Future Design FDC-C42 User guide

FDC-C42 Chamber Controller Manual Rev C
October 2022
FDC-C42 Chamber Controller
Installation –Setup –Operation - Service

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1 Introduction
This new generation of low-cost, microprocessor-based control incorporates two bright, easy to read LCD
displays which indicate process value (PV) and set point (SP). The control is powered by an 11-26 VDC
supply and incorporates a 2 Amp control relay output as a standard. The control is fully programmable for
PT100 RTD and thermocouple types J, K, T, E, B, R, S, N, L, U, P, C, and D. The input provides high
accuracy via an 18-bit A to D converter and when coupled with the fast-sampling rate, allows control of fast
processes.
1.1 Features
•LCD display
•Simple operation
•Universal input (thermocouple/RTD) with high accuracy 18-bit A-D conversion
•Fast sampling rate
•Degrees F or C operation
•Low voltage operation
•Programmable deadband alarm
•Power failure alarm
•Low battery indication
•Adjustable hysteresis for control and alarm outputs
•Process value calibration offset adjustment
•Control and alarm relay (SPST) output contacts
•Audible alarm with silence (utilizing external relay)
The FDC-C42 microprocessor-based controller, incorporates dual, easy to read 4-digit LCD readouts to
indicate process value and set point, as well as other controller operations. The unit features keys to select
the various operator views as well as control parameters. The FDC-C42 chamber controller is provided
pre-configured, specifically for low temperature chamber operation, providing simple to use, “hassle” free
operation for startup and operation of the chamber.
The FDC-C42 incorporates a (SPST) control relay output and three (SPST) alarm relay outputs. Two of
the alarm relays (AL1 for temperature and AL2 for power failure) are prewired together in order to facilitate
faster installation and connection to external alarm relays for remote indication and sounding the on-board
audible alarm (wired separately). A programmable deadband alarm set point allows the operator to
monitor/indicate alarm conditions above and below chamber operational settings.
The FDC-C42 provides digital inputs which are utilized for the power failure and low battery indicators
(compatible with MEAN WELL DRC-40/60 series power supplies). When main power is lost, the external
12Vdc backup battery will maintain power to the FDC-C42; however, the “power OK” input will be
deactivated causing the second alarm relay output (AL2) to activate and sound the audible alarm. Asilence
push-button is provided for the audible alarm, so that when a temperature and/or power failure alarm
occurs, the operator can silence the alarm.

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2 Installation
Dangerous voltages capable of causing death can be present within this instrument. Before
performing installation or troubleshooting procedures, the power to the equipment must be
switched off and isolated. Units suspected of being faulty must be disconnected and removed
to a properly equipped workshop for test and repair. Component replacement and internal
adjustments must be made by qualified maintenance personnel only.
To minimize the possibility of fire or electrical shock hazards, do not expose this instrument to
rain or excessive moisture.
This equipment is designed for installation in an enclosure which provides adequate protection
against electric shock. The enclosure must be connected to earth ground.
Do not use this instrument in areas that present hazardous conditions such as excessive shock,
vibration, dirt, moisture, corrosive gases or oil. Ambient temperature and humidity conditions
should not exceed the maximum ratings as specified in this manual.
To clean this equipment, use a soft, dry cloth. Do not use harsh chemicals, volatile solvents
such as thinner or strong detergents to clean the equipment in order to avoid deformation of
the instrument case.
2.1 Unpacking
Upon receipt of shipment, remove the controller from the carton and inspect the unit for shipping damage.
If there is any damage due to transit, report and file a claim with the carrier. Note the model number and
serial number for future reference when corresponding with our service center.
The controller is designed for indoor use only and is not intended for use in hazardous areas. It should be
located/installed in such a manner as to minimize effects of shock, vibration, and electromagnetic fields
(such as variable frequency drives), motors and transformers. It is designed to operate under the following
environmental conditions.
Environmental Parameter
Specification
Operating Temperature
-10°C to 50 °C
Humidity
0% to 90% RH (Non-condensing)
Altitude
2000 M Maximum

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2.2 Mounting
Make the panel cut out as per the dimensions shown in the following figure:

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2.3 Wiring
Electrical power in an industrial environment 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 of
twisted-pair construction with foil wrap and drain wire. The drain wire is to be attached to
ground at one end only.
The utmost care must be taken to ensure that the maximum voltage rating specified on the
controller label is not exceeded. It is recommended that the supply power of these units be
protected by a fuse or circuit breaker rated at the lowest value possible.
All units should be installed inside a suitably grounded metal enclosure to prevent live parts
being accessible to 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 the voltage, current and temperature rating of the
equipment.
The tightening torque on the screw terminals should not exceed 1 N-m (8.9 Lb-in or 10.2 Kg F-
cm). Except thermocouple wiring, all other wires used are to be standard copper conductors
with the maximum gauge not exceeding 14AWG.
Rear Terminal Layout

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The control assembly is provided with the alarm relay outputs, alarm silence push-button and audible alarm
pre-wired to aid in assembly. The pre-installed jumpers combine alarm outputs one and two (for
temperature and power failure) together so that only a single connection is required in order to activate the
external alarm relays.
One terminal of the push-button is pre-wired to the alarm outputs, so that only a single connection must be
made to the alarm silence relay. The audible alarm is pre-wired to the negative of the power supply
terminals as well as one terminal of the alarm 3 output (not used). This provides an easy termination point
for the field wiring required to active the audible alarm.
2.3.1 Main Power (Battery Backup) and Control Connections
The FDC C42 control unit was designed to use 12VDC power for its main power supply. The following
connection diagram is an example for the MEAN WELL DRC-40A power supply with built in battery charger
(UPS function).

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Power Supply
C42 Control Assembly
Terminal
Description
Terminal
Description
1
Output (V-)
-
14
N (DC-)
2
Output (V+)
-
13
L (DC+)
7
Bat Low (-)
-
1
EI COM
8
Bat Low (+)
-
3
EI2
The control relay is a single pole / single throw (SPST) configuration. The control relay will energize and
the contacts will close when the process value is at or above the set point value. The control relay will de-
energize when the process value is at or below the set-point value minus the control hysteresis. This output
is used to signal the control board to turn the compressors on and off. Event input 1 of the C42 control is
utilized for the power failure alarm indication and is active by the power failure output of the control board.

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Control Board
C42 Control Assembly
Terminal
Description
Terminal
Description
Call For Cooling
-
17
OP1 (COM)
Call For Cooling
-
18
OP1 (NO)
Power Failure Relay
-
1
EI COM
Power Failure Relay
-
2
EI1
2.3.2 Sensor Installation Guidelines
Proper sensor installation can eliminate many problems in a control system. The sensor should be placed
so that it can detect any temperature change with minimal thermal lag. Some experimentation with sensor
location is often required to find the optimum position.
Proper sensor type is also very important to obtain precise measurements. The sensor must have the
correct temperature range to meet the process requirements. In special process, the sensor may need to
meet different requirements such as leak-proof, anti-vibration, antiseptic, etc.
The FDC c42 control has been pre-configured for use with a “T” type thermocouple. The control is capable
of utilizing other thermocouple types and even RTD temperature sensors if required by simply reconfiguring
the input type selection. In the event of a sensor break, the upper LCD display will flash “SBER” and the
control relay output will de-energize.

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2.3.3 Alarm Relay Output /Audible Alarm
Connection to the alarm relays and audible alarm require external control relays that are not part of the
control assembly. One relay is utilized to provide remote contacts for customer connection for remote alarm
indication (shown as CR1 in the following diagram) and is optional. The other relay is utilized for the audible
alarm silence (shown as CR2 in the following diagram) which is required.
Note that alarm 3 (low battery) is utilized for indication only. When an alarm relay is energized, the
corresponding alarm indicator, AL1 for alarm 1 (temperature), AL2 for alarm 2 (power failure) or AL3 for
alarm 3 (low battery), will be illuminated on the upper left of the C42 LCD display. When either a high/low
temperature or power failure alarm activates, the audible alarm will sound as power from the alarm contact
will pass through the normally closed contact of relay CR2. When the silence button is pressed, the coil of
relay CR2 will be energized. Since the normally open contact of CR2 will then close, power will pass
through the relay contact and will in turn hold the relay coil energized even after the push-button is released.
This will hold the normally closed contact of the relay open, removing power from the audible alarm so that
it will no longer sound. Once both alarm conditions are no longer present, both alarm 1 and alarm 2 outputs
of the C42 will be de-energized. This will in turn remove power from the coil of relay CR2 causing it to de-
energize. This will then ensure that upon the next activation of either the temperature or power failure alarm
output, power will again pass to the audible alarm causing it to sound until the alarm condition clears or the
operator presses the silence button.

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3 Operation
The FDC-C42 controller is programmed by using four keys on the front panel. The available function keys
are listed in the following table:
Touch
Key
Function
Description
Up Key
Press and release to increase the current control set point (while in
normal control mode) or to change the value of the selected
parameter (while in the Setup Menu).
Down Key
Press and release to decrease the current control set point (while in
normal control mode) or to change the value of the selected
parameter (while in the Setup Menu).
Scroll Key
Press and hold for at least 5 seconds to enter the Setup Menu.
The upper display will show and then release the key.
Reset Key
Press and release to return the display to the home screen (while in
User Menu or Setup Menu).
The upper display is used to show the process value or menu prompt. The lower display is used to show
the set point value or menu parameter value. During power-up, the upper display will show PROG and the
lower display will show the firmware version for 6 seconds.
Note: See the FDC C-Series User Manual (FDC_C-Series_User_Manual.pdf) for additional information
on contoller specifications, error codes/troubleshooting and warranty/return information not
covered in this manual.

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3.1 Control Output Hysteresis
The control type for relay output 1 is pre-configured for cooling (direct action). The control hysteresis
(prompt O1HY) is safe-sided. The control relay’s output will operate in the following manner. For example,
the set point is -80° (F or C), and the control hysteresis value is 2.0. The control relay’s output will be
energized until the temperature reached -82° and then de-energize. When the temperature rises to -80° or
above, the control relay’s output is energized. When the control relay’s output is energized, the control
output status indicator (labeled OUT1 on the front panel) will be illuminated.
To change the control hysteresis, enter the Setup menu and access the output parameters as follows:
•Press and Hold scroll key for 5 seconds
to enter Setup menu (upper display will
show SET).
•Press up or down key repeatedly to
access output parameters (lower display
will show OUT).
•Press scroll key to cycle through output
parameters and access output 1
hysteresis (upper display will show O1HY
and lower display will show current
value).
•Press up or down key to change
hysteresis value.
•Press reset key to exit menu and return
to normal PV/SV display.
3.2 Temperature Alarm Set Point and Hysteresis
The alarm type for relay output 2 (AL1) is pre-configured for deviation band. This means that the alarm
deviation set point (A1DV) follows the control set point evenly above and below the main control set point.
The alarm hysteresis (A1HY) is safe sided.
The alarm relay’s output will operate in the following manner. For example, the main control set point is -
80° (F or C), the alarm deviation set point (A1DV) is 12° and the alarm hysteresis value (A1HY) is 0.1. The
alarm relay’s output will be energized when the temperature is outside of the deviation alarm band (below
-92° or above -68°). The alarm relay will de-energize when the temperature falls within the hysteresis band
(between -91.9° and -68.1°). When the alarm relay’s output is energized, the alarm output status indicator
(labeled AL1 on the front panel) will be illuminated.
To change the alarm set point and hysteresis values, enter the Setup menu and access the alarm
parameters as follows:

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•Press and Hold scroll key for 5 seconds
to enter Setup menu (upper display will
show SET).
•Press up or down key repeatedly to
access alarm parameters (lower display
will show ALRM).
•Press scroll key to cycle through alarm
parameters and access alarm 1
hysteresis (upper display will show A1HY
and lower display will show current
value).
•Press up or down key to change
hysteresis value.
•Press scroll key to cycle through alarm
parameters and access alarm 1 deviation
set point (upper display will show A1DV
and lower display will show current
value).
•Press up or down key to change alarm
deviation value.
•Press reset key to exit menu and return
to normal PV/SV display.
3.3 Power Status Alarm Indicators
The FDC-C42 events inputs 1 and 2 and alarm outputs 2 and 3 are pre-configured to act as power supply
status alarms. Event input 1 and alarm output 2 (AL2) are utilized to indicate a power failure. Under normal
operation, event input 1 will be activated indicating power is present. When main power is lost, event input
1 will deactivate, and in turn cause alarm 2 relay output to energize. When the alarm relay’s output is
energized, the alarm output status indicator (labeled AL2 on the front panel) will be illuminated.
Event input 2 and alarm output 2 (AL3) are utilized to indicate low battery. Under normal operation, event
input 2 will be deactivated. When the battery is low, event input 2 will be activated and in turn cause alarm
3 relay output to energize. When the alarm relay’s output is energized, the alarm output status indicator
(labeled AL3 on the front panel) will be illuminated.

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3.4 Input Offset Calibration
Each unit is calibrated at the factory before shipment. The user can still modify the calibration in the field.
The basic calibration of the controller is highly stable and set for life. User calibration allows the user to
offset the permanent factory calibration in order to:
•Calibrate the controller to meet a user reference standard.
•Match the calibration of the controller to that of a particular transducer or sensor input.
•Calibrate the controller to suit the characteristics of a particular installation.
•Remove long term drift in the factory set calibration.
To correct for an error in the process value, send the desired low
signal to the sensor input of the controller. If the process value
(the upper display) is different from the input signal, access the
offset low (OFTL) parameter by pressing and releasing the
key twice.
The upper display will indicate the OFTL parameter and the lower
display will show the current offset value. Use and keys
to change the OFTL value and adjust it by the same error seen
between the input signal and the indicated process value.
Press and release the key to return to the PV, SV display and
verify that the indicated process value now matches the input
signal. If an error is still present, repeat the procedure to adjust
the OFTL value more to correct for the error