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
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 )
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 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
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 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
~
0 99 Seconds, 0 for Linear current / Vol­tage output. **20
~
0 99 Seconds, 0 for Linear current / Vol­tage 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
Level 0
Level 1
Level 2
: 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.
**
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
Ramp Rate
or
0 55.55 C/minute or 0 ~ 99.99 F/minute~
**0.00
Offset Value for Manual Reset ( Integral Time TI=0 )
or
~
0 100.0%
Time)
10.0
C
**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
**
~
~
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 111 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 1111 value.
**
:Denotes the default setting.
:Proportional cooling.
Page 5
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
Long
View the percentage power of Heating output.
View the percentage power of Cooling output (Alarm).
Hand ( Manual ) Control
Read Peak Process Value
Calibrate A-D converter
Enter the manual control mode. Allow to adjust the percentage value of Heating output by using
or
.
Enter the manual control mode. Allow to adjust the percentage value of Cooling output (Alarm) 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 Selection.
Enter the Selection.
Enter the Selection.
Enter the updated security level of ASP1.
Enter the updated security level of RAMP.
Enter the updated
Adjust the Cold-junction compensation code. (-19.9 42.7 count)
~
Adjust the drift
~
Adjust the drift compensation code. (-6.6 6.6 count)
~
Select a proper status for Output 1.
:Output 1 ON
:Output 1 OFF
: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%
~
000 100%
~
**
:Alarm 1 ON :Alarm 1 OFF
**
**
**
**
(No function with FDC -2220.)
(No function with FDC -2220.)
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
**
Select Lock or F ree for the Security Level 0.
Select a proper status for Alarm 1.
Page 6
LOSC, HISC - Low / High Scale Range If thermocouple or PT100 is selected as input type (INPT) these parameters 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 Decimal Point Position
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 - Alarm Mode Selection for Alarm 1 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.
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.
PB, TI, TD - Constants for PID Control Refer section 5.7 for an in-depth description.
AHY1 - Hysteresis Values of Alarm 1 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 the controller does not use the RS-485 interface, the ADDR can be neglected.
5.5 SETTING-UP PROCEDURES
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. Note that the new value of parameters are entered into nonvolatile memory automatically.
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.
Page 7
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. * T o ensure that PB is not zero because that ON-OFF control is not allowable 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 MANUALL Y
* 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
Page 8
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 ALM1
CONA = REVR A1SF = NONE A1MD = DVHI (or FSHI) AHY1, SV (or ASP1)
Heating + Proportional Cooling
OUT1 ALM1
CONA = REVR A1SF = COOL CPB, DB, CCYC, SV
Page 9
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. The alarm output and indicator will be energized even if the alarm condition 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 PERCENT AGE POWER
Selecting the T ool Programs until the HAND CONTROL is obtained. 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
Page 10
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 LOSC and HISC. 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.
PTA
TC
_
COM+
_
mA
_
V
+
_
40mV
200 ohm 20mA
10V
+
_
FDC-2220
SW1
8910
11 12
6. RE-CALIBRA TION
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) Select T/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 operation is disabled to protect parameters from tampering. Unlock keypad 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
Page 11
* 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 ( observing polarity ) and select 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.
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)
FD
C
OUT
ALM
C
Dismantling the controller
-
2220
Page 12
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
- CPU or EEPROM (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)
- 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
- 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
Page 13
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
Page 14
User's Manual FDC-2220 Process / Temperature Controller
7524 West 98th Place Bridgeview, IL 60455 Phone 888-751-5444 Fax 888-307-8014
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