Future Design Orion-M FDC 100 Series Parts list manual

Orion-M FDC 100 Series Controller System Guide Rev B
February 7, 2011
Su ersedes: Rev B (March 25, 2010)
Orion-M
FDC 100 Series Controller
System Guide

Orion-M
FDC Orion-M PREFACE
Safety Information in this Manual
Notes, cautions and warnings a ear throughout this book to draw your attention to im ortant o erational and
safety information.
A “NOTE” marks a short message to alert you to an im ortant detail.
A “CAUTION” safety alert a ears with information that is im ortant for rotecting your equi ment and
erformance.
A “WARNING” safety alert a ears with information that is im ortant for rotecting you, others and equi ment
from damage. Pay very close attention to all warnings that a ly to your a lication.
This symbol (an exclamation oint in a triangle) recedes a general CAUTION or WARNING
statement.
This symbol (a lightning bolt in a lightning bolt in a triangle) recedes an electric shock hazard
CAUTION or WARNING safety statement.
Technical Assistance
If you encounter a roblem with your Orion-M controller, review all of your configuration information to verify
that your selections are consistent with your a lication: in uts; out uts; alarms; limits; etc. If the roblem
ersists after checking the above, you can get technical assistance by dialing [phone] or by faxing
your request to [phone], Monday thru Friday, 8:00 a.m. to 5:00 .m. Eastern Standard Time. You
can also email your request to su [e-mail].
An a lications engineer will discuss your a lication with you.
Please ha e the following information a ailable:
• Com lete Model #’s and/or Serial #’s for Com onent(s) in Question
• Com lete Software Version #’s
• All Configuration Information
• All User Manuals
Warranty and return information is on the back co er of this manual.
Your Comments
Your comments or suggestions on this manual are welcome. Please send them to:
Future Design Controls, P.O. Box 1196, Bridgeview, Illinois, 60455
Tele hone: [phone]; fax: [phone]
[e-mail]
The Orion-M FDC 100 Series Controller System Guide is co yrighted by Future Design Controls, Inc., ©
2009, all rights reserved (htt ://www.futuredesigncontrols.com/Orion-M.htm).
.

Orion-M
TABLE OF CONTENTS FDC Orion-M i
1 What is the Orion-M? ............................................................................................... 1.1
1.1 Features............................................................................................................................................... 1.1
2 Getting Started.......................................................................................................... 2.1
2.1 Installing the FDC 100 Series Controller ............................................................................................. 2.1
2.1.1 Communications Wiring ................................................................................................................ 2.1
3 Configuring the FDC 100 Series Controller............................................................ 3.1
3.1 Assigning the Pro er Communications Settings ................................................................................. 3.1
3.2 In ut Ty e Assignments ...................................................................................................................... 3.2
3.2.1 Input 1 Operation .......................................................................................................................... 3.2
3.3 Control Out ut Assignments ............................................................................................................... 3.3
3.3.1 Auto-Tune and Auto/Manual Operation ........................................................................................ 3.3
3.4 Loo Permissions ................................................................................................................................ 3.4
3.4.1 Set oint ermission Exception.................................................................................................... 3.4
3.4.2 Auto Tune ermission Exception..................................................................................................3.4
Appendix
Software Usage Note
Warranty
Returns

Orion-M
WHAT IS THE ORION-M? FDC Orion-M 1.1
1 What is the Orion-M?
The Orion-M is a multi-loo rocess control system combined with an embedded SCADA color touch
interface. The Orion-M rovides a configurable control latform for a variety of OEM a lications requiring u
to 15 se arate loo s of control. In addition to 15 loo s of control, the Orion-M can also rovide u to an
additional 15 in uts for rocess monitoring, for a total of 30 rocess in uts.
The system is rovided with eight 24Vdc digital in uts, two 24Vdc out uts and 6 relay out uts standard. The
Orion-M can be ex anded to a total of 16 digital in uts and 32 digital out uts. The Orion-M also rovides the
ca ability of acce ting analog in uts for remote set oint control and analog out uts ca able of retransmitting
system variables (PV, SP or %Out) to other devices such as a chart recorder. The 0-10Vdc or 4-20mA user
selectable signals are rovided through the addition of o tional analog ex ander cards.
The Orion-M com lements its versatile hardware latform by roviding a host of standard features and
configuration ca abilities, all through its visual, touch interface. The touch screen interface is an embedded,
industrial PC with all software included. No external PC software is required for setu or configuration of the
Orion-M. All of the setu and configuration data is saved to the Orion-M’s internal memory.
Individual rocess controllers, one for each loo in the system, rovide reliable, consistent and accurate
control by distributing the rocess control requirements of the system among multi le rocessors. Each loo
controller rovides full auto tune functionality with high resolution, universal rocess in uts. When cou led
with the built in ram ing rofiler of the Orion-M, it allows for automatic, timed control of all rocesses and
out uts of the system. No other control system on the market rovides the flexibility, functionality and
configurability of the Orion-M.
1.1 Features
The digital in uts of the Orion-M can be configured as alarm in uts with adjustable delay timers, as control
in uts for controlling rofile o eration or for direct control of the system’s digital out uts.
The digital out uts of the Orion-M can be used as direct out uts for controlling external equi ment related to
the a lication through software switches, called events, or be rogrammed to act as system alarm or status
out uts. All out uts have adjustable delay times for on, off and cycle times.
The Orion-M can be o erated in single set oint or automatic rofile control mode. Profile entry is made easy
through the use of co y, aste and delete menu selections. Profiles can be co ied to the external ‘USB’
memory stick and then im orted to another Orion-M controller which eliminates the need to enter du licate
rofiles into multi le Orion-M systems. When running in automatic rofile mode, the o erator can lace the
system into hold and change any control arameter without modifying the saved rofile. This gives the
o erator maximum flexibility over the controlled rocess.
Data file analysis tools (auto-trend) make looking at historical data a sim le task. Any control variable saved
to the Orion-M flash memory can be lotted on the historical data trend, for any time frame within the data
file’s total time range. Full ‘USB’ rint ca abilities from the Orion-M interface to a standard HP inkjet rinter
Model 6540, 6940, 6980 (or com atible rinter), eliminates the need for a PC, stri or circular chart-recording
device. Gra hics trends, historical and re ort rint functions are standard.
The built in Ethernet functionality includes a ‘Web Server’ to rovides access to all Orion-M data (view only), a
VNC interface for remote control and monitoring and an NTS clock, all available via a local Intranet
connection (wired or wireless), or the World Wide Web using standard software like Microsoft’s Internet
Ex lorer.

Orion-M
1.2 FDC Orion-M WHAT IS THE ORION-M?
The Orion-M rovides a rich set of tools for control interaction and data analysis. Views include system
overviews, trends, alarms, rofiles as well as historical data, alarm history and audit trail views. The menu
driven interface eliminates screen ‘clutter’ by roviding an easy to use ‘Windows’ interface for interaction
between the user and the Orion-M system.
The Orion-M can store more than one year of data on its internal com act flash card. Data logging can be
enabled manually or automatically during automatic rofile run. Data backu is rovided with the ‘USB I-
Stick’ for lug and lay transfer of files to any PC running Microsoft Windows XP o erating systems.
The Orion-M security module rovides full system security with three levels of access. Each of the three
access levels allow for inde endent user rights. U to 30 users can be entered into the system while the
audit trail tracks all o erator actions and records them.
The Orion-M control system includes the following interface features:
• Overview screen that dis lays all “runtime” information.
• Profile run and monitor views.
• Profile entry, o en, save and download interface screens.
• Current alarm and alarm history views (alarm history for u to 1 year).
• Real time trends (with adjustable X,Y limits) for all in uts.
• System and a lication setu (control loo s, monitors, in uts/out uts, alarms, etc.).
• Data logging interface screens include log oint selection and historical viewing.
• ‘Plug and Play’ memory stick functionality for data transfer/backu .
• Full USB rint ca abilities and on-line hel screens
• Web server for intranet/internet access (view only).
• VNC server for intranet/internet access (control/view).
• FTP data back-u for automatic data file transfer over intranet/internet.
• Integrated email server for alarm notification and file transfer.
• NTS clock with daylight savings time insures that the system is u to date.
• Full security with audit trail for tracking user actions.
• Maintenance counters for out ut cycles and on times.
• Hel s screens are available for most screen views; configurable in English, S anish and French
• Voice assisted hel in English, S anish and French (external s eakers required – not included).

Orion-M
GETTING STARTED FDC Orion-M 2.1
2 Getting Started
The Orion-M requires one FDC 100 Series for each control loo required in the system. Since the Orion-M is
ca able of interfacing to more than one brand of controller, refer to the Orion-M art number matrix for the
o erating system to be sure that the FD10, CM a lication software has been rovided. The Orion-M will not
o erate correctly if any other version of CM a lication software is used with an FDC 100 Series controller.
2.1 Installing the FDC 100 Series Controller
For a lications requiring several loo s of control or more, ro er lanning and arrangement of the 100
Series controllers rior to mounting is critical for o timum routing of the controller wiring. For a lications
requiring frequent access to the controllers, anel mounting rovides direct access. For a lications where
o erator access to the controllers is not required, or is desired to be ke t at a minimum, the controllers can be
mounted directly inside of an enclosure. This also reduces wiring concerns by eliminating the need to run the
sensor, communication and control wiring for each controller to and from an enclosure door.
Refer to the user’s manual for the 100 Series control being used for dimensions, a ro riate mounting and
o erating conditions, including ro er electrical connections. Connect sensor and control wiring as required,
aying close attention to all wiring recautions and guidelines as noted in the controller manual. It is
recommended that all sensor and communication wiring, to and form the 100 Series controllers, be routed
away from all high voltage and/or out ut control wiring. This will minimize the chances of electrical transients
or s ikes in the ower/control wiring from causing communications or sensor reading errors.
2.1.1 Communications Wiring
Each FDC 100 Series control used in the Orion-M system is its own inde endent loo control. However, in
order for the controllers to work as art of the system, they must communicate with the Orion-M control
module using RS485 serial communications. Therefore, each 100 Series used must be equi ed with the
RS485 communications o tion or they will not o erate as art of the Orion-M system:
FDC-9100- X X X X X 1
FDC-8100- X X X X X 1 X
FDC-4100- X X X X X 1 X
Order code 1 designates RS-485 Modbus RTU serial communications
(see articular 100 Series User’s Manual for order code descri tions)
Communications wiring must be run using a minimum of 24 AWG twisted- air, co er conductors. For short
runs (< 50 feet total), non-shielded wiring can be used as long as ro er se aration from ower/control
conductors is maintained. For communications wiring where the total length will exceed 50 feet, u to the
maximum allowed length of 650 feet, shielded twisted- air must be used.
NOTE: FDC recommends the use of shielded wire for all installations regardless of the total length in order
to maintain optimum performance and minimize the possibility of communications errors.
When using shielded twisted- air, be sure to ground the shield at only one end, referably at the Orion-M
control module. Allowing any other ortion of the cable shield to come in contact with ground, or grounding
both ends, will allow ground loo currents to flow in that section of the cable shield which can disru t
communications.

Orion-M
2.2 FDC Orion-M GETTING STARTED
Communications Wiring Example (FDC-9100 controller shown)
Communications wiring to the FDC8100/4100 series are identical to that as shown above for the FDC-9100
controller exce t the terminals are in a different location.
NOTE: Refer to the User’s Manual for the 100 Series controller used for all other connections including
power, sensor and control wiring. Since no two applications are the same, it is up to the system
designer to insure that the controllers are properly installed and wired to meet design specifications.

Orion-M
CONFIGURING THE FDC 100 SERIES CONTROLLER FDC Orion-M 3.1
3 Configuring the FDC 100 Series Controller
The unique and inherently flexible design of the Orion-M system allows the OEM to tailor each com onent of
the system to the a lication. By using inde endent loo controls, each one can be configured for various
in ut and out ut ty es, control algorithms, etc., based on the requirements of the a lication. It also allows
control loo s to be added or re laced on the system at any time, sim ly by connecting the controller to the
Orion-M’s control module, RS-485 communication link.
If the a lication requirements change and a different in ut or out ut ty e is required, or if the controller were
to fail, it can be re laced quickly, and at a lower cost as com ared to having to re air or re lace larger,
integrated multi-loo controllers. The Orion-M only requires that the communications settings for each loo
control be ro erly assigned, and that the in ut ty e of the controller is set in the Orion-M Configurator, so
that the control loo in ut and set oint can be dis layed and set ro erly through the Orion-M interface.
3.1 Assigning the Proper Communications Settings
The Orion-M can su ort u to 15 FDC 100 Series controls. They can be mixed and matched as required,
but each one must have its own communication address. The allowable address range is 1 – 15
corres onding to Loo In ut #1 – 15 in the Orion-M Configurator. Communication addresses must be
assigned to all controllers on the communications link beginning with 1, u to the total number of controllers.
As control loo s are enabled in the Orion-M Configurator, the Orion-M will automatically use the Loo In ut #
as the corres onding controller address. If more than one 100 Series controller has the same address, or a
loo in ut is enabled but a controller is not assigned to that address, the Orion-M will re ort a
communications alarm for that loo in ut when the runtime a lication is started.
NOTE: The order of the loop controls on the communication link is not important. The communications
address for a controller can be assigned regardless of its position on the link.
In addition to the communications address, the baud rate, data bits, sto bits and arity settings must also be
set to match the control module of the Orion-M. The Orion-M uses the factory default communication rate of
9600 baud, 8 data bits and 1 sto bit; however, the arity of the 100 Series controller must be changed from
the factory default of ‘even’ to ‘none’.
In addition to the communication arameters, the lock function level of the control must be set to ‘nonE’. This
ermits the Orion-M’s control module to access the necessary data values within the 100 Series Control. If
the lock function level denies access to any of the 100 Series arameters, communication errors will result.
*Required 300 Series Controller Settings for roper Communications:
• Function comlexity level (Lock): nonE
• Communication interface ty e (Conn): rtu
• Address assignment of digital COMM (Addr): 1-15 (based on system design)
• Baud rate of digital COMM (bAud): 9.6
• Data bit count of digital COMM (dAtA): 8bit
• Parity bit of digital COMM (PAri): none
• Sto bit count of digital COMM (StoP): 1bit
*See section 1-5 Menu O er iew, in the 100 Series User’s Manual for instructions on accessing the
control’s Setup Menu and setting the abo e parameters as required.

Orion-M
3.2 FDC Orion-M CONFIGURING THE FDC 100 SERIES CONTROLLER
3.2 Input Type Assignments
The FDC 100 Series controls offer a universal thermocou le/RTD in ut o tion or various linear in ut o tions
for different voltage and current ranges. The Loo In ut # for the corres onding control in the Orion-M
Configurator is set to match the selected in ut ty e of the 100 Series control. Based on this selection, the
Orion-M assumes control of certain arameters related to the in ut and automatically assigns them based on
settings made in the Orion-M.
3.2.1 Input 1 Operation
When in ut 1 of the 100 Series control is set for a tem erature in ut ty e, i.e., RTD or thermocou le, the
corres onding Loo In ut # in Orion-M Configurator must also be set to tem erature. When these selections
are made, the Orion-M will automatically set the tem erature units of the control to match the tem erature
units (degrees C or F) set in the Orion-M. If the Orion-M loo in ut ty e is set to rocess in the Configurator
for a tem erature in ut ty e, the Orion-M will change engineering units for the in ut; however, the units in the
100 Series control will not be set to match by the Orion-M. Therefore, the Orion-M may dis lay units in
degrees Fahrenheit while the reading is in degrees Centigrade or vice versa.
When in ut 1 of the 100 Series control is set for a linear in ut ty e, i.e., voltage or current, the corres onding
Loo In ut # in Orion-M Configurator must be set to rocess even if the in ut is from a tem erature
transmitter. The range and units of the tem erature transmitter are unknown to the Orion-M so they must be
manually set at the 100 Series control. If the Orion-M loo in ut ty e is set to tem erature in the Configurator
for a linear in ut ty e, the Orion-M will change engineering units for the in ut; however, the measurement will
not change. Therefore, the Orion-M may dis lay units in degrees Fahrenheit while the reading is in degrees
Centigrade or vice versa.
For either tem erature or linear in ut ty es, the Orion-M will set the decimal oint and lower and u er set
oint limits for the in ut to match the settings in the Configurator. The decimal oint and set oint limits must
match in order for the system to o erate ro erly and dis lay the correct values on the Orion-M interface.
IMPORTANT: The temperature units, decimal point and lower and upper set point limits are set once, each
time the Orion-M enters the runtime application. Do not alter the values in the 100 Series
control once they have been set or the Orion-M will not display the correct process value or
set the correct set point to the loop control which could result in a runaway condition leading
to property damage or injury to personnel.

Orion-M
CONFIGURING THE FDC 100 SERIES CONTROLLER FDC Orion-M 3.3
3.3 Control Output Assignments
The 100 Series controls have two control out uts that can be assigned to o erate as heat/cool
(indirect/direct). If only a single control out ut is used (out ut 1), for heating or cooling o eration, the Orion-M
will dis lay a ercentage of out ut of 0.0 – 100.0% for the out ut.
If both out uts are used in a heat/cool a lication (out ut 1 is heat and out ut 2 is cool), the Orion-M will
dis lay a value of -100.0% to 100.0% for the ercentage of out ut. In this case, 0.0% re resents both heat
and cool out uts are off. Values from 0.0 to 100.0% re resent the ercentage of heat out ut from off to full
on and values from 0.0 to -100.0% re resent the ercentage of cool out ut from off to full on.
NOTE: Output 2 of the 100 Series controller can be configured to act as an alarm output. If configured as
an alarm output, it will cause the Orion-M to report an incorrect percentage of output reading when
the alarm output is active.
When the output is on, it will cause an offset of -100% in the percentage of output reading shown on
the Orion-M. For example, if control output 1 is at 50% power, and output 2 is activated as an
alarm, the Orion-M will report an output of -50% (50-100). If output 1 is at full output power and
output 2 is activated, the Orion-M will report an output percentage of 0% (100-100). Therefore,
even though control output 1 is on, the Orion-M will report the output as being off.
When output 2 is off, no offset will be applied to the control output percentage of output reading.
Thus, to prevent operator confusion, it is recommended that output 2 not be used for an alarm
output function. It should be set to ‘nonE’ or used for cooling operation (CooL) only. If an alarm
output is required, the 100 Series control should be fitted with the alarm 1 output option.
3.3.1 Auto-Tune and Auto/Manual Operation
The Orion-M rovides the ability to switch each 100 Series control in the system between auto and manual
out ut o eration as well as initiating the controller’s auto-tune function. These functions are accessed from
the Orion-M runtime, Single Loo View screen via the ‘AM’ and ‘AT’ control buttons.
As long as the out ut is not rogrammed for on/off control, i.e., the ro ortional band is set to zero (0), these
functions will be available. If the ro ortional band of the control’s PID arameters is set to zero; however,
the auto-tune and auto/manual selections will be disabled.
NOTE: Output 2 of the 100 Series controller can be configured to act as an alarm output. If configured as
an alarm output, its operation will be overridden when the controller is put into manual mode. If the
alarm output is required to operate even when the controller is put into manual mode, output 2 can
not be used as an alarm output. The 100 Series controller must be fitted with the alarm 1 output
option.

Orion-M
3.4 FDC Orion-M CONFIGURING THE FDC 100 SERIES CONTROLLER
3.4 Loop Permissions
The Orion-M iSeries configuration rovides ermissions which can be set to allow the control loo set oint,
auto/manual and auto tune o erations to be erformed at the loo control itself as well as through the Orion-
M. These can allow an o erator to make changes at the loo control in cases where the Orion-M interface is
located in a remote location.
3.4.1 Set Point Permission Exception
If the control loo is configured to o erate under cascade control or is configured as an RH wet bulb loo
ty e, the set oint for the loo is generated by logic within the Orion-M. The loo will not function as
configured unless the se oint is constantly set by the Orion-M. Thus, any change made at the loo control
will be overridden by the Orion-M. If local adjustment at the loo control may be required for any reason, loo
set oint communications must be interru ted via a digital in ut to the Orion-M configured as ‘loo SP comms
disable’.
3.4.2 Auto Tune Permission Exception
If the control loo is configured to o erate under cascade control or is configured as an RH wet bulb loo
ty e, the set oint for the loo is generated by logic within the Orion-M. This set oint may constantly
fluctuate in order to rovide the ro er control action. The 100 Series controller will abort the auto tune
rocess if its set oint is changed while it is auto tuning. Thus, if auto tune is initiated at the loo control and
the Orion-M is sending a new set oint, the auto tune will be immediately aborted.
When auto tune is activated at the Orion-M, the set oint is first ‘locked in’ rior to initiating the auto tune.
This revents the set oint from being changed if the loo is a wet bulb ty e or under cascade control once
auto tune is activated. The Orion-M will maintain the current set oint at the loo control regardless of
rocess changes until the auto tune com letes.

Orion-M
APPENDIX FDC Orion-M A.1
Appendix

Orion-M
A.2 FDC Orion-M APPENDIX
Software Usage Note:
The selection, application or use of Future Design Control products or software is the purchaser or
user's responsibility. No claims will be allowed for any damages or losses, whether direct, indirect,
incidental, special or consequential.
In addition, Future Design reser es the right to make changes without notification to purchaser or
user to materials or processing that do not affect compliance with any applicable specification.
Future Design makes no warranties when using the Orion-M system.
Warranty:
Future Design Controls roducts described in this book are warranted to be free from functional defects in
material and workmanshi at the time the roducts shi ed from Future Design Controls facilities and to
conform at that time to the s ecifications set forth in the relevant Future Design Controls manual, sheet or
sheets for a eriod of one year after delivery to the first urchaser.
Future Design Controls roducts are warranted to be free from functional defects in materials and
workmanshi at the time the roducts shi ed from Future Design Controls facilities and to conform at that
time to the s ecifications set forth in the relevant Future Design Controls manual, sheet or sheets for a eriod
of one year after delivery to the first urchaser for use.
There are no ex ressed or im lied Warranties extending beyond the Warranties herein and above set forth.
Limitations: Future Design Controls rovides no warranty or re resentations of any sort regarding the fitness
of use or a lication of its roducts by the urchaser. Users are res onsible for the selection, suitability of the
roducts for their a lication or use of Future Design Controls roducts.
Future Design Controls shall not be liable for any damages or losses, whether direct, indirect, incidental,
s ecial, consequential or any other damages, costs or ex enses exce ting only the cost or ex ense of re air
or re lacement of Future Design Control roducts as described below.
Future Design Controls sole res onsibility under the warranty, at Future Design Controls o tion, is limited to
re lacement or re air, free of charge, or refund of urchase rice within the warranty eriod s ecified. This
warranty does not a ly to damage resulting from trans ortation, alteration, misuse or abuse.
Future Design Controls reserves the right to make changes without notification to urchaser to materials or
rocessing that do not affect com liance with any a licable s ecifications.
Return Material Authorization:
Contact Future Design Controls for Return Material Authorization Number rior to returning any roduct to our
facility:
7524 West 98th Place – Bridge iew, IL 60455 – Phone [phone] – Fax [phone]
http://www.futuredesigncontrols.com