FDC-2500 Self-Tune Fuzzy / PID Process / Temperature Controller

Transcription

1 User's Manual FDC-25 Self-Tune Fuzzy / PID Process / Temperature Controller UM25C

2 CONTENTS Page No Chapter Overview - Features Ordering Code Programming Port and DIP Switch Keys and Displays Menu Overview Parameters Description Chapter 2 Installation 2- Unpacking Mounting Wiring Precautions Power Wiring Sensor Installation Guidelines Thermocouple Input Wiring RTD Input Wiring Linear DC Input Wiring CT / Heater Current Input Wiring Event Input Wiring Output Wiring Output 2 Wiring Alarm Wiring Alarm 2 Wiring RS RS Analog Retransmission Chapter 3 Programming Special Functions 3- Dwell Timer Self-Tuning Reload Default Parameters Auto-Tuning Manual Tuning Signal Conditioner DC Power Supply Failure Transfer Manual Control Sleep Mode Pump Control Remote Lockout Bumpless Transfer Chapter 4 Calibration Chapter 5 Error Codes and Troubleshooting Chapter 6 Specifications Appendix A- Menu Existence / Your Settings A-2 Warranty UM25C

3 Chapter Overview Features High accuracy 8-bit input A-D Fast input sample rate ( times / second) User menu configurable Pump control Automatic programming Auto-tune function Sleep mode function Programmable inputs( thermocouple, RTD, ma, VDC ) Event input for changing function & set point Hardware lockout remote lockout protection Heater break alarm RS-485, RS-232 communication Signal conditioner DC power supply Safety UL / CSA / IEC Front panel sealed to NEMA 4X & IP65 High accuracy 5-bit output D-A Two function complexity levels Adaptive heat-cool dead band Fuzzy PID microprocessor-based control Differential control Self-tune function Soft-start " ramp and dwell timer Analog input for remote set point and CT Programmable digital filter Loop break alarm Sensor break alarm Bumpless transfer Analog retransmission A wide variety of output modules available EMC / CE EN6326 FDC-25 Fuzzy Logic plus PID microprocessor-based controller, incorporates a bright, easy to read 4-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 /32 DIN case, measuring 24 mm x 48 mm with 98 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 5 parameters in front of user menu by using SEL to SEL5 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-25 is powered by -26 or VDC / AC supply, incorporating a 3 amp. control relay output, 5V logic alarm output and a 3 amp. alarm relay output as standard whereby second alarm can be exceptionally configured into second output for cooling purpose or dwell timer. Alternative output options include SSR drive, triac, 4-2 ma and - volts. FDC-25 is fully programmable for PT, thermocouple types J, K, T, E, B, R, S, N, L, - 2mA, 4-2mA and voltage signal input, with no need to modify the unit. The input signals are digitized by using a 8-bit A to D converter. Its fast sampling rate allows the FDC-25 to control fast processes such as pressure and flow. Self tune is incorporated. The selftune can be used to optimize the control parameters as soon as undesired control result is observed. Unlike auto-tuning, Self-tune will produce less disturbance to the process during tuning, and can be used any time. Digital communications RS-485, RS-232 or 4-2 ma retransmission are available as an additional option. These options allow FDC-25 to be integrated with supervisory control system and software, or alternatively drive remote display, chart recorders or dataloggers. Three kinds of method can be used to program FDC-25.. Use keys on front panel to program the unit manually, 2. Use a PC and setup software to program the unit via RS-485 or RS-232 COMM port. 3. Palm Pilot handheld device Available first quarter of 2. 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.2 Fuzzy PID Enhances Control Stability UM25C Time 3

4 2 Ordering Code FDC-25- Power Input VAC, 5/6 HZ 5-26 VAC or VDC 9 Special Order Signal Input Alarm Communications Standard Input 5V Logic None Input - Universal Input Output RS-485 ThermocoupleJ,K,T,E,B, T, 9 Special order 2 RS-232 R, S, N, L 3 Retransmit 4-2mA/-2mA RTD PT DIN, PT JIS 4Retransmit-5V/-5V - Current 4-2mA, - 2 ma. 5 Retransmit - V Voltage-V,-5V,-5V, Special order Output - V Input 2 - None CT - 5 Amp. AC Current Relay rated 2A/24VAC Output2/Alarm2 2 Transformer 2 Pulsed voltage to None Voltage Input - V, - 5V, drive SSR, 5V/3mA Form A Relay 2A/24VAC -5V,-V. - V. 3 Isolated 2 Pulsed voltage to Event Input ( EI ) 4-2mA / - 2mA drive SSR, 5V / 3mA 4 Isolated - 5V / - 5V 3 Isolated 4-2mA/ - 2mA 9 Special Order 5 Isolated - V 4 Isolated - 5V/ - 5V 6 Triac Output 5 Isolated - V A / 24VAC,SSR 9 Special order 6 Triac Output, A / 24VAC, SSR 7 Isolated 2V / 25mA DC Example Output Power Supply Standard Model 8 Isolated 2V / 4 ma DC FDC-25-4 Output Power Supply operating voltage 9 Isolated 5V / 8mA DC Input Standard Input Output Power Supply Output Relay A Special order Output 2 Relay Range set by front keyboard Alarm 5V Logic Output Alternative between RS-232 and Input 2 RS- 485 Communication Interface Need to order an accessory CT94- if Heater Break detection is required. Accessories CT94- = -5 Amp.ACAC Current Transformer OM95-3=Isolated4-2mA/-2mAAnalogOutputModule - - Analog Output Module OM95-4=Isolated-5V/-5VAnalogOutputModule - 5V - 5V Output Module OM95-5 = Isolated - V Analog Output Module OM94-6 = Isolated A / 24VAC Triac Output Module ( SSR ) DC94- = Isolated 2V / 25mA DC Output Power Supply DC94-2 = Isolated 2V / 4mA DC Output Power Supply DC94-3 = Isolated 5V / 8mA DC Output Power Supply CM94- = Isolated RS-485 Interface Module CM94-2 = Isolated RS-232 Interface Module CM94-3 = Isolated 4-2 ma/-2 ma Retransmission Module CM94-4 = Isolated -5V/-5V - Retransmission Module CM94-5 = Isolated - V Retransmission Module CC94- = RS-232 Interface Cable (2M) UM25C = FDC-25 User's Manual Related Products PA = Hand-held Programmer for FDC Series Controller SNAA = Smart Network Adaptor for Third Party Software, Converts 255 channels of RS-485 or RS-422 to RS-232 Network SNAB = Smart Network Adaptor for FD-Net Software, Converts 255 channels of RS-485 or RS-422 to RS-232 Network VPFW2 = 2 Amp. Variable Period Full Wave SSR AC Power Module VPFW5 = 5 Amp. Variable Period Full Wave SSR AC Power Module VPFW = Amp. Variable Period Full Wave SSR AC Power Module 4 UM25C

5 3 Programming Port and DIP Switch Front Panel Access Hole Rear Terminal ON DIP Figure.3 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, -5V, -5V, -V -2 ma, 4-2 ma All parameters are Unlocked Only SP, SEL SEL5 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- SEL5 represent those parameters which are selected by using SEL, SEL2,...SEL5 parameters contained in Setup menu. Parameters been selected are then allocated at the beginning of the user menu. UM25C 5

6 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. Table.2 Keypad Operation TOUCHKEYS FUNCTION DESCRIPTION Up Key Down 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. Press for at least 3 seconds Press for at least 6 seconds Scroll Key Enter Key Start Record Key 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 Reverse Scroll Key Select the parameter in a reverse sequence during menu scrolling. Press Press Press for at least 3 seconds Press Mode Key Reset Key Sleep Key Factory Key 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. Output Indicator Output 2 Indicator Alarm Indicator 4-digit Display to display process value, set point value, menu symbol, parameter value, control output value and error code etc. C How to display a 5-digit number? For a number with decimal point the display will be shifted one digit right will be displayed by will be displayed by 4553 For a number without decimal point the display will be divided into two alternating phases will be displayed by Power On Sequence.) Display segments off for.5 secs. 2.) Display segments on for 2. secs. 3.) Display program code for 2.5 secs. 4.) Display date code for.25 secs. 5.) Display s/n code for.25 secs. 3 Silicone Rubber Buttons for ease of control setup and set point adjustment. Program Code Figure.4 Front Panel Description Table.3 Display Form of Characters 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 = Confused Character will be displayed by will be displayed by Program Version Program No. Date Code Date (3'st) Month (December) Year (999) 6 UM25C

7 5 Menu Overview 3 PV Value User or Menu 2 SV Value Setup Menu Hand (Manual) Control Mode Auto-tuning Mode Display Mode Default Setting Mode for 3 seconds Calibration Mode FILE To execute the default setting program for 3 seconds Press for 3 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 PV2 PB TI TD CJCT PVR PVRH PVRL AD ADG VG CJTL CJG REF SR MAG V2G FUNC COMM PROT ADDR BAUD DATA PARI STOP AOFN AOLO AOHI IN INU DP INL INH IN2 IN2U DP2 IN2L IN2H OUT OTY CYC OFT OUT2 O2TY CYC2 O2FT AFN AMD AFT A2FN A2MD A2FT EIFN PVMD FILT SELF SLEP SPMD SPL SPH SP2F DISF SEL SEL2 SEL3 SEL4 SEL5 SEL SEL2 SEL3 SEL4 SEL5 TIME ASP ADV A2SP A2DV RAMP OFST REFC SHIF PB TI TD CPB SP2 PB2 TI2 TD2 OHY AHY A2HY PL PL2 for 3 seconds Display Go Home The menu will revert to PV/SV display after keyboard is kept untouched for 2 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 5 parameters put in front of the user menu by using SEL to SEL5 contained at the bottom of setup menu. Set DISF (display format) value in the setup menu to determine whether PV or SV is displayed. UM25C 7

8 6 Parameter Description Table.4 Parameter Description Contained Basic Parameter Display in Function Notation Format Parameter Description Range SP Set point Low SPL High SPH Default Value. C (22. F) User Menu TIME Dwell Time Low High minutes. ASP Alarm Set point See Table.5,.6. C (22. F) ADV Alarm Deviation Value Low -2. C 2. C. C (-36. F) High ( 36. F) (8. F) A2SP Alarm 2 Set point See Table.5,.7. C (22. F) A2DV Alarm 2 Deviation Value Low -2. C 2. C. C (-36. F) High ( 36. F) (8. F) RAMP Ramp Rate Low High 5. C (9. F). OFST Offset Value for P control Low High. % 25. REFC SHIF PB TI TD CPB SP2 PB2 TI2 Reference Constant for Specific Function PV Shift (offset) Value Proportional Band Value Integral Time Value Derivative Time Value Cooling Proportional Band Value Set point 2 Proportional Band 2 Value Integral Time 2 Value Low Low Low Low Low Low Low Low -2. C (-36. F) See Table.5,.8 High 6.. C (8. F) 25. High 255 % High High High High High High 2. C ( 36. F) 5. C (9. F) sec 36. sec 5. C (9. F) sec C (. F). C (8. F) TD2 OHY AHY A2HY Derivative Time 2 Value Hysteresis Control of Alarm Hysteresis Control of Alarm 2 Low Low Low Low... High High High High 36. sec 55.6 C (. F). C (8. F). C (8. F) PL Output Power Limit Low High % PL2 Output 2 Power Limit Low High % FUNC Function Complexity Level Basic Function Mode Full Function Mode No communication function RS-485 interface 2 RS-232 interface Setup Menu COMM Communication Interface Type ma analog retransmission output 4-2 ma analog retransmission output 5 - V analog retransmission output 6-5V analog retransmission output 7-5V analog retransmission output 8 - V analog retransmission output PROT COMM Protocol Selection Modbus protocol RTU mode 8 UM25C

9 Table.6 Parameter Description ( continued 2/7) Contained Basic Parameter Display in Function Notation Format Parameter Description Range Default Value ADDR Low High Kbits/s baud rate.6 Kbits/s baud rate 2.2 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 7 data bits 8 data bits Even parity PARI Parity Bit of Digital COMM Odd parity 2 No parity bit Setup Menu STOP Stop Bit Count of Digital COMM One stop bit Two stop bits Retransmit IN process value Retransmit IN2 process value 2 Retransmit IN IN2 difference process value 3 Retransmit IN2 IN difference process value AOFN Analog Output Function 4 Retransmit set point value 5 Retransmit output manipulation value 6 Retransmit output 2 manipulation value 7 Retransmit deviation(pv-sv) Value AOLO AOHI Analog Output Low Scale Value Analog Output High Scale Value Low Low High High J type thermocouple C (32. F). C (22. F) K type thermocouple 2 T type thermocouple 3 E type thermocouple IN IN Sensor Type Selection 4 5 B type thermocouple R type thermocouple () 6 S type thermocouple UM25C 9

10 Table.6 Parameter Description ( continued 3/7 ) Contained Basic Parameter Display in Function Notation Format Parameter Description Range Default Value 7 N type thermocouple 8 L type thermocouple 9 PT ohms DIN curve PT ohms JIS curve IN IN Sensor Type Selection ma linear current input - 2 ma linear current input () 3 - V linear Voltage input 4-5V linear Voltage input 5-5V linear Voltage input 6 - V linear Voltage input 7 Special defined sensor curve INU IN Unit Selection Degree C unit Degree F unit () 2 Process unit No decimal point DP IN Decimal Point Selection 2 decimal digit 2 decimal digits Setup Menu INL IN Low Scale Value 3 Low decimal digits High INH IN High Scale Value Low High IN2 no function Current transformer input 4 - V linear voltage input IN2 IN2 Signal Type Selection 5 6-5V linear voltage input - 5V linear voltage input 7 - V linear voltage input 2 Perform Event input function IN2U IN2 Unit Selection Same as INU 2 DP2 IN2 Decimal Point Selection Same as DP IN2L IN2 Low Scale Value Low High IN2H IN2 High Scale Value Low High OUT Reverse (heating ) control action Output Function Direct (cooling) control action Relay output Solid state relay drive output 2 Solid state relay output OTY Output Signal Type ma current module UM25C

11 Table.6 Parameter Description ( continued 4/7 ) Contained Basic Parameter Display in Function Notation Format Parameter Description Range Default Value 4-2 ma current module 5 - V voltage module OTY Output Signal Type 6-5V voltage module 7-5V voltage module 8 - V voltage module CYC Output Cycle Time Low. High. sec 8. 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 Output 2 no function PID cooling control OUT2 Output 2 Function 2 2 Perform alarm 2 function 3 DC power supply module installed O2TY Output 2 Signal Type Same as OTY CYC2 Output 2 Cycle Time Low. High. sec 8. O2FT Output 2 Failure Transfer Mode Select BPLS ( bumpless transfer ) or. ~. % to continue output 2 control function as the unit fails, power starts or manual mode starts. BPLS Setup Menu No alarm function Dwell timer action 2 Deviation high alarm 3 Deviation low alarm 4 Deviation band out of band alarm 5 Deviation band in band alarm 6 IN process value high alarm 7 IN process value low alarm AFN Alarm Function 2 8 IN2 process value high alarm 9 IN2 process value low alarm IN or IN2 process value high alarm IN or IN2 process value low alarm 2 IN IN2 difference process value high alarm 3 IN IN2 difference process value low alarm 4 Loop break alarm 5 Sensor break or A-D fails Normal alarm action Latching alarm action AMD Alarm Operation Mode 2 Hold alarm action 3 Latching & Hold action UM25C

12 Table.6 Parameter Description ( continued 5/7 ) Contained Basic Parameter in Function Notation Display Format Parameter Description Range Default Value AFT Alarm Failure Transfer Mode Alarm output OFF as unit fails Alarm output ON as unit fails A2FN Alarm 2 Function Same as AFN 2 A2MD Alarm 2 Operation Mode Same as AMD A2FT Alarm 2 Failure Transfer Mode Same as AFT Event input no function SP2 activated to replace SP Reset alarm output EIFN Event Input Function 5 Reset alarm 2 output 6 Reset alarm & alarm 2 7 Disable Output 8 Disable Output 2 9 Disable Output & Output 2 Lock All Parameters Setup Menu Use PV as process value Use PV2 as process value PVMD PV Mode Selection 2 Use PV PV2 (difference) as process value 3 Use PV2 PV (difference) as process value second time constant.2 second time constant 2.5 second time constant 3 second time constant FILT Filter Damping Time Constant of PV seconds time constant 5 seconds time constant 2 6 seconds time constant 7 2 seconds time constant 8 3 seconds time constant 9 6 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 2 UM25C

13 Table.6 Parameter Description ( continued 6/7 ) Contained Basic Parameter Display in Function Notation Format Parameter Description Range Default Value Use minute ramp rate as set point SPMD Set point Mode Selection 2 3 Use hour ramp rate as set point Use IN process value as set point 4 Use IN2 process value as set point SPL SPH SP Low Scale Value SP High Scale Value 5 Low Low Selected for pump control High High LC (32. LF). LC (832. LF) SP2F Format of set point 2 Value set point 2 (SP2) is an actual value set point 2 (SP2) is a deviation value DISF Display Format Display PV value Display SV value No parameter put ahead Parameter TIME put ahead 2 Parameter ASP put ahead 3 Parameter ADV put ahead 4 Parameter A2SP put ahead 5 Parameter A2DV put ahead 6 Parameter RAMP put ahead Setup Menu SEL Select 'st Parameter 7 8 Parameter OFST put ahead Parameter REFC put ahead 9 Parameter SHIF put ahead Parameter PB put ahead Parameter TI put ahead 2 Parameter TD put ahead 3 Parameter CPB put ahead 4 Reserved, not used 5 Parameter SP2 put ahead 6 Parameter PB2 put ahead 7 Parameter TI2 put ahead 8 Parameter TD2 put ahead SEL2 Select 2'nd Parameter Same as SEL SEL3 Select 3'rd Parameter Same as SEL SEL4 Select 4'th Parameter Same as SEL Calibration Mode Menu SEL5 Select 5'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 -36 High High High BC High 4. LC UM25C 3

14 Table.6 Parameter Description ( continued 7/7 ) Contained Basic Parameter Display in Function Notation Format CJG Parameter Description Cold Junction Gain Calibration Coefficient Low Range High 99.9 Default Value REF Reference Voltage Calibration Coefficient for RTD Low High 99.9 Calibration Mode Menu SR MAG V2G PVHI PVLO MV Serial Resistance Calibration Coefficient for RTD Low High 99.9 ma Input Gain Calibration Coefficient Low High 99.9 Voltage Input 2 Gain Calibration Coefficient Low High 99.9 Historical Maximum Value of PV Low High Historical Minimum Value of PV Low High Current Output Value Low High. % MV2 Current Output 2 Value Low High. % DV Current Deviation (PV-SV) Value Low -26 High 26 Display Mode Menu PV PV2 PB IN Process Value IN2 Process Value Current Proportional Band Value Low Low Low High High High LC (9. LF) TI Current Integral Time Value Low High 4 sec TD CJCT Current Derivative Time Value Cold Junction Compensation Temperature Low Low -4. LC High High 44 sec 9. LC PVR Current Process Rate Value Low High 6383 PVRH Maximum Process Rate Value Low High 6383 PVRL Minimum Process Rate Value Low High 6383 Input Type Table.5 Input ( IN or IN2 ) Range J_TC K_TC T_TC Range Low -2 LC -2 LC -25 LC (-84 L F) (-328 L F) (-48 L F) Range High LC 37 LC 4 LC (832 L F) (2498 L F) (752 L F) E_TC B_TC R_TC S_TC - LC LC LC LC (-48 L F) (32 L F) (32 L F) (32 L F) 9 LC 82 LC LC LC (652 L F) (338 L F) (324 LF) (324 LF) Input Type Range Low Range High N_TC L_TC -25 LC -2 LC (-48 L F) (-328 L F) 3 LC 9 LC (2372 L F) (652 L F) PT.DN PT.JS -2 LC -2 LC (-346 L F) (-328 L F) 7 LC 6 LC (292 L F) (2 L F) CT Amp 9 Amp Linear ( V, ma) or SPEC UM25C

15 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. Component replacement and internal adjustments must be made by a Qualified maintenance person only. 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 specified in Chapter 6. 2 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. 2 2 Mounting Make panel cutout to dimension shown in Figure 2.. 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..77 MOUNTING CLAMP.87 SCREW Panel Figure 2. Mounting Dimensions UM25C 5

16 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. 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 2.2 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 8 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. 2.mm.8" max. Figure 2.2 Lead Termination 4.5 ~ 7. mm.8" ~.27" A RTD _ L N VAC Hz,5VA 2A/24 VAC 2A/24 VAC V,CT PTA TC PTB EI,TC PTB V,CT EI,COM AO TX AO TX B _ B _ V I OUT2 ALM2 V _ CT _ OUT ALM ALM _ ALM(LOGIC OUTPUT) CAT.II I Figure 2.3 Rear Terminal Connection Diagram 6 UM25C

17 2 4 Power Wiring The controller is supplied to operate at -26 VAC / VDC or 9-264VAC.Check that the installation voltage corresponds with the power rating indicated on the product label before connecting power to the controller. Fuse 9 ~ 264 VAC or ~ 26 VAC / VDC Figure 2.4 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. 2 5 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 A4degrees F ( A2degrees C ) or.75% 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 selection and replacement. UM25C 7

18 ON ON Thermocouple Input Wiring 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 entire distance between the controller and the thermocouple, ensuring that the t polarity is correctly observed throughout. Joints in the cable should be avoided, if possible. If the length of thermocouple plus the extension wire is too long, it may affect the temperature measurement. A 4 ohms K type or a 5 ohms J type thermocouple lead resistance will produce degree C temperature error approximately Figure 2.5 Thermocouple Input Wiring DIP Switch 2 7 RTD Input Wiring RTD connection are shown in Figure 2.6, with the compensating lead connected to terminal 9. For two-wire RTD inputs, terminals 9 and should be linked. The three-wire RTD offers the capability of lead resistance compensation provided that the Two-wire RTD should be avoided, if possible, for the purpose of accuracy. A.4 ohm lead resistance of a two-wire RTD will produce degree C temperature error Figure 2.6 RTD Input Wiring DIP Switch RTD RTD Three-wire RTD Two-wire RTD 8 UM25C

19 ON ON Linear DC Input Wiring DC linear voltage and linear current connections for input are shown in Figure 2.7 and Figure 2.8. DC linear voltage and linear current connections for input 2 are shown in Figure 2.9 and Figure 2.. Figure 2.7 Input Linear Voltage Wiring Figure 2.8 Input Linear Current Wiring DIP Switch ~V, ~5V ~5V, ~V DIP Switch ~2mA or 4~2mA Figure 2.9 Input 2 Linear Voltage Wiring Figure 2. Input 2 Linear Current Wiring ~V, ~5V ~5V, ~V ~2mA or 4~2mA R=25 ohms IN2= 5V or 5V 2 9 CT / Heater Current Input Wiring Figure 2. CT Input Wiring for Single Phase Heater CT Signal Input Make sure that the total current through CT94- not exceed 5A rms. UM25C 9

20 2 Event Input wiring Figure 2.3 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. 2 Output Wiring Max. 2A Resistive Load 2V/24V Mains Supply Max. A / 24V Load 2V /24V Mains Supply Triac Figure 2.4 Output Wiring Relay Output Triac (SSR) Output 3mA/5V Pulsed Voltage _ - 2mA, 4-2mA Load Maximum Load 5 ohms Pulsed Voltage to Drive SSR Linear Current -V, -5V -5V,-V - V Load Minimum Load K ohms Linear Voltage 2 UM25C

21 2 2 Output 2 Wiring Figure 2.5 Output 2 Wiring Max. 2A Resistive Load 2V/24V Mains Supply Max. A / 24V Load 2V /24V Mains Supply Triac Relay Output Triac (SSR) Output -2mA, 4-2mA Load -V, -5V -5V,-V - V Load Linear Current Maximum Load 5 ohms Linear Voltage Minimum Load K ohms 3mA/5V Pulsed Voltage _ Pulsed Voltage to Drive SSR UM25C 2

22 2 3 Alarm Wiring Figure 2.6 Alarm Wiring Internal Circuit 5V K V 4 5VDC Logic Output 2 4 Alarm 2 Wiring Figure 2.7 Alarm 2 Wiring Max. 2A Resistive Load 2V/24V Mains Supply Relay Output 2 5 RS RS-485 to RS-232 network adaptor Figure 2.8 RS-485 Wiring SNAA or SNAB TX TX2 Twisted-Pair Wire RS-485 TX TX2 RS-232 PC Last Unit In Network TX TX2 Max. 247 units can be linked TX TX2 Terminator 22 ohms /.5W 22 UM25C

23 ON DIP RS-232 PC COM TX TX2 9-pin RS-232 port Figure 2.9 RS-232 Wiring CC94- Note If the FDC-25 is configured for RS-232 communication, the input 2 and EI ( Event Input ) are disconnected internally. The unit can no longer perform event input function (EIFN) and input 2 function. When you insert a RS-232 module (CM94-2) to the connectors on CPU board (C25), the jumper J5 and J52 must be modified as following J52 must be shorted and J5 must be cut and left open. Location of jumper is shown in the following diagram. Jumper U52 Figure 2.2 Location of Jumper J5/J52 CN55 CN54 SW5 J52 J5 Display If you use a conventional 9-pin RS-232 cable instead of CC94-, the cable must be modified according to the following circuit diagram. To DTE(PC) RS-232 Port FDC-25 TX TX2 COM 9 4 TX TX2 COM RD TD GND Female DB-9 DCD 2RD 3TD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9RI Figure 2.2 Configuration of RS-232 Cable UM25C 23

24 2 7 Analog Retransmission The total effective resistance of serial loads can't exceed 5 ohms. The total effective resistance of parallel loads should be greater than K Ohms Indicators PLC's Recorders Data loggers Inverters etc. Load Load Load Indicators PLC's -5V,-5V - -2mA, Load Recorders - V 4-2mA Data loggers Inverters etc. Load Retransmit Current Retransmit Voltage Load Figure 2.22 Analog Retransmission Wiring Chapter 2 Programming Special Functions 3- DwellTimer Alarm or alarm 2 can be configured as dwell timer by selecting TIMR for AFN or A2FN, but not both, otherwise Er7 will appear. As the dwell timer is configured, the parameter TIME is used for dwell time adjustment. The dwell time is measured in minute ranging from to minutes. Once the process reaches the set point the dwell timer starts to count from zero until thel time out. The timer relay will remain unchanged until time out. The dwell timr operation is shown as following diagram. PV Error Code SP A or A2 ON OFF TIME Timer starts Time Time If alarm is configured as dwell timer, ASP, ADV, AHY and AMD are hidden. Same case is for alarm 2. Example Set AFN=TIMR or A2FN=TIMR but not both. Adjust TIME in minutes AMD ( if AFN=TIMR ) or A2MD ( if A2FN=TIMR ) is ignored in this case. If alarm is selected for dwell timer, an external 5V DC relay is required to drive AC load. Figure 3. Dwell Timer Function 24 UM25C

25 3-2 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 PB2, TI2, TD2 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 autottuning. Exceptions The Self-tuning will be disabled as soon as one of the following conditions occurs. SELF is selected with NONE. 2. The controller is used for on-off control, that is PB=. 3. The controller is used for manual reset, that is TI=. 4. The controller is under loop break condition. 5. The controller is under failure mode (e.g. sensor break). 6. The controller is under manual control mode. 7. The controller is under sleep mode. 8. The controller is being calibrated. Self-tune Menu or Default SELF=NONE Selects Disable Self-tuning Enable Self-tuning 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 2. process. Unlike auto-tuning, Self-tuning doesn't change control mode during tuning 3. 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. 2. Perform PID control during tuning period. 3. Available for ramping set point control and remote set point control. Operation The parameter SELF is contained in setup menu. Refer to Section -5 to obtain SELF for initiating a self-tuning. 3 3 Reload Default Values The default values listed in Table.4 are stored in the memory as the product leaves the factory. In certain occasions it is desirable to retain these values after the parameter values have been changed. Here is a convenient tool to reload the default values. Operation Press several times until. Then press. The upper display will show.use up-down key to select to. If BC unit is required, select for FILE and if BF unit is required, select for FILE. Then Press for at least 3 seconds. The display will flash a moment and the default values are reloaded. CAUTION The procedures mentioned above will change the previous setup data. Before doing so, make sure that if it is really required. FILE BC Default File FILE BF Default File UM25C 25

26 3-4 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. 2. Use the default values for PID before tuning. The default values are PB=PB2=8. F TI=TI2= sec, TD=TD2=25. 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 PB2 and TI2, otherwise, the auto-tuning program will be disabled. 3. 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. 4. Press until appears on the display. Applicable Conditions PB=, TI= if PB,TI,TD assigned PB2=, TI2=, if PB2, TI2, TD2 assigned 5. Press for at least 3 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 3.2. 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 TI2, dependent on the selection, see Section 4. ) 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. Pre-tune Function Advantage Consistent tuning results can be obtained 26 UM25C

27 Auto-tuning Begins Auto-tuning Complete PV Set Point Warm-up Cycle Waiting Cycle =2 Integral Time Learning Cycle New PID Cycle Figure 3.2 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 =2 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 9 ( 9 PU, 9. LF or 5. LC ). 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. 2. Don't change set point value during auto-tuning procedure. 3. Don't change event input state during auto-tuning procedure. 4. Use manual tuning instead of auto-tuning. ( See section 3-8 ). 5. Touch any key to reset message. UM25C 27

28 3-5 Manual Tuning 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 can try manual tuning. Connect the controller to the process and perform the procedures according to the flow chart shown in the following diagram. Use initial PID values to control the process Figure 3.3 Manual Tuning Procedure Wait and Examine the Process Wait and Examine the Process No Is steady state reached? No Is steady state reached? Yes Yes Does the process oscillate? No No Does the process oscillate? Yes Flag Flag Yes PB PBu Oscillating period Tu 2PB PB.5PB Wait and Examine the Process PB Load new PID values.7 PBu PB Tu TI.3 Tu TD No Is steady state reached? END Yes Does the process oscillate? Yes No NOTE The final PID values can't be zero. If PBu= then set PB=. If Tu < sec, then set TI= sec. No Flag=? Flag=? No Yes Yes.6PB PB.8PB PB The above procedure may take a long time before reaching a new steady state since the P band was changed. This is particularly true for a slow process. So the above manual tuning procedures will take from minutes to hours to obtain optimal PID values. 28 UM25C

29 The PBu is called the Ultimate P Band and the period of oscillation Tu is called the Ultimate Period in the flow chart of Figure 3.3. When this occurs, the process is called in a critical steady state. Figure 3.4 shows a critical steady state occasion. PV Set point If PB=PBu the process sustains to oscillate Tu Figure 3.4 Critical Steady State Time If the control performance by using above tuning is still unsatisfactory, the following rules can be applied for further adjustment of PID values ADJUSTMENT SEQUENCE SYMPTOM SOLUTION () Proportional Band ( P ) PB and/or PB2 Slow Response High overshoot or Oscillations Decrease PB or PB2 Increase PB or PB2 (2) Integral Time ( I ) TI and/or TI2 Slow Response Instability or Oscillations Decrease TI or TI2 Increase TI or TI2 Table 3.2 PID Adjustment Guide (3) Derivative Time ( D ) TD and/or TD2 Slow Response or Oscillations High Overshoot Decrease TD or TD2 Increase TD or TD2 Figure 3.5 Effects of PID Adjustment PV P action PB too low PV I action TI too high Perfect Set point Set point PB too high TI too low Perfect Time Time D action PV TD too low Perfect Set point TD too high UM25C Time 29

30 3 6 Signal Conditioner DC Power Supply Three types of isolated DC power supply are available to supply an external transmitter or sensor. These are 2V rated at 25mA, 2V rated at 4 ma and 5V rated at 8 ma. The DC voltage is delivered to the output 2 terminals. Two-line Transmitter Set OUT2= (DC Power Supply) Figure 3.6 DC Power Supply Applications mA Input Caution Don't use the DC power supply beyond its rating current to avoid damage. Purchase a correct voltage to suit your external devices. 3 7 Failure Transfer The controller will enter failure mode as one of the following conditions occurs. SBE occurs ( due to the input sensor break or input current below ma if 4-2 ma is selected or input voltage below.25v if -5 V is selected ) if PV, P-2 or P2- is selected for PVMD or PV is selected for SPMD. 2. SB2E occurs ( due to the input 2 sensor break or input 2 current below ma if 4-2 ma is selected or input 2 voltage below.25v if -5 V is selected ) if PV2, P-2 or P2- is selected for PVMD or PV2 is selected for SPMD. 3. ADER occurs due to the A-D converter of the controller fails. Output Failure Transfer, if activated, will perform. If output is configured as proportional control ( PB =),andbpls is selected for OFT, then output will perform bumpless transfer. Thereafter the previous averaging value of MV will be used for controlling output. 2. If output is configured as proportional control ( PB = ), and a value of to. % is set for OFT, then output will perform failure transfer. Thereafter the value of OFT will be used for controlling output. 3. If output is configured as ON-OFF control ( PB =),then output will be driven OFF if OFN selects REVR and be driven ON if OFN selects DIRT. Output 2 Failure Transfer, if activated, will perform. If OUT2 selects COOL, and BPLS is selected for OFT, then output 2 will perform bumpless transfer. Thereafter the previous averaging value of MV2 will be used for controlling output If OUT2 selects COOL, and a value of to. % is set for O2FT, then output 2 will perform failure transfer. Thereafter the value of OFT will be used for controlling output 2. Alarm Failure Transfer is activated as the controller enters failure mode. Thereafter the alarm will transfer to the ON or OFF state preset by AFT. Alarm 2 Failure Transfer is activated as the controller enters failure mode. Thereafter the alarm 2 will transfer to the ON or OFF state preset by A2FT. Failure Mode Occurs as. SBE 2. SB2E 3. ADER Failure Transfer of alarm and alarm 2 occurs as. Failure mode is activated Failure Transfer Setup. OFT 2. O2FT 3. AFT 4. A2FT Exception If Loop Break (LB) alarm or sensor Break (SENB) alarm is configured for AFN or A2FN, the alarm /alarm2 will be switched to ON state independentof the setting of AFT/A2FT. If Dwell Timer (TIMR) is configured for AFN/A2FN, the alarm /alarm2 will NOT perform failure transfer. 3 UM25C

31 3 8 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. (2) 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 3-2. ( 3 ) 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 3 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 2( or cooling ) control variable value MV2. Now you can use up-down key to adjust the percentage values for H or C. Means MV=38.4 % for OUT ( or Heating ) Means MV2=7.63 % for OUT2 ( or Cooling ) 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 2 provided that OUT2 is performing cooling function ( ie. OUT2 selects COOL ). Exception If OUT is configured as ON-OFF control ( ie. PB= if PB is assigned or PB2= if PB2 is assigned by event input ), the controller will never perform manual control mode. Exit Manual Control To press keys the controller will revert to its previous operating mode ( may be a failure mode or normal control mode ). 3 9 Sleep Mode To Enter Sleep Mode FUNC selects FULL to provide full function. SLEP selects YES to enable the sleep mode. Press for 3 seconds, the unit will enter its sleep mode. During sleep mode () Shut off all display except a decimal point which is lit periodically. (2) Shut off all outputs and alarms. To Exit Sleep Mode () Press to leave the sleep mode. (2) Disconnect the power. Sleep Mode Features Shut off display Shut off outputs Green Power Replace Power Switch Setup Menu FUNC=FULL SLEP=YES Sleep Function can be used to replace a power switch to reduce the system cost. Default SLEP=NONE, Sleep mode is disabled. Note If the Sleep mode is not required by your system, the SLEP should select NONE to disable sleep mode against undesirable occurrence. UM25C 3