANT: When multiple MCT controllers are connected to a single router (DHCP server), it is imperative that each MCT have a different VNC address. If multiple MCT controllers have the same VNC address, network errors may result causing the VNC server to shut down or cause the MCT to “lock-up”...

  • Page 151: Barcode Scanner

    MCT-CM entry fields will be disabled, but will display current connection information used by the MCT. In order to enter a static address, press the button to turn it off. To set the static network address, enter a valid IP Address, Subnet Mask and Default Gateway. The DNS Servers are not required, but typically the IP address of the network router is entered to provide one.

  • Page 152: Barcode Reader Communication Settings

    9.9.1.1 Setting up the Unitech MS-120-2 Barcode Scanner The following instructions are provided for the Future Design Controls recommended Unitech MS-120-2 barcode scanner. These instructions do not apply to other makes or models of scanner. Consult the manufacturer’s manual for other makes or models for information on how to set the proper communications settings.

  • Page 153: Important Notes On Barcode Reader Use

    MCT-CM Step 2 scan barcode D1 for terminator at top of page 14 and then scan the barcode for the number 3 on page 13 Step 3 scan barcode PP for preamble at bottom of page 14 and then scan the barcode for STX at top of page...

  • Page 154: Email Address Entry

    MCT-CM 9.10.1 Email Address Entry Select the “New” tab to add new email addresses to the system. For each entry, enter the recipient’s Name, Email Address and/or SMS Number (up to 50 characters each). Turn on the Email Alarm and/or SMS Alarm options to specify which addresses the alarm messages are to be sent to.
  • Page 155 MCT-CM The Login field is used to enter the login name required by the MCT to log in to your company’s mail server. You can use your login if one is not set up specifically for the MCT on your network. Contact your network administrator for assistance.

  • Page 156: Email Message

    MCT-CM 9.10.4 Email Message The MCT provides the user with the ability to send short email messages to users configured in the MCT email server. To send a message, select “Message” from the device settings, Email menu. Press the “Compose” button to create a brief message using the keypad (up to 100 characters). When you are finished entering the message, press the “Done”...

  • Page 157: Heat/Cool (Bimodal) Control

    MCT-CM Pressing the Set button allows the user to adjust the loop set point without having to leave the tuning screen in order to observe the control response. Pressing the AT button allows the user to activate/deactivate the loop auto tuning feature. When auto tune is active, the indicator on the button will be illuminated.

  • Page 158: Offline

    MCT-CM 10 Offline The Offline settings do not include the OEM setup of the MCT. Refer to the documentation provided by your OEM regarding the MCT configuration. In order to enter offline setup, automated ramp/soak program operation and data logging must be manually stopped.

  • Page 159: Service

    MCT-CM 10.1 Service The service counters provide service interval alerts and life total service numbers for each of the digital outputs available on the MCT control module. The service intervals (counter set points) are adjustable and can be set to match service intervals for equipment operated by the MCT.

  • Page 160: Service Options

    MCT-CM 10.1.1 Service Options The service display options as well as alert action can be adjusted from the Options screen. The count and hours selection buttons are used to choose what information will be shown for the digital outputs on the Service screen.

  • Page 161: Degrees C/F Units Selection

    MCT-CM 10.2 Degrees C/F Units Selection The MCT can display temperatures in either degrees Centigrade or Fahrenheit. To change the temperature display units, select “Units” from the offline Set menu. Press the button for the desired temperature units to make the selection. The choices are mutually exclusive so when one selection is made, the other will be de-selected.

  • Page 162: Time Options

    MCT-CM 10.3.1 Time Options Select the “Time Options” tab to configure the time zone and national time server clock settings. If the MCT is connected to the internet, these settings can be used to have the MCT automatically synchronize its time with one of the nationally provided time servers.

  • Page 163: Language

    MCT-CM If your locale utilizes daylight savings time, set the start and stop dates for daylight savings and turn on the “Daylight Savings Enable” option. Press the “Save” button to store the settings. The MCT will then automatically update its clock for daylight savings time.

  • Page 164: Analog Inputs

    MCT-CM 10.5 Analog Inputs The MCT supports up to 14 analog inputs which are used for remote set point inputs. Each of the available analog inputs can be configured from the ‘Analog Input’ screen. The left and right navigation buttons at the upper right of the screen allow the user to scroll through each available input.

  • Page 165: Remote Set Point Operation

    MCT-CM 10.5.1 Remote Set Point Operation Once an input is configured for loop set point control, as the analog input signal is varied, it will provide a linear set point change from the minimum to maximum value over the range of the input (2-10Vdc for voltage input and 4-20mA for current selection).

  • Page 166: Retransmitting Loop Percentage Of Output

    MCT-CM Choose which loop value is to be retransmitted for the loop by pressing the appropriate function select button; PV, SP or %Out. If ‘None’ is selected, the output will remain in the off state, i.e., 0Vdc or 4mA depending upon the output type selection.

  • Page 167: Digital Inputs

    MCT-CM NOTE: The analog outputs always treat the ‘Out Min’ field as the 0Vdc or 4mA output value and the ‘Out Max’ field as the 10Vdc or 20mA output value. This allows any portion of a control loop’s output range to be retransmitted and represented as a range of 0% to 100% of output or 100% to 0% of output.
  • Page 168 MCT-CM * Alarm Input: When selected, the input will provide a visual alarm notification on alarm screen. Using the ‘Defeat’ selection, the input can be configured to disable specific digital outputs on the MCT control module. The alarm condition will be maintained as long as the input is activated.
  • Page 169 MCT-CM * Halt Setpoint Control: When selected, the input will disable set point communications from the MCT control module to all loop controls attached to the system. This allows for direct, manual adjustment of the loop set point(s) on the process controllers. The input acts as a manual override, but still allows the MCT to gather process data for proper display and data logging purposes.

  • Page 170: Digital Input Defeat

    MCT-CM IMPORTANT: Functions performed via the digital inputs such as starting or stopping a ramp/soak program are not logged to the audit trail. These are external inputs to the control module and are not protected by security. If a digital input is programmed for the “Halt Setpoint Control” function and the input is active, any set point change entered by an operator for a control loop will be logged to the audit trail;...
  • Page 171 MCT-CM The left and right navigation buttons at the upper right of the screen allow the user to scroll through each available output. To make changes to the output’s configuration, select the desired function of the output and set any necessary delay times. Once all changes have been made, press the ‘Save’ button to save them. If you do not press the “Save”...
  • Page 172 MCT-CM Event: When selected, the output is controlled directly from the corresponding event on the Events screen. When the event is selected, the output turns on. When the event is not selected, the output turns off. NOTE: Outputs can be assigned to specific events in the MCT configurator. If an output is assigned as a system event in the configurator, the output function will not be able to be changed.
  • Page 173 MCT-CM Alarms for information on assigning the alarm to the digital output. NOTE: If more than one loop/monitor alarm is assigned to the output, the output will not operate correctly and may cycle on and off uncontrollably. Do not assign more than one alarm to an output.

  • Page 174: Digital Input Monitor

    MCT-CM *NOTE: For the output control functions listed with an asterisk (*), the output is not activated for failed FTP or email transmissions, NTS clock synchronization or communication alarms between the MCT and the control module. 10.9 Digital Input Monitor The Monitor screen provides the on/off status of all digital inputs available on the MCT control module.

  • Page 175: Monitor Offset Calibration

    MCT-CM 10.11 Monitor Offset Calibration The monitor option provides up to 15 additional process inputs, which can be configured from any combination of thermocouple, analog and RTD inputs from the optional monitor input modules. The monitor input option can also be configured to display the second input from compatible loop controllers attached to the system (one from each available control loop).

  • Page 176: Calibrate Touch

    MCT-CM The Alarm Volume adjusts how loud the internal alarm buzzer of the MCT will be when activated under an alarm condition. The volume can be set from 0 (off) to 100. To edit the alarm volume, touch the entry field and enter the desired volume level.

  • Page 177: Backlight Settings

    MCT-CM Once complete, the calibration utility will provide a notification message that the new calibration settings have been measured and to touch the screen to register the new calibration data; just touch anywhere on the screen to close the window and return to the MCT application to resume normal operation.

  • Page 178: Configuration

    MCT-CM The brightness of the display during operation is set by adjusting the “Run” slider. The default setting is 100. The “User Idle” slider is used to adjust the brightness of the display during periods of inactivity. The default setting is 5. Use caution when adjusting the “Run” slider. It is possible to set the brightness to zero (0), in which case the screen will go black and you will be no longer able to see the settings.
  • Page 179 MCT-CM IMPORTANT: Do not import configuration files that are not intended for use with the current hardware configuration of the MCT as unexpected operation may result. By default, the import/export procedure is set to operate via USB. To perform import/export operations from a remote server, use the drop-down menu to select “Cloud”.
  • Page 180 MCT-CM NOTE: The configuration functions do not affect the VNC server configuration. The enable state, VNC address, device name and password fields must be manually changed as these settings are specific to each device and must be set independently for proper VNC server operation over a network.

  • Page 181: Cloud Server Settings

    MCT-CM 10.13.1 Cloud Server Settings The “Cloud” screen provides settings for the remote configuration FileWeb server. The screen is accessed by pressing the “Set” button on the Configuration screen. Note that the “Set” button is only shown when “Cloud” is selected for the import/export configuration location.

  • Page 182: Importing An Oem Default Configuration

    MCT-CM NOTE: Make sure proper permissions are set at the server for access/creation of directories and read/write access. Also check root directory structure at the server to identify the actual root that was created for the files since there can be additional layers created by the server field and displayed in the path (see Appendix section A.2 FTP, FileWeb, DataWeb Requirements/Installation for additional information).

  • Page 183: About Mct

    MCT-CM 10.14 About MCT The “About” MCT screen provides operating system version numbers for the currently installed firmware and program of both the MCT HMI and control module. This information should be recorded prior to any service request so that proper assistance can be provided for your control model.

  • Page 184: Communications

    MCT-CM 11 Communications This section provides instructions on how to use the MCT communication interfaces. As a standard, the MCT is equipped with both an Ethernet interface and an RS232 serial interface for user communications. 11.1 Ethernet Communications The MCT provides several options for remote control and monitoring over the Ethernet communications interface.

  • Page 185: The Mct And Network Security

    MCT-CM The most commonly overlooked source of problems is cabling. Not all cables are created equal. Electrical noise generated by factory equipment or other electrical equipment in the area, could easily corrupt transmitted data over the network and cause devices to “lock up” or shut down the VNC server, both of which then require the MCT to be shut down and restarted to clear the problem.

  • Page 186: Using The Web Server

    NOTE: Contact your network administrator prior to enabling the web server of the MCT. Company policy may prohibit the use of web servers for security reasons. Future Design Controls is not responsible for the use of, nor makes any claims as to the security of the web server interface over your network. The use of the web server is the responsibility of the end user.
  • Page 187 MCT-CM...

  • Page 188: Using The Vnc Server

    VNC server to stop responding and/or shut down requiring power to be cycled to the MCT in order to reboot the system and restart the server. Future Design Controls has tested and recommends the use of RealVNC’s viewer. It has been tested for compatibility with the MCT and a free version can be obtained from http://www.realvnc.com/...
  • Page 189 MCT-CM On the Display tab, make sure the scaling is set to “No scaling” and the checkbox for “Adapt to network speed (recommended)” is checked. Next, select the Inputs tab and deselect all entries except for “Enable mouse input” and “Rate-limit mouse move events”.

  • Page 190: Recommended Vnc Viewer Settings For Tablets

    “automatically detect” or “server decides”. If the client is still unable to connect, try default encoding of Hextile and set the color option to limited colors such as 256-bit color. Future Design Controls does not write or create VNC clients (3rd party software), so final selection of client and testing is the end user responsibility.

  • Page 191: Accessing The Mct Through A Vnc Viewer

    MCT-CM 11.1.3.3 Accessing the MCT through a VNC Viewer The following examples are based on the use of the RealVNC viewer for PC/MAC. Once the default settings have been entered, just enter the IP address and port number for the MCT and click the “Connect” button to access the MCT over the network.
  • Page 192 MCT-CM Once the connection is established, the current MCT display will be shown on your desktop. The image will be a duplicate of what is on the MCT. As you manipulate the screen, the display of the MCT will also be manipulated so that any local operator will be able to see what is happening and vice versa.

  • Page 193: Using Modbus Tcp/Ip Communications

    MCT-CM 11.1.4 Using Modbus TCP/IP Communications The MCT Modbus TCP server interface allows a user to remotely monitor and control the MCT via another device or software application compatible with Modbus TCP/IP protocol. The acronym TCP stands for Transmission Control Protocol while IP stands for Internet Protocol. These protocols are used together and handle the transfer of data over the internet.

  • Page 194: Serial Communications Option

    MCT-CM 11.2 Serial Communications Option The MCT serial interface uses Modbus RTU protocol. Any device used to communicate with the MCT over the serial interface must use this protocol. The MCT communication address and parity can be set on the communications screen.

  • Page 195: Alarm Codes And Troubleshooting

    MCT-CM 12 Alarm Codes and Troubleshooting This section provides explanations of standard MCT alarms to help in diagnosing and resolving the alarm conditions. Note that the information provided here covers standard alarms only, and not alarms configured by the OEM. If you are unable to diagnose a problem through the use of this guide, contact your OEM for further assistance.
  • Page 196 MCT-CM Alarm Monitor Description Explanation/Corrective Action Memory Error Please check SD card. Indicates that the SD card cannot be accessed when checking available memory space. Verify that an SD card is properly inserted into the MCT display. Replace SD card.

  • Page 197: Appendix

    MCT-CM Appendix A.1 Modbus Communications The MCT utilizes Modbus as its standard protocol and offers both Modbus RTU serial and Modbus TCP forms. This section provides information on the supported functions and data available over the Modbus interface. It is assumed that the user is already familiar with Modbus protocol and has a basic understanding of its implementation and use.

  • Page 198: Mct Data Registers

    MCT-CM A.1.2 MCT Data Registers Some of the values contained in the MCT register base contain bit-oriented values. This means that each bit of the word indicates an on/off status for a specific setting or condition. In handling these values, it is recommended that the word be converted to its binary equivalent.

  • Page 199: Control Registers

    MCT-CM A.1.2.1 Control Registers Range Data *A Modbus Register Parameter Description Address Number Type High Unit 400001 (0x0000) System Mode Control RESERVED – DO NOT WRITE 400002 (0x0001) 400003 (0x0002) Power Out Recovery Mode 400004 (0x0003) Recovery Power Out Time...
  • Page 200 MCT-CM Range Data *A Modbus Register Parameter Description Address Number Type High Unit 400038 (0x0025) Program Loop 1 Target Setpoint -32768 32767 400039 (0x0026) Program Loop 2 Target Setpoint -32768 32767 400040 (0x0027) Program Loop 3 Target Setpoint -32768 32767...
  • Page 201 MCT-CM Range Data *A Modbus Register Parameter Description Address Number Type High Unit 400076 (0x004B) Loop 6 Process Variable (PV) -32768 32767 400077 (0x004C) Loop 6 Setpoint (SP) -32768 32767 400078 (0x004D) Loop 6 Percent Output (%Out) -100.00 100.00 400079...
  • Page 202 MCT-CM Range Data *A Modbus Register Parameter Description Address Number Type High Unit 400114 (0x0071) Monitor 9 Process Variable -32768 32767 400115 (0x0072) Monitor 10 Process Variable -32768 32767 400116 (0x0073) Monitor 11 Process Variable -32768 32767 400117 (0x0074) Monitor 12 Process Variable...
  • Page 203 MCT-CM Range Data *A Modbus Register Parameter Description Address Number Type High Unit RESERVED – DO NOT WRITE 400152 (0x0097) RESERVED – DO NOT WRITE 400153 (0x0098) RESERVED – DO NOT WRITE 400154 (0x0099) RESERVED – DO NOT WRITE 400155 (0x009A) RESERVED –...
  • Page 204 MCT-CM Reading bit-oriented parameters The value contained in these parameters is dependent upon the combination of “on” bits (1). Therefore, only the individual status of each bit has meaning, not the value of the parameter. Setting bit-oriented parameters The value that must be written to these parameters is dependent upon the combination of “on” bits. Therefore, it is necessary to know the current value of the parameter before setting it so that only the bit status you want to update is changed.
  • Page 205 MCT-CM Parameter Note: Manual operation may not be available on certain loop controls Description Value depending upon their configuration. If manual operation is not available, the bit for the loop will automatically turn off after being set. Bit0 Loop 1 in Manual...
  • Page 206 MCT-CM Parameter Description Note: Not all system events may be available on your system. Event Value names and functions are defined by system configuration. Consult your Bit0 System Event 1 system documentation or contact your OEM for information on event use.
  • Page 207 MCT-CM Parameter Description **These values are set by the MCT to indicate the operating status of the Value profile and cannot be set directly. Program Not Running Stop Program Stop Program (All Off) Hold Program Run/Resume Program Program in Autostart**...
  • Page 208 MCT-CM *B12 Parameter **The days of the week are represented as numbers: Range Low Range High Description Value 0=Sun, 1=Mon, 2=Tue, 3=Wed, 4=Thu, 5=Fri, 6=Sat High Byte Low Byte Day of Week** *B13 Parameter Range Low Range High Description Value...
  • Page 209 MCT-CM *B16 Parameter Description Note: Each bit in the word can represent a wait for condition for more Value than one input, i.e., Bit0 can be on to indicate it is waiting for loop 1, Bit0 Loop/Monitor/Digital Input 1 monitor input 1 or digital input 1.
  • Page 210 MCT-CM *B18 Parameter Description Value Bit0 Loop 1 Communications Fault Bit1 Loop 2 Communications Fault Bit2 Loop 3 Communications Fault Bit3 Loop 4 Communications Fault Bit4 Loop 5 Communications Fault Bit5 Loop 6 Communications Fault Bit6 Loop 7 Communications Fault...
  • Page 211 MCT-CM *B20 Parameter Description Value Bit0 Monitor 1 Sensor Break Bit1 Monitor 2 Sensor Break Bit2 Monitor 3 Sensor Break Bit3 Monitor 4 Sensor Break Bit4 Monitor 5 Sensor Break Bit5 Monitor 6 Sensor Break Bit6 Monitor 7 Sensor Break...
  • Page 212 MCT-CM *B22 Parameter Description Value Bit0 Loop/Monitor Alarm 17 Bit1 Loop/Monitor Alarm 18 Bit2 Loop/Monitor Alarm 19 Bit3 Loop/Monitor Alarm 20 Bit4 Loop/Monitor Alarm 21 Bit5 Loop/Monitor Alarm 22 Bit6 Loop/Monitor Alarm 23 Bit7 Loop/Monitor Alarm 24 Bit8 Loop/Monitor Alarm 25...
  • Page 213 MCT-CM *B24 Parameter Description Note: When setting manual mode (Bit0=on, Bit1=off), be sure to also set Value the current primary system (Bit4 or Bit5). To do this, read the register to Bit0 Redundancy in Manual get the current status first, set the lower two bits of the word to the desired mode, and then write the result back to the MCT.
  • Page 214 MCT-CM *B27 Parameter Description Value Bit0 Digital Input 8 On Bit1 Digital Input 9 On Bit2 Digital Input 10 On Bit3 Digital Input 11 On Bit4 Digital Input 12 On Bit5 Digital Input 13 On Bit6 Digital Input 14 On...

  • Page 215: Automatic Program Registers

    MCT-CM *B29 Parameter Description Value Bit0 Digital Output 16 On Bit1 Digital Output 17 On Bit2 Digital Output 18 On Bit3 Digital Output 19 On Bit4 Digital Output 20 On Bit5 Digital Output 21 On Bit6 Digital Output 22 On...
  • Page 216 MCT-CM The first 28 registers of the Program contain specific settings related to the program. These include auto start settings, the program name, the length of the program (number of steps), and guaranteed soak band settings. Range Data *D Modbus...
  • Page 217 MCT-CM The following 28 registers of the Program contain the data for step 1 of the Program. Range Data *D Modbus Register Number Parameter Description Address Type High Unit 402029 2028 (0x07EC) Step Time Hours 9999 402030 2029 (0x07ED) Step Time Minutes/Seconds...
  • Page 218 MCT-CM All remaining steps of the Program follow the same format and data structure as is represented for step one above. Up to the following 2744 registers are used to contain the additional step data of the Program as required for steps 2 through 99. Since few if any programs will contain the maximum of 99 steps, it is only necessary to write the step data for the number steps used in the Program.
  • Page 219 MCT-CM Parameter Range Low Range High Description Value High Byte Minutes Low Byte Seconds See note *B5 in section A.1.2.1 for information on the range of this parameters. See note *B6 in section A.1.2.1 for information on the range of this parameters.
  • Page 220 MCT-CM *E11 Parameter Description Value Bit0 Wait For Monitor 1 Bit1 Wait For Monitor 2 Bit2 Wait For Monitor 3 Bit3 Wait For Monitor 4 Bit4 Wait For Monitor 5 Bit5 Wait For Monitor 6 Bit6 Wait For Monitor 7...
  • Page 221 MCT-CM *E13 This parameter is split into upper and lower bytes. The high byte of the word is for setting the ‘wait for’ type while the lower byte contains the step number for jump step operation. High Byte (0x00XX) Parameter...

  • Page 222: Starting An Automatic Program

    MCT-CM A.1.2.3 Starting an Automatic Program Once a program has been downloaded to the MCT, two control parameters must be set in order to start the program. These are the program start step (14) and the program control (15) registers. The program start step register must first be set to the step number that the program is to start on.

  • Page 223: Ftp, Fileweb, Dataweb Requirements/Installation

    FDC Cloud “Server” Services A.2.4 Future Design Controls does not provide direct support or hosting services; however, third party support is available from our partner Mooseworks Software which can provide: 1. Complete site and installation without hosting charges (includes FDC site with custom banner, site setup, all code/data model definitions and manual).

  • Page 224: Touch Screen Interface Specifications

    MCT-CM A.3 Touch Screen Interface Specifications Technical Specifications HMI 4.3” HMI 7” (high performance) Description Size 4.3" 7" Resolution (W X H in pixels) 480 x 272 800 x 480 Display type TFT, Wide touch Screen Colors 65,536 Touch screen Type...
  • Page 225 MCT-CM Standards, Certificates and Approvals Description Details UL approval UL 508 and CSA C22.2 No.142 Low Voltage Directive 2006/95/EC EMC Directive 2004/108/EC Requirements for Emission EN 61000-6-4 :2007 Requirements for Interference Immunity EN 61000-6-2 :2005 Tick mark for Australia AS/NZS CISPR 11:2004...
  • Page 226 Cancer and Reproductive Harm: This warning is intended to address certain Prop 65 chemicals that may be found in Future Design Controls products. These products can expose you to chemicals including lead and lead compounds which are known to the State of California...

  • Page 227: Control Module Specifications

    MCT-CM A.4 Control Module Specifications Main CPU...
  • Page 228 MCT-CM...
  • Page 229 MCT-CM...
  • Page 230 MCT-CM...
  • Page 231 MCT-CM Analog I/O Card...
  • Page 232 MCT-CM...
  • Page 233 MCT-CM Digital Input Card...
  • Page 234 MCT-CM...
  • Page 235 MCT-CM Digital Output Card...
  • Page 236 MCT-CM...
  • Page 237 MCT-CM Dual Communications Card Barcode and Remote Display Communication Cartridges...

  • Page 238: Power Supply Specifications

    MCT-CM A.5 Power Supply Specifications...
  • Page 239 MCT-CM...

  • Page 240: Power-On Delay Relay Specifications

    MCT-CM A.6 Power-On Delay Relay Specifications [GE1A-C10HA110]...
  • Page 241 MCT-CM...

  • Page 242: Ordering Specifications

    MCT-CM A.7 Ordering Specifications The MCT-CM is ordered as three components, the color touch screen, firmware and the Control Module (CM) with its assorted options. The loop controls must be ordered separately. MCT-CM Sample Part Numbers (minimum of 3 component part numbers is required; (1) Display, (2) Firmware and (3) Control Module.)
  • Page 243 MCT-CM 1. Control Module (CM) Application Software 5. Optional Analog I/O (Note 3) (Note 2) (DIN Rail Mount – plug into CM) CM software for FDC C-Series R22 (note 1) 0: CM22: 0: None CM software for FDC 300 Series (note 1)
  • Page 244 USB Memory Stick UDF115-8GB 8GB High Capacity USB Memory Stick (3VDC) Replacement SD Memory Card SD-4CM* SD Memory Card (preloaded with MCT-CM i4.3 application software) SD-7CM* SD Memory Card (preloaded with MCT-CM i7 application software) *Specify: - Communication Module FC6A-SIF52 or US2000B...

  • Page 245: Support And Warranty Information

    In addition, installing Future Design Controls MCT software on hardware not obtained directly from Future Design Controls is a violation of the software license agreement. See the Future Design Controls Software License agreement on the following page. By installing and/or using...
  • Page 246 Design controls are not considered Future Design Controls products and cannot be used with Future Designs SOFTWARE. Using Future Design's SOFTWARE with any other manufacturer (or distributor) of hardware is a violation of this license and applicable copyright laws. The SOFTWARE is considered in "use" when it is installed into permanent or temporary memory (e.g.
  • Page 247 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 one year after delivery to the first purchaser for use.

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