ORION L Manual - Future Design Controls docs/Orion_manv1_1.pdfFDC-Orion-L Manual 6-17-20004 - Rev 1.1 Page 3 What is Orion: Orion is an embedded SCADA and control interface system

FDC-Orion-L Manual 6-17-20004 - Rev 1.1 Page 1

ORION _ L Manual(Orion Loop interface and SCADA system)


FDC Orion-L Manual

What is Orion: Page 3What hardware do you need for an Orion system?Orion display interface installationConnecting controllers to OrionSetting up the controllersPowering up OrionOrion Configurator

Orion Menus: Page 11Views MenuRecipes Menu Setup MenuAlarms MenuData Menu

Data Views: Page 12Single Loop ViewDual Loop ViewOverview ViewBargraphsControl TrendsProfile Run ViewAlarm Log ViewAlarm History View

Recipes: Page 15Profile RecipesSingle Setpoint Recipes

Setup: Page 19Faceplate OptionsLimits/UnitsController TuningAlarm SetpointsSystem SecurityUSB/Touch CalibrationExit Application

Data Logging: Page 27Data Logging Historical Viewer

Troubleshooting the System: Page 31My system is not working

Specifications and Drawings: Page 32Orion interface specificationsOrion interface portsOrion drawings


What is Orion:

Orion is an embedded SCADA and control interface system for FDC 300 seriescontrollers and profilers. The interface is a 5.7” Nema4 touch interface with allsoftware included on a 128MB compact flash card. No external PC software isrequired for setup or configuration.

Data from each controller can be viewed and changed from theOrion interface. Connection to controllers is via a RS485(one to many) connection.

Orion provides a rich set of tools for control interaction anddata analysis. View control data in loop view, overview, trend orbargraph format. Change setpoint, tuning parameters, alarmsetpoints or units for any controller on the link. The menu drivenInterface eliminates screen “clutter” by providing an easy to use“Windows” interface for interaction between the user and Orion system.

Orion can monitor up to 20 controls. Any of these20 controls can have their data saved to the embedded flash disk.Data file analysis tools (auto-trend) make looking at historicaldata a simple task. Any control variable saved to the Orion flash cardcan be plotted on the historical data trend, for any time frame within the datafiles total time range.

Orion can store up to 1 year of controller data (for 15 controls or less)on it’s 128MB compact flash card. The Orion “USB” interface allows the userto retrieve data files using Microsoft’s “ActiveSync”* software. Interface fromOrion to the PC is a “single” button operation and very easy to accomplish.

The Orion system software includes the following:

Single and dual loop interface views.Overview screen that shows all loops with SP interface for each loop.Profile run and monitor view for FDC 300 series profilers.Current alarm view and alarm history view (alarm history for up to 1 year)Real time bargraphs (with adjustable limits) for all loops connected to system.Real time trends (with adjustable X,Y limits) for all loop connected to system.Profile entry, open, save and download interface screens.Single setpoint recipe entry, open, save and download interface screens.System setup to include, SP limits, tuning, alarms and PC interface.Data logging interface screens to include log point’s selection and historical viewing.Online help for each interface screen.

What hardware do you need for an Orion system

FDC-2010: Orion display Interface.Orion-L: Orion 128MB smart card (Orion software included). The Orion_L card must be installed

in the display interface before power-up for all software to load on power up.CA-2010: Orion 20ft cable to connect display interface to 300 series controllers(RS485 2 wire).PS5R-SD24: 60-watt power supply (optional) to power Orion interface.ActiveSync: Microsoft interface software for PocketPC and CE.net devices. (free internet download)

* “ActiveSync”, “PocketPC” and “CE.Net “ are trademarks of the Microsoft Corporation.


Orion display interface installation:

Location ConsiderationsCare should be taken when locating equipment behind the unit to ensure that AC power wiring, PLC outputmodules, contactors, starters and relays, and any other source of electrical interference are located awayfrom the back of the unit. Particular note should be taken to the position of variable speed drives andswitching power supplies. Their input and load cables should be screened to a central star earth point.

Making a NEMA-4 MountingThe unit can be mounted into panels with a depth of 4”(105mm). It is recommended thatthe unit be mounted on the front panel of a steel enclosure, through an appropriateopening. Allow a clearance of 1”(25mm) around the sides of the unit for mountinghardware. Allow clearance for cable connections to the back of the unit. Unit depth mayvary according to cable type used. Typically, plan a depth to accommodate at least4”(105mm) behind the panel.

NEMA-4MountingPut the unit through the panel cut out. Slide the clamps into the 6 holes provided aroundthe case. Tighten the clamping screws in an even pattern until the unit is secured in thepanel. Caution! Do not over tighten mounting clamps!Note: To seal to NEMA-4 specifications, all supplied mounting clamps must be used andpanel cannot flex more than 0.010”.

Environmental ConsiderationsOrion is to be used indoors. Make sure that the display is installed correctly and that the operating limits arefollowed (See Specifications). Do not operate the unit in areas subject to explosion hazards due toflammable gases, vapors or dusts. The unit should not be installed where fast temperature variations and/orhigh humidity are present. This will cause condensation of water in the device. Do not install these terminalsin environments where have inflammable gases.

Power ConnectionsMake sure that all local and national electrical standards are met when the installing the unit. Contact yourlocal authorities to determine which codes apply.

Power RequirementsOrion can be powered by DC power only. The specified voltage rangeis +21 to 25 Volts DC. This insures compatibility with most controller DCsystems. The power conditioning circuitry inside the unit is accomplished by aswitching power supply. The peak starting current can be as high as 700mA.

Fusing RequirementsIf the display does not come on within 2 seconds of power up, removepower. An internal fuse will prevent damage if the polarity of the DC poweris incorrect. Check wiring to insure proper connections and try to power upagain. An Internal fuse will prevent damage for over voltage condition however itisn’t guaranteed. DC voltage sources should provide proper isolation from main AC power and similarhazards.

Do not power the Orion display and inductive DC loads, or input circuitry to thecontrollers, with the same power supply. Note: The 24 VDC output fromSome controllers may not have enough current to power the Orion.


Wire RoutingWire lengths should be minimized (Maximum 1600’ (500 m) shielded,1000’ (300 m) unshielded). Wires should be run in pairs with a neutral or common paired with a hot or signalline. If wiring is to be exposed to lightning or surges, use appropriate surgesuppression devices. Keep AC, high energy, and rapidly switching DC wiring separate fromsignal wires. Equip ungrounded DC supplies with a resistor and capacitor in parallel toearth ground. This provides a path for static and high frequency dissipation.Typical values to use are 1MOhm and 4700pF.

Connections: To make a connection, strip about 3/8” of insulation off the end of the wire,turn the connector screw counterclockwise until the gap is wide open, insertthe wire all the way in, and turn the screw clockwise until it’s tight.Connect positive DC line to the ‘+24V’ terminal and the DC ground to the‘0V‘ terminal.

Grounding RequirementsChassis ground must be used. DC ground is not directly coupled to Earthground internally. It is preferable not to ground DC negative return to chassisground as poor site earth’s can introduce noise into a system, but if necessaryan earth connection should be made, from the power supply return point tothe central star earth point. Ground conductors should be as short and as largein size as possible. The conductors must always be large enough to carry themaximum short circuit current of the path being considered. Groundconductors should be connected to a tree from a central star earth groundpoint. This ensures that no ground conductor carries current from any otherbranch.

CE RequirementsTo make the Orion interface comply with EMC directives, and to reduce susceptibility to electricalinterference, a separate #14 AWG ground wire should be taken to the chassis ground terminal of the powerconnector. This ground connection should be run directly to the central star earth connection point (asrecommended in most Installation Instructions).

Safety GuidelinesThis section presents recommended installation practices, and procedures. Since no twoapplications are identical, these recommendations should be considered as guidelines.The system designer should be aware that devices in Controller systems couldfail and thereby create an unsafe condition. Furthermore, electricalInterference in an operator interface (like the Orion-2010), can lead to equipment start-up,which could result in property damage and/or physical injury to the equipment operator.

If you, or your company, use any programmable control systems that requiresan operator or attendant, you should be aware that this potential safety hazardexists and take appropriate precautions. Although the specific design stepsdepend on your particular application, the following precautions generallyapply to installation of solid-state programmable control devices. In addition,these precautions conform to the guidelines for installation of Controllers asrecommended in the NEMA ICS 3-304 Control Standards.

Installing the “Orion_L” compact flash card (Important!)Orion will not run without the “Orion_L “compact flash card (provided by Future Design with the unit)installed properly into the compact flash card slot on the display interface. The “Orion_L” compact flash cardhas all software required, loaded onto the card for “Auto-Boot” operation. The compact flash cards slot onthe display interface is “keyed” so the card can only be installed in one direction. Take care when installingthe “Orion_L” compact flash card and do not force it in the slot. The card should be installed before powerup the unit up.


Connecting controllers to Orion

RS485 Communications:

Orion has a built in RS485 communications port. No RS232 to RS485 converter is necessary.RS485 communications provides an architecture that allows many controllers tobe connected to one 2 wire link. These controllers are usually wired in a parallel arrangementand each controller must have a unique address (see “Setting up the controllers” section).

Orion wiring to FDC 300 series controllers:

First make sure the 300 series control has RS485 communications on it. The last digit of thecontroller part number will be 1 if you have this option. An example part number for a1/16DIN 9300 would be 9300-10001.

The cable that connects the Orion display interface to FDC-300 series controllers is a #CA2010. This is a 20ft, 2 wire cable with a DB9 male connector at one end and a2wire connection (stripped leads) at the other end.

The resistor is only needed for networks that have long 2 wire runs. In most casesthe resistor at the end of the link is not required.

Make sure each controller has a unique address on the network. Start at address #1and work your way up to the last controller (See “Setting up the controllers” section forcontrol programming setup for communications). The Orion network must start at address#1 or the display will indicate communication errors.

Once the controllers are connected to Orion you are ready to program each control on thelink with the proper communications address. This must be done via the front keypad on thecontroller or with the FD-Set\PC configuration software. All control parameters to includeinput type, control type and alarm type must be programmed to ensure proper operation withthe Orion system.


Setting Up The Controllers:

Setting up a controller for user with Orion is quick and easy.It's also essential to ensure the system will work properly.

1) Make sure the controller is wired properly and powered up.

2) Press the "Scroll" (far left) key and "down" key simultaneously

3) "Set" will be shown on the top display. Press the "Scroll" keyto enter the setup mode.

4) The first prompt on the top display is "FunC", use the "up" or"down" arrow until the bottom display reads "FuLL". Press the"Scroll" key to move to the next prompt.

5) "Conn" will be the next prompt, press the "up" or "down" arrowuntil the bottom display reads "485". Press enter to move to next prompt.

6) "Prot" will be the next prompt, press the "up" or "down" arrowuntil the bottom display reads "rtu". Press enter to move to next prompt.

7) "Addr" will be the next prompt, press the "up" or "down" arrowuntil the bottom display reads "1 to 256". Each controller must have a uniqueaddress on the communications link. The max address for the Orion systemIs 20. Press enter to move to next prompt.

8) "bAud" will be the next prompt, press the "up" or "down" arrowuntil the bottom display reads "9.6". Press enter to move to next prompt.

9) "dAtA" will be the next prompt, press the "up" or "down" arrowuntil the bottom display reads "8bit". Press enter to move to next prompt.

10) "Pari" will be the next prompt, press the "up" or "down" arrowuntil the bottom display reads "EvEn". Press enter to move to next prompt.

11) "StoP" will be the next prompt, press the "up" or "down" arrowuntil the bottom display reads "1bit". Press enter to move to next prompt.

That's it! Press the "up" and "down" keys simultaneously on the controller torevert the controller back to the "Control' Mode".

Note: When programming input type for each controller on the Orion link, the decimal position of all300 series single setpoint controllers must be set to ‘1” (See 300 series manual for programminginstructions). When using 300 series profile controllers, decimal position can be set for 0 or 1 at thecontroller level. See Orion Configuration section (page 8) for setting the decimal point resolution atthe Orion interface.

Note: FDC 300 series single setpoint controllers provide a unique lock feature to restrict access tothe controller via the front keypad. Please see the 300 series single setpoint controller manual for“Dip switch” settings.

Powering up Orion:

Orion is setup to “Auto-Boot” the Orion software during power up. The *“Windows CE.net “ screen will bedisplayed while the power up sequence takes place. Since Orion is a “Embedded” device, the unit couldtake up to 30 seconds before the splash screen is displayed. Do not touch or click on any of the iconson the “desktop” during the power-up sequence. Trying to run two applications at the same timewill confuse user operations and possibly effect the proper operation of the Orion software.


Orion Configurator:

The Orion configurator will run the first time the Orion system is powered up.The Orion configurator allows the user to select the number of controllers on the link,tagnames and custom alarm messages for each controller, menu items that willbe accessible to the user during Orion operation and a screen that allows theuser to customize Orion with company name and address information.

Configurator Menu Items:

Number Of Controls Screen:

This screen allows the user to select the total number of controllers connectedto the Orion RS485 link. The first address programmed at the controller muststart at “1” for Orion to work properly. A maximum of 20 controllers can beentered on this screen.

Loop1 and 2 linked for profiling: Selecting this option puts Orion into “dual loop”mode operation when FDC-300 series profile controllers are connected to the RS485link and programmed for address 1 and 2. When selecting this option, the Orionconfigurator will lock addresses 1 and 2 (only at the configurator, not at the hardware level)to 300 series profile controllers. This means the user cannot select another controller typefor address 1 and 2 when configuring tagnames for each controller.

Orion’s dual loop operation treats both controllers (add1 and add2 on the RS485 link) as aone, dual loop profiler control. This means that when editing, download and running profiles,both controllers operate as a single control with single button operation for all dual loopfunctions. This gives Orion the ability to control dual loop profile operations for aswet/dry bulb or Temp/RH applications.


Controller Tagnames Screen:

The controller tagname screen allows the user to select a control typefor each drop on the Orion network (single setpoint or profiler controller) and alsoenter unique a tagname,alarm messages, eng units and decimal postion for each controller.Press the “Tagname” and alarm message fields to display a pop-up text entry dialog.

Important Note: 300 series single setpoint controllers must always be set to a decimal positionof “1” at the controller level (This is due to the unique “Auto-scaling” feature for values above 1000units). You can set the decimal position on the above screen for 0 or 1 decimal places andthe Orion interface will display the proper value during runtime operations. On 300 series profilecontrollers, you can set the decimal position for 0 or 1 at the controller level but the Orion decimalsetup on the above screen must match the setting at the controller for proper display during runtimeoperations.

Orion Enable\Disable Views Screen:

The Orion configurator provides a powerful feature that allows a system integratoror OEM to enable or disable any of the views in the Orion runtime. The provides theability to “lock out” any menu item(s) or screen(s) in the Orion runtime system. If a menu itemis disabled at the configurator, the item will be “grayed” out when the Orion runtimeis started. This provides the integrator or OEM the ability to customize the Orion system forspecific needs while disabling functions the end user might not require.

Checking a box for an item enables the feature in the Orion runtime. If the checkbox isnot checked, the feature is disabled in the Orion runtime.

IMPORTANT NOTE: If you disable the “Exit Program” function in this section, the user will not beable to quit the program! This is to make sure that Orion always boots at runtime and cannot bestopped by any user. This also protects valuable data that Orion collects. It’s kind of like your“Windows” password, if you lose it, you must order a new smart card from Future Design Controls.


Orion Customer Name\Address Screen:

The customize Name\Address screen provides the user with the ability to enter companyname, address and phone information for the Orion runtime. This informationis displayed each time the Orion runtime is started. Press each field todisplay a pop-up text entry dialog.

Exit the Orion Configurator:

From the file menu select “Exit”. Orion will advise the user that during the next power-up, theOrion runtime software will start automatically. To make Orion easy to use, each time a userexits the configurator and re-powers the Orion system, the Orion runtime software will auto-boot.This shields the end user from navigating directories to find the correct application to run.

The Orion runtime gives the user the ability to quit the Orion runtime application,(with proper security access if enabled) and enter the configurator or Orion runtime on thenext power-up of the Orion system.


Orion (Main View) Runtime Menus:

The Orion runtime menu system provides a familiar, easy to use interface while reducing screen “clutter” byeliminating extra buttons required for navigation. Each series of interface screens will have their ownseries of menus specifically focused on the tasks for the specific screen.

Shown above are the “top” level menus when the Orion runtime first loads.

View Menu:

The “Views” menu provides navigation to all standard view screens. These include loop view, bargraph,trend and profile run operation screens.

Recipes Menu:

The Recipes menu provides access to profile or single setpoint screens. From these screens a usercan open, save, edit or delete as well as download recipes to the 300 series controllers/profilers.

Setup Menu:

The setup menu provides access to system and controller setup options. System security setup isalso accessed from the “Setup” menu.

Alarms Menu:

The alarm menu provides access to current alarm values and the historical alarm viewer. Up to 40current alarms are monitored in the real time alarm window. The history alarm viewer allows the userto review alarm history from any day, for up to 1 year of previous alarm history.

Data Menu:

The data menu provides access to data log functions and the historical data viewer.

Note: The help menu is not show in the above menu layout. A “Help” menu exists for every screenin the Orion runtime.

Data Views:


Single loop View:

The single loop view displays the controllers PV, SP and %Out. Pressing the setpoint value displays anumeric keypad so the control setpoint can be changed. The left and right arrow keys on the controllerfaceplate allow the user to scroll to the next or previous controller connected to the link. The legend atthe bottom of the faceplate displays the unique tagname for the controller. During an alarm condition thescreen background will turn red to indicate to the user that an alarm exists in the system.

Dual loop View:

The dual loop view displays faceplates for dual loop operation. Interface with each loop is the same as thesingle loop interface screen.

Overview View:

The Overview view displays all controllers connected to Orion in one easy to read screen. This screen will“Self Configure” based on the number of controllers specified in the Orion configurator. PV, SP & %Out foreach loop is displayed. Pressing on the “Tagname” column selects the controller for setpoint edit. The fieldat the lower right of the screen provides a means to change the selected controllers setpoint.

Bargraphs View:


The Bargraphs view displays PV, SP & %Out bargraphs for each loop connected to the Orion link. Hi\Lowbar limits are adjustable for each loop. Pressing the next and previous keys allow the user to scroll frowardor backwards through each loop.

Overview View:

The real time trend view displays PV, SP & %Out trends for each loop connected to the Orion link. Trendzero, span and time are adjustable for each trend. Pressing the next and previous keys allow the user toscroll froward or backwards through each control trend.

Trend Setup:

Each real time trend is adjustable for zero, span and trend time in minutes. Each Orion trend stores up to 4hours of data for each loop so trend times can range from 10 minutes to 4 hours.Each time a trend setup is changed, Orion will fill the trend with previous history and then operate in “realtime” mode with the current time settings.

Profile Run View:


The Profile Run view displays PV and SP for each profile controller connected to the Orion link. Buttons forStart, Hold and Stop profile allow the user to operate each profiler from the Orion interface. Currentsegment running for the each profiler is displayed. Pressing the next and previous keys allow the user toscroll froward or backwards only through profilers connected to the Orion link. The current loaded profile foreach 300 series profiler on the link will be displayed at the bottom of the profile run screen. This allows theoperator’s to run several different profile applications and keep track of what profile is currently running onwhich loop.

In dual profile mode operation (must be set in Orion configurator), the profile run screen displays dual loopinformation on the screen (PV and SP for both loops). Start, hold and stop operations will control loops 1and 2 simultaneously. This allows users to interface dual profile operations with a single interface screen.If there are no profiler’s attached to the Orion link, the user can not access this screen.

Alarm View Screen:

The Alarm view displays all loops that are currently in alarm. Any time a controller goes into alarm thebackground on all view screens will turn red until the alarm is acknowledged. When an alarm isacknowledged, the backgrounds will return to their normal color but the alarm will stay in the alarm grid. Thealarm will only leave the grid when cleared by an operator. Only alarms that are not currently active can becleared from the alarm grid.

Alarm History Screen:


The Alarm history view displays all alarms for any daily period for up to one year. Each time an alarm isactive in Orion system, the alarm is written to a history file. History filenames are listed as month_day_year.The history alarm grid displays alarm type, date and time for each alarm.

The “Open File” button will display an “open” dialog box where the user can select any alarm history file toview.

Recipes:

The “Recipes” menu from Orion’s main menu structure provides access to the profile section ofOrion.

Profile Recipes:

The profile entry “Edit” menu provides the following functions:

New Profile: Clear all entries for new recipe generation.Copy Segment: Copy current segment data.Paste Segment: Paste current segment data.Open Profile: Open a profile for view, edit or download.Save Profile: Save current profile.Save Profile As: Save current profile under a different name.Delete Profile: Delete currently loaded profile.

The Profile section “Views” menu provide the following functions:


Main View: Returns Orion to single loop view screen.Profile Entry: Display Orion profile entry screen.Profile Plot: Display Orion profile plot screen.Profile Download: Display Orion profile download screen.

Profile Entry Screen:

The profile entry screen provides the user with the ability to enter profiles with up to 8 segments per profile.Each segment consists of a ramp and a soak with adjustable time settings for each, in hours and minutes.The left/right arrows provide navigation for next and previous segment entries. Hundreds of profiles can besaved directly to Orion’s memory card for later retrieval or download to any profiler attached to the Orionlink. Press the segment fields to display a numeric entry box for segment value entries.

Profile Plot Screen:

The profile plot screen will trend the current profile (profile that is currently open or being edited). Both Xand Y-axis values will auto-scale to the highest values for each axis. The time axis will plot the total time inminutes for the complete profile. Press the “Plot Profile” button to enable plotting of the current profile.

Profile Download Screen:


The profile download screen will download the current profile to any profile controller attached to the Orionlink. The bottom status bar will show the currently loaded profile. Profiles must be saved (if edited) beforeOrion will allow download to any controller. In dual loop profile mode, Orion will download the current profileto control addresses 1 and 2 on the Orion link for dual loop profile operation.If there are no profiler’s attached to the Orion link, the user can not access this screen.

Single Setpoint Recipes:

The “Recipes” menu from Orion’s main menu structure provides access to the single setpoint recipesection of Orion.

The Single Setpoint Recipe “Edit” menu provides the following functions:

New Recipe: Loads a new recipe and fills list will controller entries for all controls on link.Open Recipe: Open a recipe for view, edit or download.Save Recipe: Save current recipe.Save Recipe As: Save current recipe under a different name.Delete Recipe: Delete currently loaded recipe.

The Single Setpoint Recipe “Download” menu provides the following functions:


Download Setpoints Only: Download Setpoint data only to the controllers on the Orion link.

Download PID Only: Download PID data only to the controllers on the Orion link.

Download SP and PID: Download Setpoint and PID data to the controllers on the Orion link.

Single Setpoint Recipe Entry Screen:

The single setpoint recipe screen provides the user with the ability to edit, open, store and download singlesetpoint recipes to any group of controllers on the Orion link. Single setpoint recipes are used to set all (orany group) of controls to predetermined setpoints with a single menu item.

Use the “on/off" checkbox to select the control for recipe download. If the checkbox is not selected,the setpoint value will not be written to the controller. When the “document” icon is pressed (to the right ofthe on/off checkbox), the values for setpoint, P, I and D are loaded in the fields at the bottom of the screen.Press the fields to make entries for each value and then press “Accept” key to enter the values. After the“Accept” button is pressed, the list item for the controller activated will be updated with the new settings.Repeat the process for each control that should be included in the current setpoint recipe.

Setup:


The “Setup” menu from Orion’s main menu structure provides access to the setup section of Orion.

The Setup Screen “Edit” menu provides the following functions:

Open Tune File: Open a tuning for view, edit or download.Save Tune File: Save current tuning file.Save As..: Save tuning file under a different name.Delete Tune File: Delete currently loaded tuning file.

The Setup Screen “Setup” menu provides the following functions:

Faceplate Options: Set various faceplate options for loop views.Limits\Units: Set upper/lower limits for setpoint adjust for each loop.Controller Tuning: Adjust tuning values for each loop.Alarm Setpoints: Adjust alarm setpoints for each loop.System Security: Enable/disable system security settings.USB\Touch Calibration: USB connect and touch screen calibration.Exit Application: Exit Orion application.

Faceplate Options:


Faceplate options allow the user to customize the loop view screens of Orion. AutoScroll forces the loopdisplays to scroll automatically through all loops every 4 seconds. When AutoScroll is enabled, setpointscan not be changed from the loop view screens. The user can select which variable to display on thefaceplates by selecting PV, SP or %Out from the checkbox selection on the screen.

Setpoint Limits:

Setpoint limits for all loops are adjustable by pressing the limit fields and entering a new value. Make surethe limits set at the Orion interface do not exceed the limits programmed directly at the controller level. Anerror will occur if this condition exists and the user writes an “out of range” setpoint value to a controllerattached to the Orion link. Press the “Set Limits” button after low/hi limits for all loops are set. It is importantto press the “Set Limits” button to write the values to memory for power-up operation.New settings will not take effect until the “Set Limits” button is pressed.

Controller Tuning:

Tuning values for PB, reset and rate can be adjusted from the Orion interface. Tuning files can be opened,saved and downloaded to any control attached to the Orion link. Press the tuning fields to adjust the desiredtuning parameter. Press the “AT” button to enable auto tune on any 300 series single setpoint controllerattached to the Orion link. Tuning files can be opened, saved or downloaded directly from the “Edit” menu.

Alarm Setpoints:


Alarm setpoint values for Alarm 1 and 2 can be set from the Orion interface. These alarms are programmeddirectly at the controller for hi-low/deviation operation. If the alarm is programmed at the controller for hi-lowoperation, adjust the AL#1 and Al#2 setpoint fields. If the alarm is programmed at the controller for deviationoperation, adjust the AL#1 and AL#2 deviation setpoint fields. The setpoint limits for the alarm fields trackthe same values that were set for the setpoint fields under the “Limits\Units” section of the Orion interface.

System Security:

Orion provides system security settings for all levels of the interface. Password entry is required toenable/change security settings. The default password when Orion is shipped is “1234”. Once the securitysection is entered, the user can change the password as well as enable\disable security options in anysection of the interface.

Security Settings:


Orion provides advance security options for all levels of the interface. Press the “New password” field toenter a new password for security access. Check the “Enable Security” button to enable Orion’s securitysystem. Check each item in the list box if you want the user to have access to the specific Orion feature. Ifthe item is not checked, Orion will display a message that the function is not accessible due to securitysettings.

Check the “AutoLog On Startup” button if you want Orion to automatically start logging data at power-up.This ensures that data logging will start after a power-down event.

Press the “Accept” button after all settings have been made. It is important to press the “Accept” button towrite the values to memory for power-up operation. New settings will not take effect until the “Accept” buttonis pressed.

USB\Touch Calibration:

Orion provides the ability to calibrate the touch screen as well as copy data files directly from the Orioninterface. The compact flash card does not need to be removed to access data files.

To calibrate the touch screen:

Press the “Calibrate Touch” button. A “System Settings” dialog will appear with several tabs on theWindows dialog box. Press the “Calibrate” button on the first tab. Follow the onscreen instruction tocalibrate the touch screen by holding a stylus or finger on the crosshair, until the cross hair moves to thenew 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”. Pressthe screen to finalize the calibration.

There are other tabs on the “System Settings” dialog. Pressing the right arrow will scroll through the tabs.The tabs are as follows:

“LCD Settings” allows the user the turn off the backlight after a predetermined number of minutes. Thisacts as a screen saver and will prolong the display life of Orion (40,000 hours under normal conditions).

“MAC Address” Do not make changes or modify this tab.


“Save” Since Orion is an embedded device (no hard disk or moving parts), changes to touch screencalibration and LCD settings need to be saved to the Windows registry. Press the “Save Registry” buttonunder the “Save” tab after touch screen and LCD setting have been made.

“System Verison” Displays the current system version.

“Set Serial Port” Do not make changes or modify this tab. Changes to this tab will stop Orion fromcommunicating to controllers on the Orion link.

Important Note: Make sure to close the “System Settings” dialog by pressing the “OK” or “X”. Orionwill not restart runtime operations until the “System Settings” dialog box is closed. After the“System Settings” dialog closes, Orion will display a message that the interface will resume normaloperations. Press Ok to resume normal operation.

Orion data file transfer via USB port:

Orion allows users to transfer files from the compact flash card to a laptop or desktop PC via a standardUSB connection. You must first install the Orion USB driver on your computer so the computer recognizesthe Orion USB device. You can download the USB driver from www.futuredesigncontrols.com. Under the“Products” page, follow the Orion link for download. Unzip the USB driver to a directory on the computerhard disk. The first time Orion is plugged into the computer (via USB connection), Windows will recognizethat a new USB device has been connected. Point to the unpacked zip directory when Windows requeststhe location of the USB driver for the new device.

Microsoft “ActiveSync 3.7” needs to be installed on the computer or Orion will not connect. “ActiveSync 3.7”is available from the Microsoft web site at no charge. “ActiveSync” is the software used to connect handheld“PocketPC” devices to laptop or desktop computers.

After “ActiveSync” is installed on your PC, connect a USB cable to from the PC to the Orion host port on theback of the unit (See specification and drawings section for details). You will need a standard USB (Masterto host) cable available from any computer store.

After the USB cable is connected, press the “Connect to USB” button on the Orion interface. The Orioninterface will stop all runtime operations and display a connect dialog. The connection is automatic and thefollowing dialog will be displayed at the laptop or desktop computer.

* “ActiveSync”, “PocketPC” and “CE.Net “ are trademarks of the Microsoft Corporation.


Select “No” and press the “Next” button. ActiveSync will display the following dialog box on thelaptop or desktop PC. Press the “Explore” button on the toolbar to bring up the main ActiveSync

device viewer:

Double click on “My Computer” to access Orion’s directory structure:


Double click on “Storage Card” to access Orion data:

Orion Directory structure is shown below

A quick note about data and setup files. Data and setup files (Profiles, recipes and tuning files) needsome maintenance every now and then. After a period of time, storage cards fill up and files require abackup, to be moved or deleted if no longer needed. We are providing the directory structure for Orion filesfor this reason. The only files that should be moved, copied or deleted are files inside the “Data Files”,“Recipes”, “Profiles” and “Tuning” directories. All other directories shown above (and the files in them) aremodified and used by the Orion interface. Any change to these directories (renaming directories or movingfiles) will cause the Orion interface to stop operating. Never move or delete the directories listed above, onlythe files inside of them. Orion will not work if any of the above directories are move or deleted.

Please take care in backing up or deleting data files for this reason.


The “Data Files” directory holds all of Orion’s data files. These data files are in a “.csv” format and can beopened directly with Microsoft Excel or any program that opens a comma separated file format. You cancopy or empty the “Data Files” directory using standard “Windows” operations from the laptop or desktopPC.

The “Profiles”, “Recipes” and “Tuning” directories hold all setup files created by the user from the Orioninterface. You can copy or empty these directories using standard “Windows” operations from the laptop ordesktop PC.

Warning: Once files are deleted from the Orion storage card, they are gone and can not be retrieved.Once again, Do not edit, move or delete any other files or directories not listed in the aboveparagraph. Orion will not operate properly if you do so.

When you are finished transferring data files from Orion to the laptop or desktop PC, unplug the USB cablefrom the PC or Orion interface. Orion will sense that the USB connection has been terminated and display adialog that the Orion runtime will now continue. Press “OK” at the Orion interface.

Note: Connecting Orion to a laptop or destop PC is an offline operation. The Orion interface will notlog data or alarms during this condition.

Exit Application:

The Exit Orion screen allows the user to quit the Orion runtime software and return to the CE.Net operatingsystem. This operation is not recommend with the exception of users who are in charge of configuration ofthe system, due to the danger of editing or removing files by accident. Since Orion can auto-start either theruntime or configuration system on power-up, make the appropriate choice and Orion will exit to the CE.Netoperating system. On the next power-up, Orion will boot the selected configuration.


Data Logging:

The “Data” menu from Orion’s main menu structure provides access to the data logging section ofOrion.

The Datalog “Edit” menu provides the following functions:

.Open History File: Open a history file for review.Delete History File: Allows the user to delete the currently loaded history file.

The “Delete History File” function does not affect the currently running data file, only thecurrent history file loaded for review.

The Datalog “DataLogging” menu provides the following functions:

Start/Stop Logging: Main “System Data Logging” screen (above) is shown.Select Points For Logging: selection for system points written to log file.Hist Plot Time Setup: Selection of time frame for history review.Hist Plot Channel Setup: Selection of data file points for history review.Plot History Data: Plots historical data after time and point are selected.


Data logging:

Orion will log data to it’s internal compact flash card for a period of 1 year (for 15 controllers or less attachedto the link). Current data for each controller is written to the log at a fixed interval of 1-minute (1440 readingsper day). If the data logger is left running on a 24-hour basis, a new file will be generated automatically eachday at 12:00:00 AM.

The main system data logging screen is used to start or stop the logger and also add a file prefix to the filename. File names are automatically generated using m_d_y_h_m_s format (file prefix is entered before thedate/time stamp if the user enters one).

The main logging screen will display the current data file name if system logging is enabled as well as thecurrently loaded file name (on the bottom status bar) if a historical file is loaded. To start the log, press the“Logging On” button (controller variables must be assigned first by selecting the “Select Points For Logging”menu item). Any time logging is enabled, the “Logging On” button will be green.

Select Points For Logging:

The select points for logging screen allows the user to select any point(s) from the system for data logging.“Select All” and “Clear All” buttons provide a quick way to select or deselect all points in the system.Use the checkbox to enable/disable a point for logging. When completed, press the “Accept” key to writethe point selection to memory. This is important so the Orion system saves the settings for power-upoperation. New settings will not take effect until the “Accept” button is pressed.


Hist Plot Time Setup:

The History Plot Setup allows the user to select any time frame (zoom in/out) to view historical data. Ahistorical data file must be loaded (using the Edit\Open History File menu item) before data can be plotted.The History Plot Setup screen displays the start and end time for the currently loaded file in hours andminutes (24-hour clock). Press the start\end plot fields to select a time span for historical viewing. Orion willalert the user if the selected time frame is outside of the data file limits or if end plot time is before the startplot time. The minimum time for plotting data is 6 minutes.

Hist Plot Channel Setup:

The History Plot Channel Setup allows the user to plot up to 8 channels of data simultaneously. Any pointfrom the data file can be selected along with the color for each channel to be plotted. Use the drop downboxes to select a channel for the plot and the color for the channel. Press the “Add Point” button to add thepoint to the current list of historical plot channels. The “Clear All” button will clear the list of all points so anew group can be added for plotting.


Plot History Data:

The “Plot Historical Data” screen plots the data from the currently opened history file. If a file has not beenopened or data points have not been assigned to a plot, Orion will alert the user to correct the problem. Xand Y axis scales are set to “auto-scale” based on current values for each plot so no user interface isrequired.


Troubleshooting the System

My system is not working:

Most of the settings for Orion are fixed to make system setup easier.

If the system is not communicating here are some tips to get it going.

First, the system baud rate is set and cannot be adjusted. This baud rate value is fixed becauseonly FDC 300 series controllers can operate on the Orion link.

The software is also fixed for communication port 3. This is a RS485 portthat connects directly to FDC 300 series controller through a simple 2 wirenetwork.

By fixing the baud rate and port configuration we take 2 of the mostcommon problems out of the system. If you have the controller programmedfor a unique address and a baud rate of 9.6KB , your half way there.(see section on “Setting up the Controllers”)

Here are a few things to check:

1. Is the RS485 network wired to match the drawing on page 6 of this manual?2. Are all controllers on the link setup for the proper address and baud rate per page 7 of this manual?3. Does each controller on the network have a unique address programmed starting at address #1?4. Is the Orion compact flash card installed in Orion’s compact flash slot and seated securely?5. Is the compact flash card installed correctly? The card holder is keyed so it’s pretty hard to install

the card improperly but worth checking anyway.6. Do you have the proper number of controllers and the correct type for each address programmed at the

Orion configuration software? Selecting a 300 series profiler for address #1 when a 300 series singlesetpoint controller is actually attached at address 1 will cause Orion to report communication errors.

7. Setting the configuration software for more addresses than are actually on the link will create the sameproblem since Orion is trying to communicate with controllers that are not physically on the link.

8. Is your first controller on the link programmed at address #1. It really does not matter in what order youput the addresses in, just so one of the controllers starts at address 1 and ends with the last address toequal the number of the controllers on the link.

9. When calibrating the touch screen, A “System Settings” tabbed dialog is displayed. One of the dialogtabs that is not supposed to edited is “Set Serial Port”. This setting changes the communications typefor the Orion system to FDC controllers. Do not make changes or modify this tab. Changes to thistab will stop Orion from communicating to controllers on the Orion link. The tab default should be set for“RS485-2wire”.

Software Usage Note:

The selection, application or use of Future Design products or software is the purchaser or user'sresponsibility. No claims will be allowed for any damages or losses, whether direct, indirect,incidental, special or consequential.

In addition, Future Design reserves the right to make changes without notification to purchaser oruser to materials or processing that do not affect compliance with any applicable specification.Future Design Controls makes no warranties when using Future Design’s Orion system.


Orion interface specifications (5.7” STN display):

Power24VDC - 500mA maximum current draw.

Display:Display Type: STN Color LCDDisplay Size: 5.7 ÒMax Colors: 4096Resolution: 320 X 240Pixel pitch (HxV,mm): 0.36 X 0.36Luminance(cd/m2 ): 100Storage Temp (C): -20 to 60Operating Temp (C): 0 to 45Backlight: 1 CCFLContrast Ration: 30:1Backlight life: Approx 40,000 hours

TouchScreen:Type: 4 wire, analog resistiveResolution: ContinuousLight transmission: above 80%Life: 1 million activation minimal

Processor:Type: Intel Xscale PXA255 200Mhz

Memory and OS:Memory: 64MB of internal RAMOperating System: Windows CE.net

Loop Interface:Type: 300 series control/RS485 multi-drop interfaceMax Loops: 20

Data Storage:Type: 128 Mb compact flash

Connections:Serial: Com1, 2 & 3 - RS232/RS485Ethernet: 10 baseTUSB: 1 client - 2 hostSound: 16 bit sound output

Physical:Front Panel: Meets Nema4/IP65Shock: 10 to 25Hz (X,Y,Z direction 2G, 30 mins)Dimensions: 204Ó (H) x 150Ó (W) x 48Ó (D) - mmWeight: 28.21.0 oz. (0.8 kg)


Orion interface ports (RS485, USB and Ethernet)

Note: Orion only uses the wiring for RS485 communications. Pins 4 and 5 on DB9connector. Do not use or attach any of the other pins on this connector. See page 6for controller wiring to the Orion interface.


Orion Drawings:

P.O Box 1196 * 7524 BridgeView, ILL 60455 * Phone: 888.751.5444 - Fax 888.245.2883

Documents

ORION L Manual - Future Design Controls docs/Orion_manv1_1.pdfFDC-Orion-L Manual 6-17-20004 - Rev 1.1 Page 3 What is Orion: Orion is an embedded SCADA and control interface system