What is the FDC-2010-S4C Pallet Sterilizer Control System?
The FDC-2010-K5C is now shipping with V2.x firmware that provides a common hardware & software platform for Kiln and Sterilizing (Heat Treat) control system. At this time the site has not been updated to describe the features of this combination control solution.
The new v2.x may be configured as a control system for Hardwood Kilns, Heat Treat Control system or a combination Heat Treat and then Kiln Control system.
In addition LAN features include email/SMS text message on alarm, atomic clock setting, ftp file transfer of data log files to a remote PC and Remote Access to the display. The price sheet provides a summary of outputs.
The features described within the site are included in the new V2.x plus several new features unique to either Kiln or Heat Treat control systems.
The FDC-2010-S4C is a Pallet Sterilizer controller combined with a 5.7" Color Touch Screen Windows® CE computer with an embedded SCADA application.
- The FDC-2010-S4C control system is designed for dedicated Pallet Sterilizer Heat Treat appliances. Control Systems for traditional hard wood drying kilns that include features for sterilization are available - FDC-2010-K5C
The Touch Screen interface is Nema 4X, uses compact flash memory [no hard drive to fail] and is OEM configurable to meet various Sterilizer control needs. PC Supervisory Software, Future Design's MultiView [FREE] or an OEM's proprietary software can be modified to access the FDC-2010-S4C. [Each FDC-2010-S4C sterilizer includes a 2-wire/RS485 connection and with MultiView up to 31 sterilizers can be connected to a single 2- wire link.]
FDC-2010-S4C controls all sterilizer functions including chamber temperature and sterilize time, as well as monitoring three pallet probes for control of the sterilization cycle. If any of the three pallet probes drop below the sterilizer setpoint during a cycle the adjustable reset function can be used to guarantee total sterilization time.
Up to eight additional probes (J T/C or RTD), can be added to the FDC-2010-S4C and placed throughout the sterilizer chamber to provide temperature "profiling” for the system. The FDC-2010-S4C and MultiView Supervisory PC software may be configured to Auto Print temperature chart [Chamber and 3 Core temperature values] at the end of the Sterilization cycle.
FDC-2010-S4C provides a rich set of tools for sterilizer interaction and data analysis. View sterilizer data in digital or trend format. Editing setpoints for all sterilizer parameters and setup functions are easy to access with little to no learning curve for the end user. The menu driven Interface eliminates screen “clutter” by providing an easy to use “Windows®” interface for interaction between the user and FDC-2010-S4C system.
Data file analysis tools (auto-trend) make looking at historical data a simple task. Any current or previous sterilization cycle (user has access to all cycles saved internally) can be plotted on the historical data trend, for any time frame within the cycles total time range. “Drag and Zoom” capabilities allow the user to “zoom” in on any trend portion by simply dragging a finger across the trend area where “zoom” is required.
The built in Ethernet “Web Server” provides access to all sterilizer data via a local Intranet connection (wired or wireless), or the World Wide Web using standard software like Microsoft’s Internet Explorer.
Feature Review Below
Color Touch Screen: The visual interface is a 5.7”, 28-oz embedded industrial PC with all software included. No external PC software is required for setup or configuration. All sterilizer data variables are saved to FDC-2010-S4C’s internal memory (128MB storage).
Primary Operator Display Views: The Color Touch Screen Interface provides easy to view Operational screens with each View having content sensitive Help:
- Main View shows Chamber Temperature & Setpoint values, Sterilization Time setpoint [time in minutes all core probes must be above Sterilization Setpoint], Cool Down Time Set Value [time in minutes after Sterilization period to cool load], the Three Core Probes temperature values, Status [Heating, Sterilization, Cool or Off], Time Remaining [for Sterilization or Cool] and Start/Stop buttons.
- Additional Views include Live Trending, Alarm Monitor, Alarm History, Historical View of Data Log files, complete operator Audit Trail, view or print directly from interface and more - including remote computer interface to third party or Future Design Controls MultiView software.
Print Automatically at the end of Sterilization Process: The FDC-2010-S4C and MultiView Supervisory PC software may be configured to Auto Print a temperature chart [Chamber temperature, setpoint, sterilization setpoint and the 3 Core temperature values] at the end of the Sterilization cycle.
Full “USB” print capabilities from the FDC-2010-S4C interface to a standard HP inkjet printer eliminates the need for a PC, strip or circular chart-recording device. Print Automatically at the end of a Sterilization process and on demand for Graphic trends, historical data files, alarm history, operator audit trail and more are standard.
All data from each sterilizer cycle is also saved to the internal compact flashcard thereby eliminating the need for a PC for data storage. More than two years of data can be stored internally (calculated using a 4 hour sterilize cycle with 5 cycles run per day).
Additional Temperature Sensors: The FDC-2010-S4C can be expanded to accept up to 8 additional probes (J T/C or RTD) and placed throughout the sterilizer chamber to provide temperature "profiling” for the system.
Sterilizer Control Outputs: The FDC-2010-S4C comes equipped as standard with 6 relay outputs for; system active, blower/fan, heat/burner control, cool (exhaust fan after sterilization), common temperature alarm and end of sterilization cycle output. Optional relay card is available for 3-stage burner control. One PID 4-20m analog output for heat is also standard. Refer to OEM Configuration for setup information & options.
Sterilize Control Event Inputs and E-Stops: The FDC-2010-S4C sterilizer system supports up to 12 digital inputs [24 VDC] for remote “contact” alarm monitoring. The first 10 digital inputs are N.O. contacts and will act as standard indication alarms on the FDC-2010-S4C display. The last two digital inputs are special “E-Stop” inputs. When wired to these inputs, the sterilization cycle will be stopped when the inputs are closed. As long as inputs 10 and/or 11 are closed, the sterilization cycle cannot be started. These inputs can also be used as a safety to keep the sterilizer from starting a cycle. Delay times for all digital inputs are completely programmable to meet user system requirements. Any time a digital input is closed and the delay time has expired, a relay output on the PLC will actuate and can be used for a light or alarm buzzer. Refer to OEM Configuration for setup information & options.
Security: Configurable multi-level system security insures operator access to appropriate items as well as complete audit trail of operator actions. The PC based MultiView Supervisory Software offers similar security & audit trail features.
Data Acquisition: Data Logging can be enabled manually or automatically when starting a Sterilization run. Configurable to Data Log Chamber temperature, Chamber Setpoint, Core Setpoint, three Core temperature probes and up to 8 additional temperature sensors.
Data file analysis tools (auto-trend) make looking at historical data a simple task. Any control variable saved to the FDC-2010-S4C flash card can be plotted on the historical data trend, for any time frame within the data files total time range.
Alarm Monitor & History: The Alarm view displays all current alarms. Any time an alarm occurs the background on all view screens will turn red until the alarm is acknowledged. When an alarm is acknowledged, the backgrounds will return to their normal color but the alarm will stay in the alarm grid. Each time an alarm is active it is written to a history file. The Alarm history view displays all alarms for any daily period for more than a year.
Built in Ethernet “Web Server” provides access to all Sterilizer data (view only) via a local Intranet connection (wired or wireless), or the World Wide Web using standard software like Microsoft’s Internet Explorer.
Remote or Supervisory PC Connection: A standard 2 wire (RS485) PC connection is available to connect up to 31 FDC-2010-S4C’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-S4C, Future Design Controls MultiView software [FREE] is "out of the box" SCADA software ready to provide Remote PC Supervisory control.
MultiView can communicate with up to 64 devices; a maximum of 31 FDC-2010-S4C Sterilizer Controls with the remaining connections to Future Design Controls single loop 300 Series single loop process controls. The 300 Series controls could be used on other temperature, pressure or other control requirements. Click here for more information on the 300 Series single loop controls & MultiView.
Data Storage: Running the Sterilizer 24/7 the FDC-2010-S4C can store more than 1 year of data on its 128MB internal compact flash card. Data logging can be enabled manually or automatically during automatic schedule run. More than two years of data can be stored internally (calculated using a 4 hour sterilize cycle with 5 cycles run per day).
Note: If using Supervisory MultiView PC software, MultiView may be configured to Data Log independently, automatically print out a temperature chart on completion of the Sterilization process and has similar security & audit trail features of the FDC-2010-S4C control system.
File Transfer: Store & View Data on office PC: FDC-2010-S4C supports full file transfer of all files using the File Utilities to a standard “USB” I-Stick [128 MB memory device] supplied with each FDC-2010-S4C system. This allows the user to transfer all data files to the I-Stick memory device and then to a PC (for data file backup). The File Utilities also provides an easy manner to delete files on the the FDC-2010-S4C's internal “compact flash” memory. The FDC-2010-S4C data files are saved in .csv format and once transferred to a Windows XP computer may be opened with Microsoft Excel® or Orion Data Viewer software - see below.
USB I-Stick Memory Card - panel mount access: To transfer data files the 128MB I-Stick memory device must be plugged into the FDC-2010-S4C's USB port. Panel mount USB adapters are available.
Orion Data Viewer software [FREE} is an is an “easy to use” Windows® XP application that allows any sterilization cycle historical data files transferred from the FDC-2010-S4C [file utilities] via the I-Stick to be plotted and printed from a desktop computer.
