User's Manual - futuredesigncontrols.com

1 User's ManualBTC-4100/7100/8100/9100 Process / Temperature ControllerUser'sManualBTC-4100/7100/8100 /9100 Process/TemperatureControllerUser's ManualFDC4100/7100/8100/9100 Auto-Tune Fuzzy / PIDP rocess / Temperature ControllerWarning SymbolUse the ManualThis Symbol calls attention to an operating procedure, practice, or thelike, which, if not correctly performed or adhered to, could result inpersonal injury or damage to or destruction of part or all of theproduct and system. Do not proceed beyond a warning symbol untilthe indicated conditions are fully understood and DesignerUserRead Chapter 1, 2 Read All ChaptersRead Page 12 NOTE.

2 It is strongly recommended that a process should incorporate aLIMIT CONTROL like the FDC L91 which will shut down theequipment at a preset process condition in order to precludepossible damage to products or in this User's Manual is subject to change without November 2003, Future Design Controls, all rights part of this publication may be reproduced, transmitted,transcribed or stored in a retrieval system, or translated into anylanguage in any form by any means without the written permission ofFuture Design 1 Overview1-1 General -------------------------41-2 Ordering Code ---------------71-3 Programming Port ------------81-4 Keys and Displays ----------91-5 Menu Overview -------------111-6 Parameter Descriptions ---12 Page NoChapter 2 Installation2-1 Unpacking ---------------------192-2 Mounting ----------------------192-3 Wiring precautions ----------212-4 Power Wiring -----------------242-5 Sensor Installation ----------Guidelines-------------------- --242-6

3 Sensor Input Wiring --------252-7 Control Output Wiring -----252-8 Alarm Wiring ------------------282-9 Process Retransmission ------282-10 Data Communications------29 Chapter 3 Programming3-1 Lockout -----------------------313-2 Signal Input ------------------313-3 Control Outputs --------------323-4 Alarm ---------------------------373-5 Configure user Menu -----483-6 Ramp -------------------------493-7 Dwell Timer ------------------403-8 PV Shift -----------------------413-9 Digital Filter -------------------413-10 Failure Transfer -------------423-11 Auto-tuning ------------------433-12 Manual tuning -------------443-13 Manual Control -------------453-14 Data communication -----473-15 PV Retransmission----- -----47 Chapter 4 Calibration------48 Chapter 5 Specifications --53 Page NoAppendixA-1 Error Codes --------------------59A-2 Warranty -------------------------60UM91001 DChapter 1 Overview1-1 GeneralThe Fuzzy Logic plus PID microprocessor-based controller series,incorporate two bright, easy to read 4-digit LED displays, indicatingprocess value and set point value.

4 The Fuzzy Logic technologyenables a process to reach a predetermined set point in theshortest time, with the minimum of overshoot during power-up orexternal load is a 1/16 DIN size panel mount controller. FDC-7100 is a72X72 DIN size panel mount controller. FDC-8100 is a 1/8 DIN sizepanel mount controller and FDC-4100 is a 1/4 DIN size panelmount controller. These units are powered by 11-26 VAC/VDC or90-250 VAC supply, relay output asstandard. The second output can be used as cooling control, or analarm. Both outputs can select triac, 5V logic output, linear currentor linear voltage to drive external device.

5 There are six types ofalarm plus a dwell timer can be configured for the third output. Theunits 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 signalis digitized by using a 18-bit A to D converter. Its fast sampling rate,5 scans/second, allows the unit to control fast communications RS-485 or RS-232 ( excluding FDC-7100 )are available as an additional option. These options allow the unitsto be integrated with supervisory control system and programming port is available for automatic configuration,calibration and testing without the need to access the keys on using proprietary Fuzzy modified PID technology, the controlloop will minimize the overshoot and undershoot in a shortesttime.

6 The following diagram is a comparison of results with andwithout Fuzzy control with properly tunedPID + Fuzzy controlWarm UpLoad DisturbanceSetpointTemperatureTimeHigh AccuracyThis Series controllers are manufactured with custom designedASIC(Application Specific Integrated Circuit ) technology whichcontains a 18-bit A to D converter for high resolution measurement( true F resolution for thermocouple and PT100 ) and a 15-bitD to A converter for linear current or voltage control output. TheASIC technology provides improved operating performance,low cost, enhanced reliability and higher Sampling RateThe sampling rate of the input A to D converter reaches 5 fast sampling rate allows this series to control fast ControlThe function of Fuzzy control is to adjust PID parameters from time totime in order to make manipulation output value more flexible andadaptive to various processes.

7 The results is to enable a process toreach a predetermined set point in the shortest time, with the minimumof overshoot and undershoot during power-up or external CommunicationThe units are equipped with RS-485 or RS-232 interface card toprovide digital communication. By using the twisted pair wires thereare at most 247 units can be connected together via RS-485 interfaceto a host ControlAdvantageUM91001D5 Programming PortA programming port is used to connect the unit to a hand-heldprogrammer or a PC for quick configuration, also can be connectedto an ATE system for automatic testing & auto-tune function allows the user to simplify initial setup for anew system.

8 A clever algorithm is provided to obtain an optimal setof control parameters for the process, and it can be applied either asthe process is warming up ( cold start ) or as the process has beenin steady state ( warm start ).Lockout ProtectionAccording to actual security requirement, one of four lockout levelscan be selected to prevent the unit from being changed TransferBumpless transfer allows the controller to continue to control byusing its previous value as the sensor breaks. Hence, the processcan be well controlled temporarily as if the sensor is RampThe ramping function is performed during power up as well as anytime the set point is changed.

9 It can be ramping up or rampingdown. The process value will reach the set point with a predeterminedconstant FilterA first order low pass filter with a programmable time constant is usedto improve the stability of process value. This is particularly useful incertain application where the process value is too unstable to be FunctionThe units have the flexibility for user to select those parameters whichare most significant to him and put these parameters in the front ofdisplay sequence. There are at most 8 parameters can be selectedto allow the user to build his own display Input4: 90 - 250 VAC,50/60 HZ5: 11 - 26 VAC orVDC9: Special Order0: None1: RS-485 interface2: RS-232 interface ( notavailable for 7100 )3: Retransmit 4-20mA / 0-20mA4: Retransmit 1-5 V / 0-5V5: Retransmit 0-10V9: Special orderCommunications1: Standard InputThermocouple:J, K, T, E, B, R,S, N, LRTD: PT100 DIN,PT100 JIS2:0-60mV3:0-1V4:0-5V5:1-5V6:4-20mA7:0 -20mA8:0-10V9: Special OrderSignal Input0: None1: Relay rated 2A/240 VAC2: Pulsed voltage to drive SSR,5V/30mA3: Isolated 4 - 20mA/ 0 - 20mA4.

10 Isolated 1 - 5V/0-5V5: Isolated 0 - 10V6: Triac output 1A / 240 VAC,SSRC: Pulsed voltage to drive SSR,14V/40mA9: Special orderOutput 10: None1: Form C relay 2A/240 VAC9: Special orderAlarmBTC-4100-BTC-7100-BTC-8100-BTC -9100-0: None1: Form A relay 2A/240 VAC2: Pulsed voltage todrive SSR, 5V / 30mA3: Isolated 4 - 20mA/0-20mA4: Isolated 1 - 5V/0-5V5: Isolated 0 - 10V6: Triac output, 1A / 240 VAC,SSR7: Isolated 20V/25mAtransducer power supply8: Isolated 12V/40mAtransducer power supply9: Isolated 5V/80mAtransducer power supplyC: Pulsed voltage to drive SSR,14V/40mAA: Special orderOutput 21-2 Ordering Code0: Panel mount IP50 standard1: Panel mount IP65 waterresistant rubber installed2: DIN Rail mount with IP50(for 9100 only)3: DIN Rail mount with IP65(for 9100 only)OptionsUM91001D71-3 Programming PortFrontPanelRearTerminalAccess Hole11334466 Figure PortOverviewA special connector can be used to touch the programming portwhich is connected to a PC for automatic configuration, also can beconnected to an ATE system for automatic calibration and programming port is used for off-line automatic setup and testingprocedures only.