Futuredesign controls UM100 User manual

User's Manual
FDC4100/7100/8100/9100
Auto-Tune Fuzzy / PID
Process / Temperature Controller

Warning Symbol
Use 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.
Installers
System Designer
User
Read Chapter 1, 2
Read All Chapters
Read Page 12
NOTE :
It is strongly recommended that a process should incorporate a
LIMIT CONTROL like the FDC L91 which will shut down the
equipment at a preset process condition in order to preclude
possible damage to products or system.
Information in this user's manual is subject to change without notice.
Copyright November 2003, Future Design Controls, all rights 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.
UM100 V2.02

3
Contents
Chapter 1 Overview
1-1 General -------------------------4
1-2 Ordering Code ---------------7
1-3 Programming Port ------------8
1-4 Keys and Displays ----------9
1-5 Menu Overview -------------11
1-6 Parameter Descriptions ---12
Page No
Chapter 2 Installation
2-1 Unpacking ---------------------19
2-2 Mounting ----------------------19
2-3 Wiring precautions ----------21
2-4 Power Wiring -----------------24
2-5 Sensor Installation ----------
Guidelines----------------------24
2-6 Sensor Input Wiring --------25
2-7 Control Output Wiring -----25
2-8 Alarm Wiring ------------------28
2-9 Process Retransmission ------28
2-10 Data Communications------29
Chapter 3 Programming
3-1 Lockout -----------------------31
3-2 Signal Input ------------------31
3-3 Control Outputs --------------32
3-4 Alarm ---------------------------37
3-5 Configure User Menu -----48
3-6 Ramp -------------------------49
3-7 Dwell Timer ------------------40
3-8 PV Shift -----------------------41
3-9 Digital Filter -------------------41
3-10 Failure Transfer -------------42
3-11 Auto-tuning ------------------43
3-12 Manual tuning -------------44
3-13 Manual Control -------------45
3-14 Data communication -----47
3-15 PV Retransmission----- -----47
Chapter 4 Calibration ------48
Chapter 5 Specifications --53
Page No
Appendix
A-1 Error Codes --------------------59
A-2 Warranty -------------------------60
UM100 V2.0

Chapter 1 Overview
1-1 General
The Fuzzy Logic plus PID microprocessor-based controller series,
incorporate two bright, easy to read 4-digit LED displays, indicating
process value and set point value. The Fuzzy Logic technology
enables a process to reach a predetermined set point in the
shortest time, with the minimum of overshoot during power-up or
external load disturbance.
FDC-9100 is a 1/16 DIN size panel mount controller. FDC-7100 is a
72X72 DIN size panel mount controller. FDC-8100 is a 1/8 DIN size
panel mount controller and FDC-4100 is a 1/4 DIN size panel
mount controller. These units are powered by 11-26VAC/VDC or
90-250 VAC supply, incorporatinga2amp.control relay output as
standard. The second output can be used as cooling control, or an
alarm. Both outputs can select triac, 5V logic output, linear current
or linear voltage to drive external device. There are six types of
alarm plus a dwell timer can be configured for the third output. The
units are fully programmable for PT100 and thermocouple types J,
K, T, E, B, R, S, N, L with no need to modify the unit. The input signal
is digitized by using a 18-bit A to D converter. Its fast sampling rate,
5 scans/second, allows the unit to control fast processes.
Digital communications RS-485 or RS-232 ( excluding FDC-7100 )
are available as an additional option. These options allow the units
to be integrated with supervisory control system and software.
A programming port is available for automatic configuration,
calibration and testing without the need to access the keys on front
panel.
By using proprietary Fuzzy modified PID technology, the control
loop will minimize the overshoot and undershoot in a shortest
time. The following diagram is a comparison of results with and
without Fuzzy technology.
4UM100 V2.0

PID control with properly tuned
PID + Fuzzy control
Warm Up Load Disturbance
Set
point
Temperature
Time
High Accuracy
This Series controllers are manufactured with custom designed
ASIC(Application Specific Integrated Circuit ) technology which
contains a 18-bit A to D converter for high resolution measurement
( true 0.1 F resolution for thermocouple and PT100 ) and a 15-bit
D to A converter for linear current or voltage control output. The
ASIC technology provides improved operating performance,
low cost, enhanced reliability and higher density.
Fast Sampling Rate
The sampling rate of the input A to D converter reaches 5 times/second.
The fast sampling rate allows this series to control fast processes.
Fuzzy Control
The function of Fuzzy control is to adjust PID parameters from time to
time in order to make manipulation output value more flexible and
adaptive to various processes. The results is to enable a process to
reach a predetermined set point in the shortest time, with the minimum
of overshoot and undershoot during power-up or external load
disturbance.
Digital Communication
The units are equipped with RS-485 or RS-232 interface card to
provide digital communication. By using the twisted pair wires there
are at most 247 units can be connected together via RS-485 interface
to a host computer.
Figure 1.1
Fuzzy Control
Advantage
5
UM100 V2.0

Programming Port
A programming port is used to connect the unit to a hand-held
programmer or a PC for quick configuration, also can be connected
to an ATE system for automatic testing & calibration.
Auto-tune
The auto-tune function allows the user to simplify initial setup for a
new system. A clever algorithm is provided to obtain an optimal set
of control parameters for the process, and it can be applied either as
the process is warming up ( cold start ) or as the process has been
in steady state ( warm start ).
Lockout Protection
According to actual security requirement, one of four lockout levels
can be selected to prevent the unit from being changed abnormally.
Bumpless Transfer
Bumpless transfer allows the controller to continue to control by
using its previous value as the sensor breaks. Hence, the process
can be well controlled temporarily as if the sensor is normal.
Soft-start Ramp
The ramping function is performed during power up as well as any
time the set point is changed. It can be ramping up or ramping
down. The process value will reach the set point with a predetermined
constant rate.
Digital Filter
A first order low pass filter with a programmable time constant is used
to improve the stability of process value. This is particularly useful in
certain application where the process value is too unstable to be read.
SEL Function
The units have the flexibility for user to select those parameters which
are most significant to him and put these parameters in the front of
display sequence. There are at most 8 parameters can be selected
to allow the user to build his own display sequence.
6UM100 V2.0

Power Input
4: 90 - 250 VAC,
50/60 HZ
5: 11 - 26 VAC or
VDC
9: Special Order
0: None
1: RS-485 interface
2: RS-232 interface ( not
available for 7100 )
3: Retransmit 4-20mA / 0-20mA
4: Retransmit 1-5 V / 0-5V
5: Retransmit 0-10V
9: Special order
Communications
1: Standard Input
Thermocouple:
J, K, T, E, B, R,
S, N, L
RTD: PT100 DIN,
PT100 JIS
2:0-60mV
3:0-1V
4:0-5V
5:1-5V
6:4-20mA
7:0-20mA
8:0-10V
9: Special Order
Signal Input
0: None
1: Relay rated 2A/240VAC
2: Pulsed voltage to drive SSR,
5V/30mA
3: Isolated4-20mA/0-20mA
4: Isolated1-5V/0-5V
5: Isolated0-10V
6: Triac output 1A / 240VAC,SSR
C: Pulsed voltage to drive SSR,
14V/40mA
9: Special order
Output 1
0: None
1: Form C relay 2A/240VAC
9: Special order
Alarm
FDC-4100-
FDC-7100-
FDC-8100-
FDC-9100-
0: None
1: Form A relay 2A/240VAC
2: Pulsed voltage to
drive SSR, 5V / 30mA
3: Isolated4-20mA/0-20mA
4: Isolated1-5V/0-5V
5: Isolated0-10V
6: Triac output, 1A / 240VAC,
SSR
7: Isolated 20V/25mA
transducer power supply
8: Isolated 12V/40mA
transducer power supply
9: Isolated 5V/80mA
transducer power supply
C: Pulsed voltage to drive SSR,
14V/40mA
A: Special order
Output 2
1-2 Ordering Code
0: Panel mount IP50 standard
1: Panel mount IP65 water
resistant rubber installed
2: DIN Rail mount with IP50
(for 9100 only)
3: DIN Rail mount with IP65
(for 9100 only)
Options
7
UM100 V2.0
Suffix Special AA-ZZ (Standard Blank)

1-3 Programming Port
Front
Panel
Rear
Terminal
Access Hole
1
1
3
3
4
4
6
6
Figure 1.2
Programming Port
Overview
A special connector can be used to touch the programming port
which is connected to a PC for automatic configuration, also can be
connected to an ATE system for automatic calibration and testing.
The programming port is used for off-line automatic setup and testing
procedures only. Do NOT attempt to make any connection to these
pins when the unit is in normal operation.
2
2
5
5
8UM100 V2.0

1- 4 Keys and Displays
KEYPAD OPERATION
SCROLL KEY :
This key is used to select a parameter to be viewed or adjusted.
UP KEY :
This key is used to increase the value of selected parameter.
DOWN KEY :
This key is used to decrease the value of selected parameter.
RESET KEY :
This key is used to:
1. Revert the display to display the process value.
2. Reset the latching alarm, once the alarm condition is
removed.
3. Stop the manual control mode , auto-tuning mode and calibration
mode.
4. Clear the message of communication error and auto-tuning error.
5. Restart the dwell timer when the dwell timer has been time out.
6. Enter the manual control menu during failure mode occurs.
ENTER KEY : Press for 3 seconds or longer .
Press for 3 seconds to:
1. Ener setup menu. The display shows .
2. Enter manual control mode during manual control mode
is selected.
3. Enter auto-tuning mode during auto-tuning mode is
selected.
4. Perform calibration to a selected parameter during the
calibration procedure.
Press for 4.2 seconds to select manual control mode.
Press for 5.4 seconds to select auto-tuning mode.
Press for 6.6 seconds to select calibration mode.
R
9
UM100 V2.0

: Confused Character
Table 1.1 Display Form of Characters
AEINSX
BFJOTY
CGKPUZ
cHLQV
?
Dh
MRW=
Figure 1.3 Front Panel Description
Upper Display, to display process value,
menu symbol and error code etc.
Lower Display,
to display set point value,
parameter value or
control output value etc.
4 Buttons for ease of
control setup and
set point adjustment.
Output 1
Indicator
Output 2
Indicator
Alarm
Indicator
Process Unit Indicator
Manual
Mode
Indicator
Auto-tuning
Indicator
The left diagram shows program no. 6
for FDC-9100 with version 12.
The program no. for FDC-7100 is 13,
for FDC-8100 is 11 and for FDC-4100 is 12.
Display program code of the product
for 2.5 seconds.
Figure 1.4
Display of Initial Stage
OP1 OP2 ALM
CF
MAN
AT
9100
R
OP1 OP2 ALM
CF
MAN
AT
9100
R
10 UM100 V2.0