Future Design FDC-2220 User Manual

User's Manual

FDC-2220
Self-T une Fuzzy / PID
Process Temperature Controller

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. INST ALLATION 8. COMMON FAILURE CAUSES

1. INTRODUCTION

The FDC-2220 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
1/32 DIN case, measuring 24 mm x 48 mm with 98mm 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
supervisor has the flexibility of determining which parameters are accessible
by the user. 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-2220 is powered by 20-32VAC/VDC or 90-264VAC supply,
incorporating a 3 amp. control relay output and a 3 amp. alarm relay output
as standard which can be programmed into Output 2 or dwell timer.
Alternative output options include SSR drive, 4-20mA and 0-10 volts. The
FDC-2220 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-2220 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-2220
Instruction Manual

Fuzzy Rule

Fuzzy Inference
Engine

DefuzzifierFuzzifier

Numerical
information

Linguistic
information

Numerical
information

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

4 90-264VAC
5 20-32VAC/VDC
9 Other

(2) Signal Input

5 Configurable (Universa l)
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 OM 92-1)
4 0-20mA linear, max. load 500 ohms ( Module OM 92-2)
5 0-10V linear, min. impedance 500K ohms (M odule OM 92-3)
9 Other

(6) Output 2 Option

0 None

(7) Alarm Option

0 None
1 Relay rated 3A/240VAC resistive
9 Other

(8) Communication

0 None
1 RS-485
2 4-20mA retransmission
3 0-20mA retransmission
9 Other

SYSTEM

PID

FUZZY

MV

PV

_

+

SV

+

+

P I D + FUZZY CONTROL

Page 1

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.

(a) The clamp for quick mounting:

Take the clamp away and insert the controller into panel cutout install
the clamp back and push it forward till the controller firmly onto the
panel.

(b) The clamps for protection NEMA 4X / IP65:

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.

3. SPECIFICATIONS

Sensor Input Type Range (°C) * Accuracy

J Iron-Constantan -50 to 999 °C ±2 °C
K Chromel-Alumel -50 to 1370 °C ±2 °C
T Copper-Constantan -270 to 400 °C ±2 °C
E Chromel-Constantan -50 to 750 °C ±2 °C

B Pt30%RH/Pt6%RH 300 to 1800 °C ±3 °C
R Pt13%RH/Pt 0 to 1750 °C ±2 °C
S Pt10%RH/Pt 0 to 1750 °C ±2 °C
N Nicrosil-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

* Accuracy = Linearity Error + Cold Junction Compensating Error

+ Lead Compensating Error + Offset Drift Error

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 )
0-3600 seconds
0-1000 seconds
0-55.55 °C ( 99.99 °F) / minute
0-9999 minutes
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
NEMA 4X, 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 / s

2

(20g )
Flame retardant polycarbonate
110 grams

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.
Component replacement and internal adjustments must be made by qualified
maintenance personnel only.

To help minimize the possibility of fire or shock hazards, do not
expose this instrument to rain or excessive moisture.

22.2

+0.3

45

+0.5

_

0

_

0

Fig. 4.1 Mounting dimensions

3.85”

Panel

.39”

.49”

SCREW

MOUNTING
CLAMP

3.89”

Panel

14.33”

.94”

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.

Page 2

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.

35
46

or

Load

120V /240V
Mains Supply

Alarm
Output

Control
Output

Max. 3A

Resistive

Fig. 4.9 Relay Direct Drive Connections

TABLE 4.1 THERMOCOUPLE CABLE COLOUR CODES

Thermocouple

Type

Cable

Material

BritishBSAmerican

ASTM

German

DIN

French

NFE

T

Copper
Constantan

+ white

- blue
* blue

+ blue

- red
* blue

+ red

- brown
* brown

+ yellow

- blue
* blue

J

Iron / Constantan

+ yellow

- blue
* black

+ white

- red
* black

+ red

- blue
* blue

+ yellow

- black
* black

K

Nickel 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

B

Platinum /
Rhodium

+ grey

- red
* grey

* Colour of overall sheath

11

8

+

_

01V,05V

15V,010V

~

~~

~

Input Impedance = 100k ohm

11
12

+

_

0 20mA or
4 20mA

~
~

Fig. 4.7 Linear Voltage Input Connections

Fig. 4.8 Linear Current Input Connections

4.4.3 PT100 Ohm RTD Input

RTD connection are shown in Figure 4.6, with the compensating lead
connected to terminal 11. For two-wire RTD inputs, terminals 10 and 11
should be linked. The three-wire RTD offers the 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.

10
11

9

A

PT100

B

B

Fig. 4.6 RTD Input Connections

The colour codes used on the thermocouple extension leads are shown in
Table 4.1.

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. Consideration should be given to the 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.

Fig. 4.5 Thermocouple Input Connections

+

10
11

_

Fig. 4.4 Mains (Line) Supply Connections

* 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.

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

The controller is supplied to operate on 24V (20-32VAC/VDC) or 90-264V AC.
Check that the installation mains voltage corresponds to that indicated on
the product label before connecting power to the controllers.

+

_

RTD

0-10V

A

+

+

+

COM

_

TC

_

_

_

mV

mV

0-20 mA
4-20 mA

_

mA

B

PTA

B

_

V

POWER IN
90-264 VAC
50/60HZ

ALM OUT

3A/250 VAC

CNTL OUT

3A/250 VAC

LINEAR or

SSR DRIVE

1

2

3

4

5

6

L

N

N/O

N/O

N/O

C

C

C

8

9

10 11 12 13 14

TX1

TX2

INTERFACE

RS-485

I/O

FDC-2220

Fig. 4.3 Rear Terminal Connections

4.5 7.0 mm

0.18" 0.27"

~

~

2.0mm

0.08" max.

Fig. 4.2 Lead Termination

1
2

90 264VAC or
20 32VAC / VDC

~

~

Fuse

Page 3

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
optimum position.

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. OPERA TION

5.1 FRONT PANEL DESCRIPTION

OUT

FDC-2220

ALM

C

Control
Output
Indicator

Alarm
Output
Indicator

3 Silicon Rubber buttons
For ease of control set-up
and setpoint adjustment.

4-digit 0.4" red LED display indicating

process value or setpoint value.

35
46

or

120V /240V
Mains Supply

Alarm
Output

Control
Output

No Fuse
Breaker

Three
Phase
Heater
Power

Three Phase
Delta
Heater
Load

Fig. 4.10 Contactor drive Connections

Fig. 4.12 Linear Voltage / Current Connections

6
5

+

_

0 20mA,
4 20mA or
0 10V

~
~
~

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.

6
5

Load

120V /240V
Mains Supply

+

+

_

_

SSR

Fig. 4.11 SSR Drive Connections

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 OPERA TION

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

Page 4