DCP552 Mark ΙΙ Digital Control Programmer User’s Manual EN1I-6187 Issue 5 (12/01)
WARRANTY The Honeywell device described herein has been manufactured and tested for corrent operation and is warranted for a period of one year. TECHNICAL ASSISTANCE If you encounter a problem with your unit, please review all the configuration data to verify that your selections are consistent with your application; (i.e. Inputs, Outputs, Alarms, Limits, etc.). If the problem persists after checking the above parameters, you can get technical assistance by calling the following: In the U.S.A.
Unpacking Check the following when removing the DCP552 from its package. 1. Check the model No. to make sure that you have received the product that you ordered. 2. Check the DCP552 for any apparent physical damage. 3. Check the contents of the package against the Package List to make sure that all accessories are included in the package. After unpacking, handle the DCP552 and its accessories taking care to prevent damage or loss of parts.
Configuration of This User’s Manual This manual is organized as follows. Chapter 1. PRODUCT OUTLINE This chapter explains the use and features of the DCP552 and provides the basic function block and product model numbers. Chapter 2. NAMES AND FUNCTIONS OF PARTS This chapter gives the names and functions of parts of the DCP552, and input type and range number. Chapter 3. INSTALLATION AND MOUNTINGS This chapter describes the procedure for mounting the DCP552 onto an operation console.
Contents Unpacking Configuration of This User’s Manual Conventions Used in This Manual Chapter 1.
4-6 PV Input (Analog Input) Connection • • • • • • • • • • • • ■ PV input CH1 connection • • • • • • • • • • • • • • • • • ■ PV input CH2 connection • • • • • • • • • • • • • • • • • 4-7 Control Output Connection • • • • • • • • • • • • • • • • • • 4-8 Auxiliary Output Connection • • • • • • • • • • • • • • • • • ■ Auxiliary Output CH1 Connection • • • • • • • • • • • ■ Auxiliary Output CH2 Connection • • • • • • • • • • • 4-9 Event Output (Open Collector Output) Connection • 4-10 External Switch Input Conn
Chapter 6.
■ Setting G.
■ Self-diagnostic routines performed each sampling cycle • • • • • • • • ■ Self-diagnostic routines performed continuously during operation ■ Alarm code display • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ■ Alarm classification • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 10-2 Key Input Related Problems • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ■ Normal display mode problems • • • • • • • • • • • • • • • • • • • • • • • • • • ■ Parameter
Conventions Used in This Manual The following conventions are used in this manual. Handling Precautions : Handling Precautions indicate items that the user should pay attention to when handling the DCP552. NOTE : Notes indicate useful information that the user might benefit by knowing. (1)(2)(3) : The numbers with the parenthesis indicate steps in a sequence or indicate corresponding parts in an explanation. >> : Controller state after an operation DISP key, ↑ key : Indicate the DCP552 keys.
Chapter 1. 1 - 1 PRODUCT OUTLINE Features The DCP552 is a general purpose dual-loop control programmer for controlling temperature, pressure, flow rate, carbon potential (CP) and other parameters. The program provides a total of 49 patterns and up to 99 segments can be set for each pattern. Note, however, that the maximum number of segments is 2000 or less and that the maximum number of subfunctions for setting events is 4000 or less.
Chapter 1.
Chapter 1. PRODUCT OUTLINE 1 - 3 Data Configuration Overview Data is comprised of parameters and the program. Parameters are used to set the functions of the DCP552 while the program is the software that operates the controller at run time. ● A total of 49 patterns It will store up to 49 programs per channel (CH1 and CH2), with up to 99 segments per program.
Chapter 1. PRODUCT OUTLINE 1 - 4 System Configuration ■ CPL communications network-based configuration Models equipped with the optional communications interface can be connected as a slaved controller to a communications network. In this case, the user can employ as the master station a personal Computer.
Chapter 1.
Chapter 2. 2 - 1 NAMES AND FUNCTIONS OF PARTS Structure The DCP552 consists of a main unit, console, case, and terminal base. Console Provides 7-segment displays, LEDs, operation keys, and a loader interface unit. Case Terminal cover Covers power supply and prevents electric shock. Terminal base Provides terminals to connect a power supply, input, output, event output, external switch input, and auxiliary output (optional) , etc. Main unit Console and electric circuit board, etc.
Chapter 2. NAMES AND FUNCTIONS OF PARTS 2 - 2 Console The console consists of the operation keys, displays and LEDs (light emitting diodes). ■ Basic display status Basic display status shows the running condition of the DCP552 on the console. The basic display status is invoked when the DCP552 is powered up (power on).
Chapter 2. NAMES AND FUNCTIONS OF PARTS ● Display panel 1 Indicates PV and other data in basic display status. Indicates item codes in parameter setting status. Indicates set values and item codes in program setting status. ● Display panel 2 Indicates SP, time, output and other data in basic display status. Indicates set values in parameter setting status. Indicates set values in program setting status.
Chapter 2. NAMES AND FUNCTIONS OF PARTS ■ Key pad CAUTION Do not use pointed objects such as mechanical pencils or pins to press the keys on the controller. This may result in malfunction.
Chapter 2.
Chapter 2.
Chapter 2. NAMES AND FUNCTIONS OF PARTS FUNC + DISP : Display channel select key Press the DISP key while holding down the FUNC key in basic display status to select display channels. In the program setting status, press the DISP key while holding down the FUNC key to select the channel of the program to be set. FUNC + PARA : Event configuration setting key Press the PARA key while holding down the FUNC key in basic status display to switch to the event configuration setting status.
Chapter 2. NAMES AND FUNCTIONS OF PARTS 2 - 3 Input Type and Range Number ■ Input ● Thermocouple Input type Symbol Code Input range (FS) ˚C Range No. Accuracy (under standard conditions) ˚F K (CA) K46 16 K (CA) K09 0 K (CA) K08 1 0.0 to 800.0 0 to 1600 ±0.1%FS K (CA) E (CRC) K04 E08 2 3 0.0 to 400.0 0.0 to 800.0 0 to 750 0 to 1800 ±0.1%FS ±0.1%FS J (IC) T (CC) B (PR30-6) J08 T44 B18 4 5 6 0.0 to 800.0 -200.0 to +300.0 0.0 to 1800.0 0 to 1600 -300 to +700 0 to 3300 ±0.1%FS ±0.
Chapter 2. NAMES AND FUNCTIONS OF PARTS ● DC current, DC voltage Input type Symbol Code Accuracy (under standard conditions) Input range (FS) Range No. mA (Linear) C01 Z51 48 52 4 to 20mA 2.4 to 20mA mV (Linear) M01 49 0 to 10mV L02 50 51 -10 to +10mV 0 to 100mV ±0.1%FS ±0.1%FS mA C01 128 4 to 20mA ±0.1%FS (Linear) V Z51 134 129 2.4 to 20mA 0 to 1V ±0.1%FS ±0.
Chapter 3. 3 - 1 INSTALLATION AND MOUNTING Before Installation WARNING Be sure to turn off the power supply when you are installing or removing the controller. Failure to heed this warning may lead to electric shock. Do not disassemble the controller as this could lead to electric shock or malfunction. CAUTION Be sure to follow the operating requirements (regarding temperature, humidity, voltage, vibration, shock, mounting direction, atmosphere, etc.) as stated in the specifications of the controller.
Chapter 3. INSTALLATION AND MOUNTING ■ Sources of electrical interference and countermeasures •The following list notes common sources of electrical interference.
Chapter 3. INSTALLATION AND MOUNTING 3 - 2 Installation This section describes installation procedures. ■ Panel cutout dimension Use 2mm thick steel panels in setting up the DCP552. Unit : mm 450 or more 138 +1 0 138 +1 0 200 or more Handling Precautions Install the DCP552 in a location where the lower panel is not exposed to temperatures that exceed the operating temperature range (0 to 50°C). Make sure that the temperatures above and below the controller meet specified requirements.
Chapter 3. INSTALLATION AND MOUNTING ■ Installation procedures Mounting bracket Mounting (2) Mounting (1) Mounting bracket •Use the provided mounting bracket to firmly secure the upper and lower panels. •Assemble the instrument before mounting (1). Handling Precautions When the provided mounting brackets are firmly secured and there is no looseness, turn the screws only one full turn. Over-tightening the screws of the brackets can deform or damage the case.
Chapter 4. 4 - 1 WIRING Precautions on Wiring WARNING Connect the FG terminal to ground with a ground resistance of maximum 100Ω before connecting other equipment and external control circuits. Failure to do so may cause electric shock or fire. Be sure to turn off the power supply when you connect the controller. Failure to do so may lead to electric shock or fire. Do not touch a live part such as a power terminal. This may result in electric shock.
Chapter 4. WIRING Handling Precautions •Before connecting the lines, verify the model number and terminal numbers on the label affixed to the side panel of the DCP552. After completing, always double check to ensure all wiring has been performed correctly before turning on the power. •The I/O signal lines and the communications lines shall maintain at least 50cm between them and the power supply line and power supply cables. Do not route these cables through the same conduit or duct.
Chapter 4. WIRING 4 - 2 Recommended Cables To perform thermocouple input, connect a thermocouple element to the terminals. When the wiring distance is long or when connecting the thermocouple without the element to the terminals, connect via shielded compensating lead wires. NOTE •For I/O other than thermocouple, use polyethylene insulated vinyl sheathed cable for JCS-364 shielded instruments or equivalent. (general name: twisted shielded cable for instrument use) The following cables are recommended.
Chapter 4. WIRING 4 - 3 Making Terminal Connections Unit : mm 7.3 or less 7.4 To connect a line to the terminals, use crimp-style solderless wire connectors that fit an M3.5 screw. 6.6 or less ¿3.7 Handling Precautions •If the DCP552 is mounted in a location subject to noticeable vibration or impact, be sure to use round crimp-style solderless wire connectors to prevent lines from becoming disconnected from the terminals.
Chapter 4. WIRING 4 - 4 Terminal Array Wires are connected to the terminal base according to the layout shown below. DI DO 1 COM1 DI 9 11 13 15 COM2 12 25 29 33 37 5 10 12 14 16 2 1 13 6 3 2 7 14 3 15 4 8 4 16 5 5 17 2 6 6 18 3 7 4 7 19 8 8 DO COM1 9 9 10 11 20 22 26 30 11 12 DO COM2 13 14 15 16 23 31 OUT + 43 — + 44 45 OUT1 B C T/C mV.
Chapter 4. WIRING 4 - 5 Power Supply and Grounding ■ Power supply To supply power to the DCP552, use an instrument-dedicated single-phase power supply subject to minimal electrical interference.
Chapter 4. WIRING 4 - 6 PV Input (Analog Input) Connection CAUTION Current applied to current input terminals (55), (56) and (58), (59) must meet the specified range. Failure to heed this caution may lead to fire or equipment breakdown. ■ PV input CH1 connection PV input CH1 is a multi-input type input for sensors. Connect as shown below, according to the type of sensor being used.
Chapter 4. WIRING Handling Precautions •Be careful to connect the input polarities correctly. •Use shielded cable to connect the input.
Chapter 4. WIRING 4 - 7 Control Output Connection WARNING Be sure to turn off the power supply when you are installing or removing the controller. Failure to do so may cause electric shock or fire.
Chapter 4. WIRING 4 - 8 Auxiliary Output Connection WARNING Be sure to turn off the power supply when you connect the controller. Failure to do so may lead to electric shock or fire.
Chapter 4. WIRING 4 - 9 Event Output (Open Collector Output) Connection EV1 EV2 EV3 EV4 EV5 EV6 EV7 EV8 Load Load 8 Load Load 7 Load Load 6 Load Load 5 + — 17 18 19 20 9 External power supply 12 to 24V DC Max. load current : 70mA/point Max. common current : 500mA Leakage current when OFF : less than 0.1mA EV9 EV10 EV11 EV12 EV13 EV14 EV15 EV16 Load Load Load Load Load Load Load Load + — 10 11 22 23 27 28 31 32 24 External power supply 12 to 24V DC Max.
Chapter 4. WIRING 4 - 10 External Switch Input Connection 1 2 3 ADV RESET HOLD RUN SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 4 13 14 15 16 12 SW9 SW10 SW11 SW12 SW13 SW14 SW15 SW16 : With BCD 1 2 4 8 10 CH1 CH2 20cancel cancel 25 26 29 30 33 34 37 38 41 ● Internal circuit diagram of the DCP552 connecting external switch input 8.5V DC 8.5V DC Internal circuit Handling Precautions • The inputs of the DCP552 unit are provided with a built-in power supply (open voltage type, 8.5V DC).
Chapter 4. WIRING 4 - 11 Communication Connection ■ RS-485 connection SDA SDB RDA RDB SG 60 61 62 63 64 Handling Precautions • The slave station can be connected in a multi-drop configuration. • Always set a unique address to each slave station. • Attach terminating resistances (a total of four when connecting a 5-wire system) to the ends of the communications lines. Use 1/2W or greater terminating resistances of 150Ω ±5%.
Chapter 4. WIRING ● 5-wire system RS-485 connection diagram Slave station side DCP552 Terminating resistor 60 61 Terminating resistor 62 63 64 SDA SDB RDA RDB SG FG Shield Master station RDA RDB SDA SDB SG FG Shield Slave station side DCP552 60 61 62 63 64 SDA SDB RDA RDB SG FG Shield Slave station side DCP552 60 Terminating resistor Terminating resistor 61 62 SDA SDB RDA 63 RDB SG 64 FG Attach 1/2W or greater terminating resistances of 150Ω ±5% at each end of the communications lines.
Chapter 4. WIRING ● 3-wire system RS-485 connection diagram Slave station side DCP552 60 Terminating resistor 61 62 63 64 SDA SDB RDA RDB SG FG Master station Shield RDA RDB SDA SDB * * SG FG Shield Slave station side DCP552 60 61 62 63 64 SDA SDB RDA RDB SG FG Shield Slave station side DCP552 60 Terminating resistor 61 62 63 64 SDA SDB RDA RDB SG FG Attach 1/2W or greater terminating resistances of 150Ω ±5% at each end of the communications lines.
Chapter 4. WIRING ■ RS-232C connection Example of connection using SD RD SG 8 7 6 4 5 63 64 3 2 1 61 CTS RTS DSR GND DTR TxD RxD DCD Host computer (master station) Handling Precautions • Connect the slave station to the master station in a single-drop (point-topoint) configuration. • There are three (SD, RD and FG) communications terminals on the RS232C interface on the master station which may not output data if not short-circuited as shown above.
Chapter 4. WIRING ■ Connection to ST221 SDA SDB RDA RDB SG 60 61 62 63 64 3 4 1 2 5 ST221DE05DCP Handling Precautions • Attach 1/2W or greater terminating resistances of 150Ω ±5% at each end of the communications lines. • The DCP552 operates as a master station when connected to an ST221 during communications.
Chapter 4. WIRING 4 - 12 Isolation Between Input and Output Isolation between inputs and outputs are shown below. In this figure, the solid lines enclose mutually-isolated sections. Those sections bounded by dashed lines are not isolated.
Chapter 5. 5 - 1 FUNCTIONS Data ■ Data types The data types are listed below. For further information on data types, see “Chapter 7. PARAMETER SETUP” and “Chapter 8. PROGRAM SETUP”.
Chapter 5. FUNCTIONS 5 - 2 Program Pattern ■ Pattern Separate programs are set in CH1 and CH2 for each program number. Three systems for selecting programs are provided: RAMP-X, RAMP-T and RAMP-E. The first segment of each program is always RAMP-X, but the other segments can be any system and all three types can be used in one program. ● RAMP-X system This system, sets a segment of a pattern using SP and time, is called RAMP-X.
Chapter 5. FUNCTIONS ● RAMP-T system (θ setting) In the RAMP-T system, a segment is set using SP and ramp θ (theta). SP setting : within the upper and lower SP limiter range θ setting : 1 to 10000 (SPU/hour, SPU/min, SPU/sec) (Time units are selected using the C62 setup data setting.) SP is a point on the elapsed time axis in the current segment which is an extended straight line, the ramp set value of the current segment when the SP set value in the previous segment is the start point.
Chapter 5. FUNCTIONS NOTE •Select the program pattern setting system using setup data setting C61. 0: combined use of RAMP-X and RAMP-T 1: combined use of RAMP-X and RAMP-E •Select time setting units using setup data setting C62. 0: hours and minutes 1: minutes and seconds 2: 0.1 seconds •Select θ setting units using setup data setting C62. 0: SPU/hour 1: SPU/min 2: SPU/sec •Select SP setting and SP setting decimal position using setup data setting C65. 0: XXXXX 1: XXXX.X 2: XXX.XX 3: XX.XXX 4: X.
Chapter 5. FUNCTIONS ■ Events First, setup data setting C64 is used to assign CH1 and CH2 events, then the event configuration data setting is used to set event types for event outputs 1 to 16. Events are of the following four types: time event, PV event, code event and mode event. Settings are divided into two types of events: segment events and instrument event.
Chapter 5. FUNCTIONS •An On Time ≥ Off Time setting cannot be made. (See segment 3C in the figure.) Segment 3B 3C On-time Off-time No On Time is set. Output-ON ON=OFF ON>OFF Output-OFF Time •An On Time or Off Time is valid only within a segment and cannot straddle segments. In the next segment, the On time and Off time set for that segment are valid. (See segments 4 and 5 in the figure.) Thus an On Time and Off Time setting made at the end of a RAMP-X segment are ignored.
Chapter 5. FUNCTIONS •When there is a G.SOAK wait at the start of a segment and the ON Time is set to 0, the output goes on at the start of the G.SOAK wait and the On Time starts as the G.SOAK wait ends. The output time = G.SOAK time + (Off Time – On Time) (See segment 8 in the figure.) Segment On-time Off-time 8 G.SOAK wait Start of segment 8 The output goes on at the start of segment 8 when on is set to 0.
Chapter 5. FUNCTIONS •When there is a G.SOAK at the end of the previous segment, the On Time in the next segment is ignored if it is set to 0. (See segments 11 and 12 in the figure.) Thus the ON = 0 of segment 12 is not output at the end of the set time for segment 11, but when the G.SOAK wait ends. •This function can be combined with an event ON delay set using PARA. Delay works when an event goes from off to on.
Chapter 5. FUNCTIONS • Event on delay The number of the event to be delayed and the delay time can be set regardless of event type. The delay turns on the output for the duration of the delay when the event meets the conditions for going from OFF to ON. When this function is combined with the event standby function, the event on delay operates when the standby state is cleared. • Segment event progress •The output stays OFF until the program reaches a segment with an event.
Chapter 5.
Chapter 5. FUNCTIONS ● PV deviation rate event PV deviation is measured in each sampling cycle set using the event configuration data setting while on/off states are determined by comparing event setting deviation rate ∆PVs. PV deviation between sampling cycles is ignored. Event on/off switching is performed according to the sampling cycle. This function can be combined with event on delay.
Chapter 5. FUNCTIONS ● Code event Several events are used as one group and the number of output points are output as one parallel code number. Assigning code numbers to event outputs has the same effect as increasing the number of physical output points. •Code event Set event type to code event and set the number of output points (1 to 8) in auxiliary setting 1. An output code value (0 to 255) can be set for each segment. A binary coded low-order bit for the set number of output points is output.
Chapter 5. FUNCTIONS •Timed code event This function is a combination of a code event and a time event. The set code value is output at the set time. The number of settings that can be made in the first segment is the same as the number of output points. For example, for a 3-point output up to three settings can be made in the first segment. Like a time eventit, a setting within the segment period is valid and those that exceed it are ignored.
Chapter 5. FUNCTIONS •Program/segment number event A program or a binary coded segment number is set in an event type and the number of output points (1 to 7) is set in auxiliary setting 1. Or a program or a BCD code of the segment number is set in an event type and the number of output points (1 to 8) is set in auxiliary setting 1. A selection, a program designed for a specific operation or a coded segment number is output. A low-order bit code corresponding to the set number of output points is output.
Chapter 5. FUNCTIONS ● Mode event This event goes on or off depending on controller mode, alarm generation and other states. It cannot be combined with the event standby function but with the on delay function. It does not set event set values (operating points) or hysteresis. • Basic operations The following types are provided. RUN + HOLD + END + FAST HOLD READY + READY FAST END G.
Chapter 5. FUNCTIONS ■ PID group selection •Separate PID group selections can be set in CH1 and CH2 programs. •PID groups can be selected in two ways: by setting a PID segment or through automatic PID group switching. A PID group segment and automatic PID group switching can also be combined. When a PID group number is set to 0, the setting in the previous segment is continued.
Chapter 5. FUNCTIONS ■ G.SOAK (Guarantee soak) Separate G.SOAK settings can be made in CH1 and CH2 programs. G.SOAK on/off state, type and G.SOAK width is set by the segment. G.SOAK are of three types: segment start point, segment end point and the entire segment. G.SOAK time is set using the variable parameter PA46 setting. Any offset between SP and PV triggers a G.SOAK wait which narrows the distance between SP and PV to guarantee the segment execution time. G.
Chapter 5. FUNCTIONS • G.SOAK at end of segment PV and SP are compared at the end of the segment. The operation in that segment ends when the absolute value continues beyond the G.SOAK time and becomes narrower than G.SOAK width. A G.SOAK wait state continues until these conditions are met which is announced by the flashing of the linear LED at the center of the profile display. The operating condition is the same as HOLD at the end of a segment (time = set segment time). SP G. SOAK width G.
Chapter 5. FUNCTIONS ■ Repeat Separate repeat settings can be made in CH1 and CH2 programs. Repeat on/off and return destination are set by the segment with the segment number and repeat count. Operation completes at the end of a segment. If there is a repeat setting, the program returns to the start of the set destination segment and operation is resumed from there. This operation is repeated the number of times specified by the repeat count.
Chapter 5. FUNCTIONS ■ PV start Separate PV start settings can be made in CH1 and CH2 programs. When a PV start is set in the program setting, a PV start is performed in a normal RUN operation. The program looks for the first point where PV and the program pattern SP are equal (both PV and SP include bias) and starts operation from there.
Chapter 5. FUNCTIONS ■ Cycle Separate cycles can be set in CH1 and CH2 programs. The cycle function allows you to repeat operation from segment 1 to the last segment in a program pattern the number of times set in the cycle count. A total of 10,000 times can be set. When a cycle number of n is set, the total operation count is n + 1.
Chapter 5. FUNCTIONS ■ Pattern link Separate pattern links can be made in CH1 and CH2 programs. The pattern link function links patterns; the program number of the link at the destination is set in the pattern link item. An initial value of 0 indicates that linking is not performed. When the number of the program is set in the pattern link item, it forms an eternal loop. When SP at the end of the original link and SP at the destination are not equal, SP changes in a step-like manner.
Chapter 5. FUNCTIONS ■ Tag Programs that have the same number in CH1 and CH2 also share the same tag. Tags are 8-character alphanumerics, katakana or symbols that can be entered in a program. When segment 1 pattern item is set in a program setting, a total of eight characters consisting of PROG plus two characters in the program number and “__” two space characters. Example: Program No. 1 : “PROG01__” Program No.
Chapter 5. FUNCTIONS 5 - 3 Mode ■ Mode types Modes are listed below. Mode Program operation READY AUTO MANUAL READY FAST AUTO MANUAL RUN AUTO MANUAL HOLD AUTO MANUAL FAST AUTO MANUAL END AUTO MANUAL Constant value control READY AUTO MANUAL RUN AUTO MANUAL ● Program operation The program is run according to SP, time, events and other settings made in program patterns 1-49. ● Constant value control The control is run according to SP and events made with the constant value control data.
Chapter 5. FUNCTIONS ● RUN The RUN mode indicates that the program is run sequentially. MV output and events operate during PID control, ON-OFF control and other types of control. In the program RUN mode, program operation progresses according as time elapses. Note, however, that G.SOAK (guarantee soak) wait, like the HOLD mode, halts program operation. ● HOLD The HOLD mode temporarily halts program operation.
Chapter 5. FUNCTIONS ■ Mode transitions ● Program operation Mode transitions are indicated by the solid line arrows and end operation is indicated by the dashed lines in the figure below. ADV RESET END AUTO RESET END MANUAL READY AUTO READY MANUAL ADV RUN RESET RUN AUTO RUN MANUAL ADV HOLD RUN FAST FAST HOLD AUTO HOLD MANUAL FAST RESET READY FAST AUTO READY FAST MANUAL RUN RUN FAST AUTO RESET FAST MANUAL HOLD ADV ADV NOTE •AUTO ↔ MANUAL mode changes can be made in the boxes of each mode.
Chapter 5. FUNCTIONS ■ Mode transition operations Mode transitions are performed using the following operations. Although “Operation end” is not an operation, it is described here as a factor in mode transitions. ● RUN Switches from the READY, HOLD, FAST and READY FAST modes to the RUN mode. To go from the READY mode or READY FAST to the RUN mode using keys, external switches or transmission, the DCP552 must be in basic display status. ● HOLD Switches from the RUN and FAST modes to the HOLD mode.
Chapter 5. FUNCTIONS ■ Mode transition restrictions Modes can be changed using console keys, external switch inputs or through communications. The table below shows the operations that are valid for each mode.
Chapter 5. FUNCTIONS 5 - 4 Input Process Functions This section uses diagrams to describe input processes.
Chapter 5.
Chapter 5. FUNCTIONS ■ O2 sensor check (model with CP compensation) ● Objective As the O2 sensor starts to deteriorate, its output impedance increases. This function checks sensor output impedance and turns on the O2 sensor error event when the impedance exceeds 130kΩ. ● Setting •One of the values set for setup data C71 to C74 is set to 11 to assign the O2 sensor check to an external switch.
Chapter 5. FUNCTIONS 5 - 5 Output Processing Functions ■ Control output CH1 Control output CH1 is processed as shown below.
Chapter 5.
Chapter 5. FUNCTIONS ■ Control output CH2 Control output CH2 is processed as shown below.
Chapter 5.
Chapter 5. FUNCTIONS ■ Auxiliary output ● Auxiliary output 1 Auxiliary output 1 is processed as shown below by a model with one or two auxiliary output channels. Auxiliary output 1 type Setting: setup data C45 Upper and lower limit scaling Setting: setup data C46, C47 4mA Auxiliary output 1 ¥When the auxiliary output type is SP or deviation in the READY mode. Current output 4 to 20mA ● Auxiliary output 2 Auxiliary output 2 is processed as shown below on a model with two auxiliary output channels.
Chapter 6. 6 - 1 OPERATION Power Supply On When 100 to 240V AC is applied across terminals (39) and (40) on the DCP552, the display goes on in about 10 seconds and controls and other operations start. When the controller is starting up, the LEDs on the profile display go on at irregular intervals one after the other starting from top right in clock-wise order until the controller becomes ready for operation. The startup flow procedure is shown below.
Chapter 6. OPERATION 6 - 2 Basic Display Selection The console basic display status is comprised of the program number display, segment number display, display panel 1, display panel 2, basic display LEDs and the message panel. Use the DISP key or MESSAGE key to cycle through the different displays. The mode display LEDs perform the same functions both in the basic display status and during parameter settings and do not change by pressing the DISP or MESSAGE key.
Chapter 6. OPERATION ■ Program run mode displays ● DISP key function (When variable parametar PA03 is set to 0) The DISP key is used to cycle through the displays in the following order: Display A1, display A2, display A3, display A4, display A5, display A6, display A1.
Chapter 6. OPERATION ● Display A4 Select Hours and Minutes, Minutes and Seconds or 0.1 Seconds in the time unit setup data. In the setup data, also select Remaining Segment Time or Total Running Time. ● Display A5 When the remaining number of cycles is 0, cycle operation stops.
Chapter 6.
Chapter 6. OPERATION ● Display B4 ! When the remaining number of cycles is 0, cycle operation stops. ● Display B5 ● Display B6 Select Hours and Minutes, Minutes and Seconds or 0.1 Seconds in the time unit setup data.
Chapter 6. OPERATION ● Message key function (when variable parameter PA03 is set to 0) Cycles through the message panel displays. • When CH1 is displayed: Display C1, display C2, display C3, display C4, display C5, display C6, display C1. • When CH2 is displayed: Display C1, display C2, display C3, display C4, display C5, display C6, display C1.
Chapter 6. OPERATION ● Message key function (when variable parameter PA03 is set to 1) Cycles through the message panel displays. • Display D1, display D2, display D3, display D4, display D5, display D6, display D1.
Chapter 6. OPERATION ■ Constant value control mode ● DISP key function (when variable parameter PA03 is set to 0) The DISP key is used to cycle through the displays in the following order: Display E1, display E2, display E3, display E1. ● Display E1 PV SP PROG SEG PV PROFILE SP ● Display E2 PV DEV PROG SEG PV PROFILE Deviation ● Display E3 In MANUAL mode, the number of digits available for output values flash.
Chapter 6. OPERATION ● DISP key function (when variable parameter PA03 is set to 1) The DISP key is used to cycle through the displays in the following order: Display F1, display F2, display F3, display F4, display F1. When CH1 and CH2 are both in the fixed command control mode, the display show the information shown in the figures below. When only one channel is in the fixed command control mode, the displays provide the same information is shown in the program run mode.
Chapter 6. OPERATION 6 - 3 Selecting Programs A total of 49 programs can be selected with the operation keys. ■ Selecting program numbers ↑ ↓ ← → → ← ↑ ↓ ← → • Press the PROG key in the READY program run mode and basic display status. The program number starts to flash.
Chapter 6. OPERATION 6 - 4 External Switch Operation ■ External switch input A total of 16 external switch inputs are available. Each input is called SW1, SW2, etc. up to SW16. (SW: external switch input) ● Types of external switch inputs SW1 to 4 and SW9 to 16 are tied. SW5 to 8 functions are selected using setup data settings C71 to C74. SW9 to 14 are for program selections. Selections are made by entering BCD code or binary codes in the setup data C75.
Chapter 6. OPERATION • The on and off states of SW15 and SW16 determine whether external SW1 to SW14 operations are enabled or disabled. Note, however, that the autoload function and the O2 sensor check function cannot be disabled by SW15 and SW16.
Chapter 6.
Chapter 6. OPERATION ■ Read timing ● SW1 to 8 and 15 to 16 timing SW1 to 8 and 15 to 16 are read according to the timing in the figure shown below. (1) When the input changes from OFF to ON, reading starts within less than 0.2 seconds. (2) When the input changes from ON to OFF, reading starts within less than 0.2 seconds. ● SW9 to 14 and RUN, FAST (READY FAST) timing Selecting SW9 to 14 program numbers takes less than 0.
Chapter 6. OPERATION 6 - 5 Manual Operation and Auto-Tuning ■ Manual operation When outputs are indicated in the basic display status, only one digit in the output value flashes. Increasing or decreasing the output value using ↑ and ↓ keys causes the actual output to change accordingly. Unlike setting registration, there is no need to press the ENTER key. Use the ← and → keys to move the flashing digit.
Chapter 6. OPERATION • The point at which output reverses (lower limit ⇔ upper limit) during autotuning is determined from the SP and PV values at AT startup as follows. • Auto-tuning performed using a variable parameter PA08 setting of 3 or 4 and a PA93 setting of 3 or 4 cause auto-tuning to be performed on SP, PID parameters tP-A1 to tP-A7, in order.
Chapter 7. 7 - 1 PARAMETER SETUP Parameter Setup Parameter settings can be changed when the DCP552 is in the normal display mode. When not in the normal display mode, press the DISP key to invoke it. ■ Selecting parameter settings groups In the normal display mode, the keys listed in the table below can be used to select settings groups and individual items in these groups.
Chapter 7. PARAMETER SETUP ■ Modifying individual items and exiting the setting mode Pressing the ENTER key while an individual item is displayed causes the set value to flash and enables the registration state. At this point, the ↑ key and ↓ key allow you to increase or decrease the values, while the ← key and → key move the digit positions on the display at which the values flash.
Chapter 7.
Chapter 7. PARAMETER SETUP 7 - 2 Parameter Setting List NOTE “PVU (PV1)”, “PVU (PV2), “SPU (CH1)” and “SPU (CH2)” used in the “Factory Default Settings” and “User Settings” columns in the lists on the following pages have the following meaning. PVU (PV1): When the PV1 range type (setup data setting C01) is a thermocouple or resistance temperature detector, the PV1 decimal point position (setup data setting C03) causes the decimal point position to change.
Chapter 7. PARAMETER SETUP ■ Variable parameter setting .
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Chapter 7. PARAMETER SETUP ■ Detailed information on variable parameters ● PA01 (keylock) 0: 1: 2: 3: keylock disabled display of setup data setting disabled display of all settings disabled display of all settings disabled. Operation keys disabled • The following keys are disabled when PA01 is set to 1. Normal display mode: SETUP key (setup data setting) FUNC + CLR + MESSAGE keys (general reset) • The following keys are disabled when PA01 is set to 2.
Chapter 7. PARAMETER SETUP • When program settings are protected, it is not possible to copy programs or load programs from a memory card. • When PID parameters are protected, constant value control data is also protected. • When settings are protected by setup data, variable parameters, event configurations and PID parameters, they cannot be loaded from a memory card.
Chapter 7. PARAMETER SETUP ● PA17 (PID computation initialize manipulated variable) ● PA27 (PID computation initialize manipulated variable) Under the conditions listed below, a PID computation starts using the value set in PA17. • When there is a mode change from READY AUTO to RUN AUTO. • When the controller is powered up in RUN (or HOLD, FAST, END) AUTO mode. • When auto-tuning ends.
Chapter 7. PARAMETER SETUP ■ Event configuration data settings No.
Chapter 7. PARAMETER SETUP ■ Settings by event type For information on event operations, see “■ Events” (pages 5-5 to 5-14).
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Chapter 7. PARAMETER SETUP ■ Setup data setting No. Item code Factory default settings User settings Settings and descriptions 0 to 16 : t/c 48 to 52 : linear (DC current, DC voltage) 64 to 71 : RTD 96 to 103 : RTD 128 to 134: linear (DC current, DC voltage) [Description:] For details see range numbers listed in ÒSection 2-3 Input Type and Range NumberÓ (page 2-8) 0: ¡C Celsius 1: ¡F Fahrenheit [Description:] When setting C01 is set to linear, Ò-----Ó is displayed and setting cannot be performed.
Chapter 7. PARAMETER SETUP No. Item code Item Factory default settings User settings Settings and descriptions 11 C 11 PV2 range number 0 0 to 16 : t/c 48 to 52 : linear (DC current, DC voltage) 64 to 71 : RTD 96 to 103 : RTD 128 to 134: linear (DC current, DC voltage) 135 : O2 Sensor [Description:] Setting 135 cannot be made on a model without CP compensation. A model with CP compensation is tied to setting 135.
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Chapter 7. PARAMETER SETUP No. 7-30 Item code Item Factory default settings User settings Settings and descriptions 99 C 99 PV1 zener barrier adjustment ---- -20.00 to +20.00 [Description:] “----” is displayed when PV1 is not an RTD input and C98 is not equal 241. 100 C100 PV2 zener barrier adjustment ---- -20.00 to +20.00 [Description:] “----” is displayed when PV2 is not an RTD input and C98 is not equal 241.
Chapter 7. PARAMETER SETUP ■ Detailed descriptions of setup data settings ● C07 (PV1 cold junction compensation) ● C17 (PV2 cold junction compensation) • This is a selection for cold junction compensation for thermocouples. • When set to 1, perform 0°C compensation using a cold junction compensation device outside the DCP552.
Chapter 7. PARAMETER SETUP ● C63 (time display) 0: remaining segment time 1: total operation time • These are selections for display panel 1 and 2 in the normal display mode in the program run mode. • In the READY mode a setting of 0 displays the set time values for the selected segments. • In the RUN, HOLD, FAST and END modes a setting of 0 displays the remaining time in rounded hours.
Chapter 7. PARAMETER SETUP ● C93 (time proportional output system) ● C94 (time proportional output system) 0: Goes on again within time proportional cycle 1: Does not go on again within time proportional cycle • This setting determines whether the output is to go on again after the result of a PID computation has changed in a time proportional cycle (cycle time) and the output has been turned off. • The difference between the two settings is illustrated below.
Chapter 7. PARAMETER SETUP (3) Equivalent circuit showing connection of n SSRs DCP552 SSR 1 Z I0 (V0 ) VSSR' VD SSR n Z VSSR' VD Equations (3) and (4) below must be satisfied. VSSR/MIN ≤ I0 × Z+VD ≤V0 /N Equation (3) VSSR' ≤ VSSR/MAX Equation (4) (VSSR' = I0× Z + VD) (4) Equivalent circuit showing parallel connection of n SSRs DCP552 SSR 1 Z I0 (V0 ) SSR n VSSR' VSSR' VD Equations (5) and (6) below must be satisfied.
Chapter 7. PARAMETER SETUP ● C99 (PV1 zener barrier adjustment) ● C100 (PV2 zener barrier adjustment) The adjustment described below must be performed when a zener barrier is used. (1) Turn off the DCP552. When installation and wiring is completed, shortcircuit A and B on the resistance temperature detector.
Chapter 7. PARAMETER SETUP ■ Constant value control data (CH1) setting No. Item Item code Factory default settings User settings Settings and descriptions 0: Program run mode 1: Fixed command control mode Within the range of setup C66 to C67 (SP limit) 0.0 to 1000.0% A setting of 0.0 turns on ON-OFF control 0 to 3600sec No integral operation when set to 0. [Description:] When P is set to 0.0, Ò-----Ó is displayed and setting cannot be performed.
Chapter 8. 8 - 1 PROGRAM SETUP Program Setup Programming is enabled in the normal display mode. When the DCP552 is not in the normal mode display, press the DISP key to invoke it. Programming is simpler if you set down the objectives of the program on a program work sheet before you start programming. NOTE For ease of use, please enlarge the copy of the DCP551/552 Program Work Sheet located after page 12-18. ■ Selecting number of program to operate Numbers can be selected in one of two ways.
Chapter 8. PROGRAM SETUP ■ Starting programming ● Key operations Start programming by pressing the FUNC and PROG keys in the normal display mode. In the program setting state, PRG LED on the console lights and the decimal points in the program number display and the segment number display lights. Note, however, that the program setting state cannot be entered in the following cases.
Chapter 8. PROGRAM SETUP ● Description of numbered items in the figure illustrating the program setting state (1) Programming is started. Up to about 1 second after the programming state is entered, the remaining number of segments is displayed in display panel 1 and the remaining number of subfunctions is displayed in display panel number 2. The display can be held by pressing the FUNC key. (2) Move the setting items on the programming map. (3) Move the segments on the programming map.
Chapter 8. PROGRAM SETUP ■ Programming map As shown below, a programming map consists of columns of segment numbers and rows of program setting items. In the program setting state, the items in the solid lines indicated by the segment numbers and program setting items are displayed. ← key, → key : moves segments right and left ↑ key, ↓ key : moves segments up and down The figure shows a programming map from the first to the 10th segment. Programming map example: ! ' * .
Chapter 8. PROGRAM SETUP ■ Display items Items displayed are shown in the figure below.
Chapter 8. PROGRAM SETUP ● Display Segments that have not been set and unset values for SP and time are indicated by “-----”. NOTE Event settings are displayed in the two rows of the message panel. Events 1 to 8 are displayed in the top left row and events 9 to 16 are displayed in the lower left row. The meaning of the codes used are listed below.
Chapter 8. PROGRAM SETUP ■ Setting event items Handling Precautions Events assigned to the selected channel can be displayed. Note that when setup data C57 is set to 1, event items on the programming map are skipped and not displayed. ● When the event is a PV event (1) In the set value display state, move to the segement event item to be set on the programming map. (2) Press the ENTER key to make display panel 1 flash (registration of first setting).
Chapter 8. PROGRAM SETUP ● When the event is a time event (1) In the set value display state, move to the event item to be set for the segment on the programming map. (2) Press the ENTER key to make display panel 1 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting (On Time setting). Setting range: 0:00 to 500:00, 0.0 to 3000.0 (Time units are selected using setup data C62 to set Hour/min, Min/sec, 0.1 sec.
Chapter 8. PROGRAM SETUP ● When the event is a code event (1) In the set value display state, move to the event item to be set for the segment on the programming map. (2) Press the ENTER key to make display panel 1 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting – setting the event output code. Setting range : 0 to 2n – 1 (n indicates the number of output points set in event configuration 1 auxiliary setting 1.
Chapter 8. PROGRAM SETUP ● When the event is a timer code event (1) In the set value display state, move to the event item to be set for the segment on the programming map. (2) Press the ENTER key to make display panel 1 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting (output code). Setting range:0 to 2n – 1 (n indicates the number of output points set in event configuration 1 auxiliary setting 1.
Chapter 8. PROGRAM SETUP Handling Precautions In a timer code event, an On Time or Off Time setting that is the same as or exceeds the segment time is invalid. Note, however, that when there is a G.SOAK wait at the end of a segment or an END mode at the end of a program, an On Time or Off Time setting that is the same as the segment time is valid. ● When the event is an event off Such event items on the programming map are skipped and not displayed.
Chapter 8. PROGRAM SETUP ■ Setting PID groups and output limiter group number items (1) In the set value display state, move to the PID group, output limiter group number item to be set for the segment on the programming map. (2) Press the ENTER key to make display panel 1 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting (PID group number).
Chapter 8. PROGRAM SETUP ■ Setting G.SOAK (Guarantee soak) items (1) In the set value display state, move to the G.SOAK item to be set for the segment on the programming map. (2) Press the ENTER key to make display panel 1 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting – setting the G.SOAK type. Setting range:0 to 3 0: No G.SOAK 1: First G.SOAK segment 2: Last G.SOAK segment 3: Entire G.
Chapter 8. PROGRAM SETUP ■ Setting PV shift items (1) In the set value display state, move to the PV shift item to be set for the segment on the programming map. (2) Press the ENTER key to make display panel 2 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting – setting the PV shift set value. Setting range: –10000 to +10000 SPU (4) Press the ENTER key to stop the flashing on display panel 2.
Chapter 8. PROGRAM SETUP ■ Setting repeat items (1) In the set value display state, move to the repeat item to be set for the segment on the programming map. (2) Press the ENTER key to make display panel 1 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting – setting the number of the return segment. Setting range: 0 to segment number in setting (4) Press the ENTER key to stop the flashing on display panel 1 and display panel 2 starts flashing.
Chapter 8. PROGRAM SETUP ■ Setting PV start items (1) In the set value display state, move to the PV start item to be set for the segment on the programming map. (A PV start item is a program setting and is the same for each segment.) (2) Press the ENTER key to make display panel 2 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting – setting the PV start value.
Chapter 8. PROGRAM SETUP ■ Setting cycle items (1) In the set value display state, move to the cycle item to be set for the segment on the programming map. (A cycle item is a program setting and is the same for each segment.) (2) Press the ENTER key to make display panel 2 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting – setting the cycle value. Setting range: 0 to 10000 (4) Press the ENTER key to stop the flashing on display panel 2.
Chapter 8. PROGRAM SETUP ■ Setting pattern link items (1) In the set value display state, move to the pattern link item to be set for the segment on the programming map. (A pattern link item is a program setting and is the same for each segment.) (2) Press the ENTER key to make display panel 2 flash (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting – setting the pattern link value.
Chapter 8. PROGRAM SETUP ■ Setting tag items (1) In the set value display state, move to the tag item to be set for the segment on the programming map. (A tag item is a program setting and is the same for each segment.) (2) Press the ENTER key to display the cursor “__” below the leftmost of the 8 characters in the message panel “[ ]” field (registration of first setting). (3) Use the ↑, ↓, ←, and → keys to make the first setting – selecting the 8 characters for the tag.
Chapter 8. PROGRAM SETUP ■ Deleting programs (1) In the set value display state, move to the start of the segment pattern item to be deleted on the programming map. Move to the first segment of the program to delete the entire program. (2) Press the ENTER key to make display panel 1 flash (registration of first setting). (This the same as for pattern item settings.) (3) Press the FUNC and CLR keys and you are prompted to confirm program deletion. “CLEAr ” flashes in display panel 1.
Chapter 8. PROGRAM SETUP ■ Inserting and deleting segments (1) In the set value display state, move to insert segment or delete segment segment pattern item on the programming map. (2) Press the FUNC and ENTER keys and you are prompted to confirm segment insertion. “InS.” flashes in display panel 1. (3) Press the ↑ key and you are prompted to confirm segment insertion. “InS.” flashes in display panel 1. Press the ↓ key and you are prompted to confirm segment deletion. “dEL.” flashes in display panel 1.
Chapter 8. PROGRAM SETUP The set value of the inserted segment is as follows: Set SP value : same value as the original segment before insertion Set time value : 0:10, 1.0 Event items, PID groups, output limiter group number items, G.SOAK items, PV shift items and repeat items are not set. • When the 99th segment has already been set, the segment insertion indication “InS.” is not displayed.
Chapter 8. PROGRAM SETUP 8 - 2 Copying Programs The DCP552 allows you to copy programs when it is in the READY program run mode. If not in this mode, press the DISP key to invoke the normal display mode. ■ Program copy procedures (1) Invoke the program run READY program run mode. Set variable parameter PA01 to 0 or 1 and set variable parameter PA02 to 0. (2) Press the PROG key and the ↑, ↓, ←, and → key keys in the normal display mode to select the number of the program to be copied.
Chapter 8. PROGRAM SETUP 8 - 3 General Reset A general reset can be performed when the controller is in the READY AUTO mode in the normal display mode. If not in the normal display mode, press the DISP key to invoke it. A general reset has the following functions. Program settings such as program numbers 1 to 49 are all deleted. Parameters are reset to their factory defaults and the READY AUTO program run mode is invoked. ■ General reset procedures (1) Invoke the READY AUTO mode for both CH1 and CH2.
Chapter 9. 9 - 1 MEMORY CARD OPERATIONS Memory Card Type and Functions A memory card can be used to store the setup data, variable parameters, PID parameters (including constant value control data), event configuration data and multiple programs required by one DCP552. ● Memory card types The following memory cards can be used by the DCP552. Model No. Memory type SKM008A RAM Not replaceable 7.00K Max. 10 SKM016A RAM Not replaceable 14.50K Max. 26 SKM064A RAM Not replaceable 61.75K Max.
Chapter 9. MEMORY CARD OPERATIONS 9 - 2 Save Procedures Insert a memory card when the DCP552 is in the READY mode and the normal display mode. Press the SAVE key to start a save operation. “CArd ” is displayed in display panel 1 and “SAVE ” is displayed in display panel 2. An error code appears if something should go wrong during the save operation. ■ Save menu When the SAVE key is pressed in the normal display mode, the save menu panel is displayed. Use the ↑ and ↓ keys to select the desired menu.
Chapter 9. MEMORY CARD OPERATIONS ■ Procedures for formatting cards This procedure is used to format memory cards so that they can be used with the DCP552. A card has to be formatted once only. Note that any programs or parameters on a card that is formatted are deleted in this process.
Chapter 9. MEMORY CARD OPERATIONS ■ Procedures for saving all programs This procedure saves all programs on the DCP552 on a memory card. The program numbers used in the DCP552 are converted to file names on the memory card. When the “Overwrite” save function is selected, files on the card that have the same number as those in the DCP552 are overwritten by the DCP552 files.
Chapter 9. MEMORY CARD OPERATIONS ■ Procedures for saving PID parameters This procedure saves PID parameters and constant value control data on a memory card. Data delete check Delete Old Data SAVE ? Save complete PID Data SAVE Good (Displayed when there is data on the card.) Normal display mode (Save operation is not performed.) Normal display mode ■ Procedures for saving event configuration data This procedure saves event configuration data on a memory card.
Chapter 9. MEMORY CARD OPERATIONS 9 - 3 Load Procedures Insert a memory card when the DCP552 is in the READY mode and the normal display mode, and variable parameter PA05 has been set to 0. Press the LOAD key to start a load operation. “CArd ” is displayed in display panel 1 and “LOAd ” is displayed in display panel 2. An error code appears if something should go wrong during the save operation. ■ Load menu When the LOAD key is pressed in the normal display mode, the load menu panel is displayed.
Chapter 9. MEMORY CARD OPERATIONS ■ Card battery alarm panel When the voltage of the internal battery in a RAM card is too low, the data saved on the disk may be corrupted. Loading corrupted data onto the DCP552 will cause maloperation. Do not use a card whose battery voltage is too low. If you want to load the data anyway, select “Ignore” in this panel and press the ENTER key. This displays the load menu. To return to the normal display mode, select “Quit” or press the ENTER key or the DISP key.
Chapter 9. MEMORY CARD OPERATIONS ■ Procedures for loading all programs This procedure loads all programs on the memory card in the DCP552. The file numbers used on the memory card are converted to file numbers used in the DCP552. When the “Overwrite” load function is selected, programs in the DCP552 that have the same number as those on the card are overwritten by the card programs.
Chapter 9. MEMORY CARD OPERATIONS ■ Procedures for loading event configuration data This procedure loads event configuration data on the memory card onto the DCP552. Data delete check Delete Old Data LOAD ? Load completed EVENT Data LOAD Good Normal display mode (Load operation is not performed.) Normal display mode ■ Procedures for loading all parameters This procedure loads all parameters on the memory card onto the DCP552.
Chapter 9. MEMORY CARD OPERATIONS 9 - 4 Autoload Insert a memory card, press the LOAD key or use external switch inputs in the READY mode and the normal display mode to load file number 1 in CH1 and CH2 on the memory card as program 1 onto the DCP552. ■ Key operated autoload procedure ● Conditions Memory card : Program has been saved to file number 1 Variable parameter : PA05 set to 1 Mode : READY mode, normal display mode ● Operation and action Insert a memory card and press the LOAD Key.
Chapter 9. MEMORY CARD OPERATIONS ■ Auto load using external switch inputs ● Conditions Memory card : Program saved to file number 1 Setup data : any of C71 to C74 is set to 8 (autoload) Mode : READY mode, normal display mode ● Operation and action Insert a memory card and turn off the external switch used for autoload and turn it back on again. The DCP552 operates as follows. • “AUtO ” is displayed in display panel 1 and “LOAd ” is displayed in display panel 2.
Chapter 9. MEMORY CARD OPERATIONS 9 - 5 Error Message List When an error occurs, error messages such as “Card Error-XX” (XX denotes error code) are displayed on the message panel during memory card operations. The table below lists the error codes and explain their meaning. Memory card operations are aborted when an error occurs. To return to the normal display mode, press the DISP key.
Chapter 10. TROUBLESHOOTING 10 - 1 Self-Diagnostic Functions and Alarm Code Displays The DCP552 is equipped with the self-diagnostic functions described below. Alarm codes and the result of selfdiagnostics are listed on the following pages. ■ Power ON self-diagnostic routines ● RAM backup failures This routine is designed to detect errors in the RAM backup function. When a failure is detected, a general reset is performed. No alarm code is displayed.
Chapter 10. TROUBLESHOOTING ■ Alarm code display The DCP552 is designed to alternate display of the following alarm codes and normal display items in one-second intervals on display panel 1 when input failures or instrument system failures are detected. In cases of multiple alarm codes, display of the codes is alternated with normal display items, starting in order from the alarm code with the smallest number.
Chapter 10. TROUBLESHOOTING 10 - 2 Key Input Related Problems Procedures to correct key input related problems are described below.
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Chapter 10. TROUBLESHOOTING ● PID group, output limiter group number items cannot be displayed with ↑ and ↓ keys C58 ● G.
Chapter 10. TROUBLESHOOTING 10 - 3 When the BAT LED Flashes Handling Precautions Batteries that have been stored for long periods have been subject to selfdischarge and have a short service life. If required, buy new batteries. ■ BAT LED flashes The BAT LED starts flashing when low battery voltage is detected. The voltage level set in memory that trigger the LED is higher than minimum level required for storing data. Thus data loss is thus not imminent when the LED starts flashing.
Chapter 10. TROUBLESHOOTING ● Battery replacement procedures Handling Precautions • Replace the old battery with a lithium battery (model No.:81446140001). Batteries can be ordered from Honeywell sales or service office. • Do not use metal tools to remove or attach battery connectors as this could short-circuit electric circuits inside. • A capacitor backs up the memory during battery replacement. To charge this capacitor, supply power to the DCP552 for about 10 minutes.
Chapter 10. TROUBLESHOOTING (4) To prevent static discharges, remove all static electricity from your body. (5) Slide the controller completely out of the case. >>The battery is located on the right side as seen from the front of the controller. (6) Place the controller on a desk upside-down so that the battery is easily accessible. (7) Disconnect the connectors. (8) Open the tab on the black clip that secures the battery and lift out the battery. (9) Remove the old battery from the clip.
Chapter 10. TROUBLESHOOTING NOTE • Guidelines for battery service life are given below. When the DCP552 is stored with the power off under standard conditions (ambient temperature 23±2°C): 5 years When the DCP552 is stored with the power on under standard conditions (ambient temperature 23±2°C): 10 years Battery life is reduced when stored at higher temperatures. • When the BAT LED is flashing, memory data is protected if the power is on.
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Chapter 12. CALIBRATION This chapter covers the field calibrations procedures for the inputs, outputs and various functions of the DCP550 mark II controller after shipment from the factory. When calibration is made in the field, the original factory data is erased, and so the specified input/output accuracies of the controller cannot be assured. This manual is for users who are conversant with DCP550 mark II use and operation.
Chapter 12. CALIBRATION 12 - 1 Quick Reference Table for Calibration Items DCP550 mark II controllers are numbered using the following format. Format items may require different calibration procedures, as shown in Table 12-1. & ✽ ✽ ✽ ✽ ✽ ✽ ! " # $ % Table 12-1. Calibration Items for Each Model ( * + / ( * + #$ , *-+ # *.
Chapter 12. CALIBRATION Table 12-2. Item and Sub Item Table for Calibration Upper Display Shows Item Sub Item 0 0 Item change code 1 Key test 2 Display test 3 Digital input test 4 Output test (control) 5 Output test (digital output) 6 Clock adjustment 0 Item change code 1 Channel No. 2 Gain No.
Chapter 12. CALIBRATION While pressing FUNC , press SETUP and & 0.0.0.0. *A d J S PROG SEG 00 00 ENTER simultaneously. ENTER & Function test 1.0.1.1. *A d J S SETUP Key ON/OFF PROG SEG 01 00000 *A d J S Key test Key ON/OFF SETUP PV input calibration item PROG SEG 01 01 CH No. selection SETUP SEG Display test ON/OFF of display ON/OFF of display 00000 *A d J S SETUP DI ON/OFF SEG 00 SETUP 00 PROG PROG 01 ENTER PROG SEG 01 02 Gain No.
Chapter 12. CALIBRATION & ENTER & ENTER 2.0.2.2. *A d J S PROG SEG 02 00 C/J sensor calibration item 6.0.6.6. *A d J S SETUP Current input count No. Current count No. stored PROG SEG 02 01 PROG SEG 02 02 CJ CH1 zero input count After stabilized, press ENTER .
Chapter 12. CALIBRATION 7.0.7.7. *A d J S 07 00 07 01 0.0.0.0. 0.0.0.0. 07 02 * 1.1.1.1. Figure 12-1.
Chapter 12. CALIBRATION 12 - 2 Calibration Procedures ■ Enter calibration mode (1) Release keylock. (PARA PA01=0) (2) Press DISP key to permit ordinary indication condition. Change to READY (RUN and HLD are off) and AUTO (MAN off) modes. The following LEDs will illuminate after the above operations.
Chapter 12. CALIBRATION ■ Function test Press ↑, ↓, ←, →, keys to show (0.0.0.0) on upper display, then press ENTER key. ● Key test (00-01) Press SETUP key until the PROG/SEG display shows (00-01). When you press each key, the data appears in the upper display (shown in Table 12-3) and in the lower display (shown in Table 12-4). Table 12-3. Upper Display Key ENTER AT FUNC CLR PARA Data Key Data 2.0.0.0 0.2.0.0. 0.4.0.0. 0.0.4.0. 0.0.2.0 PID 1.0.0.0. 0.8.0.0. 0.0.1.0. 0.0.0.8. 0.0.0.2.
Chapter 12. CALIBRATION ● Display test (00-02) Press SETUP key until the PROG/SEG display shows (00-02). Then, each 7-segment LED, LED indicators and LCD illuminates at every 1 sec. This is to check if each LED/LCD illuminates. ● Digital input test (00-03) Press SETUP key until the PROG/SEG display shows (00-03). When you turn on or off each remote switch, the upper display will show the data described in Table 12-5. ! ! #! ↕ ↕ ↕ ! ! ! 0.0.0.0. 0.0.0.1.
Chapter 12. CALIBRATION ● Digital output test for control output (00-04) Press SETUP key until the PROG/SEG display shows (00-04). When the digit of upper display is changed by ↑, ↓, ←, →, keys, the state of 6D or 8D control output is changed as shown in Table 12-6. Since the 6D hardware is of current output (8D hardware is of open collector) specification, the ON/OFF check must be performed in meeting with the specification. Table 12-6. 0.0.0.0. 0.0.0.1. 0.0.0.2.
Chapter 12. CALIBRATION ● Built-in clock adjustment ) * PROG PV DEV OUT CYC SP TM SYN SEG . + , Figure 12-4. A: 2 digits of calendar year B: Month C: Day D: Hour (24 hour system) E: Minute F: Second Example: 1993 ……………………93 April ……………………04 5th day …………………05 3PM ……………………15 6 minutes ………………06 Not changeable NOTE 1. ↑, ↓, ←, →, keys are used to change the values, and ENTER key is used to store the values. 2.
Chapter 12. CALIBRATION ● PV zero, span (1) PV zero adjustment (a) Press SETUP key until the PROG/SEG display shows (01-03). (b) Adjust your calibration device to an output signal equal to the 0% range value (See Table 12-9), the signal need to be on the input for 10 to 15 seconds. (c) Press ENTER key after display stabilizes. (2) PV span adjustment (a) Press SETUP key until the PROG/SEG display shows (01-04).
Chapter 12. CALIBRATION Table 12-10. ! " " # $ " " # $ % $ & 11 ' × ( ) *+ ,- . ( / 0 % 0 0 %% 0 ! "$ "% 1/ 2 3 4 4 % $ % ! :0/ 8 8 W 1 $ $ % ! :0/ 8 & . % 8 $ . 8 5 9 8 ) 5 & 5 8 #5 8 #5 8 5 & . $ % 8 $ .
Chapter 12. CALIBRATION ■ Cold junction sensor calibration Scroll ↑, ↓, ←, →, keys to show (2022) on upper display, then press ENTER key. ● The cold junction input 0% (CH1) (1) Press SETUP key until the PROG/SEG display shows (02-01). (2) Connect the millivolt source between (55)(–) and (56)(+), and then input 0.2V (See Figure 12-10). (3) Press ENTER key after display stabilizes, AD count is shown on lower display.
Chapter 12. CALIBRATION ● Writing into EEPROM (1) Press SETUP key until the PROG/SEG display shows (02-09). (2) Scroll ↑, ↓, ←, →, keys to show (1.1.1.1.) on upper display. (3) Press ENTER key. ■ Current output calibration Scroll ↑, ↓, ←, →, keys to show (6.0.6.6.) on the upper display, then press ENTER key. Connect the digital ammeter across terminals (See Figure 12-9). ● OUT CH1 output calibration (1) Press SETUP key until the PROG/SEG display shows (06-01).
Chapter 12. CALIBRATION ● Writing into EEPROM (1) Press SETUP key until the PROG/SEG display shows (06-09). Scroll ↑, ↓, ←, →, keys to show (1.1.1.1.) on upper display. (2) Press ENTER key. ■ Carbon potential code calibration Scroll ↑, ↓, ←, →, keys to show (7.0.7.7.) on upper display, then press ENTER key. ● Carbon potential code calibration Press SETUP key until the PROG/SEG display shows (07-01). Scroll ↑, ↓, ←, →, keys to show (x.x.x.x.) on upper display, then press ENTER key (See Table 12-11).
Chapter 12. CALIBRATION 12 - 3 Set Up - - Figure 12-5. Thermocouple Inputs Figure 12-6. RTD Inputs Figure 12-7. RTD Inputs - - Figure 12-8.
Chapter 12. CALIBRATION - - - - Figure 12-11.
DCP551/552 Program Work Sheet [Pattern graph] SP (Unit : Program No. Preparation date: Equipment name: Product name : ) Time (Unit: hr-min, min-sec, 0.1sec) [Programming Map] Segment item Program contents (1)SP (2)Time, θ, ∆SP (1) ) (2) (1) ) (2) (1) (2) ) (1) (2) ) (1) (2) ) (1) (2) ) (1) (2) ) (1) (2) ) (1) ) (2) (1) ) (2) (1) ) (2) (1) ) (2) (1) ) (2) (1) (2) ) (1) (2) ) (1) (2) ) PID group or Output limiter group (1)PID group (2)Output limiter group (1)Type G.
DCP552 Parameter Work Sheet User name Equipment name Model No. Instrumentation staffer in charge : : :DCP552 : Preparation date Product name Tag name Business staffer in charge : : : : ■ Variable parameter setting No. Item code Item Factory default User settings settings Settings and descriptions 1 PA 01 Key lock 0 0 : Keylock disabled 1 : Display of setup data settings disabled 2 : Display of all settings disabled 3 : Display of all settings disabled. Operation keys disabled.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings Settings and descriptions 36 PA 36 Group 3 delay time 0.0 0.0 to 3000.0sec 37 PA 37 Group 4 event number 0 0 to 16 (0: No delay is specified.) 38 PA 38 Group 4 delay time 0.0 0.0 to 3000.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings Settings and descriptions 79 PA 79 PV2 equalizer compensation point No. 5 2000 PVU –19999 to +20000 PVU(PV2) 80 PA 80 PV2 equalizer compensation amount No. 5 0 PVU –1000 to +1000 PVU(PV2) 81 PA 81 PV2 equalizer compensation point No. 6 2500 PVU –19999 to +20000 PVU(PV2) 82 PA 82 PV2 equalizer compensation amount No. 6 0 PVU –1000 to +1000 PVU(PV2) 83 PA 83 PV2 equalizer compensation point No.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings Settings and descriptions 111 PA111 CP computation compensation 1.000 No.6 compensation point 0 to 2000 SPU (CH2) 112 PA112 CP computation compensation 0.000 No.6 compensation amount -1000 to +1000 SPU (CH2) 113 PA113 CP computation compensation 1.200 No.7 compensation point 0 to 2000 SPU (CH2) 114 PA114 CP computation compensation 0.000 No.
DCP552 Parameter Work Sheet ■ Event configuration data setting No. Item code Item Factory default User settings settings Settings and descriptions 1 E01-t Event 1 event type 0 0 to 253 2 E01-1 Event 1 auxiliary setting 1 ----- –19999 to +20000 (Setting range is variable according to the event types.) 3 E01-2 Event 1 auxiliary setting 2 ----- –19999 to +20000 (Setting range is variable according to the event types.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings Settings and descriptions 34 E12-t Event 12 event type 0 0 to 253 35 E12-1 Event 12 auxiliary setting 1 ----- –19999 to +20000 (Setting range is variable according to the event types.) 36 E12-2 Event 12 auxiliary setting 2 ----- –19999 to +20000 (Setting range is variable according to the event types.
DCP552 Parameter Work Sheet Event type Meaning 24 to 63 Event off Setting category ----- Operation category ----- Auxiliary 1 : None Auxiliary 2 : None Auxiliary 1 : Hysteresis Auxiliary 2 : Operating point Measuring instrument PV Auxiliary 1 : Sampling cycle Auxiliary 2 : Operating point Measuring instrument PV Auxiliary 1 : Hysteresis Auxiliary 2 : Operating point Measuring instrument Code Auxiliary 1 : No.
DCP552 Parameter Work Sheet Event type Meaning Setting category Operation category 143 Event off ----- 144 Battery voltage drop Measuring instrument Mode 145 to 253 Event off 8 ----- --------- Auxiliary settings Auxiliary 1 : None Auxiliary 2 : None
DCP552 Parameter Work Sheet ■ PID parameter (CH1) setting No. Item code Item Factory default User settings settings Settings and descriptions 1 P-1 Proportional band (PID group 1) 100.0 0.0 to 1000.0% (0.0: On-Off controi) 2 I-1 Integral time (PID group 1) 0 0 to 3600sec (0: no integral operation) 3 d-1 Derivative time (PID group 1) 0 0 to 1200sec (0: no derivative operation) 4 rE-1 Manual reset (PID group 1) 50.0 0.0 to 100.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings Settings and descriptions 36 oH-6 Manipulated variable upper limit (Output limiter group 6) 100.0 Manipulated variable lower limit to +105.0% 37 P-7 Proportional band (PID group 7) 100.0 0.0 to 1000.0% (0.
DCP552 Parameter Work Sheet No. Item code 72 tP-A3 73 P-A4 Item Factory default User Settings and descriptions settings settings Tuning point (PID group A3) 2500 SPU –19999 to +20000 SPU Proportional band (PID group A4) 100.0 0.0 to 1000.0% (0.
DCP552 Parameter Work Sheet ■ PID parameter (CH2) setting No. Item code Item Factory default User settings settings Settings and descriptions 1 P-1 Proportional band (PID group 1) 100.0 0.0 to 1000.0% (0.0: On-off control) 2 I-1 Integral time (PID group 1) 0 0 to 3600sec (0: no integral operation) 3 d-1 Derivative time (PID group 1) 0 0 to 1200sec (0: no derivative operation) 4 rE-1 Manual reset (PID group 1) 50.0 0.0 to 100.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings Settings and descriptions 36 oH-6 Manipulated variable upper limit (Output limiter group 6) 100.0 Manipulated variable lower limit to +105.0% 37 P-7 Proportional band (PID group 7) 100.0 0.0 to 1000.0% (0.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings 2500 SPU Settings and descriptions 72 tP-A3 Tuning point (PID group A3) 73 P-A4 Proportional band (PID group A4) 100.0 0.0 to 1000.0% (0.0: On-off control) 74 I-A4 Integral time (PID group A4) 0 to 3600sec (0: no integral operation) 75 d-A4 Derivative time (PID group A4) 0 76 rE-A4 Manual reset (PID group A4) 77 CP-A4 Switching point (PID group A4) 4000 SPU 0 50.
DCP552 Parameter Work Sheet ■ Setup data setting No.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings Settings and descriptions 34 C 34 Manipulated variable in PV overrange (CH1) 0.0 –5.0 to +105.0% 35 C 35 MANUAL change mode (CH1) 0 0 : Smooth 1 : Preset 36 C 36 Preset MANUAL value (CH1) 0.0 –5.0 to +105.0% 37 C 37 End of operation (CH2) 0 0 : READY mode 1 : END mode 38 C 38 Manipulated variable in READY 0.0 mode (CH2) -5.0 to +105.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings Settings and descriptions 61 C 61 Programming system 0 0 : RAMP-X and RAMP-T (θ) combined 1 : RAMP-X and RAMP-E (∆SP) combined 62 C 62 Program time unit 0 0 : Hours, min (SPU/hour for RAMP-T) 1 : Min, sec (SPU/min for RAMP-T) 2 : 0.
DCP552 Parameter Work Sheet No. Item code Item Factory default User settings settings Settings and descriptions 95 C 95 Voltage output tuning (CH1) 15 2 to 22mA 96 C 96 Voltage output tuning (CH2) 15 2 to 22mA 97 C 97 Communication port 0 0 to 15 Uses back plate terminal to setting 0. Uses loader jack to setting 1 to 15. 98 C 98 Special function 0 0 to 255 99 C 99 PV1 zener barrier adjustment — –20.00 to +20.00 100 C100 PV2 zener barrier adjustment — –20.00 to +20.
DCP552 Parameter Work Sheet ■ Fixed command control data (CH1) setting No. Item code Item Factory default User settings settings 0 Settings and descriptions 1 ConSt Control mode 0 : Program run mode 1 : Fixed command control mode 2 SP Set point 0 Within setup C66 to C67 setting (SP limit) 3 P Proportional band 100.0 0.0 to 1000.0% (0.
Index -AADV • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5-27, 5-28 Alarm • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 10-2 Attachment (orig) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 11-7 AUTO • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5-25, 5-27 Auto-tuning (AT) • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 6-16 Auxiliary device (orig) • • • • • • • • • • • • • • • • • • • • • • • • 11-7 Auxili
Mode • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5-24 Mode display LED • • • • • • • • • • • • • • • • • • • • • • • • • 2-2, 2-3 Mode event • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 5-15 Mode transition• • • • • • • • • • • • • • • • • • • • • 5-26 5-27, 5-28 Model number • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1-5 Mounting bracket • • • • • • • • • • • • • • • • • • • • • • • • • 3-4, 11-7 Mounting position • • • • •
Revision History Printed Date Manual Number 97-12 98-05 EN1I-6187 Edition Revised pages 1st Edition 2nd Edition Fly leaf 98-11 3rd Edition 00-11 4th Edition 01-12 5th Edition Description Addition of comment SAFETY PRECAUTIONS deleated i to viii Page i, ii, iii deleated 5-4 3rd item on NOTE Select ∆ SP setting→Select θ setting 5-20 Pare of explanation changed 5-27 Pare of Lise changed 6-6 Drawing and explanation replaced 6-7, 6-8 Explanation Handling Precautions (unit:%C)→(unit:%) 7-6 Section o
Printed Date Manual Number 01-12 EN1I-6187 Edition 5th Edition Revised pages 5-10 7-29 7-35 7-36 9-9 10-9 Description Diagrams of PV1-PV2 differential upper limit, PV1-PV2 differential lower limit, PV1-PV2 differential upper limit during automatic PV channel selection and PV1-PV2 differential upper limit during automatic PV channel selection deleted No.
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