Honeywell DCP552 Mark II manual

EN1I-6187 Issue 5 (12/01) DCP552 Mark ΙΙ Digital Control Programmer User ’ s Manual[...]

W ARRANTY The Honeywell device described her ein has been manufactur ed and tested for corr ent operation and is warranted for a period of one year . TECHNICAL ASSIST ANCE If you encounter a pr oblem with your unit, please r eview all the configuration data to verify that your selections ar e consistent with your application; (i.e. Inputs, Outputs,[...]

Unpacking i 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 u[...]

ii 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 typ[...]

Contents iii Unpacking Configuration of This User ’ s Manual Conventions Used in This Manual Chapter 1. PRODUCT OUTLINE 1-1 Features •••••••••••••••••••••••••••••••••••••••••••••••• 1-1 1-2 Basic Function Block Diagram •••••••••••[...]

iv 4-6 PV Input (Analog Input) Connection •••••••••••••••••••••••••••• 4-7 ■ PV input CH1 connection ••••••••••••••••••••••••••••••••• 4-7 ■ PV input CH2 connection •••••••••••••••••••?[...]

v Chapter 6. OPERA TION 6-1 Power Supply On ••••••••••••••••••••••••••••••••••••••••• 6-1 6-2 Basic Display Selection •••••••••••••••••••••••••••••••••••• 6-2 ■ Program run mode displays ••?[...]

vi ■ Setting G.SOAK (Guarantee soak) items ••••••••••••••••••••• 8-13 ■ Setting PV shift items •••••••••••••••••••••••••••••••••• 8-14 ■ Setting repeat items •••••••••••••••••••••••••?[...]

vii ■ Self-diagnostic routines performed each sampling cycle ••••••••• 10-1 ■ Self-diagnostic routines performed continuously during operation • 10-1 ■ Alarm code display •••••••••••••••••••••••••••••••••••• 10-2 ■ Alarm classification ••••?[...]

viii 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 :N otes 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 corr[...]

Chapter 1. PRODUCT OUTLINE 1 - 1 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[...]

1 - 2 Basic Function Block Diagram 1-2 Chapter 1. PRODUCT OUTLINE Input 1 •Thermocouple • Resistance temperature detector •DC current •DC voltage • Root extraction • Approximation by linearization table •Bias •Filter Input 2 •Thermocouple • Resistance temperature detector •DC current •DC voltage •O 2 sensor • Root extrac[...]

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. ● Parameters[...]

1 - 4 System Configuration 1-4 ■ 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. PRODUCT OUTLINE PC DCP552(slave station) RS-232C RS-[...]

1 - 5 Model Number 1-5 Chapter 1. PRODUCT OUTLINE Basic mode l number PV input count Carbon potential Additional processing Option E 2 1 0 0 1 2 00 DCP552 Contents Digital programmable controller (dual-loop control) Mark II 2 channels Not provided Provided Not provided Auxiliary output channel 1 Auxiliary output channel 2, comm[...]

Chapter 2. NAMES AND FUNCTIONS OF P ARTS 2 - 1 Structure The DCP552 consists of a main unit, console, case, and terminal base. 2-1 Console Provides 7-segment displays, LEDs, operation keys, and a loader interface unit. Terminal base Provides terminals to connect a power supply, input, output, event output, external switch input, and auxiliary[...]

2 - 2 Console 2-2 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). Key operations make it possible to change from the basic displa[...]

2-3 ● 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[...]

2-4 ■ Key pad Chapter 2. NAMES AND FUNCTIONS OF PARTS : Program key (PROG key) : Run/hold key (RUN/HOLD key) : Display key (DISP key) : Message key (MESSAGE key) PROG RUN/HOLD DISP MESSAGE : Left key ( ← key) : Right key ( → key) : Up key ( ↑ key) : Down key ( ↓ key) : Load key (LOAD key) : Save key (SAVE key) LOAD SAVE : Auto/manual key [...]

2-5 Chapter 2. NAMES AND FUNCTIONS OF PARTS[...]

2-6 ■ Key chord functions PROG + RUN/HOLD : Reset key Press the RUN/HOLD key while holding down the PROG key in basic status display to perform a RESET. The READY mode is invoked when a reset is performed in the RUN, HOLD, FAST, END, or READY FAST modes. This RESET operation does not work in the READY mode. PROG + DISP : Advance key Press the DIS[...]

2-7 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 h[...]

2 - 3 Input T ype and Range Number 2-8 ■ Input ● Thermocouple ● Resistance temperature detector (RTD) Chapter 2. NAMES AND FUNCTIONS OF PARTS Input type Symbol Code Accuracy (under standard conditions) ± 0.1%FS       ± 0.3%FS at -200 to -45 ˚ C ± 4.0%FS at 0 to 260 ˚ C,  ± 0.15%FS at 260 to 800 ˚ C     [...]

2-9 ● DC current, DC voltage *• The O 2 sensor is manufactured by one of the following companies: Nihon Gaishi (NGK), Marathon Monitors, Cambridge, Corning, AACC (Advanced Atmosphere Control Corporation), Barber Colman or Furnace Control. •PV2 in models with carbon potential compensation is tied to the O 2 sensor. Handling Precautions •The [...]

Chapter 3. INST ALLA TION AND MOUNTING 3- 1 Before Installation ■ Mounting position Do not install the DCP552 in locations: •exposed to high or low temperature or humidity. •exposed to direct sunlight or to the elements such as outside. •exposed to water, oil or chemicals. •exposed to corrosive or inflammable gas. •exposed to dust or sm[...]

3-2 ■ Sources of electrical interference and countermeasures •The following list notes common sources of electrical interference. (1) Relays and contacts (2) Solenoid coils and valves (3) Power lines (especially those carrying more than 90V AC) (4) Inductive loads (5) Inverters (6) Motor rectifiers (7) Phase angle control SCR (8) Wireless commu[...]

3 - 2 Installation This section describes installation procedures. ■ Panel cutout dimension Use 2mm thick steel panels in setting up the DCP552 . 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[...]

3-4 ■ Installation procedures •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 de[...]

Chapter 4. WIRING 4 - 1 Precautions on W iring 4-1 CAUTION Connect the controller as specified using designated cables and connection procedures. Failure to heed this caution may lead to electric shock, fire or malfunction. Make sure that wire scraps, chips or water do not enter inside the case of the controller . Failure to heed this caution may l[...]

4-2 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[...]

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[...]

4 - 3 Making T erminal Connections 4-4 To connect a line to the terminals, use crimp-style solderless wire connectors that fit an M3.5 screw. 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 disconnecte[...]

4 - 4 T erminal Array Wires are connected to the terminal base according to the layout shown below. 4-5 64 63 62 61 60 59 58 57 56 55 54 43 44 45 46 48 49 50 51 52 53 39 40 31 32 27 28 23 24 20 22 10 11 89 67 18 19 45 16 17 3 15 12 13 14 12 26 25 30 29 34 33 38 37 41 COM1 COM2 56 7 8 12 3 4 5 1 6 2 7 3 8 4 11 9 12 10 16 14 15 13 DO COM1 DO COM2 LOA[...]

4 - 5 Power Supply and Grounding 4-6 ■ Power supply To supply power to the DCP552 , use an instrument-dedicated single-phase power supply subject to minimal electrical interference. Handling Precautions • If electrical interference proves excessive, we recommend adding an insulating transformer and/or using a line filter. model No.: 81446364-00[...]

4 - 6 PV Input (Analog Input) Connection ■ 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. ■ PV input CH2 connection PV input CH2 is a multi-input type input for sensors. Connect as shown below, according to the type of sensor being used. 4-7 Chapt[...]

4-8 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 ● Current output (5G, 5S) ● Voltage output (6D) Handling Precautions The voltage output is a constant current circuit inside. The SSR used is set to an optimum voltage to meet the requirements of the load. Enter the value in the setup data. A normal SSR voltage has been set at the factory before shipment. ● Ope[...]

4 - 8 Auxiliary Output Connection 4-10 ■ Auxiliary output CH1 connection ■ Auxiliary output CH2 connection Chapter 4. WIRING W ARNING Be sure to turn off the power supply when you connect the controller . Failure to do so may lead to electric shock or fire.[...]

4 - 9 Event Output (Open Collector Output) Connection Handling Precautions • Do not short-circuit the positive (+) terminal of the external power supply to terminals (5) to (8), (17) to (20), (10), (11), (22), (23), (27), (28), (31), and (32) on the DCP552 . Doing so causes the open collector outputs to malfunction. (There is no short-circuit pre[...]

4 - 10 External Switch Input Connection 4-12 ● Internal circuit diagram of the DCP552 connecting external switch input Handling Precautions • The inputs of the DCP552 unit are provided with a built-in power supply (open voltage type, 8.5V DC). Always use no-voltage contacts externally. • For the no-voltage contacts, use gold contacts or other[...]

4 - 1 1 Communication Connection ■ RS-485 connection 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 ter[...]

4-14 ● 5-wire system RS-485 connection diagram Attach 1/2W or greater terminating resistances of 150 Ω ±5% at each end of the communications lines. Ground the shield FGs at one end in one location, not at both ends. SDA SDB RDA RDB SG FG SDA Shield SDB RDA RDB SG Shield Shield Master station Terminating resistor Terminating resistor Terminatin[...]

4-15 ● 3-wire system RS-485 connection diagram Attach 1/2W or greater terminating resistances of 150 Ω ±5% at each end of the communications lines. Ground the shield FGs at one end in one location, not at both ends. When only three RS-485 terminals are provided, the areas designated with an asterisk ( * ) are connected internally. SDA SDB RDA [...]

4-16 ■ RS-232C connection Handling Precautions • Connect the slave station to the master station in a single-drop (point-to- point) configuration. • There are three (SD, RD and FG) communications terminals on the RS- 232C interface on the master station which may not output data if not short-circuited as shown above. NOTE RS-232C connector si[...]

4-17 ■ Connection to ST221 Handling Precautions • Attach 1/2W or greater terminating resistances of 150 Ω ±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 60 61 62 63 64 SG 3 4 1 2 5 ST221DE05DCP SDA SDB RDA RDB[...]

4 - 12 Isolation Between Input and Output 4-18 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. Handling Precautions The loader jack is not isolated from internal digital circuits. When not in use, always replace the cap[...]

Chapter 5. FUNCTIONS 5 - 1 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 ”. 5-1 Data Parameter Variable parameter Constant value control data (CH2) Setup data PID parameter data (CH1) Event configuration data Program Pattern PV sh[...]

5 - 2 Program Pattern 5-2 ■ 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 syst[...]

5-3 ● 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 e[...]

5-4 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:[...]

5-5 ■ 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[...]

5-6 •An On Time ≥ Off Time setting cannot be made. (See segment 3C in the figure.) •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 RA[...]

5-7 •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.) •An On Time and Off Time occurring at the end of a RAMP-X segment are val[...]

5-8 •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 usin[...]

5-9 •E vent 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 st[...]

5-10 Chapter 5. FUNCTIONS SP upper limit H EV SP SP lower limit H EV SP MV upper limit H EV MV MV lower limit H EV MV[...]

5-11 ● 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 [...]

5-12 ● 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 [...]

5-13 •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,[...]

5-14 •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 design[...]

5-15 ● 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 RE[...]

5-16 ■ 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 s[...]

5-17 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 betwe[...]

5-18 • 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[...]

5-19 ■ 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 t[...]

5-20 ■ 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. PV starts are of three [...]

5-21 ■ 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. During cycle operation, the [...]

5-22 ■ 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 eter[...]

5-23 ■ Ta g 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 ch[...]

5 - 3 Mode 5-24 ■ Mode types Modes are listed below. ● 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. ● READY READY indicates that the program is ready to run[...]

5-25 ● 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[...]

5-26 ■ 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. NOTE • AUTO ↔ MANUAL mode changes can be made in the boxes of each mode. •READY and END at the end of operation can be selected using setup data C31 . •CH1 and CH2 mo[...]

5-27 ■ 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 key[...]

5-28 ■ 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. ❍ : Valid operation ❁ : Operation from basic display status valid ∆ : Returns to the first segment remaining in the READY mode. ❑ : Operation is i[...]

5 - 4 Input Process Functions This section uses diagrams to describe input processes. ■ Model without carbon potential (CP) compensation NOTE The use of equalizer (approximation by linearization table) is shown in the figure below. When a sensor with curved characteristics is used to measure PV, a linearization table is used. 5-29 Chapter 5. FUNC[...]

5-30 ■ Model with carbon potential (CP) compensation Chapter 5. FUNCTIONS Analog input 1 Cold junction compensation Wiring resistance compensation A/D conversion Input range type Square-root extraction Equalizer (approximation by linearization table) Equalizer (approximation by linearization table) Upper and lower limit alarm Temperature unit ran[...]

5-31 ■ O 2 sensor check (model with CP compensation) ● Objective As the O 2 sensor starts to deteriorate, its output impedance increases. This function checks sensor output impedance and turns on the O 2 sensor error event when the impedance exceeds 130k Ω . ● Setting •One of the values set for setup data C71 to C74 is set to 11 to assign[...]

5 - 5 Output Processing Functions 5-32 ■ Control output CH1 Control output CH1 is processed as shown below. ● Current output (with setup data C21 set to 1) Chapter 5. FUNCTIONS Initialization of PID control computation Output deviation limiter PID control computation Setting: PID parameter P / l / d / rE (for CH1) Setup data C23 Setting: variab[...]

5-33 ● Voltage, Open collector output (with setup data C21 set between 2 to 5) Chapter 5. FUNCTIONS Initialization of PID control computation Output deviation limiter PID control computation Setting: PID paramete P / l / d / rE (for CH1) Setup data C23 Setting: variable parameter PA17 , PA43 Setting: variable parameter PA14 Upper and lower output[...]

5-34 ■ Control output CH2 Control output CH2 is processed as shown below. ● 5G output (with setup data C22 set to 1) Chapter 5. FUNCTIONS Initialization of PID control computation Output deviation limiter PID control computation Setting: PID parameter P / l / d / rE (for CH2) Setup data C24 Setting: variable parameter PA27 , PA96 Setting: varia[...]

5-35 ● Voltage, Open collector output (with setup data C22 set between 2 to 5) Chapter 5. FUNCTIONS Initialization of PID control computation Output deviation limiter PID control computation Setting: PID paramete P / l / d / rE (for CH2) Setup data C24 Setting: variable parameter PA27 , PA96 Setting: variable parameter PA24 Upper and lower output[...]

5-36 ■ 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 2 Auxiliary output 2 is processed as shown below on a model with two auxiliary output channels. Chapter 5. FUNCTIONS Auxiliary output 1 type Setting: setup data C45 Setting: setup[...]

Chapter 6. OPERA TION 6 - 1 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 clo[...]

6 - 2 Basic Display Selection 6-2 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[...]

6-3 ■ 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. ● Display A1 ● Display A2 ● Display A3 When used in MANUAL mode, the number of digits [...]

6-4 ● 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. ● Display A6 Select Hours and Minutes, Minutes and Seconds or 0.1 Seconds in the t[...]

6-5 ● DISP key function (when variable parameter PA03 is set to 1) Cycles through display B1 → display B2 → display B3 → display B4 → display B5 display B6 → display B1 → ··· ● Display B1 ● Display B2 ● Display B3 When used in MANUAL mode, the number of digits available for output values flashes. Chapter 6. OPERATION[...]

6-6 ● 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. In the setup data, also select Remaining Segment Time or Total Running Time. Chapter 6. OPERATION[...]

6-7 ● 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. Handling Prec[...]

6-8 ● 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. Handling Precautions •M odels with CP computation compensation the CH2 PV values have the following meaning depending on variable parameter PA44 [...]

6-9 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 ● Display E2 ● Display E3 In MANUAL mode, the number of digits available for output va[...]

6-10 ● 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 i[...]

6-11 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. • Press the PROG key when the program or segment number starts flashing to cycle through[...]

6-12 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 [...]

6-13 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 O 2 sensor check function cannot be disabled by SW15 and SW16. ■ Selecting programs • Programs can be selected using the external switches in the READY [...]

6-14 Chapter 6. OPERATION ● Binary system Handling Precautions • When a program number of 0 is set using the external switch inputs, programs can be selected using the console keys and by transmission. • Program numbers 1 to 39 can be selected in the BCD system.[...]

6-15 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[...]

6-16 Chapter 6. OPERATION 6 - 5 Manual Operation and Auto-T uning ■ 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 p[...]

6-17 Chapter 6. OPERATION • The point at which output reverses (lower limit ⇔ upper limit) during auto- tuning 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[...]

Chapter 7. P ARAMETER SETUP 7 - 1 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 indi[...]

7-2 ■ 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 w[...]

7-3 • Example of individual item matrix (setup data) C01 C91 C11 C81 C91 C02 C92 C12 C82 C92 C03 C93 C13 C83 C93 C09 C99 C19 C89 C99 C10 C100 C20 C90 C100 C01 C02 C03 C09 C10 C01 C100 ↑ ↓ ← → ↑ ↓ ← → ↑ ↓ ← → Chapter 7. PARAMETER SETUP[...]

7 - 2 Parameter Setting List 7-4 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 [...]

7-5 ■ V ariable parameter setting PA01 PA01 PA02 PA 01 PA 02 PA 03 PA 04 PA 05 PA 06 PA 07 PA 08 PA 09 C21 PA 10 C21 PA 11 PA 12 PA 13 PA 14 PA 15 PA 16 PA 17 PA 18 PA 19 PA 20 PA 21 PA 22 PA 23 PA02 PA01 PA02 Chapter 7. PARAMETER SETUP[...]

7-6 PA 24 PA 25 PA 26 PA 27 PA 28 PA 29 PA 30 PA 31 PA 32 PA31 PA 33 PA 34 PA33 PA 35 PA 36 PA35 PA 37 PA 38 PA37 PA 39 PA 40 PA 41 PA 42 PA 43 PA 44 PA 45 PA 46 C62 C62 Chapter 7. PARAMETER SETUP[...]

7-7 PA 47 PA 48 PA 49 PA 50 PA 51 C30 PA 52 PA 53 PA 54 PA 55 PA 56 PA 57 PA 58 PA 59 PA 60 PA 61 PA 62 PA 63 PA 64 PA 65 PA 66 PA 67 PA 68 PA 69 PA 70 PA 71 C30 PA 72 PA 73 PA 74 PA 75 PA 76 PA 77 PA 78 PA 79 PA 80 PA 81 PA 82 PA 83 PA 84 PA 85 PA 86 PA 87 PA 88 PA 89 PA 90 PA 91 PA 92 Chapter 7. PARAMETER SETUP[...]

7-8 PA 93 PA 94 C22 PA 95 C22 PA 96 PA 97 PA 98 PA 99 PA 100 PA 101 PA97 PA 102 PA 103 PA 104 PA 105 PA 106 PA 107 PA 108 PA 109 PA 110 PA 111 PA 112 PA 113 PA 114 PA 115 PA 116 PA 117 PA 118 PA 119 PA 120 Chapter 7. PARAMETER SETUP[...]

7-9 ■ Detailed information on variable parameters ● PA01 (keylock) 0: keylock disabled 1: display of setup data setting disabled 2: display of all settings disabled 3: 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 + CL[...]

7-10 • 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 [...]

7-11 ● 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.[...]

7-12 ■ Event configuration data settings ■ E01-t E02-t E01-2 E01-1 E02-1 E02-2 E03-t E03-1 E03-2 E04-t E04-1 E04-2 E05-t E05-1 E05-2 E06-t E06-2 E06-3 E07-t E07-1 E07-2 E08-t E08-1 E08-2 E09-1 E09-t E09-2 E10-t E10-1 E10-2 E11-t E11-1 E11-2 E12-t E12-1 E12-2 E13-t E13-1 E13-2 E14-t E14-1 E14-2 E15-t E15-1 E15-2 E16-t E16-1 E16-2 Chapter 7. PARA[...]

7-13 ■ Settings by event type For information on event operations, see “ ■ Events ” (pages 5-5 to 5-14) . Chapter 7. PARAMETER SETUP[...]

7-14 *1 : Code event auxiliary setting 1 (number of output points) can be changed only in the READY mode. *2 : Auxiliary setting 1 (number of output points) can be changed only in the READY mode. Chapter 7. PARAMETER SETUP[...]

7-15 Chapter 7. PARAMETER SETUP[...]

7-16 *1: The meaning of auxiliary setting 1 for special segment is shown below. –2: Two segments before the final segment 1: First segment –1: One segment before the final segment 2: Second segment 0: Final segment *2: When auxiliary setting 1 of RAMP-E time monitoring is set to 0.0 sec, event output is off. *3: Auxiliary setting 1 and auxiliar[...]

7-17 Chapter 7. PARAMETER SETUP[...]

7-18 ■ PID parameter (CH1) setting P l d rE oL oH CP tP P l d rE rE P l d d rE oL oH oL oH CP tP P I D P-1 I-1 d-1 rE -1 oL-1 oH-1 P-2 I-2 d-2 rE-2 oL-2 oH-2 P-3 I-3 d-3 rE-3 oL-3 oH-3 P-4 I-4 d-4 rE-4 oL-4 oH-4 P-5 I-5 d-5 rE-5 oL-5 oH-5 P-6 I-6 d-6 Chapter 7. PARAMETER SETUP[...]

7-19 rE-6 P-7 oH-6 oL-6 I-7 d-7 rE-7 oL-7 oH-7 P-8 I-8 d-8 rE-8 oL-8 oH-8 P-9 I-9 d-9 rE-9 oL-9 oH-9 P-A1 I-A1 d-A1 CP-A1 rE-A1 tP-A1 P-A2 I-A2 d-A2 rE-A2 CP-A2 tP-A2 P-A3 I-A3 d-A3 rE-A3 CP-A3 tP-A3 P-A4 I-A4 d-A4 rE-A4 CP-A4 tP-A4 P-A5 I-A5 Chapter 7. PARAMETER SETUP[...]

7-20 d-A5 tP-A5 CP-A5 rE-A5 P-A6 I-A6 d-A6 rE-A6 CP-A6 tP-A6 P-A7 I-A7 d-A7 rE-A7 CP-A7 tP-A7 Chapter 7. PARAMETER SETUP[...]

7-21 ■ PID parameter (CH2) setting P l d rE oL oH CP tP P l d rE rE P l d d rE oL oH oL oH CP tP P I D P-1 I-1 d-1 rE -1 oL-1 oH-1 P-2 I-2 d-2 rE-2 oL-2 oH-2 P-3 I-3 d-3 rE-3 oL-3 oH-3 P-4 I-4 d-4 rE-4 oL-4 oH-4 P-5 I-5 d-5 rE-5 oL-5 oH-5 P-6 I-6 d-6 Chapter 7. PARAMETER SETUP[...]

7-22 rE-6 P-7 oH-6 oL-6 I-7 d-7 rE-7 oL-7 oH-7 P-8 I-8 d-8 rE-8 oL-8 oH-8 P-9 I-9 d-9 rE-9 oL-9 oH-9 P-A1 I-A1 d-A1 CP-A1 rE-A1 tP-A1 P-A2 I-A2 d-A2 rE-A2 CP-A2 tP-A2 P-A3 I-A3 d-A3 rE-A3 CP-A3 tP-A3 P-A4 I-A4 d-A4 rE-A4 CP-A4 tP-A4 P-A5 I-A5 Chapter 7. PARAMETER SETUP[...]

7-23 d-A5 tP-A5 CP-A5 rE-A5 P-A6 I-A6 d-A6 rE-A6 CP-A6 tP-A6 P-A7 I-A7 d-A7 rE-A7 CP-A7 tP-A7 Chapter 7. PARAMETER SETUP[...]

7-24 ■ Setup data setting C 01 C01 C0 2 C01 C01 C02 C01 C02 C01 C02 C01 C02 C01 C02 C01 C02 C01 C0 3 C01 C01 C0 4 C01 C0 5 C0 6 C01 C0 7 C01 C0 8 C01 C0 9 C01 C1 0 Chapter 7. PARAMETER SETUP[...]

7-25 C 11 C01 C 12 C11 C11 C12 C11 C12 C11 C12 C11 C12 C11 C12 C11 C12 C11 C 13 C11 C11 C 14 C 15 C 16 C11 C 17 C11 C 18 C11 C 19 C11 C 20 C11 Chapter 7. PARAMETER SETUP[...]

7-26 C 21 C2 2 C2 4 C2 3 C2 5 C2 6 C2 7 C2 8 C2 9 C3 0 C3 2 C3 1 C3 3 C C C C C Chapter 7. PARAMETER SETUP[...]

7-27 C 39 C 40 C 41 C 42 C 44 C 43 C 51 C 52 C4 8 C5 3 C5 4 C5 5 C5 6 C4 5 C45 C45 C4 6 C4 7 C48 C48 C4 9 C5 0 Chapter 7. PARAMETER SETUP[...]

7-28 C5 7 C5 8 C5 9 C6 0 C6 1 C6 2 C6 3 C6 4 C6 5 C6 6 C01 C06 C66 C67 C6 7 C6 9 C11 C16 C69 C70 C69 C70 C7 1 C7 0 C6 8 C7 2 C7 3 C7 4 C7 5 Chapter 7. PARAMETER SETUP[...]

7-29 C97 C76 C7 6 C97 C7 7 C97 C7 8 C97 C7 9 C97 C8 0 C8 1 C8 2 C8 3 C8 5 C8 6 C8 7 C8 8 C8 9 C9 0 C9 1 C9 2 C9 3 C9 4 C8 4 C 95 C9 6 C76 C80 C9 7 C9 8 I Chapter 7. PARAMETER SETUP[...]

7-30 -20.00 to +20.00 [Description:] “----” is displayed when PV1 is not an RTD input and C98 is not equal 241. ---- C 99 99 PV1 zener barrier adjustment -20.00 to +20.00 [Description:] “----” is displayed when PV2 is not an RTD input and C98 is not equal 241. ---- C100 100 PV2 zener barrier adjustment Item code Item No. User settings Setti[...]

7-31 ■ 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. ● C08 (PV1 square root extracti[...]

7-32 ● 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 remaini[...]

7-33 ● 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) a[...]

(3) Equivalent circuit showing connection of n SSRs Equations (3) and (4) below must be satisfied. V SSR/MIN ≤ I 0 × Z+V D ≤ V 0 /N Equation (3) V SSR' ≤ V SSR/MAX Equation (4) (V SSR' = I 0 × Z + V D ) (4) Equivalent circuit showing parallel connection of n SSRs Equations (5) and (6) below must be satisfied. V SSR/MIN ≤ I 0 /N [...]

7-35 ● 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, short- circuit A and B on the resistance temperature detector. (2) Turn on the DCP552 and set setup data C98 to 241. ([...]

7-36 ■ Constant value control data (CH1) setting ■ Constant value control data (CH2) setting ConSt C69 C70 SP P P I P d P I rE oL oH ConSt C66 C67 SP P P I P d P I rE oL oH Chapter 7. PARAMETER SETUP[...]

Chapter 8. PROGRAM SETUP 8 - 1 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 o[...]

8-2 ■ 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 th[...]

● 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 p[...]

8-4 ■ 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 [...]

8-5 ■ Display items Items displayed are shown in the figure below. ■ Setting pattern items (1) In the set value display state, move to the segment pattern item to be set 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 set the first setti[...]

8-6 ● 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. – : event off[...]

8-7 ■ 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.[...]

8-8 ● 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:[...]

8-9 ● 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 ran[...]

8-10 ● 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 2 n [...]

8-11 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 i[...]

8-12 ■ 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 [...]

8-13 ■ 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 [...]

8-14 ■ 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:[...]

8-15 ■ 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 [...]

8-16 ■ 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 [...]

8-17 ■ 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 [...]

8-18 ■ 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 [...]

8-19 ■ 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 [...]

8-20 ■ 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.)[...]

8-21 ■ 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[...]

8-22 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 indicatio[...]

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 PR[...]

8-24 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[...]

9-1 Chapter 9. MEMOR Y CARD OPERA TIONS 9 - 1 Memory Card T ype 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 DCP5[...]

9 - 2 Save Procedures 9-2 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[...]

9-3 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. ■ Procedures for saving single programs This procedur[...]

9-4 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[...]

9-5 Chapter 9. MEMORY CARD OPERATIONS ■ Procedures for saving PID parameters This procedure saves PID parameters and constant value control data on a memory card. ■ Procedures for saving event configuration data This procedure saves event configuration data on a memory card. ■ Procedures for saving all parameters This procedure saves all para[...]

9 - 3 Load Procedures 9-6 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 wron[...]

9-7 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 [...]

9-8 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[...]

9-9 Chapter 9. MEMORY CARD OPERATIONS ■ Procedures for loading event configuration data This procedure loads event configuration data on the memory card onto the DCP552 . ■ Procedures for loading all parameters This procedure loads all parameters on the memory card onto the DCP552 . Handling Precautions The DCP552 Mark II and the old model, DCP[...]

9 - 4 Autoload 9-10 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 : [...]

9-11 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 o[...]

9 - 5 Error Message List 9-12 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, pre[...]

Chapter 10. TROUBLESHOOTING 10 - 1 Self-Diagnostic Functions and Alarm Code Displays 10-1 The DCP552 is equipped with the self-diagnostic functions described below. Alarm codes and the result of self- diagnostics are listed on the following pages. ■ Power ON self-diagnostic routines ● RAM backup failures This routine is designed to detect error[...]

10-2 ■ 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 fro[...]

10 - 2 Key Input Related Problems Procedures to correct key input related problems are described below. ■ Normal display mode problems ● Modes and channels cannot be changed using keys ● Program number does not start flashing when PROG key is pressed ● RUN mode cannot be invoked with the RUN/HOLD key ● HOLD mode cannot be invoked with the[...]

10-4 ● ADV cannot be invoked with PROG and DISP keys ● FAST mode cannot be invoked with FUNC and → keys ● MANUAL mode cannot be invoked with A/M key ● AUTO mode cannot be invoked with A/M key ● Autotuning (AT) cannot be started with AT key PA08 PA93 PA08 PA93 PA08 PA93 PA01 PA01 P P PA01 C62 ConSt PA01 ConSt PA01 Chapter 10. TROUBLESHOO[...]

10-5 ● Autotuning cannot be canceled with AT key ● PID parameter setting state cannot be invoked with PID key ● Event configuration setting state cannot be invoked with FUNC and PARA keys ● Setup data setting state cannot be invoked with SETUP key ● Fixed command control data setting state cannot be invoked with FUNC and PID keys ● Prog[...]

10-6 ● General reset cannot be performed with FUNC, CLR and MESSAGE keys ■ Parameter setting related problems ● Registration state cannot be invoked with ENTER key ■ Program setting related problems ● Registration state cannot be invoked with ENTER key ● Item changes cannot be made with ↑ and ↓ keys ● SP values in program settings[...]

10-7 ● PID group, output limiter group number items cannot be displayed with ↑ and ↓ keys ● G.SOAK items, PV shift items and repeat items cannot be displayed with ↑ and ↓ keys ● PV start items, cycle items and pattern link items cannot be displayed with ↑ and ↓ keys ● Segment insertion and deletion cannot be confirmed with FUNC [...]

10-8 10 - 3 When the BA T LED Flashes Handling Precautions Batteries that have been stored for long periods have been subject to self- discharge and have a short service life. If required, buy new batteries. ■ BA T LED flashes The BAT LED starts flashing when low battery voltage is detected. The voltage level set in memory that trigger the LED is[...]

10-9 ● Battery replacement procedures Handling Precautions • Replace the old battery with a lithium battery (model No.:81446140- 001). 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 th[...]

10-10 (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.[...]

10-11 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. [...]

11-1 Chapter 1 1. SPECIFICA TIONS 11 - 1 Specifications θ µ µ µ µ µ µ[...]

11-2 Chapter 11. SPECIFICATIONS[...]

11-3 µ Chapter 11. SPECIFICATIONS[...]

11-4 Chapter 11. SPECIFICATIONS[...]

11-5 × × Chapter 11. SPECIFICATIONS[...]

11-6 Chapter 11. SPECIFICATIONS[...]

11-7 ■ Attachment/auxiliary devices list Chapter 11. SPECIFICATIONS[...]

11-8 Chapter 11. SPECIFICATIONS 11 - 2 External Dimensions ■ DCP552 ■ Soft dust-proof cover set (optional) Model No. : 81446141-001 (silicon rubber , transparent) 143 147 13 1 1 9 55 131 143 147 2.9 2 Unit : mm 64 63 62 61 60 59 58 57 56 55 54 52 53 51 50 49 48 47 46 45 44 43 42 41 39 40 38 37 35 36 34 33 31 32 30 29 27 28 26 25 23 24 13 12 14 [...]

Chapter 12. CALIBRA TION 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. T[...]

12 - 1 Quick Reference T able for Calibration Items 12-2 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[...]

12-3 Table 12-2. Item and Sub Item Table for Calibration 0000 1011 1111 2022 1111 6066 1111 AdJS AdJS AdJS 7077 1111 AdJS Chapter 12. CALIBRATION[...]

12-4 Figure 12-1. Calibration Flowchart (1/3) Chapter 12. CALIBRATION 0 0 0 1 1.0.1.1. AdJS 00000 AdJS 00000 AdJS 0.0.0.0. 0.0.0.0. AdJS 0 0 0 0 0 0 0 3 0 0 0 4 0 0 0 5 0 1 0 0 0 1 0 1 0 1 0 2 0 1 0 3 0 0 0 4 0 1 0 5 1.1.1.1.[...]

12-5 Figure 12-1. Calibration Flowchart (2/3) Chapter 12. CALIBRATION 0 2 0 1 6.0.6.6. AdJS 0.0.0.0. 2.0.2.2. AdJS 0.0.0.0. 0 0 0 2 0 2 0 2 0 2 0 8 0 2 0 9 0 6 0 0 0 6 0 1 0 6 0 2 0 6 0 8 0 6 0 9 1.1.1.1. 1.1.1.1.[...]

12-6 Figure 12-1. Calibration Flowchart (3/3) Chapter 12. CALIBRATION 7.0.7.7. AdJS 0.0.0.0. 0 0 0 7 0 7 0 1 0 7 0 2 0.0.0.0. 1.1.1.1.[...]

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. RUN LED is OFF HLD LED is OFF MAN LED is OFF Figure 12-2. (3) To en[...]

12-8 ■ 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. Upp[...]

12-9 ● 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[...]

12-10 ● 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) spec[...]

12-11 ● Built-in clock adjustment Figure 12-4. Example: A: 2 digits of calendar year 1993 ……………………93 B: Month April ……………………04 C: Day 5th day …………………05 D: Hour (24 hour system) 3PM ……………………15 E: Minute 6 minutes ………………06 F: Second Not changeable NOTE 1. ↑ , ↓ , ← , ?[...]

12-12 ● 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 SE[...]

12-13 Table 12-10. Chapter 12. CALIBRATION[...]

12-14 ■ 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) Pres[...]

12-15 ● 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 am[...]

12-16 ● 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 co[...]

12 - 3 Set Up Figure 12-5. Thermocouple Inputs Figure 12-6. RTD Inputs Figure 12-7. RTD Inputs Figure 12-8. mV, V, Inputs Figure 12-9. mA Inputs Figure 12-10. CJ, O 2 Sensor 12-17 Chapter 12. CALIBRATION[...]

12-18 Figure 12-11. Current Outputs Chapter 12. CALIBRATION[...]

DCP551/552 Program Work Sheet Program No. Preparation date: Equipment name: Product name : [ Pattern graph ] SP (Unit : ) [ Programming Map ]  1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Program contents (1)SP (2)Time, θ , ∆ SP (1) (2) (1) (2) (1) (2) (1) (2) (1) (2) (1) (2) (1) (2) (1[...]

User name : Preparation date : Equipment name : Product name : Model No. : DCP552 Tag name : Instrumentation staffer in charge : Business staffer in charge : 1 DCP552 Parameter Work Sheet ■ V ariable parameter setting No. Item code Item Factory default User Settings and descriptions settings settings 1 PA 01 Key lock 0 0 : Keylock disabled 1: Dis[...]

2 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 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 3000.0sec 39 PA 39 FAST X 0 0 : 2 X 1: 10 X 2: 60 X 3: 120 X 40 PA 40 CP computa[...]

3 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 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 +[...]

4 No. Item code Item Factory default User Settings and descriptions settings settings 111 PA111 CP computation compensation 1.000 0 to 2000 SPU (CH2) No.6 compensation point 112 PA112 CP computation compensation 0.000 -1000 to +1000 SPU (CH2) No.6 compensation amount 113 PA113 CP computation compensation 1.200 0 to 2000 SPU (CH2) No.7 compensation [...]

5 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 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 [...]

6 DCP552 Parameter Work Sheet Event Meaning Setting Operation Auxiliary settings type category category 0 Event off ----- ----- Auxiliary 1 : None Auxiliary 2 : None 1 Time event Segment Time Auxiliary 1 : None Auxiliary 2 : None 2 PV upper limit Segment PV Auxiliary 1 : Hysteresis Auxiliary 2 : None 3 PV lower limit 4 Deviation upper limit 5 Devia[...]

7 DCP552 Parameter Work Sheet Event Meaning Setting Operation Auxiliary settings type category category 24 to 63 Event off ----- ----- Auxiliary 1 : None Auxiliary 2 : None 64 Normal PV1 upper limit operation Measuring instrument PV Auxiliary 1 : Hysteresis Auxiliary 2 : Operating point 65 Normal PV1 lower limit operation 66 Normal PV2 upper limit [...]

8 DCP552 Parameter Work Sheet Event Meaning Setting Operation Auxiliary settings type category category 143 Event off ----- ----- Auxiliary 1 : None Auxiliary 2 : None 144 Battery voltage drop Measuring instrument Mode 145 to 253 Event off ----- -----[...]

9 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 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)[...]

10 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 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% (0.0: On-off control) 38 I-7 Integral time (PID group 7) 0 [...]

11 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 72 tP-A3 Tuning point (PID group A3) 2500 SPU –19999 to +20000 SPU 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 0 to 3600sec (0: no integral operation) 75 [...]

12 No. Item code Item Factory default User Settings and descriptions settings settings 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 g[...]

13 No. Item code Item Factory default User Settings and descriptions settings settings 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% (0.0: On-off control) 38 I-7 Integral time (PID group 7) 0 0 to 3600sec (0: no integral[...]

14 No. Item code Item Factory default User Settings and descriptions settings settings 72 tP-A3 Tuning point (PID group A3) 2500 SPU –19999 to +20000 SPU 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 0 to 3600sec (0: no integral operation) 75 d-A4 Derivative time (PID gr[...]

15 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 1 C 01 PV1 range number 0 0 to 16 : Thermocouple 48 to 52 : Linear (DC current and DC voltage) 64 to 71 : Resistance temperature detector 96 to 103 : Resistance temperature detector 128 to 134 : Linear (DC current and DC voltage) 2 C 0[...]

16 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 34 C 34 Manipulated variable in PV 0.0 –5.0 to +105.0% overrange (CH1) 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:[...]

17 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 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: 0.1 sec (SPU/sec for RAMP-T[...]

18 No. Item code Item Factory default User Settings and descriptions settings settings 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 zene[...]

19 DCP552 Parameter Work Sheet No. Item code Item Factory default User Settings and descriptions settings settings 1 ConSt Control mode 0 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% (0.0 : On-off control) 4 I Integral time 0 0 to 3600sec (0[...]

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Index index-1 -A- ADV ••••••••••••••••••••••••••••••••••• 5-27, 5-28 Alarm •••••••••••••••••••••••••••••••••••••••• 10-2 Attachment (orig) ••••••••••••••••••••?[...]

index-2 Mode •••••••••••••••••••••••••••••••••••••••• 5-24 Mode display LED ••••••••••••••••••••••••• 2-2, 2-3 Mode event ••••••••••••••••••••••••••••••••?[...]

Revision History Printed Manual Number Edition Revised pages Description Date 97-12 EN1I-6187 1st Edition 98-05 2nd Edition Fly leaf 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 Drawin[...]

Printed Manual Number Edition Revised pages Description Date 01-12 EN1I-6187 5th Edition 5-10 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 7-29 No.90 Unused → [...]

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No. CP-UM-5025E[...]