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USERS' MANUAL
713.828.7247
www.Purgit.com
PORTABLE FLARE
TEMPERATURE CONTROLLER
USERS' MANUAL
TABLE OF CONTENTS
SUMMARY OVERVIEW
INSTALLATION
OPERATION
MENUS (Overview)
PROGRAMMING MENU (1)
PROGRAMMING MENU (2)
ERROR CODES
FAILURES and CORRECTIONS
SUMMARY OVERVIEW
PORTABLE FLARE TEMPERATURE CONTROLLER
FDC9300 class Model 513000
Summary Narrative
The system uses three (3) Temperature Controllers to maintain a safe, controlled burn.
TC1 controls the PILOT temperature
TC2 controls the Detonation Arrestor
TC3 controls the SHROUD temperature
This manual addresses the details of the TC3 SHROUD Temperature Controller.
SAFETY FIRST
The fuel supply feed of the Shroud is interlocked to the Pilot as a safety fature. In operation, the shroud burner will not
be fed fuel unless the pilot is fully operational and running, because TC3 gets its operating voltage from the Pilot status.
No pilot, no fuel to the shroud burner. TC3 controls the fuel feed valve to the shroud and is designed as a fail safe
control. The valve is a ballstyle, fail close configuration, which will automatically close to the shutoff position with the
loss of air (motive power) or loop current (control signal). Additionally, Fuel will be blocked in if the loop wiring is
damaged or broken, or if power is lost.
SHORT NARRATIVE
The loop current signal is generated by TC3, and comprises a 4to20 mA electrical current, responsive to the target
operating temperature. TC3 starts with a 20 mA control signal (valve full open) and decreases linerally to 4 mA (valve
closing) as the operating temperature approaches the set point. When the temperature reaches the set point, the TC3
will hold the signal at 4 mA again to close the valve and stop the fuel. The system will thereafter throttle the valve to
maintain the temperature at the SV setting on the display.
This setpoint is always visible in the TC3 display, and can be adjusted with momentary contact keys:
THE SYSTEM IS DESIGNED TO RUN IN AN UNATTENDED MODE
S A L E S and S E R V I C E SUPPORT
Copyright© 2020 JRS Page 1 8/27/2020
Summary Narrative, continued.
The Shroud Burner uses a temperature controller which employs "Fuzzy Logic".
Because of the thermal response of the operating environment, this type of logic can selfadapt
to the leading or lagging response to PV disturbances, which helps stabilize the control.
The TC3 temperature controller is technically classified as a useradjustable microcontroller
because so many of the operating parameters are userselectable.
Shown below are displays at when operating and when cooled down.
The running temperature is 1486 Deg.F in the upper (Red) display.
The operating setpoint is 1500 Deg. F in the lower (Green) display.
The fuel valve is throttling, and the shroud temperature is approaching the setpoint of 1500 Deg. F.
Controller is backing off on fuel, linearly closing off the valve. Loop current is decreasing toward the 4 mA cutoff point.
In the SETUP MENUs (1), we set the the 5th parameter to "Reversing".
As the temperature rises, the fuel valve closes, decreasing fuel to the shroud burner.
As the temperature drops, the fuel valve opens, increasing fuel to the shroud burner.
Here the cold temperature is 75.9 Deg. F. and the SV has been set to 1500 Deg. F.
The fuel valve will be fully open; the controller is calling for fuel to get the shroud up to the setpoint.
Loop current can be measured at ~ 20 mA.
Use to raise the set point SV, and to lower the set point SV
In this example, the SV has been lowered to 1250 Deg. F.
Internal control PID algorithms will control fuel to the shroud burner
to automatically maintain the operating temperature to match the setpoint.
INSTALLATION
Only three (3) cables are required for the controller:
420 Loop Current ("Signal") at 5 and 6
DC POWER at rear panel terminal 1 and 2
KType Thermocouple at 13 and 14
DC Power is taken from the Pilot Lamp
Loop Current Signal (OUT 1) goes to the Fuel Valve positioner
Thermocouple wire comes from the Shroud Thermocouple
Be certain to verify polarity on all connections before applying power.
REAR PANEL WIRING
4 4 OFF
O 3 OFF
F 2 OFF
SWITCHES 1 ON
SWITCHES
ASBUILT
1 12 VDC + (Red)
2 12 VDC (Black)
3 not used
4 not used
5 OUT 1 (Black)
6 OUT 1 + (Red)
7 not used
8 not used
9 not used
10 not used
11 not used
12 TC + (Yellow)
13 TC (Red)
14 not used
15 not used
16 not used
Copyright 2020© JRS Page 1 C:\Users\Kevin\Desktop\MVP\Purgit\Draft Op Man\Users Manual FDC9300
OPERATION
FRONT PANEL
O P E R A T I O N
User Menu This is the normal, running display you will always see.
The TOP (RED numbers) show the current Process Variable
SHROUD TEMPERATURE of 1160 DEGREES F.
as measured by the KType thermocouple sensor.
The BOTTOM (GREEN numbers) are the Set Point, or the target shroud temperature.
You can change the set point (SV) with the UP and DOWN buttons.
The unit is designed to operate in the UNATTENDED mode. This means that temperature control is automatic.
Once the unit is safely set up and energized all you have to do is set an operating temperature with the up and down pushbuttons.
The Shroud temperature will be maintained at the setpoint shown in the bottom (Green) display.
This is the Set Value, or SV LED in the front panel display.
As shown above, the unit is still heating up at a PV temperature of 1166 Deg. F.
Because the shroud reading of 1166 is BELOW the set point of 1200, the fuel valve will be driven open, allowing the burner to continue heating the shroud.
As the top (Red) PV reading increases toward the lower (Green) SV setting, fuel will be throttled down by linearly lowering the loop current output of TC3.
With the controller output programmed for 'REVERSE' (heating) control action, the valve will throttle closed as the PV increases.
By reducing the drive (loop current) to the ball valve positioner, the valve moves toward the closed position, reducing the fuel feed to the burner.
When the shroud temperature reaches 1200 degrees F, TC3 controller will stop all fuel feed to the burner to stabilize the temperature.
By continually comparing the two readings (SVPV), TC3's program will throttle the ball valve as needed to maintain a steady, reliable shroud temperature.
Remember, you can use the UP and DOWN buttons at any time, to adjust the operating temperature if desired.
Page 1 of 1
MENUS ... OVERVIEW
O P E R A T I N G M E N U
User Menu This is the normal, running display you always see.
The TOP (RED numbers) show the current Process Variable as measu
the sensor. This is the actual SHROUD TEMPERATURE.
The BOTTOM (GREEN numbers) show the current Set Variable as ch
the Operator. This is the desired SHROUD TEMPERATURE.
t y p i c a l P R O G R A M M I N G M E N U S
Press and together to cycle through the Programming Menus
Setup Menu Use to configure the application parameters and define the inputs and outputs (I/O):
Input 1: Thermocouple type (K), temperature units, decimal point
Input 2: none, Current Transformer, 0 to 5V, 420 mA, etc.
Output 1: Direct or Reverse acting, 0 to 5V, 420 mA, relay/solid state relay, etc.
Output 2 can be a cooling relay, alarm, or dwell timer. (not used in this application)
Manual Control Autotransfer to manual when sensor break or A/D converter damaged is detected.
Relevant programming parameters are Heat (MV1) and Cool (MV2).
Refer to section 31 of Users Manual # UM9300 2.0
The manual control may be used for the following purposes:
( 1 ) To test the process characteristics to obtain a step response as well as an impulse response
and use these data for tuning a controller.
( 2 ) To use manual control instead of a close loop control if the sensor fails or the controller's
AD converter fails. NOTE that a bumpless transfer can not be used for a longer time.
See section 36. of the Manufacturer's User Manual UM9300 2.0
( 3 ) In certain applications it is desirable to supply a process with a constant demand.
Hand Mode can be used for troubleshooting.
20 mA
100%
For example, if a valve positioner needs to be calibrated, you can set the loop current to a convenient level such as 0%, 25%, 50%, 75%
Perform a 5point check using these values to tune a positioner, drive a valve or simulate a transmitter and verify receiving instrument
16 mA chart recorders or displays.
75%
This controller can be used as a voltage or mA source for testing and calibrating control loops.
First get to the HAnd display shown above.
12 mA
50%
Then hold the enter key for 45 seconds, and then release.
8 mA The top (red) display should be flashing and the bottom (green) display will show H and a number.
25% This number is the output percentage and can be changed with the up and down keys, so you can set it as needed.
To set up for manual 420 output, get to the HAnd display shown above by using the ENTER and DOWN buttons.
You can now set the output to any value betweeen 0% and 100% using the UP and DOWN key buttons.
4 mA
0%
MENUS ... OVERVIEW, continued
Autotuning Is disussed in Chapter 3 "Programming Special Functions" on page 30 of the FDC manual.
Autotuning will change the control mode during the tuning period, and will cause disturbance to the process.
This mode should only be used for initial setup for a new process, or if control results are unsatisfactory
Display Can be used to rearrange the upper display. The FDC9300 has the flexibility for you to select those
parameters which are most significant to you and put these parameters in the front of display sequence.
SEL1: Selects the most significant parameter for view and change.
SEL2: Selects the 2nd significant parameter for view and change.
SEL3: Selects the 3rd significant parameter for view and change.
SEL4: Selects the 4th significant parameter for view and change.
SEL5: Selects the 5th significant parameter for view and change.
Refer to section 31 of Users Manual # UM9300 2.0
Default Setting This function will erase your parameters and restore the unit to Factory Default settings.
A complete listing of all the default settings are shown in Table 1.4 begiinig on page 8 of the Users Manual UM9300 2.0
Users Manual in searchable PDF is available on the internet at the Future Design Controls web page
Press ENTER and DOWN ARROW five times untill "dEFt" is showing, then press ENTER one time.
The upper display will show "FiLE". Use the UP/DOWN key to select "0" or "1".
File "0" is for Deg C
File "1" is for Deg F
The press ENTER for about 5 seconds. The display will flash and the default values will be loaded in to the NV Memory.
Calibration Covered in Chapter 4 (page 38 of UM9300 2.0
Do not attempt to calibrate the controller without the appropriate calibration equipment, including:
1. Test Chamber 25 deg C to 50 deg C
2. Calibration Software
3. Fluke 5520 Calibrator
4. Calibration Fixture with programming units
CALIBRATION SHOULD BE PERFORMED ONLY BY CERTIFIED INSTRUMENT TECHS
NOTE S A F E T Y I S S U E:
Use of these modes will interrupt control of the process loop , and change some of the
previous setting data.
Make sure that Operations is aware of, and authorizes you to use these modes before
executing them.
SETUP MENU
P R O G R A M M I N G M E N U
Press and together to cycle through the Programming Menus
Stop when you see this: Then press "ENTER"
This is the first option that you should see.
go to next ...
SETUP MENU, cont...
P R O G R A M M I N G M E N U
The next five displays are for customizing the sequence of parameters shown in the USER MENU.Normal, we don't set these up.
EXIT Programming Mode
FAILURES and CORRECTIONS