FDC-2010-K5C Kiln Control System
The FDC-2010-K5C version 2.1 is a Dry Kiln and/or Pallet Heat-Treat controller combined with an operator interface color touch screen. The color touch screen is a 5.7”, 28-oz, industrial PC (Windows CE) with embedded Supervisory Control and Data Acquisition (SCADA) software. No external PC software is required for configuration or operation. All Kiln/Pallet Heat Treat data variables are saved to FDC-2010-K5C’s internal memory (1GB CF Card; no hard drive to fail) and is OEM configurable to meet various Kiln and/or Pallet Heat-Treat control needs. Click here for listing of new features in Version 2.1
Configurable by the Kiln manufacturer for a variety of control logic the FDC-2010-K5C offers the lowest component cost Windows based control system while still offering the following features:
- Intuitive ease of use with Windows style navigation
- Flexible Control configuration including up to 10 temperature sensors, display & control logic for EMC, Core Temperatures and more (moisture probes are not offered)
- Schedule / Manual control with easy Schedule file management
- Alarm Monitor, Audit Trail (operator actions) & Historical Data file management
- Security (3-levels) with operator Audit Trail files & management.
- Powerful LAN connection features (Remote Access, email, FTP, Web Server)
- Want to keep existing Circular Chart Recorders? No problem, the FDC-2010-K5C can re-transmit temperature values to existing recorders.
Clearly, the most flexible, fully featured and Easy to Use "out of the box" Kiln & Pallet Heat-Treat control system available.
Contact Future Design Controls today to further explore the many features, benefits and LOW OEM cost compared to other 3rd party solutions and/or an OEM's proprietary PC/PLC based control system. The OEM cost for the FDC-2010-K5C is well under $3K complete; no other PC's required. Note: The FDC-2010-K5C is only sold through Kiln and Pallet Heat-Treat chamber manufactures.
On-Line product reviews (web page link) with units located at our offices are available. On-Line reviews are possible utilizing the FDC-2010-K5C's embedded Remote Access VNC Server - contact us now to arrange an on-line product review. For more information on Remote Access - LAN Features.htm
Additional information and links are shown below and in the right column; click on links for additional information.
Some of these features are Kiln Specific while others are common. Click here for Pallet Heat-Treat Feature Review Pallet_Heat-Treat.htm
Custom OEM Development (web page link): Future Design Controls is willing to explore proprietary versions to include features currently not available in the standard FDC-2010-K5C (weight and/or moisture sensors with control logic, softwood multi-zone control, wafer EMC sensors, etc.). Contact Future Design Controls.
FDC-2010-K5C Base Hardware Input & Control Outputs: The base FDC-2010-K5C has 4-temperature inputs (RTD or Type J T/C) with up to 6 additional temperature inputs available (10 temperature inputs total). The unit comes complete with 24 relay outputs, 15 digital inputs, 2 mA outputs, power supply, connection cables,memory cards, etc. with no surprises beyond panel & installation costs.
FDC-2010-K5C OEM Configurations: The FDC-2010-K5C controls all Dry Kiln and Pallet Heat-Treat functions and can be configured in one of three ways: Dry Kiln only, Pallet Heat-Treat only or Combination Kiln & Pallet Heat-Treat control system.
LAN Features: The FDC-2010-K5C display is a PC running Windows CE offers powerful LAN (Local Area Network) features connecting via Ethernet:
- Remote Access (remotely control touch screen)
- Email / SMS on alarm (up to 30 email address's)
- FTP transfer of Historical files (File Transfer Protocol)
- Web Page Server (read only)
Kiln - Schedules: Manual or Automatic Mode: The FDC-2010-K5C can be run in manual or automatic schedule control mode with ramp to Setpoint capability.
Data Acquisition (data logging) of temperature sensors & setpoints can be initiated "on-demand" or automatically. Simple on-screen analysis tools and exporting Historical Data files.
Alarm Monitor & History: The Alarm view displays all current alarms. The Alarm history view displays all alarms for any daily period for multiple years
PC Supervisory Software, either Future Design's KilnView or an OEM's proprietary or other 3rd party software can be modified to access the FDC-2010-K5C via serial modbus.
The FDC-2010-K5C's embedded Remote Access VNC Server allows direct access to the touch panel as though standing in front of it. Utilizing the embedded FTP client to transfer historical files, combined with the Remote Access virtually eliminates advantages of dedicated Supervisory Software - for more information on FDC-2010-K5C embedded Remote Access: LAN Features.htm
Security: Configurable multi-level system security as well as complete audit trail of operator actions.
Data Storage: The FDC-2010-K5C can store multiple years of data on its 1GB internal compact flash card.
The FDC-2010-K5C controls all Dry Kiln and Pallet Heat-Treat functions and can be OEM Configured in one of three ways:
- Dry Kiln control: 4 sensor inputs for DB1, DB2, Wet Bulb +1 temperature input for monitor and/or core logic control. Optional hardware allows up to 6 additional temperature sensors for use as monitor only and/or for use in Core logic control to advance a stage within a schedule and whose values can also be data logged. Calculated EMC may also be used to control a stage advance or event relay output..
- Pallet Heat-Treat control: 4 sensor inputs, 1 main chamber and 3 pallet probes. Optional hardware allows up to 6 additional temperature sensors for use as monitor only (the optional monitor only sensors are view only, their values are not data logged).Click here for additional information. Click here for additional detail on Pallet Heat-Treat control system.
- Combination Dry Kiln and Pallet Heat-Treat Control: Provides temperature inputs and control functions for traditional Dry Kiln, Pallet Heat-Treat and ability to automatically begin a traditional Dry Kiln Schedule at the end of a Heat-Treat cycle. The combination unit requires optional temperature inputs (quantity four – 2 input modules); during the Heat-Treat cycle the Kiln’s Dry Bulb #1 is the Heat-Treat chamber temperature sensor with specific temperature sensors assigned as the Heat-Treat Core sensors. During Dry Kiln the Core sensors used in Heat-Treat may be used as Monitor and/or as components in Core logic control .Calculated EMC may also be used to control a stage advance or event relay output..
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Local Area Network (LAN) Features (web page link):
The LAN features described below utilize an Ethernet connection to the color touch screen from a network router.
The features described can be made available on a LAN (intranet) and if so configured (network & router) access via the Internet.
- Web Page Server: An embedded “Web Server” provides access to all Kiln/Pallet Heat-Treat data (view only) using Microsoft’s Internet Explorer or equivalent from a PC, PDA, etc.
- Email / SMS: Email and/or SMS configuration to allow automatic notification of alarm conditions to up to 30 email addresses. Historical Data, Alarm & Audit Trail files may be emailed on-demand.
- Remote Access: An embedded Remote Access Server is included allowing full access to the color touch screen as though standing in front of it from a remote PC or PDA utilizing VNC View software.
- File Transfer Protocol (FTP): Embedded FTP Client software is included allowing automatic or on-demand transfer of Historical Data files to an FTP Server PC. This feature allows an easy manner to view, archive, etc. historical data files from a remote location without the need to physically copy the files via USB flash drive and move to a remote PC.
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FDC-2010-K5C Standard & Optional Input Hardware & Control Output Descriptions: OEM Configurable
Standard Temperature Inputs: The FDC-2010-K5C base unit as standard includes inputs for two dry bulbs, one wet bulb and an additional RTD temperature input (RTD) that can be used to monitor temperature within the wood - Core temperature. The Core Temperature during automatic schedule operations allows the stage to automatically "hold" until the Core temperature exceeds or if cooling, falls below the Core Setpoint.
Standard Kiln Control outputs include Heat, Vents, Spray, Fan [configurable F/R & dwell times], deviation & process temperature alarms, Stage Advance and a host of events.
Relay Outputs: The FDC-2010-K5C comes equipped with 24 relay outputs for the control of heat, vents, spray, fans, multiple alarms, events and 7 customer programmable relay outputs. As standard 2 linear outputs are included with 3 additional linear outputs optional - see next paragraph. The temperature deviation & high process alarms are always active with the remaining control outputs enabled/disabled for manual operation or for each Stage within a Schedule.
Analog Outputs: Two analog outputs are standard and configurable by the OEM to control Fan, PID outputs for Heat, Spray, Vents or Retransmission of Dry & Wet bulb setpoints or temperatures (provide temperature input to existing recorders and/or to provide Schedule setpoints to discreet single loop controls). Additional Analog outputs are available when optional temperature sensor input cards are added. Three optional analog outputs may be added for a maximum of 5 Analog outputs and are configurable as described above.
Kiln Control Event Inputs: Fifteen 24VDC digital inputs come standard on the Orion kiln controller. Digital inputs are used for fan “sync” input, schedule hold and digital input alarm functions. All digital inputs have programmable time delays before the input is activated at the system level.
Five of the digital alarm inputs are OEM configurable to defeat event/control outputs if the alarm input is energized. For more detail on this feature refer to the OEM Config.htm or OEM Config Manual
Fan output is configurable as Relay or linear 4-20mA output [set actual % Fan Speed] with configurable Forward, Reverse & Dwell times and with an on demand display of time remaining for Fan direction..
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Schedules - Manual or Automatic (web page link): The FDC-2010-K5C can be run in manual or automatic schedule control mode with ramp to Setpoint capability. With capacity of hundreds of Schedules each with up to 99 Stages, the FDC-2010-K5C provides Schedule capacity for the most demanding Kiln operator. Schedules may be started on demand or with a "delayed start".
Schedule entry is made easy by the use of copy, paste and delete menu selections. Schedules can be copied to the external “USB” memory stick and then imported to any Orion Kiln controller which eliminates the need to enter duplicate schedules into multiple kiln controllers. Schedules can also be created using the KilnView data acquisition software and then exported to any FDC-2010-K5C device.
When running in automatic schedule mode, the operator can put the unit into hold and change any control parameters without modifying the saved schedule. This gives the operator maximum flexibility over all kiln control parameters.
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Print direct from Interface (web page link): Full “USB” print capabilities from the FDC-2010-K5C interface to a standard HP inkjet printer eliminates the need for a PC, strip or circular chart-recording device. Graphics trends, historical and report print functions are standard.
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Remote or Supervisory PC Connection: A standard 2 wire (RS485) PC connection is available to connect up to sixteen FDC-2010-K5C’s to a PC for remote monitor/control and data acquisition. Although third party software packages can be modified to communicate with the FDC-2010-K5C, Future Design Controls KilnView (web page link)software is "out of the box" ready to provide Remote PC Supervisory control.
KilnView can communicate with up to 16 FDC-2010-K5C Kiln Controls it can also communicate with up to 48 Future Design Controls single loop DIN process controls that could be used on other temperature, pressure or other control requirements.
KilnView is limited to accessing the FDC-2010-K5C only while operating as a Kiln; KilnView cannot be used when the system is operating in the Pallet Heat-Treat Sterilization mode.
The FDC-2010-K5C's embedded Remote Access VNC Server allows direct access to the touch panel as though standing in front of it. Utilizing the embedded FTP client to transfer historical files, combined with the Remote Access virtually eliminates advantages of dedicated Supervisory Software - for more information on FDC-2010-K5C embedded Remote Access: LAN Features.htm
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Data Storage: The FDC-2010-K5C can store multiple years of data on its 1GB internal compact flash card.
Data backup is provided with the 1GB “USB I-Stick” for plug and play transfer of files to any PC running Microsoft Windows XP operating system.
LAN connection and configuring the embedded FTP Client allows for easy automatic or on-demand Historical Data file transfer to a host FTP Server as well as automatic file deletion after FTP transfer.
Note: If using Supervisory KilnView PC software, (web page link) KilnView may be configured to Data Log independently and has similar security & audit trail features of the FDC-2010-K5C control system.
Accessories
Panel Mount Memory Adapter for Memory I-Stick.pdf
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