Shinko PCD-33A Instruction Manual
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Shinko PCD-33A Instruction Manual

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PROGRAMMABLE CONTROLLER
PCD-33A
INSTRUCTION MANUAL

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  • Page 1 PROGRAMMABLE CONTROLLER PCD-33A INSTRUCTION MANUAL...
  • Page 2 • Any unauthorized transfer or copying of this document, in part or in whole, is prohibited. • Shinko Technos CO., LTD. is not liable for any damage or secondary damage(s) incurred as a result of using this product, including any indirect damage.
  • Page 3 Working on or touching the terminal with the power switched ON may result in severe injury or death due to electric shock. • Be sure to turn the power to the PCD-33A OFF before cleaning. • Use a soft, dry cloth when cleaning the instrument.

  • Page 4: Table Of Contents

    Abbreviations used in this manual Symbol Term Process variable Desired value Output manipulated variable Control output Auto-tuning DC input DC voltage input, direct current input CONTENTS 1. Model 1.1 Model ------------------------------------------------------------------------------------ 5 1.2 Rated input ----------------------------------------------------------------------------- 6 1.3 How to read the model label ------------------------------------------------------- 6 2.

  • Page 5: Model

    1. Model 1.1 Model Fill in the squares with the alphanumeric characters to represent the function or type. [Example] PCD-33A R / M , C5 , – Option: Serial communication Input: Multi-input Control output (OUT): Relay contact output Standard model P C D –...

  • Page 6: Rated Input

    1.2 Rated input (Table 1.2-1) Input type Input range Resolution -200 to 1370 -320 to 2500 1 ( ) -199.9 to 400.0 -199.9 to 750.0 0.1 ( ) -200 to 1000 -320 to 1800 1 ( ) 0 to 1760 0 to 3200 1 ( ) 0 to 1760...

  • Page 7: Name And Functions Of Sections

    2 Name and functions of sections 2.1 Displays and indicators (11) (10) (Fig. 2.1-1) (1) PV display (Red) Indicates the PV (Process variable), or setting characters in the setting mode. (2) SV display (Green) Indicates the SV (desired value) or step SV, or each set value in the setting mode. (3) PTN display (Green) Indicates the Pattern number.

  • Page 8: Keys

    2.2 Keys (18) (17) (12) (16) (13) (15) (14) (Fig. 2.2-1) (12) (Increase Key) : Increases the numeric value on the SV display or switches to the next item. (13) (Decrease Key) : Decreases the numeric value on the SV display or switches to the next item.

  • Page 9: External Dimensions And Panel Cutout

    3.3 Mounting Mountable panel thickness is 1 to 8mm. Insert the PCD-33A from the front of the control panel. Slot the mounting bracket to the holes at the top and bottom of the case, and screw in place.

  • Page 10: Wiring

    • Use the solderless terminal with an insulation sleeve in which the M3 screw fits when wiring the PCD-33A terminals. • The terminal block of the PCD-33A is designed to be wired from the left side. The lead wire must be inserted from the left side of the terminal, and fastened with the terminal screw (M3).

  • Page 11: Terminal Arrangement

    Communication (RS-485) C5 4.1 Terminal arrangement or Set value digital transmission SVTC YA(-) Ground Power supply 100 to 240V AC Event output 24V DC or 24V AC (EVT) YB(+) Control output Relay Non-contact contact External operation voltage input Current Alarm 1 (A1) Insulated power Alarm 2 (A2) output P24...

  • Page 12: Wiring Examples

    Alarm unit Heater Thermocouple Electric furnace * For the relay contact output type (PCD-33A-R/M), it is recommended that a surge absorber be installed between the electromagnetic switch coils to prevent the unit from harmful effects of unexpected high level noise. (Fig.4.2-1)
  • Page 13 SA-500 Alarm unit Alarm unit Thermocouple Heater Electric furnace (Fig.4.2-2) Number of Shinko SSR units when connected in parallel (for Non-contact voltage output): SA-400 series: 5 units SA-500 series: 2 units [PCD-33A-A/M] 3-phase 100 to 240V AC or 24V AC/DC...

  • Page 14: Setup

    Alarm type, Control action, etc. according to the users’ conditions. If the users’ specification is the same as the default value of the PCD-33A, it is not necessary to set up the controller. Proceed to “6. Operation” (p.21).

  • Page 15: Basic Operation For Setup

    (19) Alarm 2 (A2) action delay timer 0 seconds Sets Alarm 2 (A2) action delay timer. (20) Event output function Time signal Selects an Event output type. output (21) Pattern end output time 0sec(Continuous Sets pattern end output time. output) (22) Direct/Reverse control action Reverse...

  • Page 16: Setting Items In Auxiliary Function Setting Mode

    5.3 Setting items in Auxiliary function setting mode 2 : Input type Selects a sensor type and temperature unit. When changing the input from DC voltage to other inputs, remove the sensor connected to this controller, then change the input. If the input is changed while the sensor is connected, the input circuit may break.
  • Page 17 • Selecting item: No decimal point 1 digit after the decimal point 2-digit after the decimal point 3-digit after the decimal point • Default value: (No decimal point) : PV filter time constant Sets the PV filter time constant. This reduces input fluctuation caused by noise. If the input changes in a step, set the time that reaches 63% of the step.
  • Page 18 (12) Alarm 1 (A1) type Selects Alarm 1 (A1) type, referring to 8.5 Alarm 1 (A1) action (pages 48, 49). Note: If an alarm type is changed, the alarm set value becomes 0 (0.0). • Selecting item: No alarm action High limit alarm Low limit alarm High/Low limits alarm...
  • Page 19 (20) Event output function Selects an Event output type from Time signal output, Pattern end output and Run output. When Event output is turned ON, EVT indicator is turned on, and terminals 12 and 13 are used for the Event output. •...
  • Page 20 [Run output] (Fig. 5.3-3) This is outputted during the program control. (Fig. 5.3-3) Temperature Step 1 Step 2 Step 3 Time Program control end Run output OFF Run output ON Run output OFF (Fig. 5.3-3) (21) Pattern end output time Sets pattern end output time after pattern end output has been selected during Event output function selection.

  • Page 21: Operation

    6. Operation Key operation for setup : Selects a program pattern number. : Increases or decreases the numeric value or switches the selecting item. Key : Registers the set value (numeric value) or selected item. By pressing the Key, the controller reverts to the Program standby mode or Program control run mode.

  • Page 22: Operation Flowchart

    6.1 Operation flowchart Power ON Automatically reverts to the Program standby (*2) (*1) mode after data is cleared. Program standby mode Data clearing Each time the key is Program control run mode pressed, the pattern number STEP on the PTN display changes. (Approx.
  • Page 23 • BY pressing the Key, the controller reverts to (*1) or (*2) from any mode. • The setting items with dotted lines are optional, and they appear only when the options are added. (Approx. 3 sec) (Approx. 3 sec) [Auxiliary function [Auxiliary function setting mode 1] setting mode 2]...

  • Page 24: Operation

    6.2 Operation (1) Turn the power supply to the controller ON. For the thermocouple and RTD inputs, the sensor input characters and temperature unit are indicated on the PV display, and the input range high limit value is indicated on the SV display for approx. 3 seconds after the power is turned ON. See (Table 6.2-1).

  • Page 25: Pattern (Step Sv/Time) Setting Mode

    Actual temp. Program pattern 1 is selected. STEP Actual temp. Program pattern 2 is selected. STEP Actual temp. Program pattern 3 is selected. STEP Actual temp. Program pattern 9 is selected. STEP (4) Pattern (step SV/Time) setting mode This mode is available for the currently selected program pattern number. The following is an example of program pattern setting and its procedures.
  • Page 26 Press the Key. Step 1 SV is registered, and STEP Step 1 time setting mode appears. Step 1 time Set the step time to (1:00) using key. STEP • Setting range: to 00:00 to 99:59 (Hour:Minute or Minute:Second) • Default value: 00:00 (Hour:Minute) Press the Key.

  • Page 27: Alarm/Time Signal Setting Mode

    (5) Alarm/Time signal setting mode Alarm/Time signal setting mode is available for the currently selected program pattern number. Settings are available only for the pattern which is now running during program control. Note: To go to the Alarm/Time signal setting mode, select an alarm type except for No alarm action from Alarm 1 (A1) and Alarm 2 (A2) type selection in “5.

  • Page 28: Pid Parameter Setting Mode

    Pattern 1 Time signal output OFF time Sets Time signal output OFF time after running STEP program control. Available only when Time signal output is selected during Event output function selection. • Setting range: 00:00 to 99.59 (Hour:Minute or Minute:Second) •...

  • Page 29: Wait Parameter Setting Mode

    Integral time Sets the integral time. STEP Off when set to 0. Not available for ON/OFF control. • Setting range: 0 to 1000 seconds • Default value: 200 seconds Derivative time Sets the derivative time. STEP Off when set to 0. Not available for ON/OFF control.
  • Page 30 [Program standby mode or Program control run mode] Press the key for 3 seconds while Actual temp. holding down the key. STEP Wait parameter setting mode appears, and (3 sec) Wait value setting item is indicated. [Wait parameter setting mode] Wait value Sets Pattern 1 Wait value.

  • Page 31: Auxiliary Function Setting Mode 1

    [Program standby mode or Program control run mode] Actual temp. STEP Auxiliary function setting mode 1 Settings/Selections in Auxiliary function setting mode 1 are common to all program pattern numbers. [Program standby mode or Program control run mode] Press the Key for 3 seconds while holding Actual temp.
  • Page 32 • Default value: Shinko protocol Instrument number Selects the instrument number. STEP Set the instrument number of the PCD-33A individually when communicating by connecting plural PCD-33A units. Available only when C5/SVTC (option) is added. • Setting range: 0 to 95 •...

  • Page 33: Auxiliary Function Setting Mode

    [Program standby mode or Program control run mode] Actual temp. STEP (9) Auxiliary function setting mode 2 The settings in Auxiliary function setting mode 2 have already been completed in Section “5. Setup” (p.14). (10) Data clearing function This function returns all set values to the default values (See pages 58, 59). This function can only be used during Program standby mode.

  • Page 34: Running

    7. Running [Before running] Before running the controller, check the mounting and wiring carefully, referring to “3. Mounting to the control panel” (p.8) and “4. Wiring” (p.10). Check that settings are applicable for the users’ conditions, referring to “5. Setup” (p.14). 7.1 How to set the program Set the following items, referring to “6.
  • Page 35 [Control action when the program control starts] Program control type selected during the selection phase will initiate. PV start: When the program control starts, step SV and step time are advanced to the PV, then the program control is performed. However, if a value set during “Step SV when control starts”...
  • Page 36 [Action after power is restored] (1) If power failure occurs during the program control run, the control resumes from the point at which power failure occurred. (2) If power failure occurs during Program standby mode, the control resumes from Program standby mode. [Indication during Wait action] PTN display : Selected program pattern number...
  • Page 37 When the program pattern is falling [The Wait function is cancelled at PV (Step SV + Wait value)] Temperature Wait cancellation range The control proceeds to the next The step at which step at PV the Wait funtion was set Step SV=500 Wait value 10 C Time...
  • Page 38 [Indication during Time signal action] If Time signal output is selected during the [Event output function selection], Event output is turned on during time signal output ON time. Time signal output ON time follows time signal output OFF time after the program control starts.

  • Page 39: Stopping Program Control

    The following shows the indication during Run output. PTN display : Selected program pattern number Actual temp. PV display : Current actual temperature STEP Step SV STEP display : Step number of the program control which is running SV display : Current step SV RUN indicator : Lit EVT indicator...

  • Page 40: Switching To Fixed Value Control

    Temperature C Step 1 Step 2 Step 3 1000 Advance Time 01.00 (1 hour) 01.00 (1 hour) 00.40(40min.) Time signal Program control run Turned ON after 1 hour Turned OFF after 1 hour and 20 minutes and 50 minutes Setting Time signal OFF time: 1 hour and 20 minutes, Time signal ON time: 30 minutes (Fig.

  • Page 41: Correcting Pv (Sensor Correction Function)

    [Time signal action during Fixed value control] During the Fixed value control, the time within the step at which Fixed value control was selected is regarded as (00:00). Time signal time measurement is carried out, ignoring this step. Step number Temperature C Advance Step SV=500...

  • Page 42: Auto-Tuning (At)

    [Auxiliary function setting mode 1] Press the Key 3 times. Sensor correction setting item is indicated. STEP Selection (Press 3 times) Set the sensor correction value with the key. STEP Setting range: -100.0 to 100.0 DC input: -1000 to 1000 (The placement of the decimal point follows the selection.) Press the Key.
  • Page 43 [Auto-tuning performing conditions] (A) When processing temperature is lower than [SV –20 (40 )] The AT process will fluctuate at the temperature 20 (40 ) lower than the SV. Temperature 20 (40 ) lower than the SV (1) Calculating PID constant (2) PID constant calculated...
  • Page 44 [If P, I, D, ARW values cannot be changed] • If auto-tuning does not finish in 4 hours after it has started, it will be cancelled automatically, and P, I, D, ARW values return to the value set before the auto-tuning was performed.

  • Page 45: Control And Alarm Action

    [How to cancel auto-tuning] Available only during AT Perform [AT is performing] Press the Key while holding down the Actual temp. key. STEP Step SV The unit enters the PID parameter setting mode, and AT Perform/Cancel item is indicated. [PID parameter setting mode] AT Perform/Cancel selection Press the key.

  • Page 46: Standard Action

    (3) Derivative time (D) Derivative action is used to restore the change in the processing temperature (PV) according to the rate-of-change. It reduces the amplitude of overshoot and undershoot width. If the derivative time is shortened, the restoring value becomes smaller, and if the derivative time is extended longer, an excessive returning phenomenon may occur and the control system may oscillate.

  • Page 47: On/Off Control Action

    8.3 ON/OFF control action Heating (reverse) control action Cooling (direct) control action Hysteresis Hysteresis Control action Relay contact output Non-contact 12V DC 0V DC 0V DC 12V DC voltage output Current 20mA DC 20mA DC 4mA DC 4mA DC output Indicator (OUT1) Green Unlit...

  • Page 48: Alarm 1 (A1) And Alarm 2 (A2) Action

    8.5 Alarm 1 (A1), Alarm 2 (A2) action High limit alarm Low limit alarm A1 hysteresis A1 hysteresis Alarm action + A1 + A1 value value value value + side + side Alarm output side side High/Low limits alarm High/Low limit range alarm A1 hysteresis A1 hysteresis Alarm action...

  • Page 49: Other Functions

    High/Low limits alarm with standby A1 hysteresis Alarm action value value Alarm output : A1 output terminals 7 and 8 are closed (ON). A1 output terminals 7 and 8 are closed (ON) or opened (OFF). : A1 output terminals 7 and 8 are opened (OFF). Standby functions.
  • Page 50 Automatic cold junction temperature compensation (Only thermocouple input type) This detects the temperature at the connecting terminal between the thermocouple and the instrument, and always maintains it at the same status as if the reference junction location temperature was at 0 (32 ).

  • Page 51: Specifications

    10. Specifications 10.1 Standard specifications Model : Programmable controller Name : PCD-33A Mounting : Flush Setting : Input system using membrane sheet key Display PV display : Red LED display 4 digits, character size, 18(H) x 8(W)mm SV display : Green LED display 4 digits, character size, 12.6(H) x6(W)mm PTN display : Green LED display 1 digit, character size, 12.6(H) x 6(W) mm...
  • Page 52 Setting resolution Step SV : Refer to Section “1.2 Rated input” (p. 6). Step time : 1 minute or 1 second Status after power is restored: The control resumes from the point at which power failure occurred. (Progressing time error after power is restored: Max. 1 minute) Controlling action •...
  • Page 53 : 100 to 240V AC 50/60Hz, 24V AC/DC 50/60Hz For the supply voltage, 100 to 240V AC is standard. For 24V AC/DC, “1” is entered after the model PCD-33A-x/M. Allowable voltage fluctuation: 100 to 240V AC: 85 to 264V AC...

  • Page 54: Optional Specifications

    Circuit insulation configuration Communication Power Event output supply Control output (OUT) External operation Alarm 1 (A1) output Alarm 2 (A2) output or Input Insulated power output (P24) When the control output (OUT) is non-contact voltage or current, A is not electrically insulated from B, and A is not electrically insulated from C. Insulation resistance or more, at 500V DC for other combinations except those mentioned above.

  • Page 55: Troubleshooting

    If SVTC option is added, external operation function cannot be used. If Set value digital transmission is selected during Communication protocol selection, step SV of the PCD-33A can be transmitted digitally to a maximum of 31 units of Shinko controllers with communication function (C5 option).
  • Page 56 <Indication> Problem Presumed cause and solution • Thermocouple or RTD is burnt out. ] is flashing [Thermocouple] on the PV display. If the input terminals of the instrument are shorted, and if a value around room temperature is indicated, the instrument is likely to be operating normally, however, the sensor may be burnt out.
  • Page 57 Problem Presumed cause and solution ] is indicated • Internal memory is defective. on the PV display. Contact our agency or us. <Keypad operation> Problem Presumed cause and solution It is impossible to select • The program control is running. a program pattern Change the mode.

  • Page 58: Character Table

    12. Character table Photocopiable material <Pattern (Step SV/Time) setting mode> Setting item Default value Data Step No. PV display Step 1 SV Step 1 time 00.00 (H:M) Step 2 SV Step 2 time 00.00 (H:M) Step 3 SV Step 3 time 00.00 (H:M) Step 4 SV Step 4 time...
  • Page 59 Step No. PV display Set value lock Unlock SV high limit 1370 SV low limit -200 Sensor correction Communication protocol Shinko protocol Instrument number Communication speed 9600bps Parity Even Stop bit <Auxiliary function setting mode 2> Setting item Default value Data Step No.

  • Page 60: Program Pattern Graphing

    13. Program pattern graphing Before setting the program, graph a program pattern and data table. Copy the program pattern table, and follow the procedures below. (1) Write down the program pattern number. (2) From Step 1, write down the step SV and step time of each step in sequence. (3) Write down Alarm 1 (A1) and Alarm 2 (A2) values and Time signal output time.
  • Page 61 This page is deliberately left blank.
  • Page 62 Program pattern (Pattern number) Step number (Desired value) Step SV ( Step time (Hour:Minute) Wait function Used/Not used Wait value P (Proportional band) I (Integral time) D (Derivative time) Proportional cycle Time signal output...
  • Page 64 For any inquiries about this unit, please contact our agency or the vendor where you purchased the unit after checking the following. [Example] • Model --------------------------- PCD-33A-R/M • Option --------------------------- C5 • Serial number ----------------- No. xxxxxx In addition to the above, please let us know the details of the malfunction, or discrepancy, and the operating conditions.

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