User`s Manual - iProcesSmart.com
Contents
1. 2 AT H Retur Key 4 INPUT RANGE amp ACCURACY IN Sensor Input Type Range C Accuracy 0 J Iron Constantan 50 to 999 C 2 C 1 K Chromel Alumel 50 to 1370 C 2 C 2 T Copper Constantan 270 to 400 C 2 C 3 E Chromel Constantan 50 to 750 C 2 C 4 B Pt30 RH Pt6 RH 300 to 1800 C 3 C 5 R Pt13 RH Pt 0 to 1750 C 2 C 6 S Pt10 RH Pt 0 to 1750 C 2 C 7 N Nicrosil Nisil 50 to 1300 C 2 C 8 RTD PT100 ohms DIN 200 to 400 C 0 4 C 9 RTD PT100 ohms JIS 200 to 400 C 0 4 C 10 Linear 10mV to 60mV 1999 to 9999 0 05 5 SPECIFICATIONS INPUT Thermocouple T C RTD Linear Range Accuracy Cold Junction Compensation Sensor Break Protection External Resistance Normal Mode Rejection Common Mode Rejection Sample Rate CONTROL Proportion Band Reset Integral Rate Derivative Ramp Rate Dwell ON OFF Cycle Time Control Action POWER Rating Consumption ENVIRONMENTAL 8 PHYSICAL Operating Temperature Humidity Insulation Breakdown Vibration Shock Net Weight Housing Materials Safety Page 1 type J K T E B R S N PT100 ohm RTD DIN 43760 BS1904 or JIS 10 to 60mV configurable input attenuation User configurable refer to Table above Refer to Table above 0 1 C ambient typical Protection mode configurable 100 ohms max 60dB 120dB2. 3 times second 0 200 0 360 F 0 3600 seconds 0 1000 seconds 0 200 0 C minute 0 360 0 F minute 0 3600 minutes With adjustable hysteresis 0 20 of SPAN 0 120 seconds Direct for cooling and reverse for heating 90 264VAC 50 60Hz Less than 5VA 10 to 50 C 0 to 90 RH non codensing 20M ohms min 500 VDC AC2000V 50 60Hz 1 minute 10 55Hz amplitude 1mm 200 m s 20g 240 grams Poly Carbonate Plastic UL CSA CE 6 INSTALLATION 6 1 DIMENSIONS 8 PANEL CUTOUT 3 62 kh 3 62 Panel Cutout Figure 6 1 Mounting Dimensions 6 2 WIRING DIAGRAM FDC 4120 90 264 VAC 1 AC1 11 Power Input 2 lacz 12 Control 3 eg edly Interface OuT1 4 21 7v 11 14 7 O 15 c SN 1 Tx2 a 6 ov 1 7 17L Alarm1 sr 18 Alarm Com 9 7 Jaro Alarm2 1012 8 OPERATION 8 1 KEYPAD OPERATION 7 7 CALIBRATION Note Do not proceed through this section unless their is a genuine need to re calibrate the controller All previous calibration data will be lost Do not attempt recalibration unless you have available appropriate calibration eq to Pri uipment If calibration data is lost you will need to return the controller your supplier who may apply a charge for re calibration ior to calibration ensure that all parameter settings are co
3. PF User s Manual FDC 4120 Self Tune Fuzzy PID Process Temperature Controller c O N T R O L S Model FDC 4120 Instruction Manual f 1 INTRODUCTION 2 NUMBERING SYSTEM 3 FRONT PANEL DESCRIPTION 4 INPUT RANGE amp ACCURACY 5 SPECIFICATIONS 6 INSTALLATION CONTENTS 7 CALIBRATION 8 OPERATION 9 ERROR MESSAGES 10 COMMON FAILURES 11 T C COLOR CODES 1 INTRODUCTION This manual contains information for the installation and operation of the Future Design model FDC 4120 Fuzzy Logic micro processor based controller The Fuzzy Logic is an essential feature of this versatile controller Although PID control has been widely accepted by industries yet it is difficult for PID control to work with some sophistic systems efficiently for examples systems of second order long time lag various setpoints various loads etc Because of disadvantage of controlling principles and fixed values of PID control it is inefficient to control the systems with plenty of varieties and the result is obviously frustrating for some systems The Fuzzy Logic control can overcome the disadvantage of PID control it controls the system in a efficient way by experiences it had before The function of Fuzzy Logic is to adjust the PID values indirectly in order to making the manipulation output value MV adjusts flexibly and quickly adapt to various processes By this way it enables a process to reach its predetermined setpoint in the
4. 25 Process Value 15 minutes lt Alarm Output t minutes 0 10 20 30 40 50 60 70 80 90 The dwell function may be used to operate an external device such as a siren to alert when a soak time has been reached ALA need to be set to the value 13 The alarm contact will now operate as a timer contact with the contact being open on the initial start up The timer begins to count down once the setpoint temperature is reached After the setting at ASP has elapsed the alarm contact closes 9 ERROR MESSAGES Solution s Re adjust i li E value Process display beyond the high a range setpoint Re adjust HL l k value Replace module Check for H cr Analog hybrid module damage outside source of damage such as transient voltage spikes Incorrect operation of auto tune Repeat procedure Increase Prop procedure Prop Band set to 0 Band to a number larger than 0 Manual mode is not allowable for an ON OFF control system r Check sum error values in memory may have changed L 5 E r accidentally I Replace RTD or sensor A L A I Sensor break emor Use manual mode operation 11 Process display beyond the low L L F range setpoint Ler Increase proportional band Check and reconfigure the control parameters Page 4 10 0 COMMON FAILURE CAUSES Common Fallure Causes and Corrective Actions Symptom Probable Causes Corrective Actions A Clean contact area on PCB 1 Keypad no function Bad connection
5. between PCB amp keypads Replace keypads a da No power to instrument Check power line connections 2 LED s will not light Power supply defective Replace power supply board 3 Some segments of the display or LED display or LED lamp defective Replace LED display or LED lamp LED lamps not lit or lit erroneously Related LED driver defective Replace the related transistor or IC chip Analog portion or A D converter defective Replace related components or board Thermocouple RTD or sensor defective Check thermocouple RTD or sensor 4 Display Unstable A Cl U i Intermittent connection of sensor wiring Check sensor wiring connections Wrong sensor or thermocouple type wrong Check sensor or thermocouple type and if 5 Considerable error in temperature input mode selected proper input mode was selected indication Analog portion of A D converter defective Replace related components or board 6 Display goes in reverse direction net cours dour scale as proces warms Reversed input wiring of sensor Check and correct No heater power output incorrect output Check output wiring and output device device used Replace output device 7 No heat or output Output device defective Replace output fuse Open fuse outside of the instrument 8 Heat or output stays on but indicator Output device shorted or power service Check and replace reads normal shorted CPU or EEPROM non volatile
6. e Level 1 O to 100 eee SH F Offset shift for process value 0 G 111 C to 111 C Add Address Code for Digital Transmission r 0 31 For Digital Transmission le Proportional Band 10 C Pb 0to 200 C set to O for on off control fe Integral Reset Time E i 0 to 3600 seconds 12059 Derivative Rate Time Y 0 to 1000 seconds E d F Local Mode Long gt 0 No control parameters can be changed 1 6 seconds 1 Control parameters can be changed L o G E Parameter Selection allows selection of additional parameters to G be accessible at level O security 0 None 6 rr gt oF SE 1 SEL 1 ASP 7 ASP rr oFSk 1 G 8 AGP 1 oF SE CE 9 ASP LASPE 1 Pirr oFSk 10 ASP2 rr Pe e in Relay y e Proportional Cycle Time ulsed Voltage AL A Oto 120 seconds inear VolumA e Input Mode Selection TIC AL 52 0 J type T C S type T C n K type T C N type T C y 2 T type T C PT100DIN AHY i E type T C PT100JIS E B type T C 10 Linear Voltage or Current y A ce R type TC Note T C Close solder gap J3 RTD Open J3 Linear 0 AH ye Levels larm Mode Selection lo Process High Alarm 8 Outband Alarm EF Process Low Alarm 9 Inband Alarm Deviation High Alarm 10 Inhibit Outband Alarm e Deviation Low Alarm 11 Inhibit Inband Alarm r E So Inhibit Process High Alam 12 Alarm Relay OFF as Dwell Inhibit Process Low Alarm Time Out Inhibit Deviation High Alarm 13 Alarm Relay ON as Dwell Con
7. to the desired position Indexs advanced continuously and cyclically by pressing this keypad Increases the parameter Decreases the parameter Resets the controller to its normal status Also stops auto tuning ou All 1 2 All All Page 2 tput percentage monitoring and manual mode operation ows more parameters to be inspected or changed Executes auto tuning function Calibrates control when in calibration level ows the set point display to indicate the control output value ows the controller to enter the manual mode 8 2 FLOW CHART 8 3 PARAMETER DESCRIPTION DESCRIPTION DEFAULT Level O ADJUSTMENT RANGE SETTING SETPOINT VALUE DISPLAY Setpoint Value of Control Undefined Low Limit to High Limit Value Long Co 6 seconds Alarm Setpoint Value ASP Low Limit to High Limit Value if AL A for AL Ag 9 1 4 or 5 0 to 3600 minutes if ALA 120r 13 200 C y le Low Limit minus set point to High Limit minus set point value ER if ALA for Al Ae 2 3 6 to 11 y Ramp Rate for the process value to limit an abrupt change of oFSE process Soft Start OOF ik y to 200 0 C 360 0 F minute if y M 0to9 ASP Oto 3600 unit minute if M 10 Offset Value for Manual Reset if E 0 0 0
8. either a fixed setpoint controller or as a single ramp controller on power up This function enables the user to set a pre determined ramp rate to allow the process to gradually reach setpoint temperature thus producing a Soft Start function A dwell timer is incorporated within the FDC 8120 and the alarm relay can be configured to provide either a dwell function to be used in conjunction with the ramp function The ramp rate is determined by the Fr parameter which can be adjusted in the range 0 to 200 0 C minute The ramp rate function is disabled when the r r parameter is set to o The soak function is enabled by configuring the alarm output to act as a dwell timer The parameterAL n needs to be set to the value 12 The alarm contact will now operate as a timer contact with the contact being closed at power up and opening after the elapsed time set at parameter ASP If the controller power supply or output is wired through the alarm contact the controller will operate as a guaranteed soak controller In the example below the Ramp Rate is set to 5 C minute AL A 12 and ASP 15 minutes Power is applied at zero time and the process climbs at 5 C minute to the setpoint of 125 C Upon reaching setpoint the dwell timer is activated and after the soak time of 15 minutes the alarm contact will open switching off the output The process temperature will eventually fall at an undetermined rate C 150 125 100 75 50
9. f Inhibit Deviation Low Alarm Time Out E 12 amp 13 only available with alarm 1 E fe Pr Hysteresis of Alarm 1 0 5 0 to 20 of SPAN HYSE C F Selection f amp 0 F 1 7 L L 1 E Resolution Selection 0 No Decimal Point 2 2 Digit Decimal 2 1 1 Digit Decimal 3 3 Digit Decimal HL i E 2 8 3 may only be used for linear voltage or current y M 10 Lon ce Control Action R ie ps 0 Direct Cooling Action 1 Reverse Heat Action Ir L Error Protection EL Output Alami Alarm2 Outputi Alami Alarm2 le Level 3 OFF OFF OFF 4 OFF OFF HE AL ON OFF 5 OFF ON 1 OFF OFF 6 ON OFF y ON ON OFF 7 ON ON ON The return key can be pressed at any time H y 5 E Aue AN FE Control This will prompt the display to return to the to So Process value Setpoint value Pitre Low Limit of Range Power Applied Fi E High Limit of Range 1000 C 1 4 120 34 Displayed for 4 seconds TL LAL Low Calibration Figure Software Version 3 4 or higher ALAL High Calibration Figure 800 C 2 8888 8888 LED test NOTES Adjusting Range of the Parameter All LED segments must be lit for 4 seconds Factory settings Process alarms are at fixed temperature points Deviation 3 Process value and setpoint indicated alarms move with the setpoints value Page 3 8 4 AUTOMATIC TUNING ak Ensure that controller is correctly configured and installed 2 Ensure Proportional Band Pb is not set at 0 3 Press Ret
10. memory Check and replace 9 Control abnormal or operation incorrect defective Key switch defective Read the setup procedure carefully Incorrect setup values Suppress arcing contacts in system to sie Electromagnetic interference EMI or eliminate high voltage spike sources 10 Display blinks entered values change Radio Frequency interference RFI Separate sensor and controller wiring from y EEPROM defective dirty power lines ground heaters Replace EEPROM 11 0 T C COLOR CODES Thermocouple Cable Color Codes Thermocouple Cable British American German French Type Material BS ASTM DIN NFE Copper Cu white blue red yellow T Constantan blue red brown blue Cu Ni blue blue brown blue Iron Fe yellow white red yellow J Constantan blue red blue black Cu Ni black black blue black ago ae brown yellow red yellow K VA blue red green purple a O red yellow green yellow white black red yellow E dida blue red white green didas green green white green r Pt 30 Rh Use E a Use Pt 6 Rh Copper Wire grey grey Copper Wire Colour of overall sheath Page 5 c O N T R O L S fd FuTUREDESIGN 7524 West 98th Place Bridgeview IL 60455 Phone 888 751 5444 Fax 888 307 8014 jenueiy sasn A9 O1JUOD nyer dw L SS3301d 02 1by 9d3
11. rrect input type C F resolution low range high range 1 Press and release the Scroll Key Turn power off the unit Remove sensor input wiring and connect a standard input simulator of the correct type to the controller input Verify correct polarity Set simulated signal to coincide with low process signal e g zero degrees Use the Scroll Key until the CAL appears on the PV Display Refer to 8 2 Use the Up and Down Keys until the SV Display represents the simulated input Press the Return Key for at least 6 seconds maximum 16 seconds then release This enters the low calibration figure into the controller s non volatile memory HEAL This indicates the high calibration point appears on the PV Display Increase the simulated input signal to coincide with high process signal e g 100 degrees Use the Up and Down Keys until the SV Display represents the simulated high input Press the Return Key for at least 6 seconds maximum 16 seconds then release This enters the high calibration figure into the controller s non volatile memory remove all test wiring and replace sensor wiring observing polarity With power on it has to wait for 12 seconds to memorize the new values of parameters once it been changed TOUCHKEYS Output Percentage Monitor Te E AT Press for 6 se Manual Mode Execution DESCRIPTION Advance the index display
12. shortest time with minimum overshooting during tuning or external disturbance Different from PID control with digital information the Fuzzy Logic is a control with language information PID control when properly tuned PID Fuzzy control PID FUZZY CONTROL Temperature PV MV Setpoint gt Warm Up Load Disturbance In addition this instrument has functions of single stage ramp and dwell auto tuning and manual mode execution Ease of use is also an essential feature with it 2 NUMBERING SYSTEM OODOODOOO Model No 1 2 8 4 5 6 7 8 1 Power Input 4 90 264VAC 5 20 32VAC VDC 9 Other 2 Signal Input Configurable Universal o Other 3 Range Code 1 Configurable 9 Other 4 Control Mode 3 _ PID ON OFF Control 5 Output 1 Option 0 20mA linear max load 500 ohms Module OM93 2 0 10V linear min impedance 500K ohms Module OM93 3 Other 6 Output 2 Option 0 None 7 Alarm Option 8 Communication None RS 485 4 20mA retransmission 0 20mA retransmission Other 3 FRONT PANEL DESCRIPTION Control Output TAN PV Alarm Outputs FDC 4120 HC Indicator D C D F F Indicator Process Value Display a amio sv Aamo i 0 4 red LED Setpoint Value Display 0 3 green LED Up Key Scroll Key ae eas Key N f
13. ure reference Make slight changes to only one setting at a time and observe the results on the process Because each of the settings interact with each other it is easy to become confused with the results if you are not familiar with process control procedures TUNING GUIDE Proportional Band Symptom Slow Response Solution Decrease PB Value High Overshoot or Oscillations Integral Time Reset Sympton Increase PB Value Solution Decrease Integral Time Slow Response Instability or Oscillations Derivative Time Rate Increase Integral Time Symptom Slow Response or Oscillations High Overshoot Solution Decrease Deriv Time Increase Deriv Time 8 6 MANUAL TUNING PROCEDURE Step 1 Adjust the integral and derivative values to 0 This inhibits the rate and reset action Step 2 Set an arbitrary value of proportional band and monitor the control results Step 3 If the original setting introduces a large process oscillation then gradually increase the proportional band until steady cycling occurs Record this proportional band value Pc Step 4 Measure the period of steady cycling PV PV Process value TIME Record this value Tc in seconds Step 5 The Control Settings are determined as follows Proportional Band PB 1 7 Pc Integral Time TI 0 5 Te Derivative Time TD 0 125 Tc 8 7 RAMP amp DWELL The FDC 4120 controller can be configured to act as
14. urn Key for at least 6 seconds maximum 16 seconds This initialises the Auto tune function To abort auto tuning procedure press Return Key and release 4 The Decimal point in lower right hand corner of PV display flashes to indicate Auto tune is in progress Auto tune is complete when the flashing stops 5 Depending on the particular process automatic tuning may take up to two hours Processes with long time lags will take the longest to tune Remember while the display point flashes the controller is auto tuning NOTE If an AT error AE Er occurs the automatic tuning process is aborted due to the system operating in ON OFF control PB 0 The process will also be aborted if the setpoint is set to close to the process temperature or if there is insufficient capacity in the system to reach setpoint e g inadequate heating power available Upon completion of Auto tune the new P I D settings are automatically entered into the controller s non volatile memory 8 5 MANUAL P I D ADJUSTMENT Whilst the auto tuning function selects control settings which should prove satisfactory for the majority of processes you may find it necessary to make adjustments to these arbitrary settings from time to time This may be the case if some changes are made to the process or if you wish to fine tune the control settings It is important that prior to making changes to the control settings that you record the current settings for fut
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