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Future Design FDC C21 User Manual

Auto-tune fuzzy / pid process / temperature controller
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FDC C21 / C91
Auto-Tune Fuzzy / PID
Process / Temperature
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Summary of Contents for Future Design FDC C21

  • Page 1 User's Manual FDC C21 / C91 Auto-Tune Fuzzy / PID Process / Temperature Controller...
  • Page 2 Information in this user's manual is subject to change without notice. Copyright February 2004, Future Design Controls, all rights reserved. No part of this publication may be reproduced, transmitted, transcribed or stored in a retrieval system, or translated into any language in any form by any means without the written permission of Future Design Controls.

  • Page 3: Table Of Contents

    Contents Page No Page No Chapter 1 Overview Chapter 5 Calibration -------48 1-1 General -------------------------4 1-2 Ordering Code ---------------7 1-3 Programming Port ------------8 Chapter 6 Specifications ---49 1-4 Keys and Displays ----------9 1-5 Menu Overview -------------11 Appendix 1-6 Parameter Descriptions ---12 A-1 Error Codes --------------------59 A-2 Warranty --------------------- ---60 Chapter 2 Installation...

  • Page 4: Chapter 1 Overview

    Chapter 1 Overview 1-1 General The Fuzzy Logic plus PID microprocessor-based controller series, incorporate a bright, easy to read 4-digit LED display, indicating process value or set point value. The Fuzzy Logic technology enables a process to reach a predetermined set point in the shortest time, with the minimum of overshoot during power-up or external load disturbance.
  • Page 5 PID control with properly tuned PID + Fuzzy control Temperature point Figure 1.1 Fuzzy Control Advantage Load Disturbance Warm Up Time High Accuracy The series are manufactured with custom designed ASIC(Application Specific Integrated Circuit ) technology which contains a 18-bit A to D converter for high resolution measurement ( true 0.1 F resolution for thermocouple and PT100 ) and a 15-bit D to A converter for linear current or voltage control output.
  • Page 6 Programming Port A programming port is used to connect the unit to a hand-held programmer or a PC for quick configuration, also can be connected to an ATE system for automatic testing & calibration. Auto-tune The auto-tune function allows the user to simplify initial setup for a new system.

  • Page 7: Ordering Code

    1-2 Ordering Code C21- C91- Power Input Display Color 4: 90 - 250 VAC, 0: Red color 50/60 HZ 1: Green color 5: 11 - 26 VAC or VDC 9: Special Order Communications 0: None 1: RS-485 interface (for C21) Signal Input 2: RS-232 interface (for C21) 1: Standard Input...

  • Page 8: Programming Port

    1-3 Programming Port Front Panel Access Hole Rear Terminal control board Programming Port pin 1 Power board Top view of C91 with housing removed Figure 1.2 Programming Port Overview A special connector can be used to touch the programming port which is connected to a PC for automatic configuration, also can be connected to an ATE system for automatic calibration and testing.

  • Page 9: Keys And Displays

    1- 4 Keys and Displays KEYPAD OPERATION SCROLL KEY : This key is used to select a parameter to be viewed or adjusted. UP KEY : This key is used to increase the value of selected parameter. DOWN KEY : This key is used to decrease the value of selected parameter.
  • Page 10 Output 2 Deviation Indicator Indicator Output 1 Indicator Output 1 Output 2 Indicator Process Unit Indicator Indicator OP1 OP2 C 2 1 Auto-tuning Indicator Manual Mode Indicator 3 Silicone Rubber Buttons for ease of control setup 4 Buttons for ease of and set point adjustment.

  • Page 11: Menu Overview

    1- 5 Menu Overview Setup menu*1 User menu *1 Calibration Mode 3 sec. 4.2 sec. 5.4 sec. 2 sec. Value LOCK Value INPT ADLO UNIT ADHI Manual 3 sec. Mode RTDL INLO RTDH 3 sec. Manual INHI CJLO Mode Value SP1L CJHI Auto-tuning...

  • Page 12: Parameter Descriptions

    1-6 Parameter Descriptions Parameter Default Parameter Description Range Notation Value 25.0 C Set point for output 1 Low: SP1L High :SP1H (77.0 F) Set point for output 2 when output 2 performs 10.0 C Low: -19999 High :45536 (18.0 F) alarm function or dwell timer : No parameter...
  • Page 13 Parameter Default Parameter Description Range Notation Value Degree C unit Degree F unit Input unit selection UNIT Process unit No decimal point 1 decimal digit Decimal point selection 2 decimal digits 3 decimal digits -17.8 C Input low sale value High: Low: -19999...
  • Page 14 Parameter Default Parameter Description Range Notation Value : Display process value normally DISP Normal display selection : Display set point 1 value normally 500.0 C 10.0 C Proportional band value High: Low: 0 (900.0 F) (18.0 F) Integral time value High: Low: 1000 sec...
  • Page 15 Parameter Default Parameter Description Range Notation Value : No Ramp Function : Use unit/minute as Ramp function RAMP Ramp Rate selection : Use unit/hour as Ramp Rate 500.0 C Ramp rate High: Low: 0 (900.0 F) : Output 2 No Function : Dwell timer action : Deviation High Alarm : Deviation Low Alarm...
  • Page 16 Parameter Default Parameter Description Range Notation Value Output 2 hysteresis value when output 2 0.1 C High: 50.0 C O2HY Low: 0.1 performs alarm (90.0 F) (0.2 F) function High: 90.0 sec. Output 2 cycle time Low: 0.1 18.0 CYC2 Cooling proportional High: 300 % Low: 50...
  • Page 17 Parameter Default Parameter Description Range Notation Value : 7 data bits Data bit count of digital DATA communication : 8 data bits : Even parity Parity bit of digital : Odd parity PARI communication : No parity bit : One stop bit Stop bit count of digital STOP communication...
  • Page 18 Parameter Default Parameter Description Range Notation Value Select 2'nd parameter SEL2 Same as SEL1 for user menu Select 3'rd parameter SEL3 Same as SEL1 for user menu Select 4'th parameter SEL4 Same as SEL1 for user menu Select 5'th parameter SEL5 Same as SEL1 for user menu...

  • Page 19: Chapter 2 Installation

    Chapter 2 Installation Dangerous voltages capable of causing death are sometimes present in this instrument. Before installation or beginning any troubleshooting procedures the power to all equipment must be switched off and isolated. Units suspected of being faulty must be disconnected and removed to a properly equipped workshop for testing and repair.
  • Page 20 Figure 2.1 Mounting Dimensions (45mm) MOUNTING CLAMP 1.77” (22.2mm) .875” SCREW Panel 3.85” .49” (12.5mm) .39” (98.0mm) (10.0mm) (45mm) 1.77” 1.77” C91 Cutout Panel (86 mm) 3.38” 3.70” (94 mm) UM0C911A-August-2024...

  • Page 21: Wiring Precautions

    2 - 3 Wiring Precautions Before wiring, verify the label for correct model number and options. Switch off the power while checking. Care must be taken to ensure that maximum voltage rating specified on the label are not exceeded. It is recommended that power of these units to be protected by fuses or circuit breakers rated at the minimum value possible.
  • Page 22 7.0mm max. 3.2mm min. Figure 2.2 Lead Termination for 2.0mm 0.08" max. Figure 2.3 Lead Termination 4.5 ~7.0 mm for C21 0.18" ~0.27" 90-250 VAC 2A/240 VAC 2A/240 VAC 47-63 Hz,10VA V+,mA+ V ,mA RS-485 RS-232 Rear Terminal Connection Figure 2.4 for C21 240 VAC 90-250 VAC...

  • Page 23: Power Wiring

    2 - 4 Power Wiring The controller is supplied to operate at 11-26 VAC / VDC or 90-250 VAC. Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller. Fuse 250 VAC or 26 VAC / VDC...

  • Page 24: Sensor Input Wiring

    Proper sensor type is also a very important factor to obtain precise measurements. The sensor must have the correct temperature range to meet the process requirements. In special processes the sensor might need to have different requirements such as leak-proof, anti- vibration, antiseptic, etc.
  • Page 25 C21 C91 Load 120V /240V Mains Supply Internal Circuit 30mA / 5V Pulsed Voltage Figure 2.11 Output 1 Pulsed Voltage to Drive SSR C21 C91 0 - 20mA, Maximum Load Load 4 - 20mA 500 ohms Figure 2.12 Output 1 Linear Current C21 C91 Minimum Load 0 - 1V, 0 - 5V...

  • Page 26: Alarm Wiring

    C21 C91 Load 120V /240V Mains Supply Internal Circuit 30mA / 5V Pulsed Voltage Figure 2.16 Output 2 Pulsed Voltage to Drive SSR C21 C91 0 - 20mA, Maximum Load Load 4 - 20mA 500 ohms Figure 2.17 Output 2 Linear Current C21 C91 Minimum Load 0 - 1V, 0 - 5V...

  • Page 27: Data Communication

    2-9 Data Communication RS-485 to RS-232 C21 C91 network adaptor SNA10A or SNA10B RS-232 Twisted-Pair Wire C21 C91 Max. 247 units can be linked C21 C91 Terminator 220 ohms / 0.5W Figure 2.21 RS-485 Wiring UM0C911A-August-2024...
  • Page 28 RS-232 9-pin RS-232 port CC94-1 Figure 2.22 RS-232 Wiring If you use a conventional 9-pin RS-232 cable instead of CC94-1, the cable must be modified according to the following circuit diagram. To DTE ( PC ) RS-232 Port 1 DCD 2 RD 3 TD 4 DTR...

  • Page 29: Process Retransmission

    2-10 Process Retransmission (C21 Only) RE + 0 - 20mA, Maximum Load Load 4 - 20mA 500 ohms RE - RE + Minimum Load 0 - 1V, 0 - 5V Load 10 K ohms 1 - 5V, 0 - 10V RE - Figure 2.24 Process Retransmission...

  • Page 30: Chapter 3 Programming

    Chapter 3 Programming Press for 3 seconds and release to enter setup menu. Press to select the desired parameter. The display indicates the parameter symbol. Press to view or adjust the value of the selected parameter. 3-1 Lockout There are four security levels can be selected by using LOCK parameter.

  • Page 31: Control Outputs

    process value INHI Figure 3.1 Conversion Curve for Linear Type Process Value INLO input signal S SL Formula : PV = INLO + ( INHI INLO ) Example : A 4-20 mA current loop pressure transducer with range 0 - 15 kg/cm is connected to input, then perform the following setup : INPT = 4 - 20 INLO = 0.00...
  • Page 32 Heat Only ON-OFF Control : Select REVR for OUT1, Set PB to 0, O1HY is used to adjust dead band for ON-OFF control, The output 1 hysteresis ( O1HY ) is enabled in case of PB = 0 . The heat only on-off control function is shown in the following diagram : Dead band = O1HY SP1 O1HY...
  • Page 33 then increase OFST 25 %, and vice versa. After adjusting OFST value, the process value will be varied and eventually, coincide with set point. Using the P control ( TI set to 0 ), the auto-tuning is disabled. Refer to section 3-12 " manual tuning " for the adjustment of PB and TD.
  • Page 34 You can use the auto-tuning program for the new process or directly set the appropriate values for PB, TI & TD according to the historical records for the repeated systems. If the control behavior is still inadequate, then use manual tuning to improve the control. See section 3-12 for manual tuning.
  • Page 35 OUT2=DE.HI SV+SP2 SV+SP2-O2HY Time OUT2 Action Figure 3.3 Output 2 Deviation Time High Alarm SP2+O2HY Time OUT2 Action Time Figure 3.4 Output 2 Process Low Alarm UM0C911A-August-2024...

  • Page 36: Alarm

    3-4 Alarm The output 2 can be selected as alarm output. There are 6 types of alarm functions and one dwell timer can be selected, and four kinds of alarm modes ( ALMD ) are available for each alarm function. A process alarm sets two absolute trigger levels.

  • Page 37: Configure Display

    Holding Alarm : ALMD = HOLD A holding alarm prevents an alarm from power up. The alarm is enabled only when the process reaches the set point value. Afterwards , the alarm performs same function as normal alarm. Latching / Holding Alarm : ALMD = LT.HO A latching / holding alarm performs both holding and latching function.

  • Page 38: Ramp

    Example for C91 Set OUT2=PVLO, LOCK=NONE, SEL1=INPT, SEL2=UNIT, SEL3=DP , SEL4~SEL8=NONE, then the display scrolling for C91 becomes: 3 - 6 Ramp The ramping function is performed during power up as well as any time the set point is changed. Choose MINR or HRR for RAMP , the unit will perform the ramping function.

  • Page 39: Dwell Timer

    3-7 Dwell Timer Output 2 can be configured as dwell timer by selecting TIMR for OUT2. As the dwell timer is configured, the parameter SP2 is used for dwell time adjustment. The dwell time is measured in minute ranging from 0.1 to 4553.6 minutes. Once the process reaches the set point the dwell timer starts to count down until zero ( time out ).

  • Page 40: Pv Shift

    3 - 8 PV Shift In certain applications it is desirable to shift the controller display value from its actual value. This can be easily accomplished by using the PV shift function. The SHIF function will alter PV only. Here is an example. A process is equipped with a heater, a sensor and a subject to be warmed up.

  • Page 41: Digital Filter

    3- 9 Digital Filter In certain application the process value is too unstable to be read. To improve this a programmable low pass filter incorporated in the controller can be used. This is a first order filter with time constant specified by FILT parameter .

  • Page 42: Failure Transfer

    3 -10 Failure Transfer The controller will enter failure mode as one of the following conditions occurs: 1. SBER occurs due to the input sensor break or input current below 1mA if 4-20 mA is selected or input voltage below 0.25V if 1-5 V is selected .

  • Page 43: Auto-Tuning

    3 -11 Auto-tuning The auto-tuning process is performed at set point. The process will oscillate around the set point during tuning process. Set a set point to a lower value if overshooting beyond the normal process value is likely to cause damage. The auto-tuning is applied in cases of : Initial setup for a new process The set point is changed substantially from the previous auto-...

  • Page 44: Manual Tuning

    Procedures: The auto-tuning can be applied either as the process is warming up ( Cold Start ) or as the process has been in steady state ( Warm Start ). After the auto-tuning procedures are completed, the AT indicator will cease to flash and the unit revert to PID control by using its new PID values.

  • Page 45: Manual Control

    SYMPTOM SOLUTION ADJUSTMENT SEQUENCE Slow Response Decrease PB (1) Proportional Band ( PB ) High overshoot or Increase PB Oscillations Slow Response Decrease TI (2) Integral Time ( TI ) Instability or Increase TI Oscillations Slow Response or Decrease TD Oscillations (3) Derivative Time ( TD ) High Overshoot...
  • Page 46 PB too low Perfect Set point P action PB too high Time TI too high Set point I action Perfect TI too low Time TD too low Perfect Set point D action TD too high Time Figure 3.9 Effects of PID Adjustment UM0C911A-August-2024...

  • Page 47: Data Communication

    3 - 14 Data Communication The controllers support RTU mode of Modbus protocol for the data communication. Other protocols are not available for the series. Two types of interface are available for Data Communication. These are RS-485 and RS-232 interface. Since RS-485 uses a differential architecture to drive and sense signal instead of a single ended architecture which is used for RS-232, RS-485 is less sensitive to the noise and suitable for a longer distance communication.

  • Page 48: Chapter 5 Calibration

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

  • Page 49: Chapter 6 Specifications

    Manual Calibration Procedures Perform step 1 to enter calibration mode. Step 1. Set the Lock parameter to the unlocked condition ( LOCK= NONE). Press and hold the scroll key until appears on the display, then release the scroll key. Press the scroll key for 2 seconds then release,the display will show and the unit enters calibration mode .
  • Page 50 Step 4. Press scroll key until the display shows . Send a 100 ohms signal to the RTD input terminals according to the connection shown below: 100 ohms Figure 5.1 RTD Calibration Press scroll key for at least 3 seconds . The display will blink a moment, otherwise the calibration fails.
  • Page 51 5520A Calibrator K-TC Stay at least 20 minutes in still- air room room temperature 25 +/- 3 C Figure 5.2 Cold Junction Calibration Setup The 5520A calibrator is configured as K type thermocouple output with internal compensation. Send a 0.00 C signal to the unit under calibration.
  • Page 52 Perform step 1 stated above , then press scroll key until the display shows . Press scroll key for at least 3 seconds. The display will blink a moment and a new value is obtained. Otherwise , if the display didn't blink or if the obtained value is equal to -199.9 or 199.9, then the calibration fails.
  • Page 53 Chapter 6 Specifications Power 90 250 VAC, 47 63 Hz, 10VA, 5W maximum 11 26 VAC / VDC, 10VA, 5W maximum Input Resolution : 18 bits Sampling Rate : 5 times / second Maximum Rating : -2 VDC minimum, 12 VDC maximum ( 1 minute for mA input ) Temperature Effect : +/-1.5uV/ C for all inputs except mA input...
  • Page 54 Characteristics: Accuracy Input Type Range @ 25 C Impedance -120 C 1000 C +/-2 C 2.2 M ( -184 F 1832 F ) -200 C 1370 C +/-2 C 2.2 M ( -328 F 2498 F ) -250 C 400 C +/-2 C 2.2 M ( -418 F 752 F )
  • Page 55 Output 1 / Output 2 Relay Rating : 2A/240 VAC, life cycles 200,000 for resistive load. Pulsed Voltage : Source Voltage 5V, current limiting resistance 66. Linear Output Characteristics Zero Span Load Type Tolerance Tolerance Capacity 500 max. 4-20 mA 3.8-4 mA 20-21 mA 500 max.
  • Page 56 DC Voltage Supply Characteristics ( Installed at Output 2 ) Ripple Type Tolerance Max. Output Isolation Voltage Current Barrier 0.2 Vp-p 20 V +/-0.5 V 25 mA 500 VAC 0.1 Vp-p 12 V +/-0.3 V 40 mA 500 VAC 0.05 Vp-p +/-0.15 V 80 mA 500 VAC...
  • Page 57 User Interface Display: Single 4-digit LED Displays Keypad: 4 keys for C91, 3 keys for C21 Programming Port: For automatic setup, calibration and testing Communication Port : Connection to PC for supervisory control Control Mode Output 1: Reverse ( heating ) or direct ( cooling ) action Output 2: PID cooling control, cooling P band...
  • Page 58 Environmental & Physical Operating Temperature: -10 C to 50 C Storage Temperature: -40 C to 60 C Humidity: 0 to 90 % RH ( non-condensing ) Insulation Resistance: 20 Mohms min. ( at 500 VDC ) Dielectric Strength : 2000 VAC, 50/60 Hz for 1 minute Vibration Resistance: 10 - 55 Hz, 10 m/s for 2 hours Shock Resistance:...

  • Page 59: Error Codes

    Table A.1 Error Codes and Corrective Actions Display Error Error Description Corrective Action Symbol Code Illegal setup values been used: Check and correct setup values of Before COOL is used for OUT2, OUT2, PB, TI and OUT1. IF OUT2 DIRT ( cooling action ) has already is required for cooling control, the been used for OUT1, or PID mode control should use PID mode ( PB...

  • Page 60: Warranty

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  • Page 63 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 64 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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