Future design Fdc-9090 User manual

User's ManualUser's Manual

FDC-9090

Self-Tune Fuzzy / PID

Process / Temperature Controller

FDC-9090

Self-Tune Fuzzy /PID

Process /Temperature Controller

Warning SymbolWarning Symbol

Use the ManualUse the Manual

This Symbol calls attention to an operating procedure, practice, or

the like, which, if not correctly performed or adhered to, could result

in personal injury or damage to or destruction of part or all of the

product and system. Do NOT proceed beyond a warning symbol

until the indicated conditions are fully understood and met.

Specifications

Wiring

Programming

Page 3

Page 4

Page 5

NOTE:

It is strongly recommended that a process should

incorporate a LIMIT like L91 which will shut down the

equipment at a preset process condition in order

to preclude possible damage to products or

system.

It is strongly recommended that aprocess should

incorporate aLIMIT like L91 which will shut down the

equipment at apreset process condition in order

to preclude possible damage to products or

system.

reserved. No part of this publication may be reproduced,

transmitted, transcribed or stored in a retrieval system, or

translated into any language in any form by any means without

the written permission of Future Design Controls.

UM9090Rev1

type J, K, T, E, B, R, S, N.

PT100 ohm RTD (DIN 43760/BS1904 or JIS)

-10 to 60 mV, configurable input attenuation

User configurable, refer to Table above

Refer to Table above

0.1 C/ C ambient typical

Protection mode configurable

100 ohms max.

60 dB

120dB

3 times / second

The Fuzzy Logic is an essential feature of this versatile

controller. Although PID control has been widely accepted by

industries, it is difficult for PID control to work with some sophistic

systems efficiently, for example, systems of second order, long

time-lag, various set points, various loads, etc. Because of

disadvantage of controlling principles and fixed values of PID

control, it is inefficient to control the systems with many

variables and the result is unacceptable control for some

systems. The Fuzzy Logic control can overcome the

disadvantage of PID control only. 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 automatically and quickly

to adapt to various processes. It enables a process to reach its

set point in the shortest time with minimum overshooting during

tuning or external disturbance.

SYSTEM

PID

FUZZY

MV PV

PID+FUZZY CONTROL

PID control with properly tuned

PID + Fuzzy control

Warm Up Load Disturbance

Set point

Temperature

Time

2. Model Order Matrix2. Model Order Matrix

FDC

(1) (2) (3) (4) (5) (6) (7) (8)

(1) Power Input

4 90-264VAC

5 20-32VAC/VDC

9 Other

(2) Signal Input

5 Configurable (Universal)

9 Other

(3) Range Code

1 Configurable

9 Other

(4) Control Mode

3 PID / ON-OFF Control

(5) Output 1 Option

0 None

1 Relay rated 3A/240VAC resistive

2 SSR Drive rated 20mA/24V

3 4-20mA linear, max. load 500 ohms (Module OM93-1)

4 0-20mA linear, max. load 500 ohms (Module OM93-2)

5 0-10V linear, min. impedance 500K ohms (Module OM93-3)

9 Other

(6) Output 2 Option

0 None

(7) Alarm Option

0 None

1 Relay rated 2A/240VAC resistive

9 Other

(8) Communication

0 None

CONTENTS

Model:FDC 9090

Instruction Manual

Model:FDC 9090

Instruction Manual

1. INTRODUCTION

2. NUMBERING SYSTEM

3. FRONT PANEL DESCRIPTION

4. INPUT RANGE & ACCURACY

5. SPECIFICATIONS

6. INSTALLATION

1. INTRODUCTION

2. NUMBERING SYSTEM

3. FRONT PANEL DESCRIPTION

4. INPUT RANGE & ACCURACY

5. SPECIFICATIONS

6. INSTALLATION

8. OPERATION

7. CALIBRATION7. CALIBRATION

8. OPERATION

8.1 KEYPAD OPERATION

8.2 FLOW CHART

8.3 PARAMETER DESCRIPTION

8.4 AUTOMATIC TUNING

8.5 MANUAL P.I.D. ADJUSTMENT

8.6 MANUAL TUNING PROCEDURE

8.7 RAMP & DWELL

6.1 DIMENSIONS & PANEL CUTOUT

6.2 WIRING DIAGRAM

9. ERROR MESSAGES9. ERROR MESSAGES

In addition, this instrument has functions of single stage ramp

and dwell, auto-tunung and manual mode execution. Ease of use

also an essential feature with it.

This manual contains information for the installation and operation

of the Future Design Control’s model FDC-9090 Fuzzy Logic

micro-processor based controller.

1. INTRODUCTION1. INTRODUCTION

9090

CON

ALM

3. FRONT PANEL DESCRIPTION3. FRONT PANEL DESCRIPTION

Process Value Display

(0.4" red LED)

Set point Value Display

(0.3" green LED)

Control Output

Alarm Output

Scroll Key

Down Key

Return Key

Up Key

4. INPUT RANGE & ACCURACY4. INPUT RANGE & ACCURACY

Input Type

Iron-Constantan

Chromel-Alumel

Copper-Constantan

Chromel-Constantan

Pt30%RH/Pt6%RH

Pt13%RH/Pt

Pt10%RH/Pt

Nicrosil-Nisil

PT100 ohms(DIN)

PT100 ohms(JIS)

-10mV to 60mV

Range( C )B

-50to999 CB

-50 to 1370 CB

-270 to 400 CB

-50to750 CB

300 to 1800 CB

0 to 1750 CB

-50 to 1300 CB

-200 to 400 CB

-1999 to 9999

Accuracy

AB2C

AB3C

AB2C

AB0.4 C

A0.05%

Sensor

RTD

Linear

5. SPECIFICATIONS5. 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:

Proportion Band:

Reset ( Integral ):

Rate ( Derivative ):

Ramp Rate:

Dwell:

ON-OFF:

Cycle Time:

Control Action:

0 - 200 C ( 0-360 F)

0 - 3600 seconds

0 - 1000 seconds

0 - 200.0 C /minute (

0 - 3600 minutes

With adjustable hysteresis (0-20% of SPAN)

0-120 seconds

Direct (for cooling ) and reverse (for heating)

B0 - 360.0 F /minute)B

CONTROL

POWER

Rating:

Consumption:

90-264VAC, 50/ 60Hz

Less than 5VA

ENVIRONMENTAL & PHYSICAL

Safety:

EMC Emission:

EMC Immunity:

Operating Temperature:

Humidity:

Insulation:

Breakdown:

Vibration:

Shock:

Net Weight:

Housing Materials:

UL873, CSA22.2/142-87, IEC1010-1

(EN61010-1)

EN50081-1

EN50082-2

-10 to 50 C

0 to 90 % RH (non-codensing)

20M ohms min. ( 500 VDC )

AC 2000V, 50/60 Hz, 1 minute

10 - 55 Hz, amplitude 1 mm

200 m/ s ( 20g )

170 grams

Poly-Carbonate Plastic

UM9090Rev1

6. INSTALLATION6. INSTALLATION

6.1 DIMENSIONS & PANEL CUTOUT6.1 DIMENSIONS & PANEL CUTOUT

Panel

(45 mm)

Figure 6.1 Mounting Dimensions

TOUCHKEYS FUNCTION DESCRIPTION

Scroll Key

Long Scroll

Press

for 6 seconds

Press and

Up Key

Down Key

Return Key

Long Return

Output Percentage

Monitor

Manual Mode

Execution

* F1: Fuse, S1: Power Switch

6.2 WIRING DIAGRAM6.2 WIRING DIAGRAM

8. OPERATION8. OPERATION

8.1 KEYPAD OPERATION8.1 KEYPAD OPERATION

Press

for 6 seconds

Press and

for 6 seconds

Increases the parameter

Advance the index display to the desired position.

Index advanced continuously and cyclically by pressing this keypad.

Decreases the parameter

Resets the controller to its normal status. Also stops auto-tuning,

output percentage monitoring and manual mode operation.

Allows more parameters to be inspected or changed.

1. Executes auto-tuning function

2. Calibrates control when in calibration level

Allows the set point display to indicate the control output value.

Allows the controller to enter the manual mode.

7. CALIBRATION7. CALIBRATION

FDC-9090

Alarm

Com.

Alarm

N/O

Control Output 1

F1 S1

90 - 264 VAC,50/60HZ

RTD

* With power on, it has to wait for 12 seconds to memorize the new values of parameters once it been changed.

Note: Do not proceed through this section unless their is a

genuine need to re-calibrate the controller. All previous

calibration date will be lost. Do not attempt re-calibration

unless you have available appropriate calibration equipment.

If calibration data is lost, you will need to return the controller

to your supplier who may apply a charge for re-calibration.

Note: Do not proceed through this section unless their is a

genuine need to re-calibrate the controller. All previous

calibration date will be lost. Do not attempt re-calibration

unless you have available appropriate calibration equipment.

If calibration data is lost, you will need to return the controller

to your supplier who may apply a charge for re-calibration.

Prior to calibration ensure that all parameter settings are

correct (input type, C / F, resolution, low range, high range).BB

1. 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).

2. Use the Scroll Key until the " " appears on the PV

Display. (Refer to 8.2)

3. Use the Up and Down Keys until the SV Display

represents the simulated input.

4. 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.

5. Press and release the Scroll Key. " " appears on

the PV Display. This indicates the high calibration point.

6. Increase the simulated input signal to coincide with high

11 process signal (e.g. 100 degrees).

7. Use the Up and Down Keys until the SV Display

represents the simulated high input.

8. 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.

9. Turn power off the unit, remove all test wiring and replace

sensor wiring (observing polarity).

1.77 “

(45 mm)

94 mm

3.70 “

86 mm

3.38 “

Long

(6 seconds)

Long

(6 seconds)

Long

(6 seconds)

SET POINT VALUE DISPLAY

PROCESS VALUE DISPLAY

Level 0

Level 3

The "return" key can be pressed at any time.

This will prompt the display to return to the

Process value/Set point value.

Power Applied:

1. Displayed for 4 seconds.

(Software Version 3.6 or higher)

2. LED test.

All LED segments must be lit for 4 seconds.

3. Process value and set point indicated.

UM9090Rev1

8.2 FLOW CHART8.2 FLOW CHART

Level 1

Level 2

8.3 PARAMETER DESCRIPTION8.3 PARAMETER DESCRIPTION

INDEX

CODE

DESCRIPTION

ADJUSTMENT RANGE

**DEFAULT

SETTING

SV Set point Value Control

*Low Limit to High Limit Value Undefined

Alarm Set point Value

* Low Limit to High Limit Value.(if =0, 1, 4 or 5)

* 0 to 3600 minutes ( if =12 or 13)

* Low Limit minus set point to high Limit minus set

point value ( if =2, 3, 6 to 11 )

Ramp Rate for the process value to limit an abrupt

change of process (Soft Start)

* 0 to 200.0 C (360.0 F) / minute ( if = 0 to 9 )

* 0 to 3600 unit / minute ( if =10 )

200 CB

0 C / min.B

Offset Value for Manual Reset ( if = 0 )

* 0 to 100%

Offset shift for process value

*-111Cto111CBB

Proportional Band

* 0 to 200 C ( set to 0 for on-off control)B

Integral (Reset) Time

* 0 to 3600 seconds

Derivative (Rate) Time

* 0 to 1000 seconds

Local Mode

0: No control parameters can be changed

1: Control parameters can be changed

Parameter Selection ( allows selection of additional

parameters to be accessible at level 0 security)

0.0 %

0CB

10 CB

120 sec.

30 sec.

Proportional Cycle Time

* 0 to 120 seconds

Relay

Pulsed Voltage

Linear Volt/mA

Input Mode Selection

0: J type T/C

1: K type T/C

2: T type T/C

3: E type T/C

4: B type T/C

5: R type T/C

Note: T/C-Close solder gap G5, RTD-Open G5

6: S type T/C

7: N type T/C

8: PT100 DIN

9: PT100 JIS

10: Linear Voltage or Current

Alarm Mode Selection

0: Process High Alarm

1: Process Low Alarm

2: Deviation High Alarm

3: Deviation Low Alarm

4: Inhibit Process High Alarm

5: Inhibit Process Low Alarm

6: Inhibit Deviation High Alarm

7: Inhibit Deviation Low Alarm

8: Outband Alarm

9: inband Alarm

10: Inhibit Outband Alarm

11: Inhibit Inband Alarm

12: Alarm Relay OFF as

Dwell Time Out

13: Alarm Relay ON as

Dwell Time Out

Hysteresis of Alarm 1

* 0 to 20% of SPAN

C / F Selection

0: F, 1: C

Resolution Selection

0: No Decimal Point

1: 1 Digit Decimal

2: 2 Digit Decimal

3: 3 Digit Decimal

(2&3mayonly be used for linear voltage or current

=10 )

Control Action

0: Direct (Cooling) Action 1: Reverse (Heat) Action

Error Protection

0: Control OFF, Alarm OFF

1: Control OFF, Alarm ON

Hysteresis for ON/OFF Control

*0 to 20 % of SPAN

Low Limit of Range

High Limit of Range

Low Calibration Figure

High Calibration Figure

NOTES: * Adjusting Range of the Parameter

** Factory settings. Process alarms are at fixed temperature points. Deviation

alarms move with the set points value.

0: None 4:

1: 5:

2: 6:

3: 7:

T/C

RTD

Linear

0.5%

2: Control ON , Alarm OFF

3: Control ON, Alarm ON

0.5%

-50 CB

1000 CB

0CB

800 CB

UM9090Rev1

8.4 AUTOMATIC TUNING

3. Press Return Key for at least 6 seconds ( maximum 16 seconds). This

initializes the Auto-tune function. (To abort auto-tuning procedure

press Return Key and release).

2. Ensure Proportional Band 'Pb' is not set at '0'.

1. Ensure that controller is correctly configured and installed.

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( ) 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 set point is set to close to

the process temperature or if there is insufficient capacity in the

system to reach set point (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. ADJUSTMENT8.5 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 future 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 Solution

Slow Response Decrease PB Value

High Overshoot or Oscillations Increase PB Value

Integral Time (Reset)

Symptom Solution

Slow Response Decrease Integral Time

Instability or Oscillations Increase Integral Time

Derivative Time (Rate)

Symptom Solution

Slow Response or Oscillations Decrease Deriv. Time

High Overshoot Increase TimeDeriv.

8.6 MANUAL TUNING PROCEDURE8.6 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(Process value)

TIME

Record this value (Tc) in seconds

Step 5: The Control Settings are determined as follows:

Proportion Band(PB)=1.7 Pc

Integral Time (TI)=0.5 Tc

Derivative Time(TD)=0.125 Tc

100

125

150

010 20 30 40 50 60 70 80 90

15 minutes

ON OFF

Process Value

Alarm Output

t(minutes)

The dwell function may be used to operate an external device such

as a siren to alert when a soak time has been reached.

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 set point

temperature is reached. After the setting at has elapsed, the

alarm contact closes.

9. ERROR MESSAGES9. ERROR MESSAGES

Symptom Cause (s) Solution (s)

Sensor break error Replace RTD or sensor

Use manual mode operation

Process display beyond

the low range set point Re-adjust value

Re-adjust value

Process display beyond

the high range set point

Analog hybrid module

damage

Incorrect operation of

auto tune procedure

Prop. Band set to 0

Manual mode is not

allowable for an ON-OFF

control system

Check sum error, values

in memory may have

changed accidentally

Replace module. Check for

outside source of damage

such as transient voltage spikes

Repeat procedure. Increase

Prop. Band to a number larger

than 0

Increase proportional band

Check and reconfigure the

control parameters

8.7 RAMP & DWELL8.7 RAMP & DWELL

The FDC-9090 controller can be configured to act as either a fixed

set point 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 set point temperature, thus

producing a 'Soft Start' function.

A dwell timer is incorporated within the FDC-9090 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 ' ' parameter which can be

adjusted in the range 0 to 200.0 C/minute. The ramp rate function

is disabled when the ' ' parameter is set to ' 0 '.

The soak function is enabled by configuring the alarm output to act

as a dwell timer. The parameter 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 .

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,B

=12 and =15 (minutes). Power is applied at zero

time and the process climbs at 5 C/minute to the set point of 125

C. Upon reaching set point, 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.

A 2 WarrantyA 2 Warranty

WARRANTY

RETURNS

No products return can be accepted without a completed Return Material Authorization ( RMA ) form.No products return can be accepted without a completed Return Material Authorization ( RMA ) form.

Future Design Controls warranties or representations of any sort regarding the fitness for

use, or the application of its products by the Purchaser. The selection, application or use

of Future Design products is the Purchaser's responsibility. No claims will be allowed for

any damages or losses, whether direct, indirect, incidental, special or consequential.

Specifications are subject to change without notice. In addition, Future Design reserves

the right to make changes without notification to Purchaser to materials or processing

that do not affect compliance with any applicable specification.

Future Design products are warranted to be free from defects in material and

workmanship for two years after delivery to the first purchaser for use. An extended

period is available with extra cost upon request. Future Design’s sole responsibility

under this warranty, at Future Design’s option, is limited to replacement or repair, free of

charge, or refund of purchase price within the warranty period specified. This warranty

does not apply to damage resulting from transportation, alteration, misuse or abuse.