FC SERIES MANUAL LOADER (CONTINUOUS OUTPUT TYPE) DATA SHEET PDB3 The FC series Manual Loader carries out remote control in combination with a controller. This product is a manual loader to be used in a process and it excels in the effect of monitoring due to adoption of a color LCD. Besides standard signals of 1 to 5 V DC, input signals from thermocouples and resistance bulbs can be handled at option. FEATURES 1. High visibility ensured with color graphic display A color LCD is adopted for graphic display of bar graph and trend screens,etc. 2. Communication function (option) RS-485 (Modbus protocol) are available. 3. Back-up (option) If the loader becomes faulty, influence over the system can be evaded by changing the built-in backup operation unit. 4. Memory card (option) Memory card can save any data, for example process input, manipulation output, WAFER output, etc. Communication RS-485 (Modbus® ) Transmission terminal PV indicator MV indicator Signal name/terminal No. Linearize square root Signal name/terminal name Manual mode output/DO8 Filter (KPV) Process variable input/PV1 (Analog input) ML MV M Forced opening constants External input terminal MH Internal input terminal Internal input terminal External input terminal External AMV input/PV2 (Analog input) PV compensation signal (KPV)/AO3 Manipulation output (voltage) (MV)/AO1 Manipulation output (current) /Mi+1, Mi-1 MV HMV (Option) Forced opening command (EXS)/Di9 Alarm KPV Manual mode command (SMV)/Di10 Upper alarm output (H)/DO9 Lower alarm output (L)/DO10 Fault output (FLT-Do)/FLT Fault FLT lamp EDSX11-135b Date Dec. 24, 2003 PDB3 SPECIFICATIONS 1. Input Signals Performance under reference condition(23± 2˚C, 55± 10%RH, Power voltage and frequency variation ± 1%, free from the effect of external noise) unless otherwise specified. 1-1 Analog input signal • Number of inputs 8 inputs • Inpute signal types : DC voltage, thermocouple (option), resistance bulb (option) Two thermocouple inputs or two resistance bulb inputs are selectable. (1) DC voltage • Input range: Selectable among 0 to 5 V DC, 1 to 5 V DC and 0 to 10 V DC Initial set before delivery : 1 to 5 V DC • Input accuracy: ± 0.1% of input span± 1 digit • Scaling (Industrial data conversion) : Settable within a range from -32767 to 32767 4, 3, 2, 1 or 0 digit below decimal point is selectable. Initial set before delivery : 0.00% to 100.00% • Industrial unit: Settable in up to 8 characters Usable characters: Alphabets numerals, symbols such as +, – ,*,etc. • Input accuracy guarantee range: –5% to 105% of input range. • Maximum continuous permissible voltage: ± 35 V • Input resistance: 1 MΩ or more • Influence by ambient temperature: ± 0.1% FS/10°C or less. • Influence by power supply fluctuation: ± 0.1% FS or less. • Isolation : Non-isolated from internal circuit. • In case of current input: Shunt resistor need to be connected to the analog input terminal. (250 Ω shunt resistor is optional item) (2) Thermocouple (option) • Types and measurable ranges: * See Table 2. • Input accuracy: ± 0.2% FS ± 1 digit [Note]B type: ± 5% between 0 to 400˚C S and R type: ±1%between 0 to 500˚C All type of TC: ± 5% under–100˚C • Reference junction compensation error: ± 1.0°C (provided measurable range is –50°C and higher) [Note]Reference junction compensation resistor is connected at external input terminal in case of thermocouple input is ordered. • Input accuracy guarantee range: –5% to 105% of input range. • Input resistance: 1 MΩ or more 2 • Allowable signal source resistance: 100 Ω or less (Zener barrier connection unallowable) • Influence by signal source resistance: About 0.25 µV/Ω • Influence by ambient temperature: ± 0.2% FS/10°C ± 1°C or less. • Influence by power supply fluctuation: ± 0.2% FS ± 1˚C or less • Burnout detection: Provided • Isolation: Isolated from internal circuit. (3) Resistance bulb (option) • Types and measurable ranges: * See Table 2. • Input accuracy: ± 0.2% FS ± 1 digit • Input accuracy guarantee range: -5% to 105% of input range • Allowable wiring resistance: 10Ω or less per wire, provided wiring resistance must be equal among 3 wires (Zener barrier connection unallowable) • Influence by ambient temperature: ± 0.2% FS/10˚C or less. • Influence by power supply fluctuation: ± 0.2% FS or less • Burnout detection: Provided • Isolation: Isolated from internal circuit. [Note] FS: full span. • Sampling period : 100 ms 1-2 Digital input signal • Number of inputs : 10 inputs • Electrical specifications : No-voltage contact or transistor contact ON/0 V, OFF/24 V, ON current/about 8 mA Isolated from the internal circuit by photocoupler. Not isolated between each digital input and output. • Contact rating : 30 V DC, 10 mA or more • Signal judgment : No-voltage contact Contact resistance; 200 Ω or less at ON, 100 kΩ or more at OFF : Transistor contact 1V max at ON., leakage current 100µA max. at OFF 2. Output Signals Performance under reference condition(23± 2˚C, 55± 10%RH, Power voltage and frequency variation ± 1%, free from the effect of external noise) unless otherwise specified. 2-1 Analog output signal (1) Control output • Number of outputs : 1 output • Output signal : 4 to 20 mA DC • Output accuracy : ± 0.2% FS • Load resistance : 600 Ω or less • Output accuracy guarantee range : 2 to 22 mA DC • Influence by ambient temperature : ± 0.2% FS/10˚C or less • Influence by power supply fluctuation : ± 0.2% FS or less • Isolation : Non-isolated from internal circuit (2) Auxiliary analog output • Number of outputs: : 4 outputs • Types of signal : Selectable among 0 to 5 V DC, 1 to 5 V DC and 0 to 10 V DC Initial set before delivery: 1 to 5 V DC • Output accuracy : ± 0.1% FS • Load resistance : 15 kΩ or more • Output guarantee range : 1 to 5 VDC : –12.5% to 112.5% : 0 to 5 VDC : 0% to 112.5% : 0 to 10VDC : 0% to 105% • Influence by power supply fluctuation : ± 0.1% FS or less •Isolation : Non-isolated from internal circuit 2-2 Digital output signal • Number of outputs : 10 outputs • Electrical specifications : Transistor open collector 1 V max. at ON, 10 µA max at OFF. Isolated from the internal circuit by photocoupler. Not isolated between each digital input and output. • Output rating : 30 V DC, 100 mA max. (resistive load) 2-3 Fault output signal (terminal symbol FLT) • Number of outputs : 1 output • Electrical specifications : Transistor open collector 1 V max. at ON, 10 µA max at OFF. Isolated from the internal circuit by photocoupler. Not isolated between each digital input and output. • Output rating : 30 V DC, 100 mA max. (resistive load) 4. Setting and Operation (1) Control output operation method • Operation key : Up key, down key and high-speed key • Operation speed : About 40 s/FS (usual), about 8 s/FS (high speed) (2) Operation mode • Kinds of operation mode : A, M and HM [Note] A : Auto mode (operation according to the remote control signal (voltage input)) M: Manual mode (control output to be manually operated by operator) HM: Hardware Manual mode (operated by back-up loader) • Changeover : Balanceless bumpless changeover [Note] Balanceless bumpless changeover is a method where each setting value is automatically balanced by the manual loader at the time of changeover. (3) Security : Setting of a password • Method : Settable in 4 numerals (within 0000 to • Password ffff) Initial set before delivery: 0000 • Contents of security : Inhibition of parameter setting (4) Other setting items : Settable in up to 8 characters • Tag name Usable characters; alphabes, numerals, symboles such as +, – ,*,etc. 5. Power Supply • Voltage rating : 100 V to 240 V AC/24 V DC • Allowable range : 85 V to 264 V AC/20 V to 30 V DC • Frequency : 47 to 63 Hz • Power consumption : 60 VA or less (100 V to 240 V AC) : 30 W or less (24 V DC) • Power supply output voltage (terminal symbol VP and PC) : 20V to 30V DC, max. 40mA 3. Display • Display unit : 16 Colors graphic liquid crystal display, with CFL back light and contrast adjust function. • Contents of display : Menu : Loop panel Bar graph display, digital display, etc. : Trend screen (max. 8 screens) : Alarm and alarm historical screen : Analog input/output and digital input/ output indication screen : WAFER connection screen : Parameter setting screen 3 PDB3 6. General performance and characteristics • Insulation resistance : 500 V DC, 50 MΩ or more. • Dielectric strength : 2,000 V AC for 1 minute between power terminal and ground terminal in case of 100 V to 240 V AC power supply : 500 V AC for 1 minute between power terminal and ground terminal in case of 24 V DC power supply. : 500 V AC for 1 minute between signal communication terminals and ground terminal • Rush current : 60 A or less. (100 V AC to 240 V AC power supply) • Clock : Set and display year, month, day, hour, minute, second accuracy : ± 100 ppm except for time lag shorter than 1 s / power ON / OFF action. • Memory backup : Protection by lithium battery. (expected battery life is about 2 years under room temperature) Parameter and program are stored nonvolatile memory. 7. Operating and storage conditions • Mounting place : Indoor • Operating temperature : 0 to 50˚C : 0 to 40°C in case of multiple mounting ( Temperature change rate : Max. 10˚C / h) • Transport and storage temperature : -20 to 70˚C ( Temprature change rate : Max. 20˚C / h) • Operating humidity : 5 to 90% RH, condensation unallowable • Transport and storage humidity : 5 to 95% RH, condensation unallowable • Operating continuous vibration : 4.9 m/s2 or less • Transport and storage shock : Fall of 60cm max. in packed status 8. Power Failure and restart Function • Permissible duration of momentary power failure : 20 ms at 90V AC (100 V to 240 V AC only) [Note] In case of 24 V DC, system power supply unit (model: PXJ) is recommended to avoid power failure problem. • Behavior at power failure detection : Control stops at detection of power failure. • Power recovery mode : Selectable initial start and continuous start 4 9. Self-Diagnosis • Control and computation circuit failure : Monitoring with watchdog timer • Input signal failure : Voltage/current input Monitoring of range over : Thermocouple and resistance bulb Monitoring of disconection • Control output signal failure : Monitoring of disconnection by read back check • Behavior at failure : FLT is indicated, FLT lamp lights, FLT output signal turns on, and manipulation output is held. 10. Structure • Enclosure : Plastic (material: PC-ABS) • Finish color : Front frame and enclosure both gray • Flame resistance : UL94V-0 • Protection : Front face; IP54 (display unit and operation key) • External dimensions (W x H x D) : 72 x 144 x 280 mm • Mass : 1.9 kg or less • Mounting method : Flush on indoor panel Vertical mounting as standard Tilted mounting allowed within backward angle 0° to 45°. 90° to 45° For panel cutout dimension, refer to Panel Cutout Dimensions • External terminal : Compression terminal type 11. Backup Function (option) • Method : With backup operation unit • Number of control output : 1 output • Output signal : 4 to 20 mA DC • Indication : Manipulation output indication (mA indication) • Indicator : 21-segment LED • Operation key : Manipulation output up, manipulation output down, loop selection • Operation resolution : 5% • Backup changeover : Changeover has been made by the HM (Hard Manual) switch. However, changeover cannot be made when the backup operation unit is faulty. : In all loops, changeover to the HM mode is blanceless and bumpless. 12. Communications (option) 12-1 RS485 interface-1 • Communication behavior : Slave • Communication protocol : Modbus® protocol • Physical specification : EIA RS-485 • Communication method : Half-duplex, bit serial : Start-stop synchronizing • Connection form : Multi-drop • Communication speed : 19.2 kbps • Communication distance : Max. 500 m in total • Number of connectable units : Max. 31 units : Fixed to 8 bits • Data length : Odd / Even / None • Parity : 1 or 2 • Stop bit : Isolated from internal circuit • Isolation : 100 Ω (optional item) • Terminator • Communication items : Parameters and process value. • RS232C / RS485 signal converter (optional item) : Code symbol: PDZT0001 14. Standards under Conformity (1) General safety : IEC 1010-1 (1990) EN 61010-1 (1993) (2) EMC : Emission EN 50081-2 (1994) Immunity EN 50082-2 (1995) 13. Memory Card Interface (option) • Specification : Compact Flash® (Based on CFA) • Compatible memory card : 5 V flash memory card Capacity 4, 20 and 32 MB : Process data logging (32 points or less) • Application • Saving period : 1s to 2h • Data storage capacity Memory card capacity Data storge 4MB about 180 thousand data 20MB about 900 thousand data 32MB about 1.35 million data [Note] The data of max. 16 points (4 screens) can be storaged at storage time as 1 s. • Format method : Dependent on this manual loader • Data readout : Readout by PC using PCMCIA card slot • Recommended memory card : Made by Sandisk corporation Sandisk CompactFlash memory card is standardized and on the market. 5 PDB3 Table 1 List of WAFERS WAFER name Bit concatevate Kinds Outline 8 Outputs digital data as word data to an external expansion I/O. Bit slicing Slices the digital data acquired as 1 word data from an external expansion I/O into each bit. 1 Encoder Encodes an input signal into a binary code. 1 Sawtooth wave generator Generates a sawtooth wave with a slope entered for each cycle time. 5 BCD Converts BCD data into binary data and binary data into BCD data. Logical operation Carries out AND,OR,NOT,XOR 6 and a combination of these logical operations. Carries out a combination of Arithmetic operation 8 addition,subtraction,multiplication and division. Carries out temperature and Temperature/pressure 1 pressure compensation through use compensation of differential pressure,compensated pressure,proper temperature. Linearize 7 Carries out segmented-line approximation with 15-segmentedline function. 1 Flip-flop RS flip-flop. Adds the change of input at each 1 Pulse width integration basic cycle to the previous integration value. Selector Compares two input values,and 1 provides High output(Large one), Low output(Small one),and result of judgement on large/small. Selects input or output via a switch 1 Changeover function.Analog hold circuit also provided. Outputs on-delay,off-delay timer 1 Timer signal via start of input signal according to timer setting. Carries out absolute value processing 1 Absolute value/sign on input and outputs the result.Also inversion judges the sign(Positive,negative)of input value and outputs the result. Extracts square root of input value 1 Square root extraction and outputs the result.Low input cutoff function equipped. Carries out lead/lag operation on the 3 Lead,lag input and outputs the results. Used as analog filter function and for various compensations. Limits the input within the range of 1 Limiter high/low limit settings,and outputs the result.Also outputs high/low limit alarm signal. Outputs signal which changes...in 2 Ramp function ramp from toward target value at the set full scale time.There are two of these wafers...in minute unit and hour unit. Carries out sequential integration on 1 Analog averaging input data,calculates the average value at each averaging time, and otuputs the result. Integrates the value obtained by 1 Analog integration multiplying the input data by a proportional constant,and outputs the result. Outputs a pulse at the set time 1 Pulse generation interval. Adds dead band compensation to 1 Dead band the input and outputs the result. 6 WAFER name Pulse No.counter Pulse No.output Decoder Running average Sample & hold Dead time ON-OFF Alarm Palse width modurator Kinds Outline 1 Detects rise of pulse and counts the number of pulses. Integrates the input signal and 1 converts it to number of pulses for output. Decodes 2-bit pure binary input and 1 outputs it to 4 terminals. Calculates ranning average of input 2 data and outputs the result. Holds the input value according to 1 sample signal(0/1)and continues the output. Usable for dead time compensation 6 control etc.Data sampling can be done in 1 sec or 1 min units. Outputs ON-OFF signal with 1 hysteresis. Compares the input and set value 1 and outputs the judgment result. 1 Performs output processing in time proportional PID control. A variety of applications are possible through combination of WAFERS. Table 2 SCOPE OF DELIVERY List of Thermocouple and Resistance Bulb Measurable range Input signal Thermocouple Manual loader, panel mounting bracket, instruction manual (depend on code symbols) Input type code Input range code Measurable range˚C J 00 0.0~400.0 J 01 01 0.0~800.0 K 02 0.0~400.0 K 03 0.0~800.0 Optional Items Specificatio Available unit PDZR2001 For compression terminal 1 PDZS2001 For compression terminal 1 1 Item Terminator Type K 04 0.0~1200.0 for communication (100 Ω) R 05 0.0~1600.0 Shunt resistor (250 Ω) B 06 0.0~1800.0 Communication cable (Note1) T 07 -200.0~200.0 For compression terminal, PDZK4xx1 With compression from PD* to PD* terminal at both ends For compression terminal, PDZK5xx1 With M3.5 solderless from PD* to PLC terminal on PLC side 9-pin connector on PC side 1 RS232C / RS485 1 T 08 -150.0~400.0 E 09 0.0~800.0 E 10 -200.0~800.0 S 11 0.0~1600.0 For compression terminal, PDZK6xx1 N 12 0.0~1300.0 from PD* to PC U 13 -200.0~400.0 WRe5-26 14 0.0~2300.0 PL2 15 0.0~1300.0 Resistance bulb Pt100 00 Communication converter PDZT0001 signal converter Manual Loader 00 0.0~150.0 Instruction Manual 01 0.0~300.0 in book form (in English) 02 0.0~500.0 Instruction Manual on 0.0~600.0 CD-ROM (in English) 03 04 -50.0~100.0 05 -100.0~200.0 06 -200.0~600.0 07 -200.0~850.0 1 Mounting bracket Instruction manual in PDZX3B01 book form 1 PDZQ2001 Instruction manual on CD-ROM 1 PDZA1001 Improved mounting 1 bracket (Note 1) These cables are used for Modbus. Length needs to be specified. Block diagram of electrical isolation Solid line shows isolation from the other units or circuits. Power supply Power supply unit DI1 to DI10 DI / DO unit Ground PV1 PV2 RS485 (Modbus) DO1 to DO10 Ground TC or RTD input unit AI / AO unit TC or RTD input unit AI1 to AI6 MI1 AO1 to AO4 Communication unit 7 PDB3 CODE SYMBOLS 1 2 3 4 5 6 7 8 9 10111213 1415 PDB 3 1 - YY 1 Description Number of control loops <5th digit code> 1 loop (1 control output) External terminal <6th digit code> Compression terminal 2 Input signal <7th digit code> 1 to 5 V DC Thermocouple Resistance bulb Pt100 A C D Note 1 Note 2 Note 2 Power supply voltage <9th digit code> 100V to 240V AC (Usable range 85V to 264V AC) 50 / 60Hz 24V DC (Usable range 20 to 30V DC) A B Operation mode <10th digit code> Auto-Manual changeable type A Backup operation unit <11th digit code> Without For 1 control output, 100 to 240 V AC For 1 control output, 24 V DC Y A D Communicatioin / Memory card interface <12th digit code> (Slave) (Master) (memory card interface) Note 3 Note 4 Without Without Without Without Without With RS485 Without Without Note 5 RS485 Without With Note 5 Y M C U Y D Instruction manual <13th digit code> Without With Instruction manual on CD-ROM (in Japanese and English) Note 1) For current input, a shunt resistor is used for conversion into voltage. Shunt resistor is optional item. Note 2) Thermocouple and resistance bulb input are opitons. Allowable up to 2 points. Note 3) Communication cable and terminator are optional items. Note 4) Recommended maker: Sandisk corporation. Note 5) Slave interface is Modbus protocol. Note 6) Input signal and measurable range initial set before delibvery is as follows. For specification of voltage input, scale is 0.00 to 100.00% For specification of thermocouple, K, 0.0 to 400.0˚C. For specification of resistance bulb is 0.0 to 150.0˚C. 8 67.5 OUTLINE DIAGRAM (Unit : mm) Panel thickness 8mm or less Terminal cover Mounting bracket 144 137.5 20 Panel 21.6 100MIN. 72 280 Mounting bracket Note) The distance between other instruments and low end of PDB shall be more than 100mm. MOUNTING BRACKET 16 160 50 205 PANEL CUTOUT DIMENSIONS For mounting multiple "n" units 250 or more 250 or more For mounting one unit 68 138 138 0 +1 +1 0 Number of +0.7 0 (72.2n-4) units n 2 +1 0 9 PDB3 EXTERNAL CONNECTION DIAGRAM Voltage input 24 V external Power supply RS-485 (Modbus) (+) (–) (+) (–) (COM) 24 V Power supply for DIO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 AI1 SC AI2 AI3 SC AI4 AI5 SC AI6 SC VP PC DI9 DI10 DO9 DO10 MOD+ MODCOM VPD PCD PCD 22 MI+2 23 MI-2 24 MI+3 25 MI-3 26 MI+4 27 MI-4 28 DO6 29 DO7 30 DO8 31 DIO-COM VPD 32 DI6 33 DI7 34 DIO-COM 35 DI8 36 OPT+ 37 OPT38 COM (+) I+2 b 39 Rcj Process Io2 A 40 variable 41 Rcj2 (–) input 2 B 42 I-2 Voltage Thermo- Resistance bulb input couple input input Manipulation output VPD PCD (+) Process variable input 1 Rcj (–) b A B 43 MI+1 44 MI-1 45 AO1 46 SC 47 AO2 48 AO3 49 SC 50 AO4 51 FLT 52 DO1 53 DO2 54 DO3 55 DO4 56 DO5 57 DI1 58 DIO-COM 59 DI2 60 DI3 61 DIO-COM 62 DI4 63 DI5 64 I+1 65 Io1 66 Rcj1 I-1 67 Voltage Thermo- Resistance bulb input couple input input G N/– L/+ Power source 100 to 240V AC ~ Power source 24V DC – + INPUT/OUTPUT TERMINAL FUNCTION (when preset WAFER) Input signal name Input terminal Output signal name Output terminal PV input I+1，I-1 Manipulation output / Voltage (MV) AO1 External AMV input I+2，I-2 Universal analog output AO2 Universal analog input AI1 PV compensation signal (KPV) AO3 Universal analog input AI2 Universal analog output AO4 Universal analog input AI3 Manipulation output / Current (MI) MI+1，MI-1 Universal analog input AI4 Don't use MI+2，MI-2 Universal analog input AI5 Don't use MI+3，MI-3 Universal analog input AI6 Don't use MI+4，MI-4 Universal digital input DI1 Universal digital output DO1 Universal digital input DI2 Universal digital output DO2 Universal digital input DI3 Universal digital output DO3 Universal digital input DI4 Universal digital output DO4 Universal digital input DI5 Universal digital output DO5 Universal digital input DI6 Universal digital output DO6 Universal digital input DI7 Universal digital output DO7 Universal digital input DI8 Manual mode output (M) DO8 Forced opening command DI9 Upper alarm output (H) DO9 Manual mode command DI10 Lower alame output (L) DO10 Analog Digital Fault output (FLT-DO) 10 FLT Don't use OPT+ Don't use OPT- PCD 11 PDB3 [Note] Windows is the registered trade mark of Microsoft corporation. [Note] Modbus is the registered trade mark of Gould Modicon. [Note] Compact Flash is the registered trade mark of Sandisk corporation. Caution on Safety *Before using this product, be sure to read its instruction manual in advance. Head Office 6-17, Sanbancho, Chiyoda-ku, Tokyo 102-0075, Japan http://www.fesys.co.jp/eng Sales Div. International Sales Dept. No.1, Fuji-machi, Hino-city, Tokyo, 191-8502 Japan Phone: 81-42-585-6201, 6202 Fax: 81-42-585-6187 http: //www.fic-net.jp/eng Information in this catalog is subject to change without notice. Printed in Japan