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Future Design FDC-2500 User Manual

Self-tune fuzzy/pid process/temperature controller
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User's Manual
User's Manual
FDC-2500
FDC-2500
Self-Tune Fuzzy / PID
Self-Tune Fuzzy / PID
Process / Temperature Controller
Process / Temperature Controller
U M 2 5 0 0 1 C - A u g u s t - 2 0 2 4

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Summary of Contents for Future Design FDC-2500

  • Page 1 User's Manual User's Manual FDC-2500 FDC-2500 Self-Tune Fuzzy / PID Self-Tune Fuzzy / PID Process / Temperature Controller Process / Temperature Controller U M 2 5 0 0 1 C - A u g u s t - 2 0 2 4...

  • Page 2: Table Of Contents

    CONTENTS Page No Page No Chapter 1 Overview Chapter 1 Overview 1-1 Features ------------------------------------------------------------------------- 1-1 Features ------------------------------------------------------------------------- 1-2 Ordering Code ---------------------------------------------------------------- 1-2 Ordering Code ---------------------------------------------------------------- 1-3 Programming Port and DIP Switch --------------------------------------- 1-3 Programming Port and DIP Switch --------------------------------------- 1-4 Keys and Displays ------------------------------------------------------------ 1-4 Keys and Displays ------------------------------------------------------------ 1-5 Menu Overview -------------------------------------------------------------- 1-5 Menu Overview --------------------------------------------------------------...

  • Page 3: Chapter 1 Overview

    Alternative output options include SSR drive, triac, 4 - 20 mA and 0 - 10 volts. FDC-2500 is fully programmable for PT100, thermocouple types J, K, T, E, B, R, S, N, L, 0 - 20mA, 4 -20mA and voltage volts.

  • Page 4: Ordering Code

    CC94-1 = RS-232 Interface Cable (2M) CC94-1 = RS-232 Interface Cable (2M) Wave SSR AC Power Module Wave SSR AC Power Module UM25001C = FDC-2500 User's Manual UM25001C = FDC-2500 User's Manual VPFW100 =100 Amp. Variable Period Full VPFW100 =100 Amp. Variable Period Full...

  • Page 5: Programming Port And Dip Switch

    1 3 Programming Port and DIP Switch 1 3 Programming Port and DIP Switch Access Hole Front Rear Panel Terminal Figure 1.3 Access Hole Figure 1.3 Access Hole Overview Overview The programming port is used to connect to P10A hand-held programmer for automatic programming, also can be connected to ATE system for automatic testing &...

  • Page 6: Keys And Displays

    1 4 Keys and Displays 1 4 Keys and Displays The unit is programmed by using three keys on the front panel. The available key functions are listed in following table. The unit is programmed by using three keys on the front panel. The available key functions are listed in following table. Table 1.2 Keypad Operation Table 1.2 Keypad Operation TOUCHKEYS...

  • Page 7: Menu Overview

    1 5 Menu Overview 1 5 Menu Overview User User PV Value Menu Menu SV Value SEL1 SEL2 SEL3 SEL4 SEL5 Setup Setup FUNC for 3 Menu Menu seconds COMM PROT ADDR TIME BAUD A1SP DATA A1DV PARI Hand (Manual) Hand (Manual) A2SP for 3 seconds...

  • Page 8: Parameters Description

    1 6 Parameter Description 1 6 Parameter Description Table 1.4 Parameter Description Table 1.4 Parameter Description Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value 100.0 C Set point 1 SP1L High:...
  • Page 9 Table 1.6 Parameter Description ( continued 2/7) Table 1.6 Parameter Description ( continued 2/7) Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value High: ADDR Low: 0.3 Kbits/s baud rate 0.6 Kbits/s baud rate 1.2 Kbits/s baud rate...
  • Page 10 Table 1.6 Parameter Description ( continued 3/7 ) Table 1.6 Parameter Description ( continued 3/7 ) Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Range Format Format Description Description Value Function Function Notation Notation N type thermocouple L type thermocouple PT 100 ohms DIN curve PT 100 ohms JIS curve...
  • Page 11 Table 1.6 Parameter Description ( continued 4/7 ) Table 1.6 Parameter Description ( continued 4/7 ) Parameter Parameter Display Display Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value 0 - 20 mA current module 0 - 1V voltage module 0 - 5V voltage module Output 1 Signal Type...
  • Page 12 Table 1.6 Parameter Description ( continued 5/7 ) Table 1.6 Parameter Description ( continued 5/7 ) Parameter Parameter Display Display Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value Alarm output OFF as unit fails Alarm 1 Failure Transfer A1FT Alarm output ON as unit fails...
  • Page 13 Table 1.6 Parameter Description ( continued 6/7 ) Table 1.6 Parameter Description ( continued 6/7 ) Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value Use minute ramp rate as set point Use hour ramp rate as set point SPMD Set point Mode Selection...
  • Page 14 Table 1.6 Parameter Description ( continued 7/7 ) Table 1.6 Parameter Description ( continued 7/7 ) Display Display Parameter Parameter Contained Contained Basic Basic Parameter Parameter Default Default Range Format Format Description Description Function Function Notation Notation Value Value Cold Junction Gain 199.9 Low: -199.9...

  • Page 15: Chapter 2 Installation

    Chapter 2 Installation Chapter 2 Installation Dangerous voltages capable of causing death are sometimes Dangerous voltages capable of causing death are sometimes present in this instrument. Before installation or beginning any present in this instrument. Before installation or beginning any troubleshooting procedures the power to all equipment must be switched troubleshooting procedures the power to all equipment must be switched off and isolated.

  • Page 16: Wiring Precautions

    2 3 Wiring Precautions 2 3 Wiring Precautions Before wiring, verify the label for correct model number and options. Switch Before wiring, verify the label for correct model number and options. Switch off the power while checking. off the power while checking. Care must be taken to ensure that maximum voltage rating specified on the Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded.

  • Page 17: Power Wiring

    2 4 Power Wiring 2 4 Power Wiring The controller is supplied to operate at 11-26 VAC / VDC or 90-264VAC.Check The controller is supplied to operate at 11-26 VAC / VDC or 90-264VAC.Check that the installation voltage corresponds with the power rating indicated on the that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller.

  • Page 18: Thermocouple Input Wiring

    2 6 Thermocouple Input Wiring 2 6 Thermocouple Input Wiring Thermocouple input connections are shown in Figure 2.5. The correct type of Thermocouple input connections are shown in Figure 2.5. The correct type of thermocouple extension lead-wire or compensating cable must be used for the thermocouple extension lead-wire or compensating cable must be used for the entire distance between the controller and the thermocouple, ensuring that the t entire distance between the controller and the thermocouple, ensuring that the t...

  • Page 19: Linear Dc Input Wiring

    2 8 Linear DC Input Wiring 2 8 Linear DC Input Wiring DC linear voltage and linear current connections for input 1 are shown in Figure DC linear voltage and linear current connections for input 1 are shown in Figure 2.7 and Figure 2.8 .

  • Page 20: Event Input Wiring

    2 10 Event Input wiring 2 10 Event Input wiring Figure 2.13 Figure 2.13 Event Input Wiring Event Input Wiring 12 13 14 12 13 14 Switch Input Switch Input Open Collector Open Collector Input Input The event input can accept a switch signal as well as an open collector signal. The The event input can accept a switch signal as well as an open collector signal.

  • Page 21: Output 2 Wiring

    2 12 Output 2 Wiring 2 12 Output 2 Wiring Figure 2.15 Figure 2.15 Max. 2A Max. 2A Output 2 Wiring Output 2 Wiring Max. 1A / 240V Max. 1A / 240V Resistive Resistive Load Load 120V /240V 120V/240V 120V/240V Mains Supply Mains Supply Mains Supply...

  • Page 22: Alarm 1 Wiring

    2 13 Alarm 1 Wiring 2 13 Alarm 1 Wiring Internal Circuit Internal Circuit Figure 2.16 Figure 2.16 Alarm 1 Wiring Alarm 1 Wiring 12 13 14 5VDC Logic Output 5VDC Logic Output 2 14 Alarm 2 Wiring 2 14 Alarm 2 Wiring Figure 2.17 Figure 2.17 Max.

  • Page 23: Rs-232

    RS-232 port CC94-1 Note: If the FDC-2500 is configured for RS-232 communication, the input 2 If the FDC-2500 is configured for RS-232 communication, the input 2 and EI ( Event Input ) are disconnected internally. The unit can no longer and EI ( Event Input ) are disconnected internally.

  • Page 24: Analog Retransmission

    2 17 Analog Retransmission 2 17 Analog Retransmission The total effective resistance of parallel The total effective resistance of parallel The total effective resistance of serial The total effective resistance of serial loads should be greater than 10K Ohms. loads should be greater than 10K Ohms. loads can't exceed 500 ohms.

  • Page 25: 3 - 2 Self - Tuning

    3 - 2 Self - Tuning 3 - 2 Self - Tuning The Self-tuning which is designed by using an provides The Self-tuning which is designed by using an innovative algorithm innovative algorithm provides Self-tune Menu Self-tune Menu an alternative option for tuning the controller. It is activated as soon as SELF an alternative option for tuning the controller.

  • Page 26: 3 - 4 Auto - Tuning

    3 - 4 Auto - Tuning 3 - 4 Auto - Tuning The auto-tuning process is performed at set point. The auto-tuning process is performed at set point. The process will oscillate around the set point during tuning process. The process will oscillate around the set point during tuning process. Set a set point to a lower value if overshooting beyond the normal Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage.
  • Page 27 Auto-tuning Auto-tuning Auto-tuning Auto-tuning Begins Begins Complete Complete Waiting Waiting Warm-up Warm-up Cycle Cycle Learning Cycle Learning Cycle New PID Cycle New PID Cycle Cycle Cycle =2 Integral =2 Integral Time Time Figure 3.2 Figure 3.2 Set Point Set Point Auto-tuning Procedure Auto-tuning Procedure Pre-tune Stage...

  • Page 28: 3 - 5 Manual Tuning

    3 - 5 Manual Tuning 3 - 5 Manual Tuning In certain applications ( very few ) using both self-tuning and auto-tuning to In certain applications ( very few ) using both self-tuning and auto-tuning to tune a process may be inadequate for the control requirement, then you tune a process may be inadequate for the control requirement, then you can try manual tuning.
  • Page 29 The PBu is called the The PBu is called the Ultimate P Band Ultimate P Band and the period of oscillation Tu is and the period of oscillation Tu is called the called the Ultimate Period Ultimate Period in the flow chart of Figure 3.3 . When this occurs, in the flow chart of Figure 3.3 .

  • Page 30: Signal Conditioner Dc Power Supply

    3 6 Signal Conditioner DC Power Supply 3 6 Signal Conditioner DC Power Supply Three types of isolated DC power supply are available to supply an external transmitter Three types of isolated DC power supply are available to supply an external transmitter or sensor.

  • Page 31: Manual Control

    3 8 Manual Control 3 8 Manual Control The manual control may be used for the following The manual control may be used for the following purposes purposes ( 1 ) To test the process characteristics to obtain a step response as well as an ( 1 ) To test the process characteristics to obtain a step response as well as an impulse response and use these data for tuning a controller.

  • Page 32: Pump Control

    3 10 Pump Control 3 10 Pump Control Pump Control function is one of the unique features of FDC-2500. Using this Pump Control function is one of the unique features of FDC-2500. Using this PUMP: A Cost Effective PUMP: A Cost Effective function the pressure in a process can be controlled excellently.

  • Page 33: Remote Lockout

    Programming Guide: Programming Guide: 1. Perform auto-tuning to the system under such condition that the material 1. Perform auto-tuning to the system under such condition that the material ( ie. pressure ) is exhausted at typical rate. A typical value for PB1 is about ( ie.

  • Page 34: Bumpless Transfer

    3 12 3 12 Bumpless Transfer Bumpless Transfer The bumpless transfer function is available for output 1 and output 2 ( provided The bumpless transfer function is available for output 1 and output 2 ( provided Bumpless Transfer Setup : Bumpless Transfer Setup : that OUT2 is configured as COOL ).

  • Page 35: Chapter 4 Calibration

    Chapter 4 Calibration Chapter 4 Calibration Do not proceed through this section unless there is a definite need to Do not proceed through this section unless there is a definite need to re-calibrate the controller. Otherwise, all previous calibration data will be re-calibrate the controller.
  • Page 36 RTD input RTD input and 10 according to the connection shown below: and 10 according to the connection shown below: 100 ohms FDC-2500 Figure 6.1 Figure 6.1 RTD Calibration RTD Calibration Press scroll key for at least 3 seconds . The display will blink a Press scroll key for at least 3 seconds .
  • Page 37 Note that a K type TC input TC input thermocouple must be used. thermocouple must be used. 5520A 5520A Calibrator Calibrator FDC-2500 Figure 6.2 Figure 6.2 K-TC Cold Junction Cold Junction Calibration Setup Calibration Setup Stay at least...
  • Page 38 The unit under calibration is powered in a still-air room with The unit under calibration is powered in a still-air room with temperature temperature . Stay at least 20 minutes for warming up. The . Stay at least 20 minutes for warming up. The DIP Switch is located at TC input .

  • Page 39: Chapter 5 Error Codes And Troubleshooting

    Chapter 5 Error Codes & Troubleshooting Chapter 5 Error Codes & Troubleshooting This procedure requires access to the circuitry of a live power unit. Dangerous accidental contact with line This procedure requires access to the circuitry of a live power unit. Dangerous accidental contact with line voltage is possible.
  • Page 40 Table 5.1 Error Codes and Corrective Actions Table 5.1 Error Codes and Corrective Actions Display Error Error Description Corrective Action Symbol Code Illegal setup values been used: PV1 is used for both PVMD Check and correct setup values of PVMD and SPMD. PV and SPMD.
  • Page 41 Table 5.2 Common Failure Causes and Corrective Actions Table 5.2 Common Failure Causes and Corrective Actions Symptom Probable Causes Corrective Actions - Clean contact area on PCB -Bad connection between PCB & keypads 1) Keypad no function - Replace keypads - No power to instrument - Check power line connections 2) LED's will not light...

  • Page 42: Chapter 6 Specifications

    Chapter 6 Specifications Chapter 6 Specifications Power Input 2 Input 2 90 264 VAC, 47 63 Hz, 15VA, 7W maximum 90 264 VAC, 47 63 Hz, 15VA, 7W maximum Resolution : Resolution : 18 bits 18 bits 11 26 VAC / VDC, 15VA, 7W maximum 11 26 VAC / VDC, 15VA, 7W maximum Sampling Rate : Sampling Rate :...
  • Page 43 Linear Output Linear Output Resolution : Resolution : 15 bits 15 bits Resolution : Resolution : 15 bits 15 bits Accuracy : Accuracy : A0.05 % of span A0.0025 %/ LC A0.05 % of span A0.0025 %/ LC Output Regulation : Output Regulation : 0.01 % for full load change 0.01 % for full load change...
  • Page 44 Environmental & Physical Environmental & Physical Operating Temperature : -10 C to 50 C Operating Temperature : -10 C to 50 C Storage Temperature : Storage Temperature : -40 C to 60 C -40 C to 60 C Humidity : Humidity : 0 to 90 % RH ( non-condensing ) 0 to 90 % RH ( non-condensing )

  • Page 45: Menu Existence / Your Settings

    A 1 Menu Existence Conditions - User Settings A 1 Menu Existence Conditions - User Settings Menu Existence Conditions Table Menu Existence Conditions Table Your Your Parameter Parameter Menu Existence Conditions Existence Conditions Settings Settings Notation Notation Exists unconditionally Exists unconditionally TIME Exists if A1FN selects TIMR or A2FN selects TIMR Exists if A1FN selects TIMR or A2FN selects TIMR...
  • Page 46 Menu Existence Conditions - User Settings Table ( continued 2/3 ) Menu Existence Conditions - User Settings Table ( continued 2/3 ) Your Your Parameter Parameter Menu Existence Conditions Existence Conditions Settings Settings Notation Notation FUNC Exists unconditionally Exists unconditionally COMM Exists if FUNC selects FULL Exists if FUNC selects FULL...
  • Page 47 Menu Existence Conditions - User Settings Table ( continued 3/3 ) Menu Existence Conditions - User Settings Table ( continued 3/3 ) Your Your Parameter Parameter Menu Existence Conditions Existence Conditions Notation Notation Settings Settings A1FN Exists unconditionally Exists unconditionally Exists if A1FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, Exists if A1FN selects DEHI, DELO, DBHI, DBLO, PV1H, PV1L, PV2H, PV2L, P12H, P12L, A1MD...

  • Page 48: Warranty

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  • Page 51 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 to cause cancer, birth defects or other reproductive harm.
  • Page 52 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 3 years after delivery to the first purchaser for use.

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