Pallet Heat-Treat Mode
Ideal for the OEM and end user - a common hardware platform that can be used for either a Kiln, Pallet Heat-Treat chamber or a Combination Kiln and Pallet Heat-Treat control system. The Pallet Heat-Treat and Kiln control system offer unique ease of use, flexible control configurations, Alarm monitoring, operator Audit Trail, Security (3-levels), Powerful LAN connection features and more, much more. For information on an On-Line product demonstration and product review click here on-line product review/demonstration.
No External Dedicated PC Required: The LAN (Local Area Network) connectivity & features eliminates the need for a remote supervisory PC to communicate directly with the FDC-2010-K5C. The 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 the need & additional cost of a dedicated remote PC - for more information on FDC-2010-K5C embedded Remote Access: this page click here for a review how Remote Access can help in Training, etc. and for detailed review of all LAN features, LAN Features.htm
The Main FDC-2010-K5C page provides information on additional features and links to common features - the balance of this page provides a review of Pallet Heat-Treat Control Logic, system Configuration & product description, Operation and related features that are also common to the Kiln configuration.
Chamber Temperature Control: A chamber temperature sensor is typically used to provide temperature control & setpoint for the chamber temperature; detail on control outputs and setpoint logic (once all Core sensors are above Sterilization SP, dropback setpoint and Analog PID Stop/Continue output logic) may be reviewed in the System OEM Configuration. The chamber heat may also be controlled off the lowest Core sensor - for detail review the System OEM Configuration.
Core Temperature Sensors, Sterilization Setpoint & Time and Cool Down Time: As standard 3 Core temperature sensors are required whose values are shown on the Main View. The Sterilization setpoint and Sterilization time (typically 134F and 33 minutes) are entered.
Sterilization Cycle: When all 3 Core sensors temperature have exceeded the Sterilization setpoint the Sterilization Cycle begins with a countdown of the configured Sterilization Time. If the the Core temperatures drop below the Sterilization setpoint for a configurable time period the cycle is aborted. If the Core temperatures remain above the Sterilization setpoint for the Sterilization time period the cycle is completed and the cool down time (fan output) is begun for the configured cool down time.
Sterilization Historical Data File: A Historical Data File (datalog file) is automatically created when the "Start" button is pressed with a screen to allow entry of a file name, Batch & Lot #'s with the system automatically appending the start time & date to the file name. The Start time and current Temperature values, setpoints and configured Sterilize time are shown. Core temperatures are stored once per minute once the Sterilization cycle (all 3 Core sensors above Sterilization setpoint) has begun . Historical data files may be viewed at any time on the color touch screen and may be easily printed on one piece of paper (sample printout) with the Start time & current values and then the approx. 33 lines of temperature data (once per minute) during the Sterilization cycle. Click here for additional information on Historical Data files.
If so configured an automatic printout of the Sterilization cycle will occur and/or transfer of the Historical Data files can be scheduled manually or if connected to a LAN automatically and/or as an email attachment sent directly from the display (alarm & audit trail files may also be sent as an email attachment)..
FDC-2010-K5C Pallet Heat-Treat Configurations (click here for information on OEM configuration)
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.
The Combination configuration also allows a schedule to be selected and automatically run at the end of the heat-treat cycle to better dry the load if needed; in this case the system will automatically start a separate historical file specific to the Schedule running.
Pallet Heat-Treat Operation: When run as a Pallet heat-treat, the simple start/stop selection by the operator allows for ease of use in running the system. The system allows for inputting a file name, batch and lot number of pallets if needed. Once run is selected the system automatically begins datalogging the heat-treat cycle. If connected to a printer (HP model 6540 or equivalent) the FDC-2010-K5C may be configured at the end of the Heat-Treat cycle to automatically print out the beginning of the cycle and the sterilization temperatures of the cycle in one-minute increments. No additional operator interface is required.
The FDC-2010-K5C runtime 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 View menu differs between the Pallet Only and Combination Kiln and Pallet configurations as Kiln functions require additional Views and the Combination unit also has a "Schedule" menu.
Shown below are the “top” level menus when the FDC-2010-K5C Pallet Heat-Treat Sterilizer with a sample view of touch screen with the View Menu active..
The main sterilizer view provides the user with all data regarding each sterilization cycle.
Assuming chamber and Sterilizer Setpoints and Sterilize & Cool down times have been set - all the operator has to do is to push the START button and then name as appropriate the file name, batch & lot #'s for the load to be sterilized; if nothing is entered the system names the file as the current date/ time.
Entering Temperature Setpoints & Times: Chamber temperature set point, sterilize temperature setpoint, sterilize time and cool time are all adjustable before the sterilization cycle is started. By pressing any of these fields, a numeric keypad will be displayed to allow the user to enter the appropriate set point. Shown below on the left is the default Operational View and on the right the numeric keypad that pops when the Sterilize SP field is touched; a similar keypad is displayed for the Chamber SP and Time entry for Sterilize & Cool down times.
Start/Stop buttons are used to start or stop the sterilization cycle. Sterilizer status and time remaining for sterilization and cool are also displayed during the cycle. Sterilize and Cool time may be set from 0-999 minutes.
End Cycle Mode: In the Pallet Heat-Treat only configuration this field is not used and has a default of N/A; see graphic above. The End Cycle Mode is used ONLY in the Combination Kiln and Pallet Heat-Treat configuration to allow choice of Stop Cycle, Jump to the Kiln mode and continue at last Dry Bulb & Wet Bulb Setpoints or Jump to the Kiln mode and Start the loaded Schedule; see graphic below.
When the “Start” button is pressed on the Main View, the cycle information screen shown below will be displayed. The user can enter information regarding the sterilization cycle. This information will be saved to the internal data file stored in internal memory as well as printed when the sterilization cycle is complete (if “USB” printing is enabled in the User Setup).
The information on this screen can be left blank if not required by the user. Pressing the “Run” key will start the sterilization cycle; the File Name and/or Lot# will be saved as Historical Data file appended by a time/date stamp. If a File Name nor Lot# are entered - the Historical Data file will be named with a time/date stamp. Up to 10 characters may be used for File Name, Batch & Lot # and Operator.
Starting a Sterilization Cycle is Simple!
The operator hits the "Start" button on the Main View and then enters Sterilizer Cycle Information or leaves blank, and then hits the "Run" button! The Sterilization Cycle will run as configured storing the temperature data and if so configured automatically print out a report!
The Pallet Heat-Treat operation may be configured to Auto print at end of Sterilization cycle - sample below showing data saved every minute. The Start time & current temperature setpoints, values and configured Sterilization time are shown at the top of the report and once the Sterilization cycle has begun (all 3-Core sensors above Sterilization setpoint) the system begins datalogging temperature values once per minute.
Regardless the Historical data file specific to a cycle can be viewed at any time and utilizing either File Utilities or with a LAN transferred to an FTP Server via Ethernet the files may be copied/moved to another PC for printing and/or archiving.
The on-board 1GB flash memory will store many years of Sterilization cycles.
A quick note about data and setup files: Data and setup files (Schedules, Alarm History and Audit files) need some maintenance every now and then. After a period of time, storage devices fill up and files require backup or file deletion when no longer needed. The “File Utilities” section of the FDC-2010-K5C interface provides all the functionality required for maintaining the internal compact flash card. The internal compact flash card should not be removed from the FDC-2010-K5C interface. Any change to compact flash directory structure (moving or deleting files with a PC) will cause the FDC-2010-K5C interface to stop operating and a new compact flash card will need to be ordered. Never move or delete the directories unless using the internal FDC-2010-K5C file utilities.
Manual Transfer: The “File Utilities” screen (found under Data Log menu group) allows the user to copy or erase files from the internal compact flash card. Complete file directories for all FDC-2010-K5C file types can be copied to the USB “I-Stick” or erased from the internal compact flash card. Complete status for file functions as well as progress bar status is displayed for the operator during copy/erase operations. Shown below are two File Utilities screens, one on the left is for Pallet Heat-Treat only and the right on the Combination Kiln & Pallet Heat-Treat configurations.
Automatic Transfer: If the control is connected to a LAN the unit's embedded FTP Client software will allow automatic and/or on-demand transfer of Historical Data files to a host PC running an FTP Server application.
The setup fields require entry of the target FTP Server’s IP address (remote FTP server machine) and the Server Directory (target directory on the Server) to transfer files. User name and password are required if the FTP server requires same (typical) or left blank if the FTP server is setup for anonymous log ins; when used the User Name & Password characters are entered with appropriate text characters but displayed on setup screen with asterisks (*).
When an FTP Server will be the target for more than one FDC-2010-K5C a directory for each FDC-2010-K5C must be set up at the FTP server so each specific control system transfers Historical files to the appropriate directory at the FTP remote Server.
When depressing the "Backup Now" or when an Auto Backup is begun the FTP transfer screen with progress bar will be shown.
The FDC-2010-K5C offers content sensitive Help screens for virtually every screen view configurable to be displayed in a choice of languages; English, Espanol (Spanish) or Francais (French). The system may also be configured to provide an audio output of the Help screens played on external PC type speaker(s).
Show Help: Provides a text screen view of the appropriate Help file. Shown below are Help screen views for the Main View of the Pallet Heat-Treat screen; the view on the left is English and the right is the same text screen in French - Spanish is not shown.
Play Help: The audio output may be helpful to hear the explanation while looking at the appropriate screen view and not a text help screen. Click here to hear audio files (.wvm files) on the same text Help file shown above; English, Spanish & French audio files.
Stop Help stops the active audio output.
Language Selection and Audio Output enable/disable:
Within the User Configuration the Help\Voice Assistance screen allows the user to configure the displayed language (English, Spanish or French; others upon request) and to enable/disable Voice Assist. Voice Assist, when enabled, will automatically play and allow the operator to view the appropriate screen while listening. The Voice Assist may be stopped prior to completion by selecting “Stop Play”.
Select the appropriate language button (default is English); the selected button will be illuminated green with the changes taking effect immediately.
To Activate/De-Activate Voice Assist depress the speaker icon; a Red X means the system is De-Activated while no Red X means the system is activated.
The FDC-2010-K5C platform provides tools for support and training.
Ability to view current output status even while control system is active provides a manner to quickly know which outputs are active (control system is saying they are active). The output status section displays the current position of all outputs/events in the system. The green LED indicates on/off status for each output. Variable output values; heat, fan, vent and spray will only be displayed if configured in the system for variable type output control.
N/A appears if analog output is not used in the system as setup in Configuration mode.
The force output screen is an offline function that provides factory personnel or maintenance the ability to manually enable/disable outputs on the FDC-2010-K5C system. This feature is used only for trouble shooting during system maintenance.
Analog output values for Heat, RH, Dmp [damper] & Fans are adjusted by pressing the field and entering a value.
Analog output testing is allowed only if system setup for analog type control output as set in the Configuration mode.
Relay outputs are energized/de-energized by clicking on the “check box” next to the output.
Pressing the “Update Relay Outputs Force” button will energize or de-energize the selected outputs.
The FDC-2010-K5C security model provides an administrator with the tools to add up to 30 users to the system. Each user must have a unique ID, full name and password. 3 levels of users are provided to include operator, supervisor and administrator levels. Specific access rights can be assigned to each user level as well as password aging for each user. For additional information on Security, click Security and Audit Trail
Once Security is setup and enabled "Audit Trail" may be enabled. When Audit Trail is turned on all operator actions are written to a daily log. A sample of a daily log is shown below showing the current user and time/date of all actions taken.
Reviewing the audit trail allows quick & easy analysis of operator actions and areas to focus procedures, training, etc. Sample Audit Trail shown below.
The FDC-2010-K5C comes standard with an embedded VNC Server that when connected to a LAN allows remote access from another PC or Windows based PDA (remote device running VNC Viewer - freeware). This remote access provides a view of the color touch screen on the PC's display with complete access to functions as though standing in front of the display. For more & detailed information refer to the manual and to LAN Features.htm and for actual VNC settings, etc., Data Logging & View Historical Data.htm:
This Remote Access allows product training to occur in an office environment or multi locations including an operator standing in front of the display.
Trouble shooting operations or mechanical issues from a remote location provides new levels of response & service. If the FDC-2010-K5C is ported to the Internet, training and service is possible from any location with internet access.
Shown below is a sample view from a PC's 19 screen
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.