Kiln only, Pallet Heat-Treat only or Combination Kiln & Pallet Heat-Treat control configurations
click on either display for larger graphic
The FDC-2010-K5C configuration program allows the OEM or user to setup all options for the FDC-2010-K5C controller runtime software. The configuration program will not run at the same time as the main runtime software, therefore, no kiln control functions are active while the OEM or operator is editing the configuration program.
The FDC-2010-K5C Configuration embedded program allows the OEM or user to setup all options for the FDC-2010-K5C controller runtime software. The Configuration program will not run at the same time as the main runtime software, therefore, no Kiln/Pallet Heat-Treat control functions are active while the OEM or operator is running or editing the Configuration program.
The Configuration program is a powerful tool that allows full customization of the FDC-2010-K5C controller. Text editing for all inputs, outputs and event names can be customized via the Configuration program. The FDC-2010-K5C control functionality may also be edited via the Configuration program.
The Configuration program will run the first time power is applied to the FDC-2010-K5C controller. The Configuration program can also be run when the runtime software is exited and the “Run Configuration On Next Power Up” option is selected; the next time the unit is re-powered the Configuration will run.
As the Configuration program effects the controls’ functions we strongly recommend a detailed review of the system security and at minimum enable security and assign a password to minimize unauthorized access to the Configuration program.
The FDC-2010-K5C Configuration provides the following functionality:
For information on an On-Line product demonstration and product review click here on-line product review/demonstration.
The FDC-2010-K5C controller Configuration menu system provides a familiar, easy to use interface while reducing screen “clutter” by eliminating extra buttons required for navigation. Each series of interface screens will have their own series of menus specifically focused on the tasks for the specific screen.
The “File” menu provides the exit function for the Configuration. After selecting this menu item, the system will advise the operator to re-power the unit so all new setting will take affect.
The Setup#1 menu provides the main group of setup items for the kiln/pallet controller.
The Setup#2 menu provides the delay time setting for Core advance, configure 4-20mA analog outputs, pallet setpoint option, stage burner setpoints, control cycle time and EMC functions.
The Kiln / Pallet Sensor Setup screen allows for the setup of the system as either a Kiln only, Pallet Heat-Treat only, Kiln / Pallet Heat-Treat combination or “Pallet Control Off Lowest Probe”; the latter being a derivative of the Pallet Heat-Treat only configuration.
Initial Configuration: When the Configuration program is run for the first time the screen provides four system operation selection buttons: “Kiln Control”, “Pallet Control”, “Kiln and Pallet Control” and “Pallet Control Off Lowest Probe”. Initially all the buttons are gray in color indicating none have been selected. Once a selection has been made the button background turns green indicating the selection is active. The “Pallet Control Off Lowest Probe” selection button is removed if either “Kiln Control” or “Kiln and Pallet Control” option is selected. “Pallet Control Off Lowest Probe” is ONLY available when system is to be used as a Pallet Heat-Treat control system (see description below).
Kiln Control: When the “Kiln Control” button is selected, the system will perform as a kiln only. The standard kiln operation consists of 4 temperature probe inputs; Dry bulb 1, dry bulb 2, wet bulb and an optional 4th temperature input that can be selected or deselected (not functional) for use as an extra monitor probe or as “core” probe. The system will internally switch dry bulb control between dry bulb 1 and dry bulb 2 based on fan direction as programmed. When the 4th temperature probe is used as a “core” - when selecting kiln options the operator can input a core value that will allow for a stage advance based on the selected “core(s)” going above or below (cool down) set value.
The main Kiln screen and associated screens will change dynamically to properly display associated programming associated with kiln only operation.
Pallet Heat-Treat Control: When the “Pallet Control” button is selected the system will perform as a Pallet Heat-Treat control. The standard Pallet Heat-Treat operation consists of 4-temperature probe inputs; a main chamber probe and 3 pallet probes. The heat is controlled with reference to the Chamber temperature sensor and setpoint. The main screen dynamically changes to properly display on pallet only operation screens.
The “Pallet Control Off Lowest Probe” control logic requires the selection of both the “Pallet Control” and “Pallet Control Off Lowest Probe” with both buttons selected and backgrounds must be green. “Pallet Control Off Lowest Probe” cannot be selected individually or in combination with “Kiln and Pallet Control” configuration. The resultant control logic compares the Chamber Setpoint to the lowest of all active sensor inputs (Chamber & Pallet sensors 1-3; optional monitor sensors are not considered “active sensor inputs”). The temperature input currently used for the control logic has a small arrow pointing to its’ value.
Combination Kiln and Pallet Heat-Treat: When the “Kiln and Pallet Control” button is selected the system will allow the FDC-2010-K5C to operate as a Kiln OR Pallet Heat-Treat control depending on the selection from the main runtime screen. The combination system consists of 8 temperature inputs, these are:
1) Dry bulb 1 3) Wet bulb (Kiln only) 5) Pallet Probe #1 7) Pallet Probe #3
2) Dry bulb 2 (Kiln only) 4) 4th probe input (Kiln only) 6) Pallet Probe #2 8) Monitor Probe
Input #1: Dry Bulb #1 is also used as the Chamber sensor when system is operating in the Pallet Heat-Treat mode.
Inputs #5 - 7: When operating as in the Kiln mode Pallet Probes 1-3 can be monitor points and/or Core with control logic.
This screen allows selection of type of probes/sensors wired to the analog input cards. This is a GLOBAL setting. All probes wired to inputs, must be of the same selected type for use as kiln, pallet heat-treat or combination system.
The button appearing with GREEN background is the active global probe selection.
The probe names will dynamically change depending on type of Kiln/Pallet Heat Treat operation selected.
If system is selected to be Kiln only, selections seen will be Core and Monitor 1-6. When configuration will not use Core or additional Monitor probes leave boxes “unchecked”. If core and/or additional monitor probes are to be used “check” the appropriate box to activate.
When using as a Pallet Heat-Treat only you MUST “check” Pallet Probe 3 to active the 3rd pallet probe.
After checking appropriate box you MUST press Update to activate selected probes. Active probes will then indicate a green light in the box to the left of probe selection.
(Note: When configured as Pallet Heat-Treat ONLY any optional Monitor Probes (Probes 4-6) will not be data logged; their values may be viewed only.
The Relay/Analog Setup screen allows the user to set the type of control for fans, vents, heat and spray outputs. Output can be set for either relay or analog types. All analog outputs are 4-20mA with the exception of the fan output, which is 0-10VDC.
Vents can be setup to operate on dry bulb or wet bulb with wet bulb being the default value. Based on the setting made on this screen, the main runtime will dynamically change screen values to represent either relay operation interface or analog (variable) interface for the setting of kiln parameters.
If the Vent and Fans outputs are set for relay operation, the fields in the main runtime will display the vent that is active (up to 3 vent positions) as well as the fan direction (forward or reverse). If these outputs are set for analog, the vents and fans will show actual output for each within a range of 0 to 100%. When the system is setup for analog type operation the user can enter actual values for vents and fans within the range of 0 to 100%
Note: When vents are set for auto in runtime, user cannot enter a setpoint value since the vents will operate off of the wet bulb or dry bulb setpoint.
The Edit Option Names screen allows the user to edit the names for each of the kiln options. Kiln options can be set in manual or automatic mode in the runtime software. Kiln options are settable functions that equate to kiln operations such as heat enable, spray control, vents, etc. Up to 7 customer events correspond to relay outputs (for each event) and can be used for any special operation that requires a relay output in manual operation or during automated schedule operation (different options can be set per stage).
Be careful when renaming events since some of the events correspond to specific kiln functions. Events like Kiln On, Heat Enable, Spray and Vents operate specific kiln functions so renaming these events could be confusing to the end user during kiln operation.
The “Restore Defaults” button will always reset the name to factory default values if required.
Note: Names are limited to 14 characters with exception of the 6 fields with default descriptions of MP1 through MP6, which are limited to 4 characters.Following is a brief description of each of the kiln events:
Kiln On: Main kiln switch. No kiln operations are active unless this event is turned on.
Heat Enable: Heat control is enabled when this event is on.
Spray On: Activates spray output(s) continuously when this event is on
Vent 1 On: Activates Vent #1 relay output continuously when this event is on
Vent 2 On: Activates Vent #2 relay output continuously when this event is on
Vent 3 On: Activates Vent #3 relay output continuously when this event is on
Vent Auto: Vents operate off of wet bulb when this event is on (selectable for DB also)
Fans Fwd: Activates fan forward relay output.
Fans Rev: Activates fan reverse relay output.
Fans Auto: Fans operate (fwd, rev) based on timing settings in runtime setup mode.
Mon1: Monitor probe when used as pallet, monitor/core probe when used as kiln.
Mon2: Monitor probe when used as pallet, monitor/core probe when used as kiln.
Mon3: Monitor probe when used as pallet, monitor/core probe when used as kiln.
Mon4: Monitor probe when used as pallet, monitor/core probe when used as kiln.
Mon5: Monitor probe when used as pallet, monitor/core probe when used as kiln.
Mon6: Monitor probe when used as pallet, monitor/core probe when used as kiln.
EMC Active: Indicates when EMC is active in a running kiln schedule during runtime
Stage Alarm: Activates stage alarm relay output. Used to alert operator to check load during stage.
Cust Event 1: Activates customer 1 relay output. Can be used for any relay output requirement.
Cust Event 2: Activates customer 2 relay output. Can be used for any relay output requirement
Cust Event 3: Activates customer 3 relay output. Can be used for any relay output requirement
Cust Event 4: Activates customer 4 relay output. Can be used for any relay output requirement
Cust Event 5: Activates customer 5 relay output. Can be used for any relay output requirement
Cust Event 6: Activates customer 6 relay output. Can be used for any relay output requirement
The FDC-2010-K5C control provides 15 digital inputs mapped to specific kiln functions and programmable alarms.
The first two digital inputs are used for the syncing of fans for heat/spray operation and remote profile hold.
Digital inputs 3 to 7 (5 digital inputs) can be used for indication alarms as well as shutting down specific kiln operations while the alarm is active. Refer to Alarm Delays/Outputs Disable below for configuring events or outputs to be defeated with a specific digital inputs.
Digital inputs 8 to 11 (4 digital inputs) are indication alarms only with no “disable” functionality. The main FDC-2010-K5C alarm output will be energized during any digital alarm condition.
There are 5 Digital Inputs mapped for Schedule management; Schedule Start, Hold & Abort, Stage Advance and Previous Stage.
The above screen allows the user to edit the names for all alarm inputs as well as restore the names to factory defaults if required. Press the desired text name to edit the text. Press the “Accept” key when all names have been edited.
Note: The "Fans Input" and "Profile Hold" names cannot be changed. All other inputs/alarms may have up to 22 characters.
The relay output screen allows the user to rename the system outputs to meet specific kiln requirements. The “Restore Defaults” button will restore all names to factory defaults if required. Press the desired text name to edit the text. Press the “Accept” key when all names have been edited.
The FDC-2010-K5C controller provides the ability to monitor all system IO for trouble shooting as well as providing the ability to “energize” or “de-energize” any system output (force outputs in offline mode only when kiln is not running). This unique feature gives the kiln operator the flexibility to trouble shoot hardware when system problems arise in the field.
Note: Output names may have up to 25 characters.
More Information on this to force any system output click: Kiln System User Settings.htm:
The Options Enable/Disable screen allows the user to enable or disable any kiln event in the runtime software. This is used to customize the system to meet specific kiln requirements. If a specific event function is not required for the kiln, it can be disabled form this screen. When kiln events are disabled at the configuration level, the event will be disable in the runtime software so the operator can no select the event in the manual or automated schedule mode. Clicking the checkbox on will enable the event while clicking the checkbox off will disable the event.
The FDC-2010-K5C control provides up to 15 digital inputs mapped to specific kiln functions and programmable alarms. The first two digital inputs are used for the syncing of fans for heat/spray operation and remote profile hold.
Digital inputs 3 to 7 can be used for indication alarms as well as shutting down specific kiln operations. Digital inputs 8 to 11 are indication alarms only with no “disable” functionality. The main FDC-2010-K5C alarm output will be energized during any digital alarm condition. By clicking the text for each alarm type, the user can enter a delay for the input before the alarm will be activated (delay starts after the input is energized). This gives the user/OEM the ability to customize the system to specific kiln needs.
If shutdown 1 to 7 is selected, pressing the “Disable” button will display following screen. This screen allows the user to select which events are disabled during the selected alarm input condition. A check next to the event will disable the function when the digital input is energized. The event will be enabled after the digital input is de-energized.
The Customize Name screen allows the user to customize the main splash screen when the Orion runtime starts. This is used so the OEM name and contact information is shown each time the FDC-2010-K5C controller is powered up. Press the desired field to enter text with a maximum of 20 characters per field.
The Core Advance Delay is applicable to Kiln functions only; it does NOT apply to Pallet Heat-Treat configuration. If configuring a Pallet Heat-Treat only control no changes are required or suggested to this section.
The Core advance delay screen allows the user to enter a time delay before the system indicates a “core temp met” condition during automated schedule operations. This core setting ONLY effects system operation when using as a kiln and the core feature is active. This delay is used eliminate “false” conditions due to noise or probes that “bounce” during system operation. Press the number field to enter a value.
Delay may be set between 0 and 999 seconds.
This screen is active only when system is configured as a Kiln or Combination Kiln Pallet Heat-Treat system; when configured as a Pallet Heat-Treat only system this screen is “grayed” out. Note: when configured as a Pallet Heat-Treat ONLY, Analog output card #1 defaults to Heat output with no remaining analog outputs active.
When configured as a Kiln or Combination Kiln Pallet Heat-Treat system the analog outputs are configurable as shown below:
The Configure Analog Outputs screen allows configuration of the two standard and up to three optional 4-20mA outputs as control outputs for Heat, Spray, Vent, Fan and Retransmission of Dry and Wet Bulb temperatures or setpoints. The 8 Analog Output configurations (five maximum analog outputs) are listed as:
Heat Output %: PID Control Output for Heat
Vent Output %: PID Control Output for Vent
Fan Output %: Operator Set Output for Fan
Spray Output%: PID Control Output for Spray
DB PV Retransmission: Dry Bulb Process Variable [temperature] Retransmission
DB SP Retransmission: Dry Bulb Setpoint Value Retransmission
WB PV Retransmission: Wet Bulb Process Variable [temperature] Retransmission
WB SP Retransmission: Wet Bulb Setpoint Value Retransmission
The “Select Analog Output” field is used to select the appropriate hardware analog output to be configured. Refer to the FDC-2010-K5C Operational Manual, Wiring, page 11, to identify the appropriate input card number to be configured.
The Configure Analog Outputs screen displays 4 of the 8 Analog Output types at one time. The scroll bar on the right allows viewing of the remaining 4 output selections [DB/WB PV/SP Retransmission].
To configure an output type select the appropriate check box to the left of the output description, depress the
Accept button and confirm “Yes” that the output will be configured. The Black box shown to the left of the selected output description will turn Green to indicate the configured output type; after configuration the check in the box will no longer be displayed.
Whenever one of the four Retransmission outputs is selected the Lower & Upper Range fields will appear as shown in the above graphic. If one of the control outputs, Heat, Vent, Fan or Spray is selected, the Lower & Upper Range fields will not be visible.
When configuring an Analog output for Retransmission, Dry or Wet bulb temperature or setpoint retransmission, the Lower & Upper Range points may be configured to a different range than the factory default setting of 0 to 100F. The range displayed is the span over which the 4-20mA will be transmitted.
The above graphic shows the Upper & Lower Range fields meaning one of the four Retransmission options has been selected but is not visible as the scroll bar position is at the top of the output option list showing the first four Analog Output Options. The first four Analog Output Options are the Control Outputs; the four Retransmission Outputs are shown below the Control Output Options.
Retransmission Lower & Upper Range may be set between –148.0 to 932.0 degrees F or C.
Factory default values are 0 to 100 degrees F or if unit is configured for Celsius –17.8 to 37.8 C.
The Analog Control Type screen is only applicable to Pallet Heat-Treat configuration.
For Kiln only and Combination Kiln Pallet Heat-Treat configurations this selection does NOT affect Kiln control functions.
Stop Analog Control button will force the proportional heat analog output (4-20mA) output to 0% (4ma) once all 3 pallet probes reach sterilization setpoint. This feature is advantageous systems where large burners are used which require no control after the sterilizer setpoint is reached.
Continue Analog Control button selection will allow the proportional heat analog output to continue controlling the burner to maintain the chamber setpoint, regardless if sterilization setpoint is reached.
The Burner Stage Setpoint screen is only applicable to Pallet Heat-Treat configuration.
For Kiln only and Combination Kiln Pallet Heat-Treat configurations this selection does NOT affect Kiln control functions.
Stage burner outputs are active for Pallet Heat-Treat only and Combination Kiln Pallet Heat-Treat configurations, and only apply to Pallet Heat-Treat operations;
Burner outputs are located on the main PLC at outputs Q2, Q3 and Q4.
These outputs are configurable as deviation settings that are active BELOW the deviation from main chamber setpoint. Press on number field and enter in deviation value from setpoint output is to energize/de-energize the output.
Deviation values range is: -100 to +100.
Control cycle times are used when heat and spray proportional relay outputs are required for system operation. The FDC-2010-K5C controller supports on/off, on/off time proportioning and analog output control (4-20mA) for heat and spray control.
If time proportioning outputs are required (relay cycles on and off based on proportional band settings), enter the desired cycle times for both control outputs. Relay and analog output work concurrently so if “PID” analog outputs are used, enter a cycle time of at least 20 seconds for both heat and spray cycle times. Cycle times may be set between 0 and 300 seconds.
EMC = Equilibrium Moisture Content and is a calculated value derived from the active Dry Bulb and Wet Bulb temperatures.
The EMC Operations screen is applicable to Kiln functions only; it does NOT apply to Pallet Heat-Treat configuration. If configuring a Pallet Heat-Treat only control no changes are required or suggested to this section.
A green button background indicates feature selected.
“EMC Setpoint Displayed in Schedule” dynamically shows or removes the EMC setpoint selection box from the schedule option screen. If not using EMC function it is best to leave as “not selected”; a green button background indicates the feature is selected and will be dynamically shown in the option screen.
The following two selections are mutually exclusive.
“Stage Alm Only” will allow the stage alarm output to energize when the EMC value for a stage goes below the EMC value set in a running schedule.
“Cont Next Stage” will cause a stage advance when the set EMC value in a stage goes below the EMC value set in a running schedule.
Return to: Main Kiln FDC-2010-K5C Page
Pallet Heat-Treat operational mode Pallet_Heat-Treat.htm
Kiln Information Links below:
Main Views, Monitor Probes, Set Manual Outputs, Trending, Alarm Monitor & History and Audit Trail
Pallet Heat-Treat operational mode - see Pallet_Heat-Treat.htm
Drying Schedule View, Schedule Edit/Run, Schedule Run, Hold, Stop; Drying Schedule View, Schedule Entry, Plot Schedule, Edit Schedules, Run Schedule, Advance to Next or Previous Stage and Add Subtract Time.
Optional temperature Monitor sensors; monitor only or used as additional Core Temperatures for Kiln Heat-Treat/Sterilize.
Description of EMC calculated values shown on Kiln's Main View and control logic if so configured.
Kiln mode: PC based KilnView Software Package.htm:
KilnView PC Software Review - communicate with up to 16 FDC-2010-K5C Controls as well as up to 48 single loop controls (applies to FDC-2010-K5C Kiln operational mode only; KilnView may not be used in the Pallet Heat-Treat operational mode).
Review of Pallet Heat-Treat Sterilization mode; available configurations, control logic, operation, etc.
Links below offer descriptions common to both the Kiln & Pallet Heat-Treat operational modes and/or configuration
System Data Logging Start: Kiln mode on start up, on Schedule Start or on Demand and in Pallet Heat-Treat mode on cycle start. History Data View and printing as graph or averages with High & Low values, etc. File Utilities to manually copy and/or delete Historical Data, Alarm, Audit and Schedule files and if connected to LAN, FTP Historical Data files to PC based FTP Server.
Description of LAN standard features: Remote Access (embedded VNC Server), email/SMS text on alarm, FTP of Historical Data files (embedded FTP client), Web page (embedded web page server) & Atomic Clock time/date update
Print Data Views, Historical Data files including Data Log files, Alarm files, Audit Trail files, Recipe files, etc.
Multi level Security & Audit Trail Setup.
Import/Export Data Log, Schedule, Alarm & Audit directories from Compact Flash Card to I-Stick Memory via USB port.
User Configurable FDC-2010-K5C Settings: Decimal Point, Control Tuning, LAN settings, Input Offsets, Temperature Alarm Setpoints, Remote I/O Monitor, Degrees C/F, Setpoint Limits, Force System outputs allowing easy testing of all outputs without running control system, Kiln mode Fan Direction & Dwell Times, Kiln mode Schedule Recovery [Power Loss] and more.
OEM FDC-2010-K5C Control System Configuration as Kiln only, Pallet Heat-Treat only or Combination Kiln & Pallet Heat-Treat control system. Configure control outputs as relay on/off or analog output; Configure Linear Outputs as either Control or Retransmission of Dry & Web Bulb setpoints or temperatures; Names for Digital Inputs, Control & Alarm Outputs, Event Outputs; Configure up to 7 DI that can disable Control outputs and logic [schedule hold, heat enable, Fans, Spray Auto, etc.]; Configure additional Monitor / Core Temperature inputs
Information to schedule an on-line demonstration of the FDC-2010-K5C control system
Information on multi-language Help screens, Audio output and on-board tools to troubleshoot control system.
Review of features that if connected to 3rd party energy monitoring devices (Load Monitor / Shedding) to reduce energy costs by wiring digital inputs to start/stop/hold schedules and/or disable specific outputs until appropriate.
Panel Mount USB Adapter, standard and Nema 4X, providing front panel access to USB port for memory I-Stick and/or printing direct from the FDC-2010-K5C interface.
Dimensional Drawings, mechanical specifications and sample wiring diagrams.
Contact information & links to download touch screen software updates.