Kiln System User Configuration
click on either display for larger graphic
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. Shown below is a view of the FDC-2010-K5C configured as a Kiln Control with a drop down menu shown and available menu descriptions shown below; the menu offering when configured as a Pallet Heat-Treat only differs in that Schedule menu is not shown AND the Main View menu does not include Kiln View, Drying Schedule View or Set Manual Outputs, all of which are Kiln specific.
Shown above are the “top” level menus when the FDC-2010-K5C runtime first loads. A Help menu exist for every screen but is not shown in the menu items above.
Setup Menu: The setup menu provides access to system and controller setup options. These options include control tuning, fans setup, schedule recovery options as well as offline settings for date/time etc.
This "Setup" DOES NOT describe the OEM configuration of the FDC-2010-K5C; OEM configuration allows for Kiln only, Pallet Heat-Treat only and a Combination Kiln Pallet Heat-Treat operational modes.
Below is Settings Menu for Kiln only & Combination Kiln & Pallet Heat-Treat Control
Below is the Settings menu for the Pallet Heat-Treat only configuration
The Setup Screen “Setup” menu provides the following functions:
Kiln System Settings: Settings for web server/IP address display.
Fan Direction Setup: Settings for fan direction and dwell timing.
Temperature Alarm Settings: Settings for Temperature alarms.
PC Remote/Local Mode: Settings PC control or Orion local control of schedules, setpoints, etc.
Schedule Recovery: Settings Schedule recovery during power loss.
Control Tuning: Loop tuning for temp, vents and spray.
IO Monitor: IO monitor for system inputs.
Analog Input Alarm Delays: Delay settings for each input before probe failure alarm occurs.
Offline System Setup: Access to offline system settings (Temp Units C/F, Setpoint Limits, Force System Outputs, Data/Time, Help\Voice Assistance configuration, etc.)
The Setup Screen “Views” menu returns the user to the main kiln view:
This screen is used to view the device IP address and to configure the following; Serial Modbus communications address, VNC information, (Virtual Network Computing), enable/disable the embedded Web and VNC Servers.
The proprietary embedded VNC Server allows Remote Access to the system from PC type devices running standard VNC Viewer software (freeware).
Modbus Address: The Factory Default address is 1. When connecting more than one FDC-2010-K5C to a supervisory software package, such as KilnView, a different address must be assigned, 1-31 in numeric order. Maximum address capacity is 31 while Future Design Controls KilnView can communicate with up to 16 FDC-2010-K5C control systems.
Remote Access: VNC Protect, VNC Add/Pwd, Device Name & Device Password are used to configure the proprietary embedded VNC Server for Remote Access on a local area network (LAN) (wired or wireless). The LAN may be limited to the local network environment (intranet) or if so configured by your Network Administrator access via the Internet. A standard VNC Viewer (client) running on any PC may be remotely used for monitor and/or control of the system touch screen. Viewer software offered by “RealVNC v4.x “and later versions work with our embedded proprietary VNC Server (http://www.RealVNC.com)
VNC Protect is used to enable or disable VNC Security. If enabled the Device Password field must have a password entered; from 1 to 20 password characters may be entered; the text characters are displayed during setup but shown as asterisks (*) on screen view below.
Device Name is used to easily identify specific FDC-2010-K5C systems when viewing the device remotely. The Device name is shown on the top of the displays window frame; leaving this field blank will result in the default name of “Device” when the system is viewed utilizing VNC.
The VNC address is used to separate each FDC-2010-K5C or other computer(s) having a VNC Server on the network. Each FDC-2010-K5C should have a unique VNC display address (1 through 255). The FDC-2010-K5C configures the two digit codes to the VNC addressing protocol starting at port 5900; 0 = port 5900 through 255 = port 6155. For additional information on VNC your Network Administrator should visit http://www.RealVNC.com
Web Server: The “Web Server On” and “VNC Server On” buttons turns on or off the FDC-2010-K5C’s embedded Web and VNC Servers; the Server’s are “on” when the button color is green. The Web Server page is Read Only and provides current process values with alarm & event status while the VNC Server provides Remote Access capability utilizing a VNC Viewer (RealVNC version 4.x and above). Both Servers are accessible via a local Intranet or Internet (World Wide Web) wired or wireless routers and/or switches.
The "Save" button must be pressed any time changes are made to the fields on this screen.
For more information on FDC-2010-K5C embedded Web Server & Remote Access VNC Server including screen capture from a Remote PC as well as email & FTP features - click LAN Features
Fan Direction is applicable to Kiln only & Combination Kiln & Pallet Heat-Treat Configurations.
The fan direction setup screen allows an operator to set the forward/reverse and dwell time for the fans. Press the desired field to make a change to the value. Fan Time may be set between 0 and 999 minutes. Dwell Time may be set between 0 and 32,700 seconds [0 and 545 minutes/9.08 hours].
The temperature alarm settings screen allows an operator to set alarm points for both dry bulb and wet bulb. Process high and deviation hi/low alarms are supported as well as a common deadband settings for all alarm setpoints. Deadband settings are “safe sided” which means the alarm will energize at the alarm setpoint and de-energize when the temperature falls outside of the alarm setpoint + deadband setting. Press the desired field to make a change to the value.
Process High and Deviation High & Low Alarms may be set between 0 and 999 degrees C or F. Alarm Deadband maybe set between 1 and 100 degrees C or F.
Fan Direction is applicable to Kiln only & Combination Kiln & Pallet Heat-Treat Configurations.
The Orion kiln control can operate in local or PC remote mode. When running in PC remote mode, the remote PC can control the setpoints for dry bulb, wet bulb, fans, vents and all kiln manual output events. While in remote mode, the Orion interface will not allow the operator to change any of these parameters from the front touch screen since the remote PC is in control of all manual/schedule operations. While in local mode, the operator has control over all setpoints as well as automatic schedule operations from the front touch screen interface. When using the FDC “KilnView” PC software, the Orion kiln control can operate in local mode as well as connect to the remote PC since “KilnView” has been designed specifically for the Orion Kiln controller.
Fan Direction is applicable to Kiln only & Combination Kiln & Pallet Heat-Treat Configurations.
The schedule recovery screen allows the user to set the startup state of the kiln in the event of a power failure while a schedule is running. When programmed for “Continue”, if the power out time value has not been exceeded, the schedule will continue upon power up. If the time has been exceeded, the kiln will power up in the “Off” state with all control outputs off. Select the desired state (checkbox) and press the “Set” button to enter the value into memory. Press the time field to change the time exceeded value which may be set between 0 and 1,800 minutes [30 hours].
The Control tuning screen allows the user to adjust the Proportional, Integral [Reset], Derivative [Rate], known as PID parameters, when PID control is configured for Temperature (Heat) & Vent Control (staged outputs (shown above) or if so configured analog PID control) within the Temperature Tab and Spray control under its' own Tab. For more detailed information refer to the FDC-2010-K5C manual or click here for FDC-2010-K5C Control Tuning Page.htm.
Deadband applies to on/off control and is the difference in degrees C or F between when the relay opens & closes around setpoint and may be set from 0 to 50 degrees C or F.
Offset is applicable to both PID and on/off control. With PID Offset is a "manual" reset of the proportional band around setpoint. When the proportional band is set to zero (0) the control output is on/off. With on/off control Offset shifts the control point the plus or minus value configured in the Offset field. Offset for Proportional or on/off control may be set + / - 80 degrees C or F.
When Vent control is configured for relay operation as in the graphic shown below, this display provides setting of deviation setpoint values for the vents [Vent deviation values are referenced to either the Dry or Wet bulb setpoint as configured by the Kiln OEM.]
If variable vent control is configured in the system, the setpoint deviations for relay vent control [as shown in graphic below] will dynamically change to PID settings for vents. When using on/off control for heat and spray, PID values should be left at 0 so the relay outputs do not proportion based on the entered PID settings.
The IO monitor screen displays digital output status as well as additional kiln data. 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 for heat, fan, vent and spray will only be displayed if configured in the system for variable type output control.
See Force System Outputs under Off Line Settings below to manually force & test each output.
The analog input alarm delay screen allows a user to enter the time delay before a probe failure alarm will indicate at the FDC-2010-K5C alarm monitor. This delay is adjustable to allow the system to ignore probe alarm conditions as long as they are less than the delay time entered in the delay time field. Delay settings may be set between 0 and 100 seconds.
When configured as a Pallet Heat-Treat only or Combination Kiln & Pallet Heat-Treat controller a Pallet Menu drop down is shown.
The drop back setpoint screen allows the user to enable and enter the drop back setpoint information. The drop back setpoint (when enabled) will change the main chamber setpoint from its’ value at the start of the sterilize cycle, to the drop back value after all 3 pallet probes reach the sterilize setpoint (sterilization begins). The Drop Back Value is adjustable from 0 to 500 units.
The Drop Back Setpoint occurs after the delay time entered in seconds that all pallet probes were above Sterilization setpoint. The time value is adjustable o to 9,999 seconds (0 to166 minutes/2.75 hours)
At the end of the sterilization cycle, the main chamber setpoint will be returned to the setpoint value at the beginning of the sterilization cycle (time when operator presses “Start” button).
The restart time delay screen allows the user to select a time delay before the sterilizer restarts it’s timing cycle. This feature is used to make sure that all of the sterilizer probes maintain the sterilizer setpoint, for the complete sterilize time entered by the user. If any sterilizer probe drops below the sterilizer setpoint for a time that is equal to or greater than the time delay, the sterilize timer will be reset to “0” and the sterilizer cycle will be started from the beginning. Value adjustable from 0 to 999 seconds.
The Printer Options screen allows the user to select whether to use a local printer connected directly to the FDC-2010-K5C system. When configured that the “USB Printer is Used” the FDC-2010-K5C system will automatically print each sterilization cycle at the end of the cycle. FDC-2010-K5C can be connected to a standard “USB” inkjet printer (HP model 6540 or equivalent) via one of the standard USB host ports on the back of the FDC-2010-K5C interface. No drivers are necessary; operation is “plug and play”
When configured to auto print at end of the Sterilization cycle (USB Printer Used) a printout will look similar to the sample shown below with data saved and printed every minute.
Note that the system will save the Start time and only save temperature data once system is in the Sterilization cycle (all core sensors above Sterilization setpoint). The sample shown below has the same time for Start Heat Cycle and Sterilization Cycle Data; Typically there would be 30+ minutes between the Start Heat Cycle & beginning of Sterilization Cycle Data; temperature data from the Start Heat Cycle to the beginning of the Sterilization Cycle is not saved or printed.
Email settings allow the administrator or user to enter up to 30 user accounts to receive email/text message alarms. The message sent will include the Alarm name as configured by your vendor.
These same email user accounts may also be used when viewing Alarm, Audit & Historical Data files to forward the opened file to any specific user directly from the FDC-2010-K5C. Sample graphic directly below, with Alarm History file open click on the envelope and the Select Email Address window pops, add appropriate email addresses and hit Send.
The Email settings are entered and maintained within three different tabs as shown below.
Address Entry Tab: Provides manner to create email & SMS text message address file and configure for email and/or SMS message upon alarm. A Contact Name, email address and text message address, (phone number and carrier), can be entered.
Email Addresses Tab: Provides listing of email address’s and manner to delete Contact file information.
Email Settings Tab : Provides fields for the main email server information. The network administrator will typically provide the email server information. Only enter a user name and password if your email account requires it to send emails. The "Subject" field will be the email header to the recipient when the email/text message is sent from the system so each FDC-2010-K5C on a network can be identified.
The Setup Screen “Views” menu returns the user to the main kiln online setup view:
The Offline system setup mode allows the user to access the date\time functions, adjustment of temperature units and calibration of the touch screen. This is an offline mode, which means it cannot be entered while a schedule is running. Real time data for the kiln is not collected while in the offline mode. All kiln functions are non-operational while in the “offline mode”
Temp Units \Decimal Select: Settings for temperature units and decimal point
Setpoint Limits: Settings for min/max setpoint limits.
Input Offsets: Settings for input offset calibration (DB, WB, MC probes).
Force System Outputs: Allows operator to force system outputs for troubleshooting.
Set Date/Time: Settings for system date/time, enable/set Daylight Savings and auto time setting via Ethernet LAN to government NTS server.
Touch Screen Calibration: Calibrate touch screen.
Help\Voice Assistance: Select Language for Help and enable\disable audio Help output (voice help)
The temperature units display allows an operator to change the system temperature units between degrees “C” and degrees “F”. Press each button to change to the desired units and then the "Set" button. The button for the current unit setting will be illuminated green.
Note: When changing from C/F or F/C the system automatically converts temperature values to the appropriate F/C with the exception of Setpoint Limits described directly below. Setpoint Limits are set to default values of 0 and 500 whenever temperature units are changed F/C or C/F. Values automatically converted are: Alarm setpoints, Input Offsets, Schedule Setpoint values, current Dry & Web bulb temperatures and setpoint values shown on main views.
The Input Offset screen allows the user to enter a calibration offset for each sensor attached to the FDC-2010-K5C. The actual sensor temperature and offset for each sensor is displayed. Each time an offset value is entered, the updated temperature value (with offset) will be displayed. Each system is calibrated at the factory and requires no offset. Only factory authorized personnel should access the calibration screen.
The Input Offset screen allows the user to enter a calibration offset for each sensor attached to the FDC-2010-K5C. The actual sensor temperature and offset for each sensor is displayed. Each time an offset value is entered, the updated temperature value (with offset) will be displayed. Each system is calibrated at the factory and requires no offset. Only factory authorized personnel should access the calibration screen. Input Offsets may be set between -30 to +30 degrees.
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 values are adjusted by pressing the field and entering a value. 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 set date\time display allows the user to set the system date and time, Time Zone, enable NTS connection to auto update time-date and to enable & set Daylight Savings. This settings should be done before any kiln operations are initiated from the FDC-2010-K5C display system. All data files as well as other functions in the system require the correct date and time for proper operation. Press each field to change the value; press the “Set Time” button and "Save" buttons anytime an entry is made to enter the data to internal memory.
Press the “Calibrate Touch” button. A “System Settings” dialog will appear with several tabs on the Windows dialog box. Press the “Calibrate” button on the first tab. Follow the onscreen instruction to calibrate the touch screen by holding a stylus or finger on the crosshair, until the cross hair moves to the new position. After all positions have been cycled, the directions on the screen will display the following: “New calibration settings have been measured. Press enter key to accept the new settings”. Press the screen to finalize the calibration.
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:
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 Exit application screen allows the user to quit the FDC-2010-K5C runtime software and return to the CE.Net operating system. This operation is not recommend with the exception of users who are in charge of configuration of the system, due to the danger of editing or removing files by accident.
Refer to the Security Section for information o security configuration options to limit access to Operator and/or Supervisor / Administrator level users.
If an operator or authorized user is allowed to exit the Kiln and/or Pallet Heat-Treat application the default screen is shown below; note no desktop or other means to navigate within the Windows CE operating system.
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.