FDC-9300 Self-Tune Fuzzy / PID Process / Temperature Controller

Transcription

1 User's Manual FDC- Self-Tune Fuzzy / PID Process / Temperature Controller

2 CONTENTS Page No Chapter Overview - Features Ordering Code Programming Port and DIP Switch Keys and Displays Menu Overview Parameters Description Chapter Installation - Unpacking Mounting Wiring Precautions Power Wiring Sensor Installation Guidelines Thermocouple Input Wiring RTD Input Wiring Linear DC Input Wiring CT / Heater Current Input Wiring Output Wiring Output Wiring Event Input Wiring Alarm Wiring Alarm Wiring RS Analog Retransmission RS Chapter Programming Special Functions - Rearrange User Menu Dwell Timer Manual Control Failure Transfer Signal Conditioner DC Power Supply Bumpless Transfer Self-Tuning Auto-Tuning Manual Tuning Pump Control Sleep Mode Remote Lockout Heater Break Reload Default Parameters Chapter Calibration Chapter Error Codes and Troubleshooting Chapter Specifications Appendix A- Menu Existence / Your Settings A- Warranty UM.

3 Chapter Overview Features Two function complexity levels User menu configurable Adaptive heat-cool High accuracy -bit input A High accuracy -bit output D A Fast input sample rate ( times / second) dead band Pump control Fuzzy + PID microprocessor-based control Automatic programming Differential control Auto-tune function Self-tune function Sleep mode function EMC / CE EN- & EN- Front panel sealed to NEMA X & IP Unique Valuable " Soft-start " ramp and dwell timer Programmable inputs( thermocouple, RTD, ma, VDC ) D Analog input for remote set point and CT Event input for changing function & set point Programmable digital filter Hardware lockout + remote lockout protection Loop break alarm Heater break alarm Sensor break alarm + Bumpless transfer RS-, RS- communication Analog retransmission Signal conditioner DC power supply A wide variety of output modules available Approvals UR / CSA / CE / RHoS Compliant FDC- Fuzzy Logic plus PID microprocessor-based controller, incorporates a bright, easy to read -digit LED display, indicating process 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. The units are housed in a / DIN case, measuring mm x mm with mm behind panel depth. The units feature three touch keys to select the various control and input parameters. Using a unique function, you can put at most parameters in front of user menu by using SEL to SEL contained in the setup menu. This is particularly useful to OEM's as it is easy to configure menu to suit the specific application. FDC- is powered by - or - VDC / AC supply, incorporating a amp. control relay as standard. Up to two additional optional relay outputs can be supported. Output two can be a cooling relay or alarm or dwell timer.the third relay performs as a programmable alarm. Alternative output options include SSR Drive, Triac, / - ma and - volts. FDC- is fully programmable for PT, thermocouple types J, K, T, E, B, R, S, C, P, - ma, -ma and voltage signal input, with no need to modify the unit. The input signals are digitized by using a -bit A to D converter. Its fast sampling rate allows the FDC- to control fast processes such as pressure and flow. Self tune is incorporated. The self- tune can be used to optimize the control parameters as soon as undesired control result is observed. Unlike auto-tune, Self-tune will produce less disturbance to the process during tuning, and can be used any time. The function of Fuzzy Logic is to adjust PID parameters internally in order to make manipulation output value MV more flexible and adaptive to various processes. PID + Fuzzy Control has been proven to be an efficient method to improve the control stability as shown by the comparison curves below Temperature PID control when properly tuned PID + Fuzzy control Set point Warm Up Load Disturbance Figure. Fuzzy PID Enhances Control Stability UM. Time

4 Ordering Code FDC-- Power Input - VAC, / HZ - VAC or VDC Special Order Signal Input Alarm Communications Standard Input None None Input - Universal Input Form A Relay RS- A / VAC Thermocouple J, K, T, E, B, RS- Form B Relay R, S, N, L Retransmit -ma/-ma A / VAC RTD PT DIN, PT JIS Retransmit - V/ - V Special order Current - ma, -ma. Retransmit - V Voltage -V,-V,-V, - - Special order Output - V Input -CT and Analog Input None CT-Amp.AC AC Current Relay rated A/VAC Output/Alarm Transformer Pulsed voltage to None Analog Input - ma, drive SSR, VDC@mA Form A Relay A/VAC - ma, -V,-V, - -ma/-ma - Pulsed voltage to -V,-V. - V. Isolated ohm load max. drive SSR, V / ma Input - Event Input ( EI ) -V/-VIsolated - -ma/-ma - Isolated Special Order Min impedance K ohm load Max - V Isolated -V/-VIsolated - Example Min. Impedance K Triac Output Min impedance K - V Isolated Standard Model A / VAC,SSR Min impedance K FDC-- C Pulsed voltage to Triac Output, A / VAC, SSR - operating voltage drive SSR, VDC@ma V / ma DC Isolated Input Standard Input Special order Output Power Supply Output Relay V / ma DC Isolated Output Relay Output Power Supply Alarm Form A Relay V / ma DC Isolated RS- Communication Interface Output Power Supply C Pulsed voltage to drive SSR, ma A Special order Accessories CT- = - Amp. AC Current Transformer OM- = Isolated - ma/- ma Analog Output Module OM- = Isolated -V/-V - Analog Output Module OM- = Isolated - V Analog Output Module OM- = Isolated A / VAC Triac Output Module ( SSR ) DC- = Isolated V / ma DC Output Power Supply DC- = Isolated V / ma DC Output Power Supply DC- = Isolated V / ma DC Output Power Supply CM- = Isolated RS- Interface Module CM- = Isolated RS- Interface Module CM- = Isolated - ma / - ma Retransmission Module CM- = Isolated - V / - V Retransmission Module CM- = Isolated - V Retransmission Module CC- = RS- Interface Cable (M) UM. = FDC- User's Manual Range set by front keyboard Alternative between RS- and EI Need to order an accessory CT- if Heater Break detection is required. Related Products SNAA = Smart Network Adaptor for Third Party Software, Converts channels of RS- or RS- to RS- Network UM.

5 SW Programming Port and DIP Switch Access Hole Rear Terminal ON DIP Front Panel Control Chassis Bottom View Figure. Access Hole Overview The programming port is used to connect to PA hand-held programmer for automatic programming, also can be connected to ATE system for automatic testing & calibration. TC, RTD, mv DIP Switch ON OFF Input Select Lockout -V, -V, -V, -V - ma, - ma All parameters are Unlocked Only SP, SEL SEL are unlocked Only SP is unlocked All Parameters are locked Table. DIP Switch Configuration Factory Default Setting The programming port is used for off-line automatic setup and testing procedures only. Don't attempt to make any connection to these pins when the unit is used for a normal control purpose. When the unit leaves the factory, the DIP switch is set so that TC & RTD are selected for input and all parameters are unlocked. Lockout function is used to disable the adjustment of parameters as well as operation of calibration mode. However, the menu can still be viewed even under lockout SEL- SEL represent those parameters which are selected by using SEL, SEL,...SEL parameters contained in Setup menu. Parameters been selected are then allocated at the beginning of the user menu. UM.

6 Keys and Displays The unit is programmed by using three keys on the front panel. The available key functions are listed in following table. Table. Keypad Operation TOUCHKEYS FUNCTION DESCRIPTION Press for at least seconds Press for at least seconds Up Key Down Key Scroll Key Enter Key Start Record Key Press and release quickly to increase the value of parameter. Press and hold to accelerate increment speed. Press and release quickly to decrease the value of parameter. Press and hold to accelerate decrement speed. Select the parameter in a direct sequence. Allow access to more parameters on user menu, also used to Enter manual mode, auto-tune mode, default setting mode and to save calibration data during calibration procedure. Reset historical values of PVHI and PVLO and start to record the peak process value. Press Press Press Press for at least seconds Press Reverse Scroll Key Mode Key Reset Key Sleep Key Factory Key Select the parameter in a reverse sequence during menu scrolling. Select the operation Mode in sequence. Reset the front panel display to a normal display mode, also used to leave the specific Mode execution to end up the auto-tune and manual control execution, and to quit the sleep mode. The controller enters the sleep mode if the sleep function ( SLEP ) is enabled ( select YES ). By entering correct security code to allow execution of engineering programs. This function is used only at the factory to manage the diagnostic reports. The user should never attempt to operate this function. Set point Value Indicator Output Indicator How to display a -digit number? Power On Sequence Alarm Indicator Alarm / Output Indicator For a number with decimal point the Process Value Indicator display will be shifted one digit right Process Unit Indicator -. will be displayed by -. Upper Display,. will be displayed by A A PV to display process value, LC LF menu symbol and error For a number without decimal point code etc. the display will be divided into two alternating phases Lower Display, SV to display set point value, - will be displayed by parameter value or control OUT output value etc..) Display segments OFF for. secs..) Display segments ON for. secs.) Display Program Code for. secs.) Display Date Code for. secs..) Display S/N for. secs Program Code Confused Character FDC- Figure. Front Panel Description Table. Display Form of Characters Silicone Rubber Buttons for ease of control setup and set point adjustment. A E I N S X B F J O T Y C G K P U Z c H L Q V? D h M R W = will be displayed by - will be displayed by Program Version Program No. Date Code Date ('st) Month (December) Year () UM.

7 Menu Overview PV Value SV Value User Menu Press to enter Setup Mode. Press to select parameter. The upper display indicates the parameter symbol, and the lower display indicates the selection or the value of parameter. SEL SEL SEL SEL SEL Setup Menu Hand (Manual) Control Mode Auto-tuning Mode Display Mode Default Setting Mode for seconds Calibration Mode FILE To execute the default setting program for seconds Press for seconds to enter the auto-tuning mode Apply these modes will break the control loop and change some of the previous setting data. Make sure that if the system is allowable to use these modes. H C PVHI PVLO H C DV PV PV PB TI TD CJCT PVR PVRH PVRL AD ADG VG CJTL CJG REF SR MAG VG MAG UM. FUNC COMM PROT ADDR BAUD DATA PARI STOP AOFN AOLO AOHI IN INU DP INL INH IN INU DP INL INH OUT OTY CYC OFT OUT OTY CYC OFT AFN AMD AFT AFN AMD AFT EIFN PVMD FILT SELF SLEP SPMD SPL SPH SPF SEL SEL SEL SEL SEL TIME ASP ADV ASP ADV RAMP OFST REFC SHIF PB TI TD CPB DB SP PB TI TD OHY AHY AHY PL PL for seconds Display Go Home The menu will revert to PV/SV display after keyboard is kept untouched for minutes except Display Mode Menu and Manual Mode Menu. However, the menu can revert to PV / SV display at any time by pressing and. The flow chart shows a complete listing of all parameters. For actual application the number of available parameters depends on setup conditions, and should be less than that shown in the flow chart. See Appendix A- for the existence conditions of each parameter. You can select at most parameters put in front of the user menu by using SEL to SEL contained at the bottom of setup menu.

8 Parameter Description Table. Parameter Description Contained Basic Parameter Display in Function Notation Format User Menu Parameter Description Range SP Set point Low SPL High SPH Default Value. C (. F) TIME Dwell Time Low High. minutes. ASP Alarm Set point See Table.,.. C (. F) ADV Alarm Deviation Value Low -. C (-. F) High. C (. F). C (. F) ASP Alarm Set point See Table.,.. C (. F) ADV Alarm Deviation Value Low -. C (-. F) High. C (. F). C (. F) RAMP Ramp Rate Low High. C (. F). OFST REFC SHIF PB TI Offset Value for P control Reference Constant for Specific Function PV Shift (offset) Value Proportional Band Value Integral Time Value Low Low Low Low Low -. C (-. F) High High High High High. %. C (. F). C (. F) sec... C (. F) TD Derivative Time Value Low High. sec. CPB Cooling Proportional Band Value Low High % DB Heating-Cooling Dead Band Negative Value= Overlap Low -. High.% SP Set point See Table.,.. C (. F) PB Proportional Band Value Low High. C (. F). C (. F) TI Integral Time Value Low High sec TD Derivative Time Value Low High. sec. OHY AHY AHY PL Output ON-OFF Control Hysteresis Hysteresis Control of Alarm Hysteresis Control of Alarm Output Power Limit Low Low Low Low... High High High High. C (. F). C (. F). C (. F) %... PL Output Power Limit Low High % FUNC Function Complexity Level Basic Function Mode Full Function Mode No communication function RS- interface RS- interface Setup Menu COMM Communication Interface Type - ma analog retransmission output - ma analog retransmission output - V analog retransmission output - V analog retransmission output - V analog retransmission output - V analog retransmission output PROT COMM Protocol Selection Modbus protocol RTU mode UM.

9 Table. Parameter Description ( continued / ) Contained Basic Parameter Display in Function Notation Format ADDR Parameter Description Address Assignment of Digital COMM Low Range High Default Value. Kbits/s baud rate. Kbits/s baud rate. Kbits/s baud rate. Kbits/s baud rate. Kbits/s baud rate BAUD Baud Rate of Digital COMM. Kbits/s baud rate. Kbits/s baud rate. Kbits/s baud rate. Kbits/s baud rate. Kbits/s baud rate DATA Data Bit count of Digital COMM data bits data bits Even parity PARI Parity Bit of Digital COMM Odd parity No parity bit Setup Menu STOP Stop Bit Count of Digital COMM One stop bit Two stop bits Retransmit IN process value Retransmit IN process value Retransmit IN IN difference process value Retransmit IN IN difference process value AOFN Analog Output Function Retransmit set point value Retransmit output manipulation value Retransmit output manipulation value Retransmit deviation(pv-sv) Value AOLO AOHI Analog Output Low Scale Value Analog Output High Scale Value Low Low - - High High C (. F). C (. F) J type thermocouple K type thermocouple T type thermocouple IN IN Sensor Type Selection E type thermocouple B type thermocouple R type thermocouple () S type thermocouple UM.

10 Table. Parameter Description ( continued / ) Contained Basic Parameter Display in Function Notation Format Parameter Description Range Default Value C type thermocouple P type thermocouple PT ohms DIN curve PT ohms JIS curve IN IN Sensor Type Selection - ma linear current input - ma linear current input () - V linear Voltage input - V linear Voltage input - V linear Voltage input - V linear Voltage input Special defined sensor curve INU IN Unit Selection Degree C unit Degree F unit Process unit () No decimal point DP IN Decimal Point Selection decimal digit decimal digits Setup Menu INL IN Low Scale Value Low - decimal digits High INH IN High Scale Value Low - High IN no function Current transformer input - ma linear current input - ma linear current input IN IN Signal Type Selection - V linear voltage input - V linear voltage input - V linear voltage input - V linear voltage input INU IN Unit Selection Same as INU DP IN Decimal Point Selection Same as DP INL INH OUT IN Low Scale Value IN High Scale Value Low Low - - High High Reverse (heating ) control action Output Function Direct (cooling) control action Relay output Solid state relay drive output Solid state relay output OTY Output Signal Type - ma current module UM.

11 Table. Parameter Description ( continued / ) Contained Basic Parameter Display in Function Notation Format Parameter Description Range Default Value - ma current module - V voltage module OTY Output Signal Type - V voltage module - V voltage module - V voltage module CYC OFT Output Cycle Time Low. High. sec. Output Failure Transfer Mode Select BPLS ( bumpless transfer ) or. ~. % to continue output control function as the unit fails, power starts or manual mode starts. BPLS Output no function PID cooling control OUT Output Function Perform alarm function DC power supply module installed OTY Output Signal Type Same as OTY CYC Output Cycle Time Low. High. sec. OFT Output Failure Transfer Mode Select BPLS ( bumpless transfer ) or. ~. % to continue output control function as the unit fails, power starts or manual mode starts. BPLS Setup Menu No alarm function Dwell timer action Deviation high alarm Deviation low alarm Deviation band out of band alarm Deviation band in band alarm IN process value high alarm IN process value low alarm AFN Alarm Function IN process value high alarm IN process value low alarm IN or IN process value high alarm IN or IN process value low alarm IN IN difference process value high alarm IN IN difference process value low alarm Loop break alarm Sensor break or A-D fails Normal alarm action Latching alarm action AMD Alarm Operation Mode Hold alarm action Latching & Hold action UM.

12 Table. Parameter Description ( continued / ) Contained in Basic Parameter Display Function Notation Format AFT AFN Parameter Description Alarm Failure Transfer Mode Alarm Function Range Alarm output OFF as unit fails Alarm output ON as unit fails Same as AFN Default Value AMD Alarm Operation Mode Same as AMD AFT Alarm Failure Transfer Mode Same as AFT Event input no function SP activated to replace SP PB, TI, TD activated to replace PB, TI, TD SP, PB, TI, TD activated to replace SP, PB, TI, TD Reset alarm output EIFN Event Input Function Reset alarm output Reset alarm & alarm Disable Output Disable Output Disable Output & Output Lock All Parameters Setup Menu Selects remote setpoint active Use PV as process value Use PV as process value PVMD PV Mode Selection Use PV PV (difference) as process value Use PV PV (difference) as process value second time constant. second time constant. second time constant second time constant FILT Filter Damping Time Constant of PV seconds time constant seconds time constant seconds time constant seconds time constant seconds time constant seconds time constant SELF Self Tuning Function Selection Self tune function disabled Self tune function enabled SLEP Sleep mode Function Selection Sleep mode function disabled Sleep mode function enabled UM.

13 Table. Parameter Description Contained Basic Parameter Display in Function Notation Format Parameter Description Range Use SP or SP (depends on EIFN) as set point Default Value Use minute ramp rate as set point SPMD Set point Mode Selection Use hour ramp rate as set point Use IN process value as set point Use IN process value as set point SPL SPH SP Low Scale Value SP High Scale Value Low Low - - Selected for pump control High High C (. F). C (. F) SPF Format of set point Value set point (SP) is an actual value set point (SP) is a deviation value No parameter put ahead Parameter TIME put ahead Parameter ASP put ahead Parameter ADV put ahead Parameter ASP put ahead Parameter ADV put ahead Parameter RAMP put ahead Setup Menu SEL Select 'st Parameter Parameter OFST put ahead Parameter REFC put ahead Parameter SHIF put ahead Parameter PB put ahead Parameter TI put ahead Parameter TD put ahead Parameter CPB put ahead Parameter DB put ahead Parameter SP put ahead Parameter PB put ahead Parameter TI put ahead Parameter TD put ahead SEL Select 'nd Parameter Same as SEL SEL Select 'rd Parameter Same as SEL Calibration Mode Menu SEL Select 'th Parameter Same as SEL SEL Select 'th Parameter Same as SEL AD ADG VG CJTL A to D Zero Calibration Coefficient A to D Gain Calibration Coefficient Voltage Input Gain Calibration Coefficient Cold Junction Low Temperature Calibration Coefficient Low Low Low Low - High -. High. -. High. -. C High. C UM.

14 Table. Parameter Description ( continued / ) Contained Basic Parameter in Function Notation CJG Display Format Parameter Description Cold Junction Gain Calibration Coefficient Low -. Range High. Default Value REF Reference Voltage Calibration Coefficient for RTD Low -. High. Calibration Mode Menu SR Serial Resistance Calibration Coefficient for RTD Low -. High. MAG VG MAG PVHI PVLO ma Input Gain Calibration Coefficient Low -. Voltage Input Gain Calibration Coefficient ma Input Gain Calibration Coefficient Low Low Historical Maximum Value of PV Low - Historical Minimum Value of PV Low - High High High High High... MV Current Output Value Low High. % MV Current Output Value Low High. % Display Mode Menu DV PV PV PB TI TD CJCT PVR Current Deviation (PV-SV) Value IN Process Value IN Process Value Current Proportional Band Value Current Integral Time Value Current Derivative Time Value Cold Junction Compensation Temperature Current Process Rate Value Low Low Low Low Low Low Low Low C - High High High High High High High High. C (. F) sec sec. C PVRH Maximum Process Rate Value Low - High PVRL Minimum Process Rate Value Low - High Input Type J_TC K_TC T_TC E_TC B_TC R_TC S_TC Range Low Range High Input Type Range Low Range High - C (- F) C ( F) C_TC C ( F) C ( F) - C (- F) C ( F) P_TC C ( F) C ( F) - C (- F) C ( F) PT.DN - C (- F) C ( F) - C (- F) C ( F) PT.JS - C (- F) C ( F) C ( L) C ( F) CT Amp Amp C ( F). C ( F) C ( F). C ( F) Linear ( V, ma) or SPEC - Table. Input ( IN or IN ) Range UM.

15 Chapter 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. Component replacement To minimize the possibility of fire or shock hazards, do not expose this instrument to rain or excessive moisture. Do not use this instrument in areas under hazardous conditions such as excessive shock, vibration, dirt, moisture, corrosive gases or oil. The ambient temperature of the areas should not exceed the maximum rating Unpacking Upon receipt of the shipment remove the unit from the carton and inspect the unit for shipping damage. If any damage due to transit, report and claim with the carrier. Write down the model number, serial number, and date code for future reference when corresponding with our service center. The serial number (S/N) and date code (D/C) are labeled on the box and the housing of control. Mounting Make panel cutout to dimension shown in Figure.. Take both mounting clamps away and insert the controller into panel cutout. Install the mounting clamps back. Gently tighten the screws in the clamp till the controller front panels is fitted snugly in the cutout.. MOUNTING CLAMP. Panel cutout Figure. Mounting Dimensions Panel SCREW... UM.

16 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. All units should be installed inside a suitably grounded metal enclosure to prevent live parts being accessible from human hands and metal tools. All wiring must conform to appropriate standards of good practice and local codes and regulations. Wiring must be suitable for voltage, current, and temperature rating of the system. The " stripped " leads as specified in Figure. below are used for power and sensor connections. Beware not to over-tighten the terminal screws. Unused control terminals should not be used as jumper points as they may be internally connected, causing damage to the unit. Verify that the ratings of the output devices and the inputs as specified in Chapter are not exceeded. Electric power in industrial environments contains a certain amount of noise in the form of transient voltage and spikes. This electrical noise can enter and adversely affect the operation of microprocessor-based controls. For this reason we strongly recommend the use of shielded thermocouple extension wire which connects the sensor to the controller. This wire is a twisted-pair construction with foil wrap and drain wire. The drain wire is to be attached to ground at one end only..mm." max. Figure. Lead Termination. ~. mm." ~." _ OUT ALM+ _ OUT + L N - VAC A / VAC A / VAC - HZ, VA EI AO+ AO _ TC+ TC EI+ TX TX PTA PTB PTB COM + _ A B B EVENT + _ INPUT V CAT.II I ALM JA JB A / VAC AI AI+ CT CT+ _ CT + _ + AI Figure. Rear Terminal Connection Diagram UM.

17 Power Wiring The controller is supplied to operate at - VAC / VDC or -VAC.Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller. Fuse ~ ~ VAC or VAC / VDC Figure. Power Supply Connections This equipment is designed for installation in an enclosure which provides adequate protection against electric shock. The enclosure must be connected to earth ground. Local requirements regarding electrical installation should be rigidly observed. Consideration should be given to prevent from unauthorized person access to the power terminals. Sensor Installation Guidelines Proper sensor installation can eliminate many problems in a control system. The probe should be placed so that it can detect any temperature change with minimal thermal lag. In a process that requires fairly constant heat output, the probe should be placed closed to the heater. In a process where the heat demand is variable, the probe should be closed to the work area. Some experiments with probe location are often required to find this optimum position. In a liquid process, addition of a stirrer will help to eliminate thermal lag. Since the thermocouple is basically a point measuring device, placing more than one thermocouple in parallel can provide an average temperature readout and produce better results in most air heated processes. 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. Standard sensor limits of error are +/-degrees F (+/- degrees C ) or.% of sensed temperature (half that for special ) plus drift caused by improper protection or an over-temperature occurrence. This error is far greater than controller error and cannot be corrected on the sensor except by proper UM.

18 ON ON Thermocouple Input Wiring IThermocouple input connections are shown in Figure.. The correct type of thermocouple extension lead-wire MUST be used for the entire distance from thermocouple sensor to connection to the controller. Splices and joints should be avoided if at all possible. POLARITY MUST be observed when connecting thermocouples. If the length of thermocouple plus the extension wire is too long, it may affect the temperature measurement. A ohms K type or a ohms J type thermocouple lead resistance will produce degree C temperature error approximately. Figure. Thermocouple Input Wiring DIP Switch + RTD Input Wiring RTD connection are shown in Figure., with the compensating lead connected to terminal. For two-wire RTD inputs, terminals and should be linked. The three-wire RTD offers the capability of lead resistance compensation provided that Two-wire RTD should be avoided, if possible, for the purpose of accuracy. A. ohm lead resistance of a two-wire RTD will produce degree C temperature error. Figure. RTD Input Wiring DIP Switch RTD RTD Three-wire RTD Two-wire RTD UM.

19 ON ON + Linear DC Input Wiring DC linear voltage and linear current connections for input are shown in Figure. and Figure.. DC linear voltage and linear current connections for input are shown in Figure. and Figure.. Figure. Input Linear Voltage Wiring Figure. Input Linear Current Wiring DIP Switch DIP Switch ~V, ~V + ~V, ~V ~ma or ~ma Figure. Input Linear Voltage Wiring Figure. Input Linear Current Wiring ~V, ~V ~V, ~V + ~ma or ~ma + CT / Heater Current Input Wiring Figure. CT Input Wiring for Single Phase Heater + CT Signal Input Total current CT- not to exceed A RMS. UM.

20 + Output Wiring Max. A Resistive Load V/V Mains Supply -ma, -ma + Load + Maximum Load ohms Relay Output Linear Current VDC@ma or Pulsed Voltage -V, -V -V,-V - V + Load + Minimum Load Kohms Pulsed Voltage to Drive SSR Linear Voltage Max.A/V Load V /V Mains Supply Triac Figure. Output Wiring Triac (SSR) Output Direct Drive UM.

21 Output Wiring Max. A Resistive Load V/V Mains Supply - ma, - ma + Load + Maximum Load Ohm max Relay Output Linear Current Figure. Output Wiring VDC@ma or Pulsed Voltage + -V, -V -V,-V - V + Load + Minimum Load Kohm Pulsed Voltage to Drive SSR Linear Voltage Max. A / V Load V /V Mains Supply Triac Triac (SSR) Output UM.

22 Event Input wiring Figure. Event Input Wiring + Open Collector Input Switch Input The event input can accept a switch signal as well as an open collector signal. The event input function ( EIFN ) is activated as the switch is closed or an open collector ( or a logic signal ) is pulled down. Alarm Wiring Max. A Resistive Load V/V Mains Supply Figure. Alarm Wiring Note Both Form A and B contacts are available for alarm relay. Order a correct form for alarm to suit for your application. Relay Output Alarm Wiring Max. A Resistive Load V/V Mains Supply Figure. Alarm Wiring Relay Output UM.

23 RS- RS- to RS- network adaptor Figure. RS- Wiring SNAA or SNAB TX TX Twisted-Pair Wire RS- TX TX RS- PC TX TX Max. units can be linked TX TX Terminator ohms /.W Analog Retransmission Figure. Analog Retransmission Wiring Indicators PLC's Recorders + Load Load Data loggers Inverters etc. + Load Load + + -V,-V - -ma, Load - V -ma Retransmit Current Do not exceed ohms total load Indicators PLC's Recorders Data loggers Inverters etc. Load Retransmit Voltage Minimum load must be greater than K ohms. UM.

24 RS- PC TX TX COM -pin RS- port Figure. RS- Wiring CC- Note If the FDC- is configured for RS- communication, the EI ( Event Input ) is disconnected internally. The unit can no longer perform event input function (EIFN). When you insert a RS- module (CM-) to the connectors on CPU board (C), the jumper JP on terminal board (T) must be modified as following J must be shorted and J must be cut and left open. Location of JP is shown in the following diagram. CN M M T-B RY JP Figure. Location of Jumper JP JA JP J J JB CN If you use a conventional -pin RS- cable instead of CC-, the cable must be modified according to the following circuit diagram. To DTE(PC) RS- Port FDC- TX TX COM TX TX COM RD TD GND Female DB- DCD RD TD DTR GND DSR RTS CTS RI Figure. Configuration of RS- Cable UM.

25 Chapter Programming Special Functions This unit provides an useful parameter " FUNC " which can be used to select the function complexity level before setup. If the Basic Mode ( FUNC = BASC ) is selected for a simple application, then the following functions are ignored and deleted from the full function menu RAMP, SP, PB, TI, TD, PL, PL, COMM, PROT, ADDR, BAUD, DATA, PARI, STOP, AOFN, AOLO, AOHI, IN, INU, DP, INL, INH, EIFN, PVMD, FILT, SLEP, SPMD and SPF. Basic Mode capabilities () Input Thermocouple, RTD, Volt, ma () Input CT for heater break detection () Output Heating or Cooling ( Relay, SSR, SSRD, Volt, ma ) () Output Cooling ( Relay, SSR, SSRD, Volt, ma ), DC Power supply. () Alarm Relay for Deviation, Deviation Band, Process, Heater Break, Loop Break, Sensor Break, Latch, Hold or Normal Alarm. () Alarm Relay for Deviation, Deviation Band, Process, Heater Break, Loop Break, Sensor Break, Latch, Hold or Normal Alarm. () Dwell Timer () Hardware Lockout () Heater Break Alarm () Self-Tune () Loop Break Alarm () Auto-Tune () Sensor Break Alarm () ON-OFF, P, PD, PI, PID Control () Failure Transfer () User Defined Menu (SEL) () Bumpless Transfer () Manual Control () PV Shift () Display Mode () Programmable SP Range () Reload Default Values () Heat-Cool control () Isolated DC Power Supply If you don't need () Second setpoint () Second PID () Event input () Soft start (RAMP) () Remote set point () Complex process value () Output power limit () Digital communication () Analog retransmission () Power shut off (Sleep Mode) () Digital filter () Pump control () Remote lockout then you can use Basic Mode. Rearrange User Menu The conventional controllers are designed with a fixed parameters' scrolling. If you need a more friendly operation to suit your application, the manufacturer will say " sorry " to you. The FDC- has the flexibility for you to select those parameters which are most significant to you and put these parameters in the front of display sequence. SEL Selects the most significant parameter for view and change. SEL Selects the 'nd significant parameter for view and change. SEL Selects the 'rd significant parameter for view and change. SEL Selects the 'th significant parameter for view and change. SEL Selects the 'th significant parameter for view and change. Range NONE, TIME, A.SP, A.DV, A.SP, A.DV, RAMP, OFST, REFC, SHIF, PB, TI, TD, C.PB, SP, PB, TI, TD When using the up-down key to select the parameters, you may not obtain all of the above parameters. The number of visible parameters is dependent on the setup condition. The hidden parameters for the specific application are also deleted from the SEL selection. Example SEL selects TIME SEL selects A.DV SEL selects OFST SEL selects PB SEL selects NONE Now, the upper display scrolling becomes PV SEL SEL SEL SEL SEL UM.

26 Dwell Timer Alarm or alarm can be configured as a dwell timer by selecting TIMR for AFN or AFN but not BOTH. Otherwise Er will appear. As the dwell timer is configured, the parameter TIME is used for the dwell time adjustment. The dwell time is measured in minutes ranging from to. minutes. Once the process reaches the setpoint the dwell timer begins to count from zero until time out. The timer relay output will remain unchanged until the dwell time has timed out. Then output will change state. The dwell timer operation is shown in the example below. PV Error Code SP If alarm is configured as dwell timer, ASP, ADV, AHY and AMD are hidden. Same case is for alarm. A or A ON OFF TIME Timer starts Time Time Figure. Dwell Timer Function Example Set AFN=TIMR or AFN=TIMR but not both. Adjust TIME in minutes AMD ( if AFN=TIMR ) or AMD ( if AFN=TIMR ) is ignored in this case. If a form B relay is required for dwell timer, then order form B alarm and configure AFN. Form B relay is not available for alarm. Manual Control The manual control may be used for the following purposes ( ) To test the process characteristics to obtain a step response as well as an impulse response and use these data for tuning a controller. () To use manual control instead of a close loop control as the sensor fails or the controller's A-D converter fails. NOTE that a bumpless transfer can not be used for a longer time. See section -. ( ) In certain applications it is desirable to supply a process with a constant demand. Operation Press until ( Hand Control ) appears on the display. Press for seconds then the upper display will begin to flash and the lower display will show. The controller now enters the manual control mode. Pressing the lower display will show and alternately where indicates output ( or heating ) control variable value MV and indicates output ( or cooling ) control variable value MV. Now you can use up-down key to adjust the percentage values for H or C. The controller performs open loop control as long as it stays in manual control mode. The H value is exported to output ( OUT ) and C value is exported to output provided that OUT is performing cooling function ( ie. OUT selects COOL ). UM. Exit Manual Control To press keys the controller will revert to its previous operating mode ( may be a failure mode or normal control mode ). Means MV=. % for OUT ( or Heating ) Means MV=. % for OUT ( or Cooling ) Exception If OUT is configured as ON-OFF control ( ie. PB= if PB is assigned or PB= if PB is assigned by event input ), the controller will never perform manual control mode. UM.

27 Failure Transfer Failure Mode Occurs as The controller will enter failure mode as one of the following conditions occurs. SBE. SBE occurs ( due to the input sensor break or input current below ma. SBE if - ma is selected or input voltage below.v if - V is selected ) if. ADER PV, P- or P- is selected for PVMD or PV is selected for SPMD.. SBE occurs ( due to the input sensor break or input current below ma Failure Transfer of outout and output if - ma is selected or input voltage below.v if - V is selected ) if occurs as PV, P- or P- is selected for PVMD or PV is selected for SPMD.. Power start ( within. seconds ). ADER occurs due to the A-D converter of the controller fails.. Failure mode is activated. Manual mode is activated Output Failure Transfer, if activated, will perform. Calibration mode is activated. If output is configured as proportional control ( PB =),andbpls is selected for OFT, then output will perform bumpless transfer. Thereafter Failure Transfer of alarm and alarm the previous averaging value of MV will be used for controlling output. occurs as. If output is configured as proportional control ( PB = ), and a value of. Failure mode is activated to. % is set for OFT, then output will perform failure transfer. Thereafter the value of OFT will be used for controlling output. Failure Transfer Setup. If output is configured as ON-OFF control ( PB =),then output will be. OFT driven OFF if OFN selects REVR and be driven ON if OFN selects DIRT.. OFT. AFT Output Failure Transfer, if activated, will perform. AFT. If OUT selects COOL, and BPLS is selected for OFT, then output will perform bumpless transfer. Thereafter the previous averaging value of MV will be used for controlling output. Exception If Loop Break (LB) alarm or. If OUT selects COOL, and a value of to. % is set for OFT, then sensor Break (SENB) alarm is output will perform failure transfer. Thereafter the value of OFT will be configured forafn or AFN, the alarm/ used for controlling output. will be switched to ON state independent Alarm Failure Transfer is activated as the controller enters failure mode. of the setting of AFT/ AFT. If Dwell Timer Thereafter the alarm will transfer to the ON or OFF state preset by AFT. (TIMR) is configured for AFN/AFN, the alarm / alarm Alarm Failure Transfer is activated as the controller enters failure mode. will not perform failure transfer. Thereafter the alarm will transfer to the ON or OFF state preset by AFT. Signal Conditioner DC Power Supply Three types of isolated DC power supply are available to supply an external transmitter or sensor. These are V rated at ma, V rated at ma and V rated at ma. The DC voltage is delivered to the output terminals. + Two-line Transmitter + Set OUT = DC Power Supply Figure. DC Power Supply Applications + - ma Caution Don't use the DC power supply beyond its rating current to avoid damage.purchase a correct voltage to suit your external devices. See ordering code in section -. UM.

28 Bumpless Transfer The bumpless transfer function is available for output and output ( provided Bumpless Transfer Setup that OUT is configured as COOL ).. OFT = BPLS. OFT = BPLS Bumpless Transfer is enabled by selecting BPLS for OFT and/or OFT and activated as one of the following cases occurs Bumpless Transfer Occurs as. Power starts ( within. seconds ).. Power Starts ( within. seconds ). The controller enters the failure mode. See section - for failure mode. Failure mode is activated descriptions.. Manual mode is activated. The controller enters the manual mode. See section - for manual mode. Calibration mode is activated descriptions.. The controller enters the calibration mode. See Chapter for calibration mode descriptions. As the bumpless transfer is activated, the controller will transfer to open-loop control and uses the previous averaging value of MV and MV to continue control. Without Bumpless Transfer Set point PV Power interrupted Large deviation Sensor break Time Figure. Benefits of Bumpless Transfer Since the hardware and software need time to be initialized, the control is abnormal as the power is recovered and results in a large disturbance to the process. During the sensor breaks, the process loses power. With Bumpless Transfer Set point PV Power interrupted Sensor break Small deviation Load varies Time After bumpless transfer configured, the correct control variable is applied immediately as the power is recovered, the disturbance is small. During the sensor breaks, the controller continues to control by using its previous value. If the load doesn't change, the process will remain stable. Thereafter, once the load changes, the process may run away. Therefore, you should not rely on a bumpless transfer for a longer time. For fail safe reason, an additional alarm should be used to announce the operator when the system fails. For example, a Sensor Break Alarm, if configured, will switch to failure state and announces the operator to use manual control or take a proper security action when the system enters failure mode. Warning After system fails, never depend on bumpless transfer for a long time, otherwise it might cause a problem to the system to run away. UM.

29 Self Tuning The Self-tuning which is designed by using an innovative algorithm provides an alternative option for tuning the controller. It is activated as soon as SELF is selected with YES. When Self-tuning is working, the controller will change its working PID values and compares the process behavior with previous cycle. If the new PID values achieve a better control, then changing the next PID values in the same direction, otherwise, changing the next PID values in reverse direction. When an optimal condition is obtained, the optimal PID values will be stored in PB, TI, TD or PB, TI, TD which is determined by Event Input conditions. When Self-tuning is completed, the value of SELF will be changed from YES to NONE to disable self-tuning function. When the Self-tuning is enabled, the control variables are tuned slowly so that the disturbance to the process is less than auto-tuning. Usually, the Selftuning will perform successfully with no need to apply additional auto- Self-tune Menu or Default SELF=NONE Selects Disable Self-tuning Enable Self-tuning Exceptions The Self-tuning will be disabled as soon as one of the following conditions occurs. SELF is selected with NONE.. The controller is used for on-off control, that is PB=.. The controller is used for manual reset, that is TI=.. The controller is under loop break condition.. The controller is under failure mode (e.g. sensor break).. The controller is under manual control mode.. The controller is under sleep mode.. The controller is being calibrated. If the self-tuning is enabled, the auto-tuning can still be used any time. The self-tuning will use the auto-tuning results for its initial values. Benefits of Self-tuning. Unlike auto-tuning, Self-tuning will produce less disturbance to the. process. Unlike auto-tuning, Self-tuning doesn't change control mode during tuning. period. It always performs PID control. Changing set point during Self-tuning is allowable. Hence, Self-tuning can be used for ramping set point control as well as remote set point control where the set point is changed from time to time. Benefits of Self-tune. Less disturbance to the process.. Perform PID control during tuning period.. Available for ramping set point control and remote set point control. Operation The parameter SELF is contained in setup menu. Refer to Section - to obtain SELF for initiating a self-tuning. UM.

30 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-tuning value The control result is unsatisfactory Operation. The system has been installed normally.. Use the default values for PID before tuning. The default values are PB=PB=. F TI=TI= sec, TD=TD=. sec, Of course, you can use other reasonable values for PID before tuning according to your previous experiences. But don't use a zero value for PB and TI or PB and TI, otherwise, the auto-tuning program will be disabled.. Set the set point to a normal operating value or a lower value if overshooting beyond the normal process value is likely to cause damage.. Press until appears on the display. Applicable Conditions PB=, TI= if PB,TI,TD assigned PB=, TI=, if PB, TI, TD assigned. Press for at least seconds. The upper display will begin to flash and the auto-tuning procedure is beginning. NOTE Any of the ramping function, remote set point or pump function, if used, will be disabled once auto-tuning is proceeding. 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 ). See Figure.. If the auto-tuning begins apart from the set point ( Cold Start ), the unit enters Warm-up cycle. As the process reaches the set point value, the unit enters waiting cycle. The waiting cycle elapses a double integral time ( TI or TI, dependent on the selection, ) then it enters a learning cycle. The double integral time is introduced to allow the process to reach a stable state. Before learning cycle, the unit performs pre-tune function with a PID control. While in learning cycle the unit performs post-tune function with an ON-OFF control. Learning cycle is used to test the characteristics of the process. The data are measured and used to determine the optimal PID values. At the end of the two successive ON-OFF cycles the PID values are obtained and automatically stored in the nonvolatile memory. After the auto-tuning procedures are completed, the process display will cease to flash and the unit revert to PID control by using its new PID values. During pre-tune stage the PID values will be modified if any unstable phenomenon which is caused by incorrect PID values is detected. Without pre-tune stage, like other conventional controller, the tuning result will be strongly related to the time when the auto-tuning is applied. Hence different values will be obtained every time as autotuning is completed without pre-tune. It is particularly true when the auto-tuning are applied by using cold start and warm start. UM. Pre-tune Function Advantage Consistent tuning results can be obtained

31 Auto-tuning Begins Auto-tuning Complete PV Set Point Warm-up Cycle Waiting Cycle = Integral Time Learning Cycle New PID Cycle Figure. Auto-tuning Procedure Pre-tune Stage Post-tune Stage PID Control ON-OFF Control PID Control Cold Start Time PV Set Point Auto-tuning Begins Pre-tune Stage Waiting Cycle = Integral Time Pre-tune Stage Learning Cycle Post-tune Stage Auto-tuning Complete New PID Cycle PID Control ON-OFF Control PID Control Warm Start Time If the auto-tuning begins near the set point ( warm start ), the unit passes the warm-up cycle and enters the waiting cycle. Afterward the procedures are same as that described for cold start. Auto-Tuning Error If auto-tuning fails an ATER message will appear on the upper display in cases of If PB exceeds ( PU,. F or. C ). or if TI exceeds seconds. or if set point is changed during auto-tuning procedure. or if event input state is changed so that set point value is changed. Auto-Tuning Error Solutions to. Try auto-tuning once again.. Don't change set point value during auto-tuning procedure.. Don't change event input state during auto-tuning procedure.. Use manual tuning instead of auto-tuning. ( See section - ).. Touch any key to reset message. UM.