Future Design FDC-9200 User manual

User's Manual
FDC-9200
Self-Tune Fuzzy / PID
ProcessTemperatureController

The function of Fuzzy Logic is to adjust the PID parameters internally in
order to make the manipulation output value MV more flexible and adaptive
to various processes.
The Fuzzy Rule may like these:
If temperature difference is large, and temperature rate is large, then
MV is large.
If temperature difference is large, and temperature rate is small, then
MV is small.
¦
¦
¦
PID + Fuzzy Control has been proven to be an efficient method to improve
the control stability as shown by the comparison curves below:CONTENTS
1.INTRODUCTION 5.OPERATION
2. NUMBERING SYSTEM 6. RE-CALIBRATION
3. SPECIFICATIONS 7. ERROR MESSAGE & DIAGNOSIS
4. INSTALLATION 8. COMMON FAILURE CAUSES
1.INTRODUCTION
The FDC-9200 Fuzzy Logic plus PID microprocessor 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 setpoint in the shortest time, with the minimum of overshoot
during power-up or external load disturbance. The units are housed in a
1/16 DIN case, measuring 48 mm x 48 mm with 75 mm behind panel depth.
The units features three touch keys to select the various control and input
parameters. Using a unique command called " CONFIGURE LEVEL ", a
supervisorhastheflexibilityofdeterminingwhichparameters are accessible
bytheuser. Also the scrolling sequence of parameters are fully configurable
according to your requirement. This is particularly useful to OEM's, as it is
easy to limit access to suit the specific application.
The FDC-9200 is powered by 20-32 or 90-264VAC supply, incorporating a
3 amp. control relay output and dual 3 amp. alarm relays output as standard
which second alarm can be exceptionally configured into second output
for cooling purpose or dwell timer. Alternative output options include SSR
drive, 4-20mA and 0-10 volts. The FDC-9200 is fully programmable for
PT100, thermocouple types K, J, T, E, B, R, S, N, 0-20mA, 4-20mA and
voltage signal input, with no need to modify the unit.
Digital communications RS-485 or 4-20mA retransmission are available as
an additional option. These options allow the FDC-9200 to be integrated
with supervisory control systems and software, or alternatively drive
remote display, chart recorders or data-loggers.
In last nearly a hundred years although PID control has been used and
proved to be an efficient controlling method by many industries, yet the PID
is difficult to deal with some sophisticated systems such as second order
systems, long time-lag systems, during setpoint change and / or load
disturbance circumstance etc. The PID principle is based on a mathematic
modeling which is obtained by tuning the process. Unfortunately, many
systems are too complex to describe in numerical terms precisely. In
addition, these systems may be variable from time to time. In order to
overcome the imperfection of PID control, the Fuzzy Technology is
introduced. What is the Fuzzy Control ? It looks like a good driver. Under
different speeds and circumstances, he can control a car well with
experiences he had before and does not require the knowledge of kinetic
theory of motion. The Fuzzy Logic is a linguistic control which is different
from the numerical PID control. It controls the system by experiences and
does not need to simulate the system precisely as been controlled by PID.
The basic theory used in this controller is described in the following block
diagrams:
Safety Symbol
The 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. do not
proceed beyond a safety symbol until the indicated conditions are fully
understood and met.
Model: FDC-9200
Instruction Manual
Fuzzy Rule
Fuzzy Inference
Engine DefuzzifierFuzzifier
Numerical
information
Linguistic
information
Numerical
information
SYSTEM
PID
FUZZY
MV
PV
_
+
SV
+
+
P I D + FUZZY CONTROL
2. NUMBERING SYSTEM
Model No. -
(1) (2) (3) (4) (5) (6) (7) (8)
Warm Up Load Disturbance
PID control when properly tuned
PID + Fuzzy control
Setpoint
Temperature
Time
(1) Power Input
490-264VAC
520-32VAC/VDC
9Other
(2) Signal Input
5Configurable (Universal)
9Other
(3) Range Code
1Configurable
9Other
(4) Control Mode
3PID + Fuzzy /ON-OFF Control
(5) Output 1 Option
0None
1Relay rated 3A/240VAC resistive
2SSR Drive rated 20mA/24V
34-20mA linear, max. load 500 ohms (Module OM92-1)
40-20mA linear, max. load 500 ohms (Module OM92-2)
50-10V linear, min. impedance 500K ohms (Module OM92-3)
9Other
(6) Output 2 Option
0None
(7) Alarm Option
0None
2Dual relays rated 2A/240VAC resistive
(Second relay available for propational cooling Output 2)
9Other
(8) Communication
0None
1RS-485
24-20mA retransmission
30-20mA retransmission
9Other
Page1

Panel
2.9”
.53”
.43”
SCREW
MOUNTING
CLAMP
1.77”
1.77”
3. SPECIFICATIONS 4. INSTALLATION
Dangerous voltages capable of causing death are sometimes
present in this instrument. Before installation or beginning any trouble
shooting 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.
Componentreplacementandinternaladjustmentsmustbemadeby qualified
maintenance personnel only.
To help 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 subject to 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 Section 3.
4.1 UNPACKING:
Upon receipt of the shipment remove the instrument from the carton and
inspect the unit for shipping damage. If any damage due to transit is
notices, report and file a 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 located inside the control.
4.2 MOUNTING
Make panel cutout to dimension shown in Figure 4.1.
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 panel is fitted snugly in the cutout.
Sensor Input Type Range (°C) * Accuracy
JIron-Constantan -50 to 999 °C±2 °C
KChromel-Alumel -50 to 1370 °C±2 °C
TCopper-Constantan -270 to 400 °C±2 °C
EChromel-Constantan -50 to 750 °C±2 °C
BPt30%RH/Pt6%RH 300 to 1800 °C±3 °C
RPt13%RH/Pt 0 to 1750 °C±2 °C
SPt10%RH/Pt 0 to 1750 °C±2 °C
NNicrosil-Nisil -50 to 1300 °C±2 °C
RTD PT100 ohms (DIN) -200 to 400 °C±0.4 °C
RTD PT100 ohms (JIS) -200 to 400 °C±0.4 °C
Linear 4 - 20 mA -1999 to 9999 ±0.05%
Linear 0 - 20 mA -1999 to 9999 ±0.05%
Linear 0 - 1 V -1999 to 9999 ±0.05%
Linear 0 - 5 V -1999 to 9999 ±0.05%
Linear 1 - 5 V -1999 to 9999 ±0.05%
Linear 0 - 10 V -1999 to 9999 ±0.05%
INPUT
Linear Voltage Input Impedance:
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 & PHYSICAL
Safety:
Protection:
EMC Emmission:
EMC Immunity:
Operating Temperature:
Humidity:
Insulation:
Breakdown:
Vibration:
Shock:
Moldings:
Weight:
100 K ohms
0.1 °C / °C ambient typical
Protection mode configurable
100 ohms max.
60dB
120dB
5 times / second
0-200 °C ( 0-360 °F )
0-3600seconds
0-1000seconds
0-55.55 °C ( 99.99 °F) / minute
0-9999minutes
With adjustable hysteresis 0-11.0 °C( 0.1-19.9 °F)
0-99 seconds
Direct ( for cooling ) and reverse ( for heating)
90-264VAC, 50 / 60 Hz
Less than 5VA
UL , CSA, CE
NEMA4X,IP65
EN50081-1,EN55011
IEC801-2, IEC801-3, IEC801-4
-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 / s2 (20g )
Flame retardant polycarbonate
150 grams
* Accuracy = Linearity Error + Cold Junction Compensating Error
+ Lead Compensating Error + Offset Drift Error
4.3 WIRING PRECAUTIONS
* Before wiring, verify the label for correct model number and options.
Switch off the power when checking.
* Care must be taken to ensure that maximum voltage ratings specified in
Section 3 are not exceeded.
* It is recommended that power to these instruments 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 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 voltage, current,
and temperature ratings of the system.
* The " stripped " leads as specified in Figure 4.2 below are used for
power and sensor connections.
* Take care 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
Table 4.1 on are not exceeded.
* Electric power in industrial environments contains a certain amount of
noise in the form of transient voltages 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 from 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.
Fig. 4.1 Mounting dimensions
Page2

4.4 CONNECTION AND WIRING
The following connections for outputs and inputs are provided at the rear
of the controller housing:
4.4.1 Mains (Line) Input
Thecontrollerissuppliedtooperateon24V(20-32VAC/VDV) or 90-264VAC.
Check that the installation mains voltage corresponds to that indicated on
the product label before connecting power to the controllers.
4.4.3 PT100 Ohm RTD Input
RTD connection are shown in Figure 4.6, with the compensating lead
connected to terminal 14. For two-wire RTD inputs, terminals 13 and 14
shouldbelinked. Thethree-wireRTDoffersthe capability of lead resistance
compensation provided that the three leads should be of same gauge and
equal length.
4.4.4 DC Linear Input
DC linear voltage and linear current connections are shown in Figure 4.7
and Figure 4.8.
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 regidly
observed. Considerationshouldbe given tothe prevention of unauthorised
personnel from gaining access to the power terminations.
4.4.2 Thermocouple Input
Thermocouple input connections are shown in Figure 4.5. 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 correct polarity is observed throughout. Joints in the
cable should be avoided, if possible.
The colour codes used on the thermocouple extension leads are shown in
Table 4.1.
4.4.5 Relay Output Direct Drive
Figure 4.9 shows connections using the internal relay to drive a small load.
The current does not exceed 3 amperes.
Fig. 4.4 Mains (Line) Supply Connections
TABLE 4.1 THERMOCOUPLE CABLE COLOUR CODES
Thermocouple
Type Cable Material British
BS American ASTM German DIN French NFE
TCopper
Constantan
+ white
- blue
* blue
+ blue
- red
* blue
+ red
- brown
* brown
+ yellow
- blue
* blue
JIron / Constantan + yellow
- blue
* black
+ white
- red
* black
+ red
- blue
* blue
+ yellow
- black
* black
KNickel Chromium
Nickel
Aluminium
+ brown
- blue
* red
+ yellow
- red
* yellow
+ red
- green
* green
+ yellow
- purple
* yellow
R
S
13% Copper
10% Copper
Nickel
+ white
- blue
* green
+ black
- red
* green
+ red
- white
* white
+ yellow
- green
* green
BPlatinum /
Rhodium
+ grey
- red
* grey
* Colour of overall sheath
Fig. 4.6 RTD Input Connections
Fig. 4.5 Thermocouple Input Connections
Fig. 4.7 Linear Voltage Input Connections
Fig. 4.8 Linear Current Input Connections
Fig. 4.9 Relay Direct Drive Connections
4.5 7.0 mm
0.18" 0.27"
~
~
2.0mm
0.08" max.
Fig. 4.2 Lead Termination
12345678
910 11 12 13 14 15 16
NL
90-264 VAC
POWER IN
50/60 HZ
ALM2
OUT2 ALM1 OUT1
TX1 TX2
PTA mV
mV
V
RTD
ABB
T/C
0-20mA
4-20mA
0-10V
Interface
+
+
+
V
mA
TC Com.
Fig. 4.3 Rear Terminal Connections
+
13
14
_
13
12
14
A
PT100
B
B
14
15
+
_0 20mA or
4 20mA
~
~
357
468
or or
Load 120V /240V
Mains Supply
Alarm 2
/Control
Output 2
Alarm1
Output
Control
Output 1
Max. 3A
Resistive
14
16
+
_15V,010V
~~
01V,05V
~~
Input Impedance = 100k ohm
1
2
90 264VAC or
20 32VAC / VDC
~
~
Fuse
Page3

4.4.6 Relay Output Contactor Drive
4.4.7 SSR Drive Output
Controllers fitted with the SSR drive output produce a time-proportional
non-isolated pulse voltage (0-20V nominal, output impedance 660 ohms).
The connections are shown in Figure 4.11
4.5 SENSOR PLACEMENT
Proper sensor placement 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 close to the heater. In processes
where the heat demand is variable, the probe should be closer to the work
area. Some experimenting with probe location is often required to find this
optimumposition.
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 will provide an average temperature
reading and produce better results in most air heated processes.
Proper sensor type is also a very important factor in obtaining precise
measurements. The sensor must have the correct temperature range to
meet the process requirements. In special processes the sensor might
have to have different requirements such as leak-proof, anti-vibration,
antiseptic, etc.
Standard sensor limits of error are ±4 degrees F (±2 degrees C) or 0.75%
of sensed temperature (half that for special) plus drift caused by improper
protection or an over-temperature occurance. This error is far greater
than controller error and cannot be corrected at the sensor except by
proper selection and replacement.
5. OPERATION
5.1 FRONT PANEL DESCRIPTION
Fig. 4.10 Contactor drive Connections
Fig. 4.12 Linear Voltage / Current Connections
4.4.8 Linear Output
There are three types of linear output modules (See Section 2) can be
selected for control output (OUT 1). The connections are shown in Figure
4.12.
Fig. 4.11 SSR Drive Connections
or 7
3
84
Load
120V /240V
Mains Supply
+
++
_
__
SSR
73
84
+
+
_
_
0 20mA,
4 20mA or
0 10V
~
~
~
or
FDC-9200
A1
SV
OUT
A2 PV FC
3 Silicon Rubber buttons
For ease of control set-up
and setpoint adjustment.
Control Output
Setpoint Value
Alarm Outputs
Process Value
357
468
or or
Alarm 2
/Control
Output 2
Alarm1
Output
Control
Output 1
120V /240V
Mains Supply
No Fuse
Breaker
Three
Phase
Heater
Power
Three Phase
Delta
Heater
Load
TOUCHKEYS FUNCTION DESCRIPTION
Up Key Press and release quickly to select the desired digit of a numerical parameter
to change. Press and hold to increase the value of the selected digit for a
numerical parameter or to change the selection for an index parameter.
Down Key Press and release quickly to select the desired digit of a numerical parameter
to change. Press and hold to decrease the value of the selected digit for a
numerical parameter or to change the selection for an index parameter.
(Direct) Scroll Key Select the parameter in a direct sequence. Also used to select the tool
program parameters.
Long Scroll / Enter Key Select the protected parameters in higher security level, also used to actuate
the execution for the selected tool program whenever the display is showing a
tool program.
Reverse Scroll / Calibration
Verification Key Select the parameter in a reverse sequence during parameter scrolling, or verify the display accuracy for various input types during the calibration mode.
Lock Key Disable keypad operation to protect all the parameters from tampering.
Tool Program Key Select the tool program in sequence.
Reset / Exit Key Unlock keypad operation and reset the front panel display to a normal display
mode, also used to leave the tool program execution or ending the autotune
and manual control execution.
Autotune Key Press and hold both keys for at least 3.2 seconds then release to start
execution of autotune program.
Engineering Key By entering correct security code to allow execution of engineering programs.
This function is used only in the factory to speed up the production. The user
should never attempts to operate this function.
Press
for at least 3.2 seconds
Press and
Press and
Press and
and
Press and
Press
for at least 3.2 seconds
and
Press
for at least 3.2 seconds
5.2 KEYPAD OPERATION
* With power on, it has to wait for 12 seconds to memorize the new values of parameters once it been changed.
Page4

The following chart shows a typical (default) access sequence of parameters. Note 1 shows how to modify the display sequence and how to delete
unused parameters.
Alarm1 Set Point Value or Dwell
Time ( = or )
Ramp Rate
Offset Value for Manual Reset
( Integral Time TI=0 )
Alarm 2 Set Point Value
Shift Process Value
Proportional Band of Output 1
Integral (Reset) Time of Output 1
Derivative (Reset) Time of Output 1
Hysteresis of Alarm 1
Hysteresis of Alarm 2
Hysteresis of ON-OFF control
Address of the unit for the
communication
Low Scale of Range Adjust for
your process
High Scale of Range Adjust for
your process
Power Limit of Output 1
Power Limit of Output 2
Input Type Selection
Select Unit
Resolution Selection
Control Action of Output 1
Alarm 1 Mode
Alarm 1 Special Function
Alarm 2 Mode
Alarm 2 Special Function
Proportional Cycle Time of Output 1
Cooling Cycle time
Cooling P Band
Dead Band for PB and CPB
~
0 3600 seconds **120
~
0 1000 seconds **40
~
~
~
~
~
~
0 11.0 C or 0.1 19.9 F **0.0
0 11.0 C or 0.1 19.9 F **0.0
0 11.0 C or 0.1 19.9 F **0.0
~0 40 **0
Minimum value for the selected Input (INPUT) to High
Scale (HISC) **-17.7 C
Low Scale (LOSC) to maximum value for the selected
Input (INPUT) **537.7 C
~
0 100%
**100
~
0 100%
**100
Same as
~
0 99 Seconds, 0 for
Linear current / Vol-
tage output. **20
~
0 99 Seconds, 0 for
Linear current / Vol-
tage output. **20
~
~
-111.0 111.0 C or
-199.9 199.9 F,
**0.0 C
:0 10V
~
:1 5V
~
:0 5V~
:0 1V
~
:0 20mA
~
:4 20mA
~
:PT100 JIS
:PT100 DIN
:J TYPE T/C
:K TYPE T/C
:T TYPE T/C
:E TYPE T/C
:B TYPE T/C
:R TYPE T/C
:S TYPE T/C
:N TYPE T/C
**
Long
Long
: degree C
:degree F
:process unit
**
Voltage or
Current Input)
:1 Digit Decimal
: No Decima
Point Used.
:2 Digit Decimal
(only for Linear
Voltage or
Current Input)
**
:Direct
(Cooling)
Action.
:Reverse
(Heating)
Action.
**
:Alarm with Hold
Function.
:Dwell Timer ON as
Time Out.
:No Special Function
:Alarm with Latch
Function.
:Alarm with Latch &
Hold Function.
:Dwell Timer OFF
as Time Out.
**
:Deviation High
Alarm.
:Full Scale High
Alarm.
:Full Scale Low
Alarm.
:Deviation Band
High Alarm.
:Deviation Band
Low Alarm.
:Deviation Low
Alarm.
**
:No Special Fun-
ction.
:Alarm With Hold
Function.
:Alarm with Latch
Function.
:Alarm with Latch
& Hold Function.
:Proportional
cooling.
**
5.3 FLOW CHART OF PARAMETERS
Normal Display Process value / setpoint value
Low scale to high scale value ** 100.0 C
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or
or 0 55.55 C/minute or 0 ~ 99.99 F/minute~ **0.00
~
0 100.0% **0.0
~~
0 200.0 C or 0 360.0 F 0 : For ON-OFF control
**10.0 C
~
~
~
~
Low scale high scale value (for Full scale Alarm), -111.0 111.0 C or -199.9
199.9 F (for Deviation and Deviation Band Alarm), 0 9999 minutes (for Dwell
**
~
~
~
Low scale high scale value (for Full scale Alarm),
-111.0 111.0 C or -199.9 199.9 F (for Deviation
and Deviation Band Alarm), 10.0 C
**
~~
0.0 200.0 C or 0.1
360.0 F **10.0 C
-111.0 111.0 C or -199.9 199.9 F **0.0 C
~
~
Note 1:Using the Tool Program ( Refer to sec. 5.4 and sec. 5.6.5 for the configuration of security level ) the display sequence and the security level for
11 any parameter are configurable. Also any unused parameter can be removed from the display sequence to simplify the operation.
Note 2:Using long scroll key ( press and hold for at least 3.2 seconds ) to select parameters in higher security level.
Note 3: To chang the value of a numerical parameter ( the value of which is denoted by a number ) press and release the or key to select the
111111desired digit ,then press and holld the or key to chang the value of the value selected digit.
To chang the value of an index parameter ( the value of which is abbreviated by letters ) press and hold the or key to select the desired
1 111 value.
**:Denotes the default setting.
10.0 CTime)
Level 1 Level 0
Level 2
Page5

Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
View the percentage power
of output 1. (Heating)
View the percentage power
of output 2. (Cooling)
Hand ( Manual )
Control
Read Peak
Process Value
Calibrate
A-D converter
Enter the manual control mode.
Allow to adjust the percentage value of
output 1 by using or .
or
or
or
or
or
or
or
Change the value of
security level for the
selected parameter .
Change the value of
security level for the
selected parameter .
Change the value of
security level for the
selected parameter .
Display the rest of
parameters according
to the standard access
sequence.
or
or
or
or
or
Calibrate the A-D and Enter the
Cold-Junction compensation
Enter the drift compensation code.
Calibrate the 0 20mA and Enter it.
~
Enter the status.
Enter the status.
Enter the status.
Enter the Selection.
Enter the Selection.
Enter the Selection.
Enter the updated
security level of ASP1.
Enter the updated
security level of RAMP.
Enter the updated
security level of DB.
Adjust the Cold-junction
compensation code.
(-19.9 42.7 count)
~
Adjust the drift
compensatio
~
Adjust the drift
compensation code.
(-6.6 6.6 count)
~
Select a proper status for Output 1.
:Output 1 ON :Output 1 OFF
Select Lock or F ree for the Security Level 0.
:Protect (Lock) all the Level 0 parameters
:Allow all the Level 0 parameters to be adjustable.
Select Lock or F ree for the Security Level 1.
:Protect (Lock) all the Level 1 parameters
:Allow all the Level 1 parameters to be adjustable.
Select Lock or F ree for the Security Level 2.
:Protect (Lock) all the Level 2 parameters
:Allow all the Level 2 parameters to be adjustable.
View the maximum (peak) process value.
View the minimum (peak) process value.
5.4 FLOW CHART OF TOOL PROGRAMS
Define
protection
mode for the
status of
control and
alarm outputs
to ensure a
safe condition
while the
control fails.
Lock
parameters
Configure
Security
levels for all
parameters.
:Security LEVEL
= 0 :Put the parameter
in LEVEL 0.
= 1 :Put the parameter
in LEVEL 1.
= 2 :Put the parameter
in LEVEL 2.
Reset the maximum and
minimum process values.
Reset the maximum and
minimum process values.
000 100%
~
**
(No function with FDC -9200.)
(No function with BTC -9200.)
**
**
**
Select a proper status for Alarm 1.
:Alarm 1 ON :Alarm 1 OFF
**
Select a proper status for Alarm 2.
:Alarm 2 ON :Alarm 2 OFF
**
Select a proper status for Output 2..
:Output 2 ON :Output 2 OFF
**
Page6

the controller does not use the RS-485 interface, the ADDR can be
neglected.
LOSC, HISC - Low / High Scale Range
IfthermocoupleorPT100isselectedasinputtype(INPT)theseparameters
are used to define the range of the setpoint adjustment. Otherwise, If
linear process input is selected, these parameters are used to define the
range of the process value and setpoint adjustment, refer section 5.14 for
more details.
PL1, PL2 - Power limit for Heating and Cooling Outputs
These parameters limit maximum heating and cooling percentage power
during warm up and in proportional band. These are used only for those
processes that heat or cool with full speed are dangerous or not
satisfactory with the results. For normal applications these parameters
are set to 100%.
INPT - Input Type selection
Select a correct type in accordance with the input connection.
UNIT - Process Unit
Select a correct unit for the process. for linear process input select Pu
(Process Unit) if the unit is other than °C or °F.
RESO- Select Decimal Point Position (Resolution)
This parameter defines the position of the decimal point on the process
value and setpoint.
Value DecimalPointPosition
xxxx
xxx.x
xx.xx
Note that is used only for linear process input.
CONA - Control Action of Output 1
Select (Reverse) action for heating process, that is to increase
output power as the process value decreases ( or setpoint increases).
Select (Direct) action for cooling process, that is to increase
output power as the process value increases (or setpoint decreases).
A1MD, A2MD - Alarm Mode Selection for Alarm 1 and Alarm 2
Refer section 5.10 for an in-depth description.
A1SF - Alarm 1 Special Function
Select a hold function or latch function for Alarm 1. See section 5.10 for
more details. Select or to reconfigure Alarm 1 output
as a dwell timer. See section 5.13 for more details.
A2SF - Alarm 2 Special Function
Select a hold function or latch function for Alarm 2. See section 5.10
for more details. Select COOL to reconfigure Alarm 2 as cooling
output.
CYC, CCYC - Proportional Cycle Time of Output 1 and Cooling Outtput
Select a proper value for the process in accordance with the output
devices fitted. See section 5.5.2 for further discussion.
CPB,DB - Cooling P Band, Cooling Dead Band
Refer section 5.9 for description. If no cooling is fitted for the controller,
these parameters may be neglected.
5.5.1 Learning the Parameters
SV - Setpoint Value
This parameter is the desired target of the process. It can be adjusted
within the range defined by the Low Scale Value (LOSC) and High Scale
Value (HISC). The default value is 100°C (212°F).
ASP1 - Alarm 1 Setpoint Value or Dwell Time
This sets the levels at which the alarm 1 will operate if AISF is selected for
alarm function. If AISF is selected for dwell timer ( or ),
ASP1 is used as setting value of dwell timer. The timer start to count as the
process value reaches the setpoint value, see section 5.10 and 5.13 for
more details.
RAMP-Ramp Rate
This forces the process to warm up (or cool) with a predetermined rate as
power applied. Setting this parameter to zero if no ramp is needed. The
process will warm up (or cool) with maximum speed.
OFST - Offset Value for Manual Reset
For those systems it is desired to perform manual reset control by setting
integral time ( TI ) to zero, OFST is adjusted to compensate the deviation
between PV and SV. If PV is too low for reverse control action (or too high
for direct control action) then increase value of OFST. If TI is not zero,
OFST is unchangeable.
SHIF - Shift Process Value
This value will be added to the process value so that the process value will
be read with minimum error. For those process with bad circulation may
use this parameter to compensate the temperature difference between
sensor and the process.
ASP2 - Alarm 2 Setpoint Value
This sets the levels at which the alarm 2 will operate if A2SF is selected for
alarm function. If A2SF is selected for cooling, Alarm2 will perform a
cooling output which is governed by CCYC, CPB and DB, while adjusting
ASP2 will have no effect on the control
PB, TI, TD - Constants for PID Control
Refer section 5.7 for an in-depth description.
AHY1, AHY2 - Hysteresis Values of Alarm 1and Alarm 2
These values define the dead bands for alarm action. As the process
value exceeds the boundary of the dead band and stays within the band
the alarm will remain same status.
HYST - Hysteresis Value of ON-OFF Control
This parameter defines a dead band for the ON-OFF control.
ADDR - Address of the unit for the communication
This parameter provides an identity code for the RS-485 interface. Note
that it is not allowable to set the same ADDR code for those controllers
communicating with same computer to prevent line contention problems. If
5.5 SETTING-UPPROCEDURES
As power applied, the model number of the controller and its software
version number will be displayed for 3.2 seconds, then all the display
segments and LED indicators will be lit for 3.2 seconds. After the 6.4
seconds of initial cycle the controller enters the normal display mode, the
display shows the current process value and the alternative display shows
the setpoint value. The display will continuously flash in cases of:
(1) during executing autotune program
(2) during executing manual mode program
(3) warning that the next parameter is a higher level parameter as scroll
key is depressed. The warning message will maintain a duration of
3.2 seconds. If the scroll key is released after the duration elapses
the display will indicate the code of next parameter ( in the display)
and its value ( in the alternative display ), otherwise, the display will
return to normal mode to indicate process value and setpoint value.
The display will blink a moment as a new value of parameter is written into
the non-volatile memory. The display is also used to indicate the error
messages in case of abnormal condition occurs. Subsequently, each
depression of the scroll key will step down the controller through the
default sequence of displays shown in Table of section 5.3. If unfortunately
the desired parameter passed on the display, it can still be retained by
pressing and to prevent frustration. The sequence of displays
can be reconfigured by changing the security level of parameters as
described in subsequent section.
5.5.2 Initial Setup
Access the keypads to view the value of each parameter. For an
undesirable value of parameter perform up and down key to obtain a
correct value, then proceed to the next parameter until all parameters are
verified. Notethat the new value of parameters are entered into nonvolatile
memoryautomatically.
The adjustment of proportional cycle time (CYC and CCYC) is related to
the speed of process response and the output device fitted. for a faster
process it is recommended to use SSR ( to select SSR Drive Output) or
SCR ( to select linear current or voltage output) to drive the load. The
relay output is used to drive magnetic contactor in a slow process. If a
long cycle time is selected for a fast process an unstable result may
occur. Theoretically the smaller the cycle time is selected, the better
control can be achieved. But for relay output, the cycle time should be as
large as possible (consistent with satisfactory control) in order to maximize
relay life.
Page7

5.6 AUTO-TUNE
The process is tuned at setpoint. The process will oscillate
about the setpoint during auto-tune. Set a setpoint to a lower value if
overshoot beyond the normal process value is likely to cause damage.
The auto-tune program is applied during:
* Initial set-up
* The setpoint is changed substantially from the previous auto-tune
* The control result is unsatsifactory
The auto-tune procedures:
* To ensure that all parameters are configured correctly.
*Toensurethat PB is not zero because that ON-OFF control is notallowable
to perform auto-tune.
* Set the setpoint to the normal operating process value ( or to a lower
value if overshoot beyond the normal process value is likely to cause
damage) and use normal load conditions.
* Press and hold both up and down keys for 3.2 seconds then release
together. The display is flashing during execution of auto-tune
program.
Auto-tune " teaches " the controller the main characteristics of the process.
It " learns" by cycling the output on and off. The results are measured and
used to calculate optimum PID values which are automatically entered in
nonvolatile memory.
During the second period of auto-tune the controller performs PID control
to verify the results and finally an OFST value is obtained and entered in
the memory.
To stop the auto-tune, press both up and down key then release together,
the display will stop to flash. But if the controller has entered in the
verifying period, the display will continue to flash until auto-tune is finished.
5.5.5 Configure Security Levels of Parameters
The user of the controller may often complain that the operation is so
complicated, most of parameters are unused for them and it takes long time
to get a parameter to access. You will no longer worry about this. One of
the versatile functions of this controller is that the security level for each
parameter can be redefined arbitrarily. One of four levels (Level 0, Level
1, Level 2 and Level 3) can be assigned to any parameter. The parameters
with lower level will be displayed before those parameters with higher
level as one performs scroll key. Furthermore, the level 3 parameters will
never be displayed on the front panel. Hence the user can assign level 3
to those unused parameters and assign level 0 to those most frequently
used parameters according to his requirements. Then the unused
parameter will never appear on the display to avoid confusion and the
display sequence of parameters is reconfigured.
To configure level for each parameter one can follow the flow chart in
section 6.4 by pressing and keys to reach ,
then perform key to get the desired parameter. The display indicates
the level of the parameter. Now one can change the level value for that
parameter by using up key or down key. Finally press and hold
3.2 seconds or longer, now the new level value is entered. If the
level value is unchanged the above operation for entering can be omitted.
For example: If ASP1, RAMP are configured as level 0, PB, TI, TD are
configured as leve 1, and the other parameters are configured as level 3,
the scrolling sequence of parameters will be as follows:
5.7 TUNING THE CONTROLLER MANUALLY
* To ensure that all parameters are configured correctly
* Set PB to zero. Set HYST to the smallest ( 0 °C or 0.1 °F )
* Set the setpoint to the normal operating process value ( or to a lower
value if overshoot beyond the normal process value is likely to cause
damage) and use normal load conditions.
* Switch on the power supply to the heater. Under these conditions, the
process value will oscillate about the setpoint and the following
parameters should be noted:
(1) The peak to peak variation (P) of the first cycle in °C or °F ( i.e. the
difference between the highest value of the first overshoot and the
lowest value of the first undershoot ).
Normal Cycle time Cycle time too long
(oscillates)
The follow table provides cycle time recommendations to avoid premature
relay failure:
Note: For an ON-OFF control ( by setting PB = 0) the cycle time selection
may be ignored.
Output Device
(OUT1 or Cooling Output) Cycle Time ( CYC or CCYC ) Load ( resistive)
Relay
20 sec or more
recommended
10 sec. minimum
2A / 250VAC
or contactor
5 sec. minimum 1A / 250VAC
Solid State Relay Drive 1- 3 sec. SSR
Linear Current / Voltage 0.1 sec. Phase control module
5.5.3 FAIL-SAFE Configuration
FAIL-SAFE is a Tool Program used to define an ON or OFF status of failure
for Output 1 (OUT1), Alarm 1 Output (ALM1). Press and ,
then release both keys until FAIL-SAFE is viewed in the display windows.
Then press scroll key to obtain the desired output which is shown in the
display. Now press and hold up or down key to change the status which
is shown in the display. Note that if the desired value is different from the
original one, a long scroll (pressing scroll key 3.2 sec.) has to be operated
to enter the new value before proceeding to the next Tool Parameter . If
the FAIL-SAFE status is not critical for a process as the controller fails, the
configuration of this section can be omitted.
5.5.4 LOCK Parameter
According to the flow chart shown in section 6.4, one can reach LOCK
PARA and obtain LEVEL ( ~ ) which is shown in the display
and the Lock status ( LOCK or FREE ) is shown in the display. For example,
if we select LOCK for , and press scroll key 3.2 seconds to enter the
selection, then all the parameters configured in level 2 can not be changed.
A LOCK message will be indicated in display if one attemps to change a
locked (protected) parameter.
PID+FUZZY
Verifying period
PID Control
Teaching Period
ON-OFF Control
Setpoint
Value
PB,TI,TD
Obtained
Auto-tune
finished
OFST Value
Obtained
Process
Value
SV ASP1 RAMP PB TI TD
Page8

5.9 COOLING CONTROL
Cooling Control Options:
Functions of CPB and DB:
The cooling P band CPB and dead band DB are measured in degree.
(2) The cycle time (T) of this oscillation in seconds (see following Figure).
* The control setting should then be adjusted as follows:
PB = P (°C or °F)
TI = T (seconds)
TD = T/4 (seconds)
The PID parameters determined by the above procedures are just rough
values. If the control results by using above values are unsatisfactory, the
following rules may be used to further adjust the PID parameters:
5.8 ON-OFF CONTROL
The alarm output if configured as alarm function performs an ON-OFF
control basically. Adjust the P band to PB = 0, an additional channel of
ON-OFF control with variable hysteresis is obtained. Hysteresis is
measured with degree. It is also named differentials or deadband
sometimes. Refer to following Figure for the description of ON-OFF control.
ON-OFF control may introduce excessive process variation even if the
hysteresis is minimized to the smallest. If the ON-OFF control is set,
parameters TI, TD and CCT will have no effect on the system, nor can the
manual mode and the auto-tune program be executed.
PV
Time
D action
Perfect
TD too high
TD too low
SP
PV
Time
Time
P action
SP
100%
0%
100%
0%
Reverse
Action
Action
(CONA=REVR)
(CONA=DIR)
Direct
OUTPUT
SP+HYST/2
SP-HYST/2
SV+DB
CPB
SV
DB
Negative
DB
Positive
100%
0%
Cooling
Output
PV( C or F)
P
T
SV
PV
Time
PV
Time
P action
Perfect
PB too high
PB too low
SP
PV
Time
I action
Perfect
TI too low
TI too high
SP
Effect of PID adjustment on process response:
ADJUSTMENT SEQUENCE SYMPTON SOLUTION
(1) Proportional Band (P) Slow Response Decrease PB
PB High overshoot or
Oscillations Increase PB
(2) Integral Time (I) Slow Response Decrease TI
TI Instability or
Oscillations Increase TI
(3) Derivative Time (D) Slow Response or
Oscillations Decrease TD
TD High Overshoot Increase TD
Output
Configurations Heating Output Cooling Output Adjustment of Parameters
ON-OFF Cooling
( No Heating) None OUT1 CONA = DIRT
HYST
SV
Proportional Cooling
( No Heating) None OUT1 CONA = DIRT
PB, TI, TD, CYC, SV
Heating +
ON-OFF Cooling OUT1 ALM2
CONA = REVR
A2SF = NONE
A2MD = DVHI (or FSHI)
AHY2, SV (or ASP2)
Heating +
Proportional Cooling OUT1 ALM2 CONA = REVR
A2SF = COOL
CPB, DB, CCYC, SV
Page9

5.10 ALARM
There is a independent alarm available by adjusting the alarm special
function A1SF and A2SF. The following descriptions of this section are
based on Alarm 1.
* Latch Alarm: A1SF =
When selected, the alarm output and indicator latch as the alarm occurs.
Thealarmoutput and indicator will be energized even if the alarmcondition
has been cleared unless the power is shut off.
* Hold Alarm: A1SF =
When selected, in any alarm mode, prevents an alarm on power up. The
alarm is enabled only when the process value reaches setpoint value
(SV).
Example: Hold function used with deviation low alarm
* Lach & Hold Alarm: A1SF =
When selected, in any alarm mode, prevents an alarm on power up. The
alarm is enabled only when the process value reaches setpoint value
(SV). Thereafter, the alarm acts as a latch alarm described above.
* Hysteresis (AHY1) adjustment
Example: No special function used with deviation high alarm,
SV = 100 °C, ASP1 = 10 °C, AHY1 = 4 °C
5.11 VIEWING THE OUTPUT PERCENTAGE POWER
Selectingthe Tool Programs until the HAND CONTROL isobtained.
Press scroll key, the display will show the process value and the display
will show the percentage power of output 1 such as . To view the
cooling output, press scroll key again. The lower display will show the
percentage power of alarm 2 such as , if alarm 2 is reconfigured as
cooling output (A2SF = COOL). If alarm 2 is configured as alarm, the
percentage power is invalid and should be ignored.
The range of the output percentage power is within 0 and 100 (%). If an
on-off control is selected, only 0 and 100 are displayed. For a proportional
control, the output percentage power represents the duty cycle of the
output ON-state.
Example: is viewed with cycle time CYC = 10 sec.
The output 1 act as follows:
0 1020304050607080
25
50
75
100
125
150
C
t (minutes)
Process Value
4 sec. 6 sec.
OFF
ON
OUTPUT
Time
5.12 MANUAL CONTROL
Following the procedure as in section 5.11, then press and hold the scroll
key for 3.2 seconds and release, the controller will enter the manual
control mode. The display begins to flash. The output percentage power
can be adjusted by using up or down keys. Note that for an on-off control
with PB = 0, the manual control is not allowable to be used. An error
message will be shown in the display.
The manual control is used during:
* Teaching the process
* The controller fails
The manual control is an open loop control The process may rise
to a dangerous value (temperature). Special attention to the process has
to be given to prevent a system damage.
5.13 RAMP & DWELL
The controller can be configured to act as either a fixed setpoint controller
or as a single ramp controller on power up. This function enables the user
to set a predetermined ramp rate (RAMP) to allow the process to gradually
reach setpoint temperature thus producing a " soft start " function.
A dwell timer is incorporated within the controller and the alarm 1 can be
configured by setting A1SF = or to provide either a
dwell function or a soak function to be used in conjunction with the ramp
function.
5.13.1 Ramp Function
If the ramp function is selected, the process will increase or decrease at
a predetermined rate during initial power up, or with setpoint changes/
process variations.
The ramp rate is determined by the " RAMP " parameter which can be
adjusted in the range 0 to 55.55 °C / minute ( 99.99 °F / minute). The ramp
rate function is disabled when the " RAMP " parameter is set to " 0 ".
In the example below the " RAMP " is set to 5.00 °C / minute, power is
applied at zero time and the process value climbs to the 125 °C setpoint
over a period of 20 minutes. This process temperature is held until the
setpoint value is changed to 150 °C at 40 minutes. The process value then
climbs to the new setpoint over a period of 5 minutes and the new setpoint
is held. At 70 minutes the setpoint value is decreased to 75 °C and the
process value falls to the new setpoint over a period of 15 minutes.
: Alarm on
No special function: A1SF=
SV
SV+ASP1
*
Without
hold alarm
alarms on
power up
SV SV SV
SV+ASP1
*
With hold alarm
No alarm
on power up
Alarm
enabled
Alarm
operates
normally
there after
*
Full scale
high alarm
A1MD
ASP1 *
Full scale
low alarm
A1MD
ASP1
SV+ASP1+ 1/2AHY1
SV+ASP1
SV+ASP1- 1/2AHY1
Below 108 C
alarm off
Below 112 C
alarm off
* * *
Above 112 C
alarm on
Above 112 C
alarm on
112
110
108
Above 108 C
alarm stays on
112
110
108
Below 108 C
alarm off
112
110
108
Process proceeds
SV
SV+ASP1
*
Deviation
high alarm
A1MD
SV
SV+ASP1
*
Deviation
low alarm
A1MD
(ASP1 negative)
SV
*
*
Deviation band
high alarm
A1MD
SV- ASP1
SV+ ASP1
SV
*
*
Deviation band
low alarm
A1MD
SV- ASP1
SV+ ASP1
Page10

5.15 READ PEAK PROCESS VALUES
The maximum and minimum values of the process value are continuously
updated and stored in the memory as power up. Press both and
to obtain " READ PEAK " Tool Program. Press scroll key to select
or which is shown in lower display. Now the upper display
will show the high peak value or low peak value of the process.
To reset the values, press and hold the scroll key for 3.2 second and
release, this moment both low peak value and high peak value will be
revised by the current process value.
This Tool Program provides an useful function for monitoring the stability of
the process.
5.14 RE-RANGING LINEAR PROCESS INPUTS
Select an appropriate Input Type ( INPT). Define the range by adjusting
LOSCandHISC. In the example below, INPT = 4-20 (mA),LOSC= 0, HISC
= 100.0, RESO =
For a 4 mA input the process value will read 0 (=LOSC), and for a 20 mA
input the process value will read 100.0 (HISC). For a 10 mA input the
process value will read 37.5. If the input signal is beyond the limits, an
error message LLEr or HLEr will be shown in the upper display.
5.13.2 Ramp & Soak Function
The soak function is enabled by configuring the alarm 1 to act as a dwell
timer. If A1SF is set to ( time out on), the alarm 1 relay will now
operate as a timer contact, with the contact being opened at power up and
closing after the elapsed time set at parameter ASP1. If A1SF is set to
( time out off), a reverse action of alarm 1 relay will perform.
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 " is set to 5.00 °C / minute, A1SF = time
out off, and ASP1 = 20 ( 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 20 minutes,
the alarm 1 relay will open, switching off the output. The process
temperature will eventually fall at an undetermined rate.
01020304050
25
50
75
100
125
150
C
t (minutes)
Process Value
ON OFF
Alarm 1
output
20 minutes
0
(LOSC)
100.0
(HISC)
PV
420
Input Signal (mA)
LLEr HLEr
01020304050
25
50
75
100
125
C
t (minutes)
Process Value
ON
OFF
Alarm 1
output
30 minutes
5.13.3 Dwell Function
The dwell function is enabled by configuring the alarm 1 to act as a dwell
timer. If A1SF is set to (time out on), the alarm 1 relay will now
operate as a timer contact with the contact being opened on initial start up.
The timer begins to count down once the setpoint temperature is reached.
After the setting at ASP1 has elapsed, the alarm 1 relay closes.
The dwell function may be used to operate an external device, such as a
siren to alert (for example) when a soak time has been reached.
In the example below, the ramp rate has been set to " 0 ", A1SF=
and ASP1 = 30 (minutes). Initial start up is a zero time and the process
climbs to the 125 °C setpoint with a maximum rate. Once setpoint is
reached, the dwell timer begins to count. After 30 minutes the alarm 1
relay closes. The controller will continue to operate as a fixed setpoint
controller. Timer reset on power up only.
12 13 14 15 16
PTA TC _COM+ _
mA _ V
+
_
40mV
200 ohm 20mA
10V
+_
FDC-9200
SW1
6. RE-CALIBRATION
Do not proceed through this section unless there is a definite need
to re-calibrate the controller. All previous calibration data will be lost. Do
not attempt recalibration unless you have available appropriate calibration
equipment. If calibration data is lost, you will need to return the controller
to your supplier who may charge you a service fee to re-calibrate the
controller.
*Equipment needed
(1) Standard millivolt source with range 0-100mV, accuracy ±0.01%
(2) Standard voltage source with range 0-10V, accuracy ±0.01%
(3) Standard current source with range 0-20mA, accuracy ±0.01%
(4) Standard ohm source with range 0-300 ohm, accuracy ±0.01%
(5) Standard thermometer with range 0-50.0 °C, accuracy ±0.2 °C
(6) A cooling fan or at the best a calibration fixture equiped with a fan
and a push-button switch
(7) Thermocouple simulator
* Calibration Setup
(1)SelectT/C input, UNIT = °C, RESO =
(2) Switch the power off
(3) Disconnect the sensor wiring
(4) Connect the input terminals of the controller to the signal sources
according to the following diagram
(5) Install a fan to blow the cold-junction compensator which is located at
the rear edge of the lower PCB to prevent the cold-junction compensator
from warming up
5.16 LOCK / UNLOCK PARAMETERS
* Lock all the parameters
press and hold both for 3.2 seconds then release, the keypad
operationisdisabled to protect parameters from tampering. Unlockkeypad
operation, press both up and down keys then release.
* Lock parameters in the same security level
Refer to section 6.6.4 for the operation
Page11

* Calibration Procedures
(1) Press both scroll and down key, then release. Tool program will
appear on the upper and lower displays. Repeat above operation until
appear on the displays.
(2) Press and release the scroll key. The display will show a
number with a prefix " "
(3) Use the up and down keys to change the value on the display
until this value coincide with the ambient temperature in degree C
which is measured by the standard thermometer.
(4) Press the scroll key for at least 3.2 seconds, then release. The
display will blink a moment and then show the ambient temperature in
degree C.
(5) Press and release the scroll key. The display will show a number with
a prefix " " , and the display will show 0.00.
(6) Press and hold down the push-button switch SW1. Don't release
SW1. Press the scroll key for at least 3.2 seconds, then release. The
display now will show 20.00. Release SW1.
(7) Press and release the scroll key. The display will show a number
with a prefix " ". If the number is not equal to 0.0, use the up and
down keys to set the value to 0.0. Then press the scroll key for at
least 3.2 seconds, then release. The " " code is reset.
* Verify Calibration Accuracy
(1) Operate the key pads until the display reaches the calibration mode
( appear on the displays ).
(2) Press and release the scroll key until a code is shown in the display.
The display will indicate process value with respect to the 0-20mA
input. Feed a standard signal to the correct mA input terminals and
examine the accuracy of the display.
(3) Press and release the scroll key again until a code is shown in the
display. Now the display will indicate process value with respect to
the INPT type selected. Feed a standard signal to the appropriate input
terminals and examine the accuracy of the display.
(4) Press and , then release quickly, the display will indicate
process value with respect to the PT100/DIN input. Feed a standard
signal to the PT100 input terminals and examine the accuracy of the
display.
(5) Press and , then release quickly, the display will indicate
process value with respect to the 0-10V input. Feed a standard signal
to the voltage input terminals and examine the accuracy of the display.
* Warm-up drift correction for thermocouple input after completing the
above calibration procedure, connect a thermocouple to terminal 13 and
14(observingpolarity)andselect a correct " INPT " for the thermocouple.
Switch the power on and let the controller to be powered for at least 30
minutes. If the controller does not measure a correct temperature for the
thermocouple, the following procedures may be employed to correct the
error.
(1) Perform procedure (1) and (2) stated in calibration procedures.
(2) Press and release the scroll key.
(3) Press and release the scroll key again. Now the " " code with zero
value is obtained on the display.
(4) Use the up and down keys to change the " " code value until the
display shows a correct temperature. The unit of " "code
value is always in degree C independent of the selection of " UNIT ".
(5) Press the scroll key for at least 3.2 seconds, then release. The
display will blink a moment and show an accurate temperature. If the
accuracy of the controller is still unacceptable, replace the controller.
7. ERROR MESSAGE & DIAGNOSIS
This procedure requires access to the circuitry of a live power unit.
Dangerous accidental contact with line voltage is possible. Only qualified
personnel are to perform these procedures. Potentially lethal voltages are
present.
Experience has proven that many control problems are not caused by a
defective instrument. See chart below and Table 7.1 for some of the other
common causes of failures:
* Line wires are improperly connected
* No voltage between line terminals
* Incorrect voltage between line terminals
* Connections to terminals are open, missing or loose
* Thermocouple is open at tip
* Thermocouple lead is broken
* Shorted thermocouple leads
* Short accross terminals
* Open or shorted heater circuit
* Open coil in external contactor
* Burned out line fuses
* Burned out relay inside control
* Defective solid-state rellays
* Defective line switches
* Burned out contactor
* Defective circuit breakers
If the points listed on the chart have been checked and the controller does
not function. it is suggested that the instrument be returned to the factory
for inspection.
Do not attempt to make repairs. It usually creates costly damage. Also, it
is advisable to use adequate packing materials to prevent damage in
shipment.
FDC-9200
A1
SV
OUT
A2 PV FC
Press both sides of the latch located on
rear terminal block.Hold tightly and
remove the terminal block from the
housing.
(1)
Expand the rear edge of the housing by
using a tool. Pull out the PCB from the
(2)
Dismantling the controller
Page12

TABLE 7.1 TROUBLESHOOTING
Sympton Probable Causes (s) Solution (s)
1) Keypad no function - Bad connection between PCB & keypads - Clean contact area on PCB
- Replace keypads
2) LED's will not light - No power to instrument
- Power supply defective - Check power line connections - Replace power supply board
- LED display or LED Lamp defective
- Related LED driver defective - Replace LED display or LED lamp - Replace the related transistor or IC chip
4) Process Display shows: - Sensor break error - Replace RTD or sensor
- Use manual mode operation
5) Process Display shows: - Input signal beyond the low range, sensor fails
- Incorrect input type selected
6) Process Display show: - Input signal beyond the high range,sensor fails
- Incorrect input type selected
7) Process Display shows: - A to D module damage
8) Process Display shows:
9) Process Display shows: - Check and reconfigure the control parameters
10) Process Display shows: - Fail to enter data into EEPROM - Replace EEPROM
11) Process Display shows:
12) Process Display shows: - Attempt to change a locked parameter - Unlock procedures stated in section 5.16
13) Display Unstable - Analog portion or A-D converter defective
- Thermocouple, RTD or sensor defective
- Intermittent connection of sensor wiring
- Replace related components or board
- Check thermocouple, RTD or sensor
- Check sensor wiring connections
14) Considerable error in temperature indication
- Reversed input wiring of sensor - Check and correct
16) No heat or output - Check output wiring and output device
- Replace output device
- Replace output fuse
- Check and replace
18) Control abnormal or operation incorrect - Check and replace
- Read the operation procedure carefully
- Overflow error, data out of range during
execution of software program
- Wrong sensor or thermocouple type. Wrong
input mode selected.
- Analog portion A-D converter defective
- Replace sensor
- Check sensor or thermocouple type, correct
input selection
- 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 if there is a noise comming in. Solve
the problem by means of item (19).
3) Some segments of the display or LED lamps
not lit or lit erroneously.
- Check sum error, values in memory may have
changed accidentally
- Incorrect operation of auto tune procedure.
Prop. Band set to 0
- Manual mode is not allowable for an ON-OFF
control system
- Replace sensor
- Check sensor or thermocouple type, correct
input selection
17) Heat or output stays on but indicator reads
normal
-CPUorEEPROM(non-volative memory)
defective. Key switch defective
- Operation of control incorrect
- Output device shorted, or power service
shorted
19) Display blinks, entered values change by
themselves - Electromagnetic interference (EMI), or Radio
Frequency interface (RFI)
-EEPROMdefective
- Suppress arcing contacts in system to eliminate
high voltage spike sources. Separate sensor
and controller wiring from " dirty" power lines,
ground heaters
-ReplaceEEPROM
- No heater power (output), incorrect output
device used
- Output device defective
- Open fuse outside of the instrument
15) Display goes in reverse direction ( counts
down scale as process warms)
- Check sensor or thermocouple type and if
proper input mode was selected
- Replace related components or board
Page13

ommon Failure Causes and Corrective Actions
Symptom Probable Causes Corrective Actions
1) Keypad no function -Bad connection between PCB & keypads - Clean contact area on PCB
- Replace keypads
2) LED's will not light - No power to instrument
- Power supply defective
- LED display or LED lamp defective
- Related LED driver defective
- Check power line connections
- Replace power supply board
- Replace LED display or LED lamp
- Replace the related transistor or IC chip
3) Some segments of the display or
LED lamps not lit or lit erroneously.
4) Display Unstable
5) Considerable error in temperature
indication
6) Display goes in reverse direction
( counts down scale as process warms )
- Analog portion or A-D converter defective
- Thermocouple, RTD or sensor defective
- Intermittent connection of sensor wiring
- Replace related components or board
- Check thermocouple, RTD or sensor
- Check sensor wiring connections
- Wrong sensor or thermocouple type, wrong
input mode selected.
- Analog portion of A-D converter defective
- Check sensor or thermocouple type and if
proper input mode was selected
- Replace related components or board
- Reversed input wiring of sensor - Check and correct
7) No heat or output
- No heater power ( output ), incorrect output
device used
- Output device defective
- Open fuse outside of the instrument
- Check output wiring and output device
- Replace output device
- Replace output fuse
8) Heat or output stays on but indicator
reads normal
- Output device shorted, or power service
shorted - Check and replace
9) Control abnormal or operation incorrect
- CPU or EEPROM ( non-volatile memory )
defective. Key switch defective
- Incorrect setup values
- Check and replace
- Read the setup procedure carefully
10) Display blinks; entered values change
by themselves
- Electromagnetic interference ( EMI ), or
Radio Frequency interference ( RFI )
- EEPROM defective
- Suppress arcing contacts in system to
eliminate high voltage spike sources.
Separate sensor and controller wiring from
" dirty " power lines, ground heaters
- Replace EEPROM
8.0 COMMON FAILURE CAUSES
Page14

User's Manual FDC-9200 Process / Temperature Controller
7524 West 98th Place
Bridgeview, IL 60455
Phone [phone]
Fax [phone]