FDC-2010-K5C

New Features offered in Version 2.1

 

click on either display for larger graphic

One Hardware Platform Configurable to function as Kiln only, a Pallet Heat-Treat Sterilization or Combination Kiln & Pallet Heat-Treat control system

Ideal for the OEM and end user - a common hardware platform that can be used for either a Kiln, Pallet Heat-Treat chamber or for those kilns/chambers that were designed as a dual purpose product that can either run traditional Kiln and on a different day high throughput heat-treat sterilizing. In addition to dual purpose kilns/chambers, the combination Kiln Pallet Heat-Treat control provides a solution for Heat-Treat applications that after the sterilization cycle require a drying schedule to remove excess moisture still left in the lumber to minimize the potential for mold. 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 Combination Kiln & Pallet Heat-Treat unit's default display on power up or selecting Main View is the Kiln view.

Click for more information on the Kiln and Pallet Heat-Treat features.

Shown below are graphics of the Main View for each configuration. The Kiln View is first and is the same for Kiln only and the Combination unit. The Pallet Heat-Treat view differs in the Combination configuration as it allows configurable action at the end of the sterilization cycle. Samples shown are Pallet Heat-Treat only and Combination unit with Combination unit's End of Cycle Mode selections.

Combination Unit End of Sterilization Cycle choices

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Kiln Function: EMC display and control logic for Stage Advance or Relay output

The Kiln View displays all important kiln information.  Actual values for both dry bulbs and wet bulb are displayed as well as the setpoints for each of these variables.  Calculated values for EMC and %RH are shown; these values are derived from the wet bulb and active dry bulb temperatures. (EMC = Equilibrium Moisture Content).

The FDC-2010-K5C may be configured by the OEM to allow EMC control logic; Stage Advance or an Event Relay outputs. When configured for EMC, the EMC setpoint will dynamically appear in the Schedule Entry screen. The user may enter the EMC setpoint in the Schedule Entry screen AND the “EMC Active” stage option (shown on 2nd options page) must be selected. When EMC value has dropped to EMC setpoint the configured logic will occur; Stage Advance or Event Relay output to signal EMC has been achieved.

Above Schedule Entry screen depicts not only the EMC setpoint but also shows the system has been OEM configured to have analog output for Fans and Vent both of which are set as a percent (0-100%) per Stage. If Fan & Vent were typical relay output as on or off (fan's reverse, forward & dwell are configured elsewhere) these fields would not be shown.

Above are the Stage Option screens, note the EMC Active selection must be selected AND an EMC setpoint entered to allow the configured EMC control logic to be active for a specific Stage.

Notes:
DB Gar Soak and WB Gar Soak shown on sample Screen #2 refer to “Dry Bulb Guaranteed Soak” and “Wet Bulb Guaranteed Soak”; for more information refer to Main Schedule Review.

MON2 – MON6 shown on sample Screens #1 & #2 are shaded out. This is due to OEM configuration of the options. OEM Configuration may not only change the option names but also if they are active; MON2 – MON6 are not active. (MON = Monitor Temperature Sensor)

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Kiln Function: Easy configuration for Kiln Heat-Treat (not same as Pallet Heat-Treat)

A Sterilization process may be run in a traditional Kiln by use of the standard Core temperature input and typically adding several optional Monitor temperature inputs. Developing and running a Schedule that includes the following will allow a Sterilization process utilizing multiple Monitor Probes.

Monitor Probe Control Logic options (when running automatic schedules):
A “core” setpoint field is available on every stage.  When a “core” sensor & any additional “monitor” temperature inputs are configured within a system, and a “core” setpoint value is entered, a Stage Advance will occur when the “Core” and configured monitor sensors achieve the Core setpoint. Note: the monitor sensors to be included in the control logic are user selectable per stage - in same fashion as EMC setpoint and option selection as described in the previous section.)

An automatic Stage Advance on Temperature Rise is useful during “sterilization” processes that require all temperature probes be above a specific temperature before sterilization “time down” is allowed to begin/continue. 

Unlike the Pallet Heat-Treat configuration control logic the Kiln Schedule approach does NOT offer control logic to abort the Schedule if during the "sterilization" stage one or more of the core temperatures fall below the Core setpoint. However, there is Guaranteed Soak feature for both the active Dry & Wet bulbs that will stop the Stage timer if either the Dry or Wet bulb temperatures fall outside the configured band around their respective setpoints.

All temperature probes may be data logged to the Historical Data file to provide history of the Schedule and specifically the Sterilization Stage.

Click here for more information on Pallet Heat-Treat and Kiln configurations & features and here for Kiln Schedules.

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Pallet Heat-Treat Function:

Auto print at end of Sterilization Cycle with tabular report

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”. Printer Option screen and sample printout are shown below.

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Chamber heat control:

Traditional SP w/PID or on/off control output

The main sterilizer view provides the user with all data regarding each sterilization cycle.  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.  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.

The chamber manufacturer can configure the FDC-2010-K5C to control Chamber temperature by comparing SP (Chamber Setpoint) to the Main Temp sensor (chamber sensor) and the system will control the heat by the configured control logic, on/off or proportional output (PID). For more information on on/off and proportional control (PID click on Control Tuning.

Temperature Control off Lowest Core Probe

The FDC-2010-K5C may be configured by the OEM for the temperature control output (on/off or proportional) to be based upon the lowest temperature sensor wired to the system. In this configuration the sensor used for Main Temp is seen by the FDC-2010-K5C as a Pallet sensor with the same Sterilization logic as Pallet 1 - 3.
The screen graphic below the green arrow shows which temperature sensor is currently being used for temperature control output; in this example pallet 2.

Main View when configured as Temperature Control off Lowest Probe

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Chamber heat control: 3-staged outputs

The Burner Stage Setpoint screen is only applicable to Pallet Heat-Treat configuration and is configured by the OEM.

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.

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Sterilization cycle has begun: drop back setpoint

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).

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Sterilization cycle has begun: PID analog only - stop or continue control

The Analog Control Type screen is only applicable to Pallet Heat-Treat configuration and is configured by the OEM.

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.

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LAN Features:

Embedded VNC Server - Remote Access via Ethernet LAN (intranet or internet)

The FDC-2010-K5C as standard has an embedded VNC Server allowing easy & complete Remote Access on a standard Ethernet Local Area Network (LAN) with appropriate password protection.

Remote Access via PC or Windows enabled PDA running VNC Viewer (freeware) provides local (Intranet) or Internet access to your control system as though standing in front of the touch screen.

Shown below is a screen capture of how the VNC Viewer will display the FDC-2010-K5C on 19” PC screen.
The Views Menu header had just been clicked with the mouse causing the View menu to drop down.
The graphic below taken with XP Pro, PC’s running Vista can size the remote display to any size fitting the screen.

The embedded VNC Server is in addition to the Web Page that was included in the previous versions. The Web Page is still offered; for further information go to LAN Features.htm:

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email / SMS messages on Alarm

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.

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FTP - Automatic or on-demand Historical File transfer to FTP Server

The FDC-2010-K5C has an embedded FTP Client application (File Transfer Protocol) allowing Historical Data File transfer to an FTP Server via Local Area Network (LAN)  (wireless or wired network).

When utilizing FTP all the saved Historical Data files (data log files or as described above under File Utilities “Data Files”) may be transferred to the target FTP Server on demand (Backup Now) and/or automatically when selecting “Auto Backup (2:00AM). If the FTP transfer fails an alarm log will be created; if “Delete Internal Data Files After FTP” is selected the files will NOT be deleted until they are successfully transferred.

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.

The LAN may be local only (intranet) or world-wide-web (internet) if so configured.

Details on FTP \ WAN (Wide Area Network) LAN setup are outside the scope of this manual; end users should review with their respective Network Administrator to configure the appropriate network hardware & software to utilize the FDC-2010-K5C embedded FTP Client functions.

When depressing the "Backup Now" or when an Auto Backup is begun the FTP transfer screen with progress bar will be shown.

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Time/Date auto set via Ethernet (internet connection required) to a Time Server

All data files as well as other functions in the system require the correct date and time for proper operation.
The set date\time menu selection provides three different screen tabs, Set Time, Time Options (INCLUDING connection to a NTS internet Server) & DST Settings. The auto connection to a government NTS Server is new to version 2.1 as well as layout of the Time/Date configuration screens; all three configuration Tabs are shown below.

Set Time Tab:
Use the appropriate fields to set the date, time and day of the week; press the “Set Time” button to enter the data to internal memory.

Time Options Tab:  (Kiln only configuration)
Time Zone: Select the Local Time Zone from the drop down menu.

NTS Server: The NTS (USA National Time Service) hosts several Servers providing the current time and date. If the FDC-2010-K5C is connected to a LAN (Ethernet connection) with Internet access it can be configured to access the selected NST server every day at 2:00AM to update its’ system time & date. To enable this feature select a NTS Server from the drop down menu (13 different USA government sites) and check the “Enable NTS Clock”.

DST Settings Tab: (Kiln only configuration)
The "DST" tab provides the ability to set the start/end of daylight savings, as well as enable daylight savings operation for the device. If you have selected a time zone that uses daylight savings under the "Time Options" tab, the daylight savings option must be used for the correct time to be displayed.

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Help Configuration & Audio Output

Multi-Languages (English, French & Spanish)

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).

The Help\Voice Assistance screen allows the user to configure the displayed language (English, Spanish or French) 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”.

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.

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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