fj FuTuUREDEsion oNTROLS FDC-4000 Chamber Controller Installation — Setup — Operation - Service Future Design Controls, Ine. 7524 West 98” Place Bridgeview, IL 60455 ‘Tol: (888) 751-8444 Fax: (886) 307-8014 1 FDC 4000 Manat Rev (10007),q@ FUTUREDESIGN c oN TROLS FDC-4000 Chamber Controller [4-1 Features * Simple operation * Type ‘T" Thermocouple / RTD Input * Degrees F or C operation * Low voltage operation * Programmable deadband alarm * Power failure alarm * Low baltery indication * Adjustable hysteresis for control and alarm outputs * Process value calibration offset adjustment * “RingBack" mode for audible alarm * Wake" mode for battery operation indication of PV * Control and Alarm relay (DPDT) output contacts The FDC-4000 rmicroprocessor-based controller, incorporates dual, easy to read 4-digit LED displays. The LED displays indicate process value and set-point, as well as other controller operations. This unit features keys to select the various operator views as well as control parameters. The FDC-4000 has been designed spectfically for low temperature chamber operation, providing simple to use, “hassle” free operation for startup and operation of the chamber, The FDC-4000 incorporates a (DPDT) control relay output and a (DPDT) alarm relay output as standard. Programmable deadoand alarm set-points allow the operator to moniterfindicate alarm conditions above and below chamber operational settings. “RingBack” operation allows an operator to silence the audible alarm for a programmable length of time. If the time has elapsed and the alarm condition still exists, the audible alarm will re-energize to alert the operator to the pre-existing alarm condition. Power failure mode will alert the operator when main power to the chamber is lost. During power failure, the audible alarm will sound and the alarm contact will be energized while on battery back-up. ‘While operating on battery back-up power, pressing the [©) key will display the current chamber temperature on the top LED display until the key is released. 2 FDC 4000 Manual Rev (10/07)2-1 Installation ] Aro minimize the possibility of fire or electric shock hazards, do not expose this instrument to rain or excessive moisture. A Do not use this instrument in areas under hazardous conditions such as excessive shock, vibration, dirt, moisture, corroslve gases or oll, The ambient temperature of the areas should not exceed the maximum ratings. 2-2 Unpacking Upon receipt of the shipment, remove the unit from the carton and inspect it for shipping damage. If there is any damage due to transit, report and file @ claim with the carrier. Write down the model number and serial number for future reference when corresponding with our service center. 2-3 Mounting Make panel cutout to the dimensions shown in the following figure: 7.50" cuTouT ° ~4.00' ——#+——4.09" pee Thoas: o2slle ! Figure 2.1 Mounting Dimensions 3 FOC 4000 Mana Rev (10007)2-4 Power Wiring rerun ical rinawurs Ses nel) alsa 588] Lacon feat (on neasoe][oSo: Figure 2.2 Controller Circuit Board Avis 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 rigidly observed. Consideration should be given to prevent unauthorized persons access to the power terminals. Main Power Conneetion to the Circuit Board ~ The FDC-4000 controller uses. 12Volts AC for its main power supply to the circuit board. An optional step-down transformer can be provided to supply the required power to the controller. Battery Back-Up — Back-up-power to the controller can be provided in the event of a main power fallure. A 6Volt DC Lead: Acid Rechargeable Batlery is. recommended for battery back-up. The controller unit will automatically recharge and maintain the rechargeable battery. A non-rechargeable 6Volt DC battery may also be used. However, before connecting the non-rechargeable battery to the controller circuit board, remove jumper H7. This will prevent the controller from sending a charge current to the battery. Note: Not removing this jumper (H7) may cause the non-rechargeable battery to leak or explode. A low battery (Lo ba) indication will be shown on the lower display when the battery voltage is below 5.5Volts. Also, the audible alarm will give a brief “chirp” approximately every 30 seconds while the low battery condition exists. When the controller is operating only on battery power, both LED displays will go blank to conserve power. When the main power is restored, there will be a 7 second delay before energizing the control relay to allow the main power source to stabilize. 4 FDC 4000 Manual Rev (10/07)2-5 Sensor Installation Guidelines Z i Proper sensor installation can eliminate many problems in a control system. The sensor should be placed so that it can detect any temperature change with minimal thermal lag. Some experimentation with sensor location is often required to find the optimum position Proper sensor type is also a very important factor to obtain precise measurements. The sensor must have the correct temperature range to meet the ‘process requirements. In special processes, the sensor may need to meet different requirements such as leak-proof, anti-vioration, antiseptic, etc. ‘The FDC-4000 controller has been designed to use a type "T” Thermocouple or Platinum RTD (2 or 3-wire) temperature sensor. Figure 2.2 shows the proper connection of the sensors to the controller. The controller will auto-detect which type of sensor is connected to the unit (for Input #1). In order for the controller to do this, the sensor must be connected before power is applied to the controller. Input #1 is used to display PV (on the upper LED display). Input #2 can only be a type “T” Thermocouple sensor. Input #2's temperature value is displayed while in the Factory Mode (prompt IN2). In the event of a sensor break, the display will show “Hi? and the control relay output will remain energized. 2-6 Control Relay Connection to the control relay is made using the screw clamp terminal blocks provided on the controller circuit board (Figure 2.2). The control relay is a “double pole / double throw” (OPDT) configuration. The normally open (NO) and normally closed (NC) configuration when the control relay output is not energized is shown én Figure 2.2. The control relay will energize when the process value is at or above the set-point value. The control relay will de-energize when the process value is at or below the set-point value minus the control hysteresis (prompt OHY). The contro} relay will also de-energize when the controller is operating on battery power. The control relay is a latching type relay which means that the contacts will remain in their present state (open or closed) even when all power is removed from the controller. [2-7 Alarm Relay Connestion to the alarm relay is made using the screw clamp terminal blocks provided on the controller circuit board (Figure 2.2). The alarm relay is a “double pole / double throw" (DPDT) configuration. The normally open (NO) and normally closed (NC) configuration when no alarm condition is present is shown in Figure 2.2. The alarm relay will be energized when the process value Is outside of the deadband temperature for the set-point or when the controller is operating on battery power. The alarm relay is a latching type relay which means that the contacts will remain in their present state (open or closed) even when all power is removed from the controller. 5 FDC 4000 Marl Rev (10007)[2-8 Control/Alarm Relay Hysteresis Operation Control type for relay 2 output is cooling (direct) only. The control hysteresis (prompt OHY) is safe sided. The control relay’s output will work in the following manner. For example, the control set-point value is -80° (F or C) and the control hysteresis value is 2.0. The control relay’s output will be energized until the temperature reaches -82 deg and then de-energize. When the temperature rises, to -80 deg or above, the control relay's output will again energize to maintain cooling in chamber. Note: When the control relay’s output is energized, the control output status LED (labeled "OUT" on the front panel) will be lit. ‘Alarm type for relay 1 is deadband only. The alarm deadband (prompt ASP) follows the main controller set-point and is set evenly above and below the main controller set-point. For example, a main controller set-point value of -80° and a 10° deadband value equals alarm points at -70° and -90°, The alarm relay is energized only when the temperature is outside of the alarm deadband. Note: The upper LED display will flash when the temperature is outside of the alarm deadband (if alarm, prompt A1, is enabled in the Factory Mode and SHIP mode is not active). ‘Alarm hysteresis (prompt AHY) is safe sided. The alarm relay’s output will work. in the following manner. For example, the main controller set-point value is -80° (F or C), the alarm deadband value (prompt ASP) is 10° and the alarm hystaresis value (prompt AHY) is 2.0. The alarm relay will energize when the temperature is above -70° or below -80°. When the temperature falls within the hysteresis band (between -72° and -88°), the alarm relay will de-energize, 2-9 Door Sensor ee ‘The FDC-4000 controller can be used to detect when the door to the chamber is open. A simple on/off switch is connected to the “door sensor” screw clamp terminal block shown in Figure 2.2. When the switch is opened, the audible alarm will give short, quick “chirps" to indicate that the door is open. If this feature is not needed, simply place a wire jumper between the.two terminals. 6 FDC 4000 Manval Rev (10/07)3-4 Keys and Displays The FDC-4000 controller is programmed by using three keys on the front panel. The available key functions are listed in following table. Note: Only use the tip of your finger to depress the keys. Using a rigid object such as a pen, screwdriver or even your finger-nail may permanently damage the keypad. "TOUGHKEYS [FONCTION DESCRETION Press and Tse To REGGE The conta el-pont [Wits hi ronal contel made) [2] [uprey for to change lower daply program poramotor (wile in User Menu Factory Mode Praga and old fo sectrtan-emen pee Press and tease To decrease he contol sep (eh nomal coniel made) LY) | Down key for to change lover eplay pogrom poramoe (ste User Menu oF Factory | Modo). Press and eld to accolrato decrement pees, ras and Wold or alas? seconds a release (wha neal ean made] To mressng cases pont at ras Vee a ae tee Sea al ee mnt power or on bettery power. While unit is in an alarm condition, the external alarm vey tein aig hemioeet aiee e rercee nermal ore Fre a tel day unter aopemie sae tae 0 iy ower. Chamber tmperstra wil bo dspayod unl kay is released. Alar contact villain neiized wise operating on batlery power. Prati bah hays | Curent Pawar | Olepays curent AC power. 1TOVAC) as org as Kaye ae pases power e mullsnesiey | Reading {HVAC or 220VAC, cw cap 170, Node i Oy ave ding roam contol moe (we top display» PY, Lowe, disk 'SP), NiAon beter power. russ bo keys | “Energize auc slam and lam ay opi as Tg ws Los are pessoa. Mode | ‘inukeneousy | alarm Test ison active during neal contol made (ahen top daplay ” PY, Lower cisplay [vio] | SPENIA on bat pow "Not: We he conte cleyng torpor in rom convl nose presscaste o ess th vonn Keys {Schange th set pint valn. This satan nade dose lap to power mazes The upper display is used to show the process value or menu prompt. The lower display is used to show the set-point value or menu value. Both displays are blank white on battery power unless the [9] button is pressed to display the process value. Note: When operating on battery power, the battery status LED {labeled “BAT” on the front panel) will be lit. coacoe” [| corse cect. a Sate AJATELET IT. [N[als Blb{FlFls| slofo]t clelefalk tele [rly ele [HAIL |e fay |v Ofd[ ht h[Mfa[R] -{w) 5 Corbet once Table 3.2 Display Form of Characters Spying rarer Figure 3.1 Front Panel View 7 FDC 4000 Manat Rev (1007)3-2 Menu Parameter Descriptions ‘Tariana | Parana | Danley | —Paramter Descrpon Range Sata Tr | Presta | rome Valve ae er °T bearee Cunt z ee °F ogres Funt cE SHF F _ | PY Shi aaah Vales wing200) WeaxtezOD) | 0.0 an [ASP ‘isi Deadband Value | Win) Wax (100) | 18°F time (10°C) BAY [AY] Pieris Gira toc man [ai (OA) War TaOCRET AT] 0. Q ORY | oH &_| Hustoresis Convo for Gutout [Min (0-1 Wax: (14.0°CR52°F) | 0.7 RB [rh PN Ringaack Tne Wns (OMB) wax (60 ny | —O ey [Nels cea ine he sr Way rss he up’ dey wl cle Wah ie panes ier show above. The is | teperconty wi osowthe pone the ever donay wi ow te wie fore Pees tho Up or ‘Dowr aye oenge he pressed vo shawn aswel Ar ast er rot anys, resin th eat ye on ark the ormel cr) mac = pp, SP = wer Sap). The neal Ss eve back he normal dey mae wha he User soe matress oy lor seo Aor promps wi ry be syed confured or evng nthe Factory Mode re promis ae cond or We, frost aryl arog : Shp NE Wome Pe Facoy | sup nent time the. chamber is | OFF. ship Made Not Acive Mode SHP | coweredup alarm actvaton’s | on gnemrare mene off delayed for 8 hours. 2 ea ‘SPL ‘SP adjust LOW limit ‘Min: (-150) ‘Max: (200) | -100 SPH SP achat Hat ‘in: 750) wax (200) | 700 oO) | | Rim satis OFF namnis ot ace en OF Amis aive xen [IRD | aay | Temperature bis GsIaVeE w | OFF Prt et assayed hoermode | OF nome! User Mena 2° Prem splayed inusermose SHE | GHP | PV shit eed vahie ‘OFF Prompt ot dsplayedin sermede | 0% for 10 splayed in User Mert: 0 _ Prompt displayed in user mode sects. | Asp | FIG P| arm deadband vans ‘GFF promptret epayesinusermode | OF Use tepiayed in User Mont 29 Pom) cays inner ose pow ARY | AAG) | Alm hyteresis vae ‘OFF prompt ot spayed nuearmove | OF _ ‘eplayed in User Men 07 Prong spayed nuance vawen [OTRY | gHY | Control autputrystorans | OFF bent rat splayed mser mois 29 Doel ispleyed In User Menu 27 Prompt dsleyed in vser mado ‘ser RB |p | RnaBack value deslayedio [OFF promt rot osployein sw moa O° Pres rt User enw 2 Proms spayed usr made i cath | SP —] gp Serpant amuse sans | GFF oarcragametsenee ome 20 _Serpom suntan! ented 1N2 ine _| Trermocoupie input #2 ‘ispiays temperature of secand probapal | Ga Fait Ostnions 'SHP- Shp mode crt ores clay tne for alr (@ haus) ern power SPL—_Lower mi of user adjusabe setpoint range (ne decinal pln). ‘SPH: Uppor lei of user adusabia sat pam range (ta decimal pin) ‘At: wn erabiardeabie, INU: Temperature uns selection for contol (degrees F or 0) SHE: PV hit (fia) coibration valu, to calibre inputs temperature val (1 deci point ASP Atm Davai! val (no dsl po). AAKY: Nam output hysteresis (1 decral por ‘GHY: —Contot output hystaros (1 cocal pa, FRB: RingBack time (tines). Tne dela alvated ater alam silence ston is prassed hon FingBackis ace ding ronmal ard batlary power codons (ro decir pan). Sse: Enabledsobie user rom aqlusing stom value. Iz: _ Display he temperate val Ong 32 (ype thormecouple Note: When in User Manu or Factory Node, the unper LED wil spay the programming prompt and the FLED wl spay the numeric vale to match Upper eeplay prop. UpyLown arows wl Scust he ower sp. vals. The Scr key wi acvance to the net menu pram, 8 FDC 4000 Manual Rev (10/07),[4-4 Error Codes and Troubleshooting a] Anis procedure requires access to the circuitry of a live power unit. Dangerous accidental contact with line voltage is possible. Only qualified ‘personnel are allowed to perform these procedures. Potentially lethal voltages are present. Troubleshooting Procedures: (1) Ifan error message is displayed, refer to Table 4.2 to see what caused the error and apply the corrective action. (2) Check each point listed below. Experience has proven that many control problems are caused by defective external devices or improper wiring. ‘ Line wires are improperly connected * No voltage between ine terminals * Inecrrect voltage between line terminals * Connections to terminals are open, mis = Thermocouple is open at tip * Thermocouple lead is broken * Shorted thermocouple leads * Short across terminals ing or loose ‘Symptom ___ Probable Cause. * Onen or shorted cooling circuit * Open ecil in external contactor * Bumed outline fusos * Bumed out relay inside control * Defective solid-state relays Detective ine switches * Burned out contactor * Defective circuit breakers Corrective Action — Keypad not Bad comnsdtion between PCB and 7 Remove and re-nsert lx cable of = Inernittent connection of sensor wiring, + Analog portion or AID converter ofecive, functioning keypad. keypad info connector on PCB. =Replace keypad. TED's wilnat ight. [= No power tonstramant = Check power ine connections, = Power supply defecive. ~ Roplaos power supply board, ‘Some segrnenis of | ~LED display or LED lamp detective = Replace LED display or LED lari. display nat Horiit | = Related LED chiver defective, = Replace the related IC chip, feroneousy Display unstable ~Thiamasouple or RTD sensor defecive, | ~ Check output of sensor + Check senor wiring connections. Replace related components on ‘rout boars. ‘Considerable erorin | - Wiong sensor or Hermaccuple WDE. emperature indication Incorrect"Shift value enterad In contra. ~ Check sencor Or Heitiacouple ‘ype. “Access USER MENU and configure ‘Shift value. Display goos i reverse [~ Reversed wing of Sensor, rection (sisplayed temp increases as nock wing and eotreck Radio Frequency interference (RF), process temp ocreases). - ‘Cool output stays on | - Oulpul device shared or power sonico | - Check and replace, Dut neater reads shorie, norm ‘Control sbsommal or | “Tneoredt setup values. Read setup procoduras carcilly Operation incartoel. | - CPU or EEPROM (non-volatile memory) | ~ Chock and roplaco, | stectve, Disay Binks. Electramagnale nterierence (EM ar | ~ Suppress arcing conladi in system to eliminate high votage spike = Soparate sensor and controler \wiking from “ity* power Ines, = Check all round” connections. FDC 4000 Manu Rev (10407)Table 4.1 Common Fallure Causes and Corrective Actions —_ Evior Code Error Description Corrective Action “Eri Butlon on Keypad collapsed or stuck. Raplacs keypad. Error readinghering io nonswalaie mame | Fleplace EEPROM (equiee Fetrniog unto Be factory for __| serneay ‘Upscale sensor weak Check sensor connections val ouput of sensors veld Table 4.2 Error Codes and Corrective Actions 5-1 Controller Specifications _ Power Requirements User Interface ‘Main: T2VAC (420A), BVA Max. Dual &Digit LED Displays: Battery Back-up: 6 VDC. Upper Dsplay 0.55" (14mm) (Lead Acid Re-chargeable, 1.2Ah min.) Lower Display 0.40" (10mm) Battery Charge Current: < 400mA. Keypad (3 touch keys) Accuracy Overall Dimen: 41 Digt x (458.75em x 215.90mm) Input #1 Type “T” Thermocouple or Environmental Platinum 100 Ohm RTD (0.00385 Ohms/OhmC) Operating Temp: Dto +60%C Storage Temp: -40 to +60" Input #2 Humidity: 0 to 90% RH Type "T Thermocouple {on-condensing) Input Type PT.100, Approvals Range Low | -230°C | UL/CUL/CE Pending (-382°F) | _(418 °F) Range High 400 °C T 300°C Backup Battery Life 7s2°6)_|__(572°F) 70 hours using BVOC, 1.28 rechargeable battery Table 5.1 Input Ranges Sensor Break Detection Sensor open for TC or RTD Sensor Break Response Time <4 caconds for TC or RTO Control Mode Control Output: Direct (Cooling) On/Off with adjustable set-point and hysteresis. ‘Alarm Output: Programmable Deadband with adjustable hysteresis. Control and Alarm Output DPT Relay, 2A @ 30 VDC, 2A @ 125 VAC, 1A @ 230VAC (all resistive loads) 10 FDC 4000 Marwal Rey (10007)(60 Watis total switching power) 6-1 Controller Part Number . FDC-4000- i i 4 ia Power Input Communications 4: T2VAC. To/230vAc 0: None transformer supped ‘ 1 R885 itrface dbus) 9: Special Order \ eee Signal Input Ha lone * Sander input 1: Relay (POT rated 201 25VAC (Band) Thermocouple ‘ay (OPDY rated 20125 RID: P7100 DWN. eee ee Output 0: None 4: Relay (DPDN rated 24/1 25VAC -(Diect) [7-4 Warranty Future Design Controls warranties or representations of any sort regarding the finass for use, or the application of is products by the Purchoser. The selection, application or use of Future Desigh pris is the Purchasers reeponsbity. No claims wil be alowed for any damages oF losses, whether dct, nde, indental, special or consequent. Specifications are subject to ‘ange without notice. In edaion, Future Design reserves the right to make changes witout noiffeation to Purchaser to matetials or processing that do nt affect compliance with any Applicable specifcation Future Design products are warrented tobe fee from defects in material and workmanship for one year after Govery fo the frst purchaser for use. An excended porod is avaiable wih exra cost upon request, Puture Design's sole responsblly unde this waranty, t Futuro Dosign’s option, is ited to replacement or repair, free of charge, or refund of purchase price within the warranty period specified This warranty does not apply to damage reeling fom Transpariaion,aleation, misuse or abuse RETURN MATERIAL AUTHORIZATION: Please contact Future Design Controls for Return Material Authorization Number prior to returning to factory, Future Design Controls, Inc. 7524 West 98” Placo Bridgeview, IL 60455 Tol: (888) 751-5444 Fax: (888) 307-8014 wwnw.futuredesigncontrols.com u PDC 4000 Manna Rev (10107)