Future Design FDC-9090 User Manual

9090 User's Manual9090 User's Manual

FDC-9090

FDC-9090

Self-Tune Fuzzy / PID

Self-Tune
Process

Process / Temperature Controller

Fuzzy / PID

/ Temperature Controller

Warning SymbolWarning Symbol

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.

Use the ManualUse the Manual

Specifications

Wiring

Programming

Warranty

NOTE:

It is strongly recommended that a process should

It is strongly recommended that a process should

incorporate a LIMIT like L91 which will shut down the

incorporate
equipment

equipment at a preset process condition in order

preclude possible damage to products or

to

to preclude possible damage to products or

system.

system.

Copyright a August 2001, 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.

at a preset process condition in order

Page 3

Page 4

Page 6

Page 11

a LIMIT like L91 which will shut down the

2

UM9090Rev3.0

Model:FDC 9090

Model:FDC 9090

Instruction Manual

Instruction

1. INTRODUCTION

1. INTRODUCTION

2. NUMBERING SYSTEM

2.

NUMBERING SYSTEM

3. FRONT PANEL DESCRIPTION

3.

FRONT PANEL DESCRIPTION

4. INPUT RANGE & ACCURACY

4.

INPUT RANGE & ACCURACY

5. SPECIFICATIONS

5.

SPECIFICATIONS

6. INSTALLATION

6.

INSTALLATION

6.1 DIMENSIONS & PANEL CUTOUT

6.2 WIRING DIAGRAM

1. INTRODUCTION1. INTRODUCTION

This manual contains information for the installation and operation

of the Future Design Control’s model FDC-9090 Fuzzy Logic
micro-processor based controller.

The Fuzzy Logic is an essential feature of this versatile
controller. Although PID control has been widely accepted by
industries, it is difficult for PID control to work with some sophistic
systems efficiently, for example, systems of second order, long
time-lag, various set points, various loads, etc. Because of
disadvantage of controlling principles and fixed values of PID
control, it is inefficient to control the systems with many
variables and the result is unacceptable control for some
systems. The Fuzzy Logic control can overcome the
disadvantage of PID control only. It controls the system in a
efficient way by experiences it had before. The function of Fuzzy
Logic is to adjust the PID values indirectly in order to making the
manipulation output value MV adjusts automatically and quickly
to adapt to various processes. It enables a process to reach its
set point in the shortest time with minimum overshooting during
tuning or external disturbance.

PID control with properly tuned
PID + Fuzzy control

Set point

In addition, this instrument has functions of single stage ramp
and dwell, auto-tunung and manual mode execution. Ease of use
also an essential feature with it.

2. Model Order Matrix2. Model Order Matrix

FDC

(1) Power Input

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

9 Other

(2) Signal Input

5 Configurable (Universal)

9 Other

(3) Range Code

1 Configurable
9 Other

(4) Control Mode

3 PID / ON-OFF Control

(5) Output 1 Option

0 None
1 Relay rated 3A/240VAC resistive
2 SSR Drive rated 20mA/24V
3 4-20mA linear, max. load 500 ohms (Module OM93-1)
4 0-20mA linear, max. load 500 ohms (Module OM93-2)
5 0-10V linear, min. impedance 500K ohms (Module OM93-3)

9 Other

(6) Output 2 Option

0 None

(7) Alarm Option

0 None
1 Relay rated 2A/240VAC resistive

9 Other

(8) Communication

0 None

CONTENTS

Temperature

Load Disturbance

Warm Up

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

Manual

7

. OPERATION

7

. OPERATION

7.1 KEYPAD OPERATION
AUTOMATIC TUNING

7.2
MANUAL P.I.D. ADJUSTMENT

7.3
RAMP & DWELL

7.4
MANUAL TUNING PROCEDURE

7.5
FLOW CHART

7.6
PARAMETER DESCRIPTION

7.7

8. CALIBRATION8. CALIBRATION

9. ERROR MESSAGES9. ERROR MESSAGES

PID+FUZZY CONTROL

MV

SYSTEM

PID

+

+

FUZZY

Time

PV

_

+

3. FRONT PANEL DESCRIPTION3. FRONT PANEL DESCRIPTION

Sensor

J
K
T
E
B
R
S

N
RTD
RTD

Linear

CON

ALM

Iron-Constantan
Chromel-Alumel
Copper-Constantan
Chromel-Constantan
Pt30%RH/Pt6%RH
Pt13%RH/Pt
Pt10%RH/Pt
Nicrosil-Nisil
PT100 ohms(DIN)
PT100 ohms(JIS)

-10mV to 60mV

Control Output

Alarm Output

Scroll Key

4. INPUT RANGE & ACCURACY4. INPUT RANGE & ACCURACY

IN

0
1
2
3
4
5
6
7
8
9

10

5. SPECIFICATIONS5. SPECIFICATIONS

INPUT

Thermocouple (T/C):
RTD:
Linear:

SV

Range:
Accuracy:
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

Approvals:

EMC Emission:
EMC Immunity:
Operating Temperature:
Humidity:
Insulation:
Breakdown:
Vibration:
Shock:
Net Weight:
Housing Materials:

Process Value Display
(0.4" red LED)

Set point Value Display

PV

SV

C

(0.3" green LED)

Down Key

Return Key

9090

Up Key

Input Type

J, K, T, E, B, R, S, N.
PT100 ohm RTD (PTDN or JIS)

-10 to 60 mV, configurable input attenuation
User configurable, refer to Table above
Refer to Table above

0.1 C/ C ambient typical
Protection mode configurable
100 ohms max.
60 dB
120dB
3 times / second

0 - 200 C ( 0-360F)
0 - 3600 seconds
0 - 1000 seconds
0 - 200.0 C / minute (
0 - 3600 minutes
With adjustable hysteresis (0-20% of SPAN)
0-120 seconds
Direct (for cooling ) and reverse (for heating)

90-264VAC, 50/ 60Hz
Less than 5VA

UR File E196206, CSA 209463
CE., RoHS Compliant
EN50081-1
EN50082-2

-10 to 50 C
0 to 90 % RH (non-codensing)
20M ohms min. ( 500 VDC )
AC 2000V, 50/60 Hz, 1 minute
10 - 55 Hz, amplitude 1 mm
200 m/ s ( 20g )
170 grams
Poly-Carbonate Plastic

Range( C/F )

-50/999C -58/1830F

-50/1370C -58/2498F

-270 to 400 C -454/752F

-50/750C -58/1382F

300/1800C 572/3272F

0/1750C 32/3182F
0/1750C 32/3182F

-50/1300C -58/2372F

-200/400C -328/752F

-200/400C -328/752F

-1999 to 9999

0 - 360.0 F / minute)

2

Accuracy

+/-2 C(4F)

+/-2 C(4F)

+/-2 C(4F)

+/-2 C(4F)

+/-2 C(4F)

+/-2 C(4F)

+/-2 C(4F)

+/-2 C(4F)

+/-0.4 C(.8F)

+/-0.4 C(.8F)

+/-0.05%

UM9090Rev3.0

3

6. INSTALLATION6. INSTALLATION

6.1 DIMENSIONS & PANEL CUTOUT6.1 DIMENSIONS & PANEL CUTOUT

(45 mm)

1.77 “

1.77 “

(45 mm)

Panel

3.38 “

86 mm

3.70 “

Figure 6.1 Mounting Dimensions

6.2 WIRING DIAGRAM6.2 WIRING DIAGRAM

FDC-9090

Alarm
Com.

1

Alarm

2

N/O

RTD

7. OPERATION7. OPERATION

7.1 KEYPAD OPERATION7.1 KEYPAD OPERATION

TOUCHKEYS FUNCTION DESCRIPTION

3

_

_

4

V

+

+

5

* F1: Fuse, S1: Power Switch

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

6

7

8
9

10

Scroll Key

94 mm

S1

F1

90 - 264 VAC,50/60HZ

+
_

Control Output 1

Advance the index display to the desired position.
Index advanced continuously and cyclically by pressing this keypad.

7.2 AUTOMATIC TUNING

1. Ensure that controller is correctly configured and installed.

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

3. Press Return Key for at least 6 seconds ( maximum 16 seconds). This
initializes the Auto-tune function. (To abort auto-tuning procedure
press Return Key and release).

4. The Decimal point in lower right hand corner of PV display flashes to
indicate Auto-tune is in progress. Auto-tune is complete when the
flashing stops.

5. Depending on the particular process, automatic tuning may take up
to two hours. Processes with long time lags will take the longest to
tune. Remember, while the display point flashes the controller is
auto-tuning.

NOTE: If an AT error( ) occurs, the automatic tuning process

is aborted due to the system operating in ON-OFF control(PB=0).
The process will also be aborted if the set point is set to close to
the process temperature or if there is insufficient capacity in the
system to reach set point (e.g. inadequate heating power
available). Upon completion of Auto-tune the new P.I.D. settings
are automatically entered into the controller's non-volatile memory.

7.3 MANUAL P.I.D.ADJUSTMENT7.3 MANUAL P.I.D.ADJUSTMENT

Whilst the auto-tuning function selects control settings which should prove
satisfactory for the majority of processes, you may find it necessary to
make adjustments to these arbitrary settings from time to time. This may
be the case if some changes are made to the process or if you wish to
'fine-tune' the control settings.

It is important that prior to making changes to the control settings that
you record the current settings for future reference. Make slight changes
to only one setting at a time and observe the results on the process.
Because each of the settings interact with each other, it is easy to become
confused with the results if you are not familiar with process control
procedures.

TUNING GUIDETUNING GUIDE

Proportional Band
Symptom
Slow Response
High Overshoot or Oscillations

Integral Time (Reset)
Symptom
Slow Response
Instability or Oscillations

Derivative Time (Rate)
Symptom
Slow Response or Oscillations
High Overshoot

Solution
Decrease PB Value
Increase PB Value

Solution
Decrease Integral Time
Increase Integral Time

Solution
Decrease Deriv. Time
Increase TimeDeriv.

Press
for 6 seconds

Press
for 6 seconds

Press and

Press and
for 6 seconds

Up Key

Down Key

Return Key

Long Scroll

Long Return

Output Percentage
Monitor

Manual Mode
Execution

Increases the parameter

Decreases the parameter

Resets the controller to its normal status. Also stops auto-tuning,
output percentage monitoring and manual mode operation.

Allows more parameters to be inspected or changed.

1. Executes auto-tuning function

2. Calibrates control when in calibration level

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

Allows the controller to enter the manual mode.

4

UM9090Rev3.0