FDC-2010-K5C -

Hardware Dimensions & Specifications

 

click on either display for larger graphic

 

Color Touch Screen Dimensions & Specifications

 

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Specifications: PLC CPU and onboard Digital I/O

CPU - DC Digital Inputs

CPU - Digital AC/DC Outputs

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Digital Input 24VDC Module

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Relay Output Module - 16 Relays

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Analog Input Modules

Graphic 1 of 3

The two Analog Input Cards supplied as standard each accept two RTD inputs [one Wet bulb, two Dry Bulbs and one Core Temperature] with one OEM configurable 4-20mA output per card:
Module Part # FC4A-LO3AP1

Optional Analog Input Cards have two linear 4-20mA inputs and one OEM configurable 4-20mA output: Part # FC4A-LO3A1

Analog Input Module: Graphic 2 of 3

Analog Input Module: Graphic 3 of 3

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RS485 Communication Module

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Power Supply Specifications, Temperature Derating & Dimensions for PLC & Color Touch Screen

Power Supply Temperature Derating Curves

Power Supply Dimensions

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PLC Wiring - CPU Input/Output

Digital Input Assignments (24VDC inputs):
(I0)        Fans input – N.0. Heat and spray control is defeated unless input is closed. If heat/spray control is required when fans are in dwell condition or off, wire the input so it is always closed. Performs as indicated for ALL systems.
(I            Schedule Hold. – N.O. contact, SOT input or momentary switch. (Hold only active if schedule in run).
(I2)         Programmable alarm input – N.O. contact, contact closed = alarm condition. Any of the kiln events/outputs can be defeated when the input is energized. Event/output defeat is completely configurable.
(I3)         Programmable alarm input – N.O. contact, contact closed = alarm condition. Same type as I2
(I4)         Programmable alarm input – N.O. contact, contact closed = alarm condition. Same type as I2
(I5)         Programmable alarm input – N.O. contact, contact closed = alarm condition. Same type as I2
(I6)         Programmable alarm input – N.O. contact, contact closed = alarm condition. Same type as I2
(I7)         Indication Alarm 1 Input Only– N.O. contact, contact closed = alarm condition. (Performs in ALL modes)

Com(S) - signal of VDC supply (Sink)
         
NOTE: I1 - !6 are applicable for Kiln Only or Combination system when running in Kiln mode.

Standard additional digital inputs are located on #FC4A-N08B1 card (SEE PAGE 13)

Note: During any alarm condition triggered by the above digital inputs, output Q10(16 pt. relay card) will be energized. Alarm acknowledgement/silence is performed from the Orion display interface.

Main CPU Digital Output Assignments: [Outputs Q0 & Q1 are transistor source outputs; others are relay outputs
Note: Additional 16 relay outputs are referenced on page 14 describing the 16-relay output module
Q0       Dry Bulb deviation hi/low alarm - Only.
Q1       Wet Bulb deviation hi/low alarm - Only.
Q2       Stage Burner # 2  (Performs in Heat Treat Only or Combination when running in Heat Treat mode only)
Q3       Stage Burner # 3  (Performs in Heat Treat Only or Combination when running in Heat Treat mode only)
Q4       Stage Burner # 4  (Performs in Heat Treat Only or Combination when running in Heat Treat mode only)
Q5       Vent 1 Closed  (Performs in ALL modes)
Q6       Vent 2 Closed  (Performs in ALL modes)
Q7       Vent 3 Closed   (Performs in ALL modes)

NOTE: Q0 – Q1 are applicable for Kiln Only or Combination system when running in Kiln mode.

Note:  3-position vent control is programmable via the Orion display interface. Deadband for each vent “open” position is programmable.  Deadband is “safe sided” which means the output will energize at the deviation setpoint and de-energize when the temperature falls outside of the deviation setpoint  + deadband setting.

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The FDC-2010-K5C uses one 8-point 24VDC digital input card with 3 of the 8 digital inputs utilized by the kiln control. Wiring for the card is as follows for standard kiln systems.

24VDC Digital Input Assignments (8 point input card with 3 inputs active):
(I0)         Indication Alarm 2 Input Only– N.O. contact, contact closed = alarm condition. (Performs in ALL modes)
(I1)         Indication Alarm 3 Input Only– N.O. contact, contact closed = alarm condition. (Performs in ALL modes)
(I2)         Indication Alarm 4 Input Only– N.O. contact, contact closed = alarm condition. (Performs in ALL modes)
(I3)         Schedule Start– N.O. contact, SOT input or momentary switch.  
(I4)         Schedule Advance Next Stage– N.O. contact, SOT input or momentary switch.
(I5)         Schedule Advance Prev Stage– N.O. contact, SOT input or momentary switch
(I6)         Schedule Stop Input– N.O. contact, SOT input or momentary switch
(I7)         not used               
COM       - signal of VDC supply (Sink)
COM       - signal of VDC supply (Sink)
               
NOTE:  I3 – I6 are applicable to Kiln Only or when used as Kiln in combination systems.

Note1: See Page 12 for CPU mounted digital inputs

Note2: When using Schedule Start input (I3), a schedule must first be downloaded to the PLC from the Orion interface.  The schedule loaded into the PLC from the Orion interface is the schedule that will run when the Schedule Start input is activated.

Note: The FDC-2010-K5C is equipped with RS485 communications.  This module allows the FDC-2010-K5C to communicate with a PC using Future Design’s “KilnView” Software or with other 3rd party software.  Please see page 9 for wiring of the communications link.                 

Note: Click here to reference CPU mounted digital inputs

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The FDC-2010-K5C uses one 16-point AC relay output card.  Wiring for the card is as follows for standard kiln systems.

 

Relay Outputs Assignments (16 point relay card) based upon Control System Configuration:
Kiln Control and Heat Treat Sterilizer Control shown separately directly below

Kiln ONLY Control Outputs                                             Heat Treat ONLY Sterilizer Control Outputs
Q0   Main Relay Heat output(PID or On-Off if PB=0)            Q0  Main Relay Heat output (PID or On-Off if PB=0)
Q1   Spray output                                                              Q1  Not Used
Q2   Fans Forward                                                            Q2  Blower/Fan On (Active during ALL Heat Treat Cycles)
Q3   Fans Reverse                                                             Q3  Not Used     
Q4   Hi Temp Dry Bulb/Wet Bulb Output                              Q4  Hi Temp Chamber Temperature       
Q5   Stage Alarm                                                               Q5  Not Used             
Q6   End Of Schedule relay                                                 Q6  End Of Sterilization Cycle –Energized after Cooldown
Q7   Call for Heat/Blower Active Relay                                 Q7  Call for Heat/Blower active Relay (Active during ALL cycles)
Com 0  Common connection for relays Q0-Q7                     Com 0 Common connection for relays Q0-Q7
Com 0  Common connection for relays Q0-Q7                     Com 0 Common connection for relays Q0-Q7
Q10  Main Alarm Relay active on alarm condition                  Q10  Main Alarm Relay active on alarm condition
Q11 Not used                                                                    Q11   Cool Down Relay On during Cooldown ONLY
Q12  Customer Programmable Event 1 Output                      Q12   Not Used
Q13  Customer Programmable Event 2 Output                      Q13   Not Used
Q14  Customer Programmable Event 3 Output                      Q14   Not Used
Q15  Customer Programmable Event 4 Output                      Q15   Not Used
Q16  Customer Programmable Event 5 Output                      Q16   Not Used     
Q17  Customer Programmable Event 5 Output                      Q17   Not Used     
Com 1 Common connection for relays Q10-Q17                   Com 1  Common connection for relays Q10-Q17
Com 1 Common connection for relays Q10-Q17                  Com 1   Common connection for relays Q10-Q17

Note: Q10 Alarm output energizes on any Digital input alarm OR Process / Deviation Alarm condition.
Note: Refer to page 12 for description of 6 relays located on CPU

Relay Outputs Assignments (16 point relay card) based upon Control System Configuration:
Combination Kiln Control & Heat Treat Sterilizer Control

Control Outputs                                                                 
Q0  Kiln & Heat Treat:            Main Heat output (PID or On/Off if PB=0)
Q1  Kiln:                               Spray output (PID or On/Off if PB=0)
Q2  Kiln & Heat Treat:            Fans Forward
Q3  Kiln & Heat Treat             Fans Reverse
Q4  Kiln & Heat Treat:            Hi Temperature Alarm: Kiln Dry Bulb & Wet Bulb / Heat Treat Sterilizer Chamber
Q5  Kiln:                                Stage Alarm
Q6  Kiln & Heat Treat:            End Of Schedule/Cycle Relay
Q7  Kiln & Heat Treat:            Call for Heat (Kiln-Active when Heat selected in Stage, Heat Treat- Active during ALL Cycles)
Com 0   Common connection for relays Q0-Q7
Com 0   Common connection for relays Q0-Q7       
Q10   Kiln & Heat Treat:        Main Alarm Relay (Digital Input or Process/Deviation alarm condition)
Q11   Heat Treat:                  Cool Down Relay (Active when in Cool Down ONLY)
Q12   Kiln:                            Customer Programmable Event 1 Output
Q13   Kiln:                            Customer Programmable Event 2 Output
Q14   Kiln:                            Customer Programmable Event 3 Output
Q15   Kiln:                            Customer Programmable Event 4 Output
Q16   Kiln:                            Customer Programmable Event 5 Output
Q17   Kiln:                            Customer Programmable Event 5 Output
Com 1   Common connection for relays Q0-Q7
Com 1   Common connection for relays Q0-Q7

Note: Click here to reference CPU mounted Digital Outputs

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The Standard FDC-2010-K5C Kiln Control is equipped with two analog input cards as standard; each card accepts two RTD inputs and has one configurable 4-20mA output.  Up to 3 additional analog input cards (4-20mA inputs only) can be added to monitor up to six sensors (moisture probe or temperature sensors using temperature transmitters).  Wiring for the cards is as follows: 

Note:  Number of analog input card will vary based on kiln requirements.

 

Wiring & function for the analog input cards are dependent upon the FDC-2010-K5C configuration; Kiln Control, Heat Treat Sterilizer or combination Kiln and Heat Treat Sterilizer.  Analog inputs are configurable as RTD or Type J T/C.

For information on System Configuration refer to “FDC-2010-K5C_Configuration_Manual_v2.x”.

Below are descriptions for each configuration.

Dry Kiln ONLY Configuration

Input #1 Card assignments:
Input #1          Dry Bulb #1 Input (RTD)
Input#2           Dry Bulb #2 Input (RTD)
Output#1         4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint.

Input #2 Card assignments:
Input#1           Wet Bulb Input (RTD)
Input#2           Core Probe (RTD)
Output#1         4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint.

Input #3 Card assignments (Dry Kiln): (Optional)
Input #1          Monitor/Core #1 Temperature Input with Core logic if selected; temperature value is datalogged.
Input #2          Monitor/Core #2 Temperature Input with Core logic if selected; temperature value is datalogged.
Output #1        4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint. (Default – Fan)

Input #4 Card assignments (Dry Kiln): (Optional)
Input #1          Monitor/Core #3 Temperature Input with Core logic if selected; temperature value is datalogged.
Input #2          Monitor/Core #4 Temperature Input with Core logic if selected; temperature value is datalogged.
Output #1        4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint. (Default – Spray)

Input #5 Card assignments (Dry Kiln): (Optional)
Input #1          Monitor/Core #5 Temperature Input with Core logic if selected; temperature value is datalogged.
Input #2          Monitor/Core #6 Temperature Input with Core logic if selected; temperature value is datalogged.
Output #1        4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint. (Default – DB PV)

Heat Treat Sterilizer ONLY Configuration

Input #1 Card assignments (Heat Treat Sterilizer): (Standard)
Input #1        Chamber Temperature
Input #2         Pallet Probe #1
Output #1        4-20mA  (Default - Heat)

Input #2 Card assignments (Heat Treat Sterilizer): (Standard)
Input #1          Pallet Probe #2
Input #2          Pallet Probe #3
Output #1        4-20mA Not Used

Input #3 Card assignments (Heat Treat Sterilizer): (Optional)
Input #1          Monitor #1 Temperature Input with no control/Core logic; temperature value is VIEW only.
Input #2          Monitor #2 Temperature Input with no control/Core logic; temperature value is VIEW only.
Output #1        4-20mA Not Used

Input #4 Card assignments (Heat Treat Sterilizer): (Optional)
Input #1          Monitor #3 Temperature Input with no control/Core logic; temperature value is VIEW only.
Input #2          Monitor #4 Temperature Input with no control/Core logic; temperature value is VIEW Only.
Output #1        4-20mA Not Used

Input #5 Card assignments (Heat Treat Sterilizer): (Optional)
Input #1          Monitor #5 Temperature Input with no control/Core logic; temperature value is VIEW only.
Input #2          Monitor #6 Temperature Input with no control/Core logic; temperature value is VIEW only.
Output #1        4-20mA Not Used

Combination Dry Kiln and Heat Treat Sterilization Configuration

Input #1 Card assignments (Combination Dry Kiln Heat Treat Sterilizer):
Input #1       Dry Kiln function          Kiln Dry Bulb #1 Input (Forward)
Heat Treat Sterilize function:              Heat Treat Chamber Temperature (Forward)

Input #2      Dry Kiln Function:          Dry Bulb #2 Input (Reverse)
                  Heat Treat Sterilize function:   Heat Treat Chamber Temperature (Reverse)

Output #1   4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint. (Default - Heat)

Input #2 Card assignments (Combination Dry Kiln Heat Treat Sterilizer):
Input #1      Dry Kiln function:            Kiln Wet Bulb Input
                  Heat Treat function:         None

Input #2      Dry Kiln function:            Kiln Monitor/Core Sensor
Heat Treat function:                           None

Output #1   4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint. (Default - Vent)

Input #3 Card assignments (Combination Dry Kiln Heat Treat Sterilizer):
Input #1      Dry Kiln function:            Kiln Monitor/Core #1 Temperature Input
                  Heat Treat function:         Heat Treat Core Sensor #1

Input #2      Dry Kiln function:             Kiln Monitor/Core #2 Temperature Input
                  Heat Treat function:          Heat Treat Core Sensor #2

Output #1    4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint. (Default – Fan)

Input #4 Card assignments (Combination Dry Kiln Heat Treat Sterilizer):
Input #1      Dry Kiln function:             Kiln Monitor/Core #3 Temperature Input
                  Heat Treat function:           Heat Treat Core Sensor #3

Input #2      Dry Kiln function:             Kiln Monitor/Core #4 Temperature Input
                  Heat Treat function:          Heat Treat Monitor #4 Temperature Input

Output #1    4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint. (Default – Spray)

Input #5 Card assignments (Combination Dry Kiln Heat Treat Sterilizer)
Input #1     Dry Kiln function:              Kiln Monitor/Core #5 Temperature Input
                 Heat Treat function:           Heat Treat Monitor #5 Temperature Input

Input #2     Dry Kiln function:               Kiln Monitor/Core #6 Temperature Input
                 Heat Treat function:            Heat Treat Monitor #6 Temperature Input

Output #1   4-20mA OEM configurable: control output for Heat, Spray, Vent, Fan or retransmission of Dry Bulb or Wet bulb process variable or setpoint. (Default – DB PV)

A ferrite bead has been included for each analog input to provide additional protection for electrical “Noise” long runs of sensor signal wires can pick up. See drawing below for correct installation of this device.

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The order of arrangement for PLC I/0 modules is important, and should be installed (from left to right) in the following order.

1.)  FC4A-HPC3: RS485 Card
2.) FC4A-D20RS1:  Main CPU
3.) FC4A-R161:       16-point relay output module
4.) FC4A-N08B1:     8-point 24 VDC input module
5.) FC4A-L03AP1: Temperature Input Cards [T/C or RTD] for two Dry Bulbs and one configurable Analog Output.
6.) FC4A-L03AP1: Temperature Input Cards [T/C or RTD] for Wet Bulb, Core and one configurable Analog Output.

Optional Temperature Input Cards – up to three cards may be installed
7.) FC4A-L03AP1:  Temperature Input Cards [T/C or RTD] for two Monitor temperature inputs and one Analog Output (total of 3 additional cards with each having two Temperature inputs [T/C or RTD] and one 4-20mA output); the Ma output on each card is configurable for control or retransmission type outputs.

 

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Return to: Main Kiln FDC-2010-K5C Page

Pallet Heat-Treat operational mode Pallet_Heat-Treat.htm

Kiln Information Links below:

Kiln mode: Primary Operator Display Views.htm

Main Views, Monitor Probes, Set Manual Outputs, Trending, Alarm Monitor & History and Audit Trail

Pallet Heat-Treat operational mode - see Pallet_Heat-Treat.htm

 

Kiln mode: Main Schedule Views.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.

 

Kiln mode: Additional Temperature Monitor Sensors.htm

Optional temperature Monitor sensors; monitor only or used as additional Core Temperatures for Kiln Heat-Treat/Sterilize.

 

Kiln mode: Kiln EMC Operation.htm:

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).

 

Pallet Heat-Treat Sterilization Mode.htm

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

 

Data Logging & View Historical Data.htm:

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.

 

LAN Features.htm

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

 

Printing Functions:

Print Data Views, Historical Data files including Data Log files, Alarm files, Audit Trail files, Recipe files, etc.

 

System Security & Audit Trail.htm:

Multi level Security & Audit Trail Setup.

File Utilities.htm:
Import/Export Data Log, Schedule, Alarm & Audit directories from Compact Flash Card to I-Stick Memory via USB port.

System User Settings.htm:

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 System Configuration.htm:

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

 

On-Line Demo.htm

Information to schedule an on-line demonstration of the FDC-2010-K5C control system

 

Help-Support.htm

Information on multi-language Help screens, Audio output and on-board tools to troubleshoot control system.

 

Energy Saving.htm

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.

 

I-Stick Panel Mount Mounting Adapter.htm

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.

 

FDC-2010-K5C Hardware Dimensions & Specifications.htm

Dimensional Drawings, mechanical specifications and sample wiring diagrams.

 

FDC-2010-K5C Contact Techncial Support and Touch Screen Software Updates.htm

Contact information & links to download touch screen software updates.

 

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Future Design Controls 888.751.5444 csr@futuredesigncontrols.com