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demig DE-CP Series Operating Instructions Manual

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Demig Prozessautomatisierung GmbH
Operating instructions
Control system of the
series DE-CP
V.24/06/001
Chapter: Introduction • 1
Bedienungsanleitung Control system of the series DE-CP

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  • Page 1 Demig Prozessautomatisierung GmbH Operating instructions Control system of the series DE-CP V.24/06/001 Chapter: Introduction • 1 Bedienungsanleitung Control system of the series DE-CP...

  • Page 2: Table Of Contents

    Demig Prozessautomatisierung GmbH Table of contents Chapter: Introduction ..........................4 Introductory notes ............................4 1.1.1. General handling ............................4 1.1.2. CE conformity ..............................4 1.1.3. Installation instructions ......................... 5 1.1.4. Structure of this instruction manual ..................5 1.1.5. Security icons ..............................5 1.1.6.
  • Page 3 Demig Prozessautomatisierung GmbH 6.2.1. Memory buffering maintenance ....................37 6.2.2. Cleaning and maintenance of the membrane keypad and screen 37 Cards/ Power Supply ..........................37 6.3.1. Types and position in the device ..................... 37 6.3.2. Exchange of cards (DE-CP X2X only with external ECB bus) ....... 38 6.3.3.

  • Page 4: Chapter: Introduction

    • 1.1.2. CE conformity The control systems of the DE-CP series comply with the standards and directives listed in the declaration of conformity. In order to ensure that these are adhered to, the following must be observed by you: It is the responsibility of the commissioning engineer to comply with all •...

  • Page 5: Installation Instructions

    Customer repairs to the control system are not permitted • • In case of improper use of the regulatory system, as well as violation of the listed provisions, the company demig process automation assumes no liability, and the associated declaration of conformity loses its validity. 1.1.3. Installation instructions When delivering your control system, inspect it for damage.

  • Page 6: Disclaimer

    1.2.1. General system description The process controllers of the DE-CP series have been developed on the basis of many years of experience from both control and process engineering aspects, whereby great attention has been paid to adaptability to the tasks set and operability.

  • Page 7: The Program Structure

    Demig Prozessautomatisierung GmbH The operation of the configuration software for the configuration of the displayed function blocks such as digital/analog inputs and outputs, internal PLC as well as the definition of the controller structures and the symbolic programming can be foand in the operating instructions "Operation and service description configuration software".
  • Page 8 Demig Prozessautomatisierung GmbH The principle of this programming philosophy is that process programs each consist of a sequence program and a parameter set. Sequence program contains the actual process phases ("heating", "cooling", etc.) with the associated process data (setpoints, section times, etc.).

  • Page 9: General Information On The Operation Of The Control System

    General information on the operation of the control system The control system of the DE-CP series is operated by a multi-level menu. Depending on the type, the entries are made via the touch screen, a connected mouse, the internal membrane keyboard or an externally connected PC keyboard.

  • Page 10: Menu

    Demig Prozessautomatisierung GmbH 1.3.1. Menu 1.3.1.1. Menu bar The selection of a main or submenu item is done via a menu bar, which is displayed at the edge of the screen. The position can be adjusted individually. Touchscreen The menu items (functions) are called up directly by finger press on the touch screen.

  • Page 11: System For Alarms And Messages

    Demig Prozessautomatisierung GmbH .. the number of alarms and messages. By pressing with finger pressure or mouse you get directly into the processing area..Date and time..the IP addresses of the plant controller. By pressing with finger press or mouse, the IP addresses are updated.

  • Page 12: General Key Assignment

    Demig Prozessautomatisierung GmbH 1.3.4. General key assignment 1.3.4.1. Membrane keyboard on the controller and external PC keyboard Membrane Function keyboard keyboard Help system (display of topic-related help "F1" texts) Special function (see respective specification in the menu), e.g.: Initiating Save Operations •...
  • Page 13 Demig Prozessautomatisierung GmbH Switch to Testing • Special function (see respective specification in the menu), e.g.: Change access permission • "F7" Copy the program module & paste it • behind it Show an alphanumeric keypad • Special function (see respective specification in the menu), e.g.:...
  • Page 14 Demig Prozessautomatisierung GmbH Forward movement between input fields • Special function (see respective specification in the menu), e.g.: Abort of input operations without data • transfer "ESC" Exit the current menu level to the next • higher Jump to ESC field •...

  • Page 15: The Help System

    Demig Prozessautomatisierung GmbH Change of sign • Insert or delete rows • Delete button Deletes the character after the current cursor "Del" Shift position. 1.3.5. The Help System The control system help system is designed in such a way that the operator presses the “F1/?”...

  • Page 16: Definitions

    Demig Prozessautomatisierung GmbH 1.3.6. Definitions 1.3.6.1. Programs Sequence program Program consisting of preconfigured program blocks (process phases) ( see 4. Chapter: "Edit") Program blocks preconfigured process phases (e.g., program start, heating, cooling) from which sequence programs are created ( see 4. Chapter: "Edit")
  • Page 17 Demig Prozessautomatisierung GmbH Measurements Measurements graphical display (line diagram) of the process variable curve of completed, stored treatment processes Trend bar chart display as trend barometer of current processsize deviations (see 3. Chapter: "Trend") Alarms Important events in the process flow that must be acknowledged by the operator (see 8.
  • Page 18 Demig Prozessautomatisierung GmbH Manual function, through which manual interventions are possible for current process variables Automatic function, which resets manual interventions to automatic mode for current process variables Compensation Compensation function with which the analog inputs of a configured actual encoder can be adjusted...

  • Page 19: Submenu: Commands

    Demig Prozessautomatisierung GmbH Chapter: GUI Submenu: Commands The following steps are offered in the submenu: Commands Commands Start Stop Reset Time Shift Manually Controls Step chains back to previous menu Operation of the controller with start, stop and reset of...

  • Page 20: Submenu: Time Difference

    Demig Prozessautomatisierung GmbH Configured step chains to control processes. Step chains 2.1.1. Time difference Increase step Decrease step Close Left Right Set value Help size size With this function, the current temporal position in the process program can be changed by shifting the process time bar.
  • Page 21 Demig Prozessautomatisierung GmbH manual intervention during the running process. The operator can Manually change process variables of the current process program. Downshift to automatic. Automatic Chapter: GUI • 21 Bedienungsanleitung Control system of the series DE-CP...

  • Page 23: Submenu: Program Management

    Demig Prozessautomatisierung GmbH Submenu: Program Management following steps are offered in the submenu: Program management Program management Active Program memory Switch system Load Delete back to previous menu Switch system Switch to a different control system. Load a process program from the data memory into the memory of Load the control system.

  • Page 24: Submenu: Active

    Demig Prozessautomatisierung GmbH 2.2.1. Active Program management Active Active Prog. Active Param. Sys. Param. With this function, a current sequence program consisting of preconfigured program modules (process phases) can be created or changed. The operator is automatically guided to the necessary entries of the variable data.
  • Page 25 Demig Prozessautomatisierung GmbH Test the created or modified program. Test With this function, the curves of ramp data of the individual setpoint channels created in the sequence programs can be displayed graphically and numerically for test purposes. Open Right Help...

  • Page 26: Submenu: Program Memory

    Demig Prozessautomatisierung GmbH Error window Open the error window to display program errors. Editing the current parameter set Active Param. Editing of system parameters Sys. Param. 2.2.2. Program memory Program management Program memory Program Parameter Proc.Progr.. Table With this function, a program can be created or changed in the program memory of the controller.
  • Page 27 Demig Prozessautomatisierung GmbH With this function, a sequence program can be created or Program changed from the program memory, which consists of preconfigured program blocks (process phases). Remove Close Open Save Test Error window Help Ramp Ramp back to the previous menu.
  • Page 28 Demig Prozessautomatisierung GmbH Select Scaling. Scale Left Right Select the program section. Zoom Zoom Reset Toggle zoom on and off. Insert a new ramp into the existing program. Ramp Remove Delete ramp from existing program. Ramp Open the error window to display program errors.
  • Page 29 Demig Prozessautomatisierung GmbH Create a new flow program. Save the created or modified program. Save Test the created or modified program. Test With this function, the curves of ramp data of the individual setpoint channels created in the sequence programs can be displayed graphically and numerically for test purposes.
  • Page 30 Demig Prozessautomatisierung GmbH Append a new row to the selected one Add Row Move selected row up Move the selected row down Down Delete row Delete Row Chapter: GUI • 30 Bedienungsanleitung Control system of the series DE-CP...

  • Page 31: Submenu: Delete

    Demig Prozessautomatisierung GmbH 2.2.3. Delete Deselect Select Close Delete Go back to the previous menu. Close Select Select all offered files. Deselect Deselect all offered files. Delete selected files. Delete Chapter: GUI • 31 Bedienungsanleitung Control system of the series DE-CP...

  • Page 33: Submenu: Measurements

    Demig Prozessautomatisierung GmbH Submenu: Measurements The following steps are offered in the submenu: Measurements Measurements Active Archived Config. Delete back to previous menu After selecting the desired recorder, the active recording is displayed in a Active line chart. After selecting the desired recorder, a selection menu with all or recorder-...

  • Page 35: Submenu: Alarms

    Demig Prozessautomatisierung GmbH Submenu: Alarms The following steps are offered in the submenu: Alarms Alarms Alarms Messages The alarm and reporting system is designed in such a way that certain plant and process-related situations trigger alarms or messages, e. g., via the internal PLC.

  • Page 36: Chapter: Service And Technical Data

    Demig Prozessautomatisierung GmbH Chapter: Service and technical data Abstract Warning In order to prevent loss of treatment programs and measurement recordings, a data backup should be carried out before any intervention in the hardware of the system! This chapter describes how necessary maintenance work is carried out, •...

  • Page 37: General Maintenance

    3.3.1. Types and position in the device The flexibility of the control systems of the DE-CP series is not only due to the configuration and commissioning software, but also to the large number of available hardware extensions. These expansion cards can be combined with each other as desired.

  • Page 38: Exchange Of Cards (De-Cp X2X Only With External Ecb Bus)

    Demig Prozessautomatisierung GmbH 3.3.2. Exchange of cards (DE-CP X2X only with external ECB bus) Possible reasons for changing cards: Replacement of the card in case of defect • Additional card for e.g., plant expansion, modernization, automation • The replacement of cards, which are inserted into the device from behind and screwed, can be carried out by the personnel themselves, taking into account the following procedure.Service...

  • Page 39: Disturbances

    Demig Prozessautomatisierung GmbH 3.3.3. Disturbances Hardware-related faults can have very different characteristics and can be detected in different ways. The spectrum ranges from a total failure of the entire system to the incorrect display of process variables. Possible measures for troubleshooting...
  • Page 40 Demig Prozessautomatisierung GmbH Interference with digital Checking the mating Disconnect the mating and analog inputs and plugs for correct fit plug and plug it in outputs again Communication errors Check cable If necessary, replace between controllers connections, check cables or interfaces,...
  • Page 41 (Support@demig.de). In conversation, the technician can use the checklist and specific questions to narrow down the fault location and initiate measures more easily more effectively.
  • Page 42 As a rule, loaner devices are provided free of charge. e) Serviceuse Of course, technicians can also be requested directly from demig Prozessautomatisierung GmbH or via the respective plant manufacturers. This refers to the task areas software or hardware.

  • Page 43: Update Of The System Software

    3.4.2. Performing the update with "FileTranferManager" The program "FileTransferManager (FTM)" can be downloaded from the website of demig Prozessautomatisierung GmbH. This makes it much easier to perform an update. The description of the procedure is presented in a separate operating manual, which can also be downloaded.

  • Page 44: Connection Types With The Control System

    3.5.1. Network connection (Ethernet) The control system of the DE-CP series can either be integrated into a network via a fixed IP or assigned a dynamic IP via a DHCP server. The settings are made in the menu "Utilities function Settings".
  • Page 45 Once the connection between the PC and the control system has been established, the access password will be asked: Password for read access: demig Password for full access: DEcontrol Chapter: Service and technical data • 45 Bedienungsanleitung Control system of the series DE-CP...
  • Page 46 Demig Prozessautomatisierung GmbH With "OK" the password is transferred and the slider screen is displayed on the 3.5.2.2. Changing VNC Passwords The passwords for read or full access can be changed in the control system. To do this, exit the control program with "Alt" + "X" (or "Shift" + "F8" on the membrane keyboard).
  • Page 47 Demig Prozessautomatisierung GmbH Here the new password can be assigned (consisting of 5-8 numbers and/or letters, upper and lower case!). For verification, after entering the new password for the first time, it must be repeated in the next step. In the following screen, the new password for read access is then requested: This must also consist of 5-8 numbers and/or letters and must also be re- entered for verification.

  • Page 48: Order Numbers For Spare Parts

    Demig Prozessautomatisierung GmbH Order numbers for spare parts Sales contact details: Phone +49 (0) 271 77202-32 E-mail: vertrieb@demig.de 3.6.1. Power supplies Article Designation Description 340 435 24V Power supply 120W/24V 5A 3.6.2. I/O Cards Article Designation Description 601 613 AD8 Card Dual Sensor...

  • Page 49: Communication

    Demig Prozessautomatisierung GmbH 3.6.3. Communication Article Designation Description 551 408 Profi-Bus connector axial with switchable termination 551 416 Profi-Bus plug 90° with switchable termination 602 600 Plug DP with Pt100 analog connection DP 602 618 DP connection cable Connection Module DP 3.6.4.

  • Page 50: Specifications

    COM DE9 DIN-RS232/RS422/RS485 externally expandable • 1x USB 3.1 Gen.2 Type-C • 2x USB 3.1 Gen.2 Type A • 1x USB Demig IO • Various protocols integrated: e.g. ModBus TCP and RTU (Master/Slave) • Profibus/Profinet communication "optional" (Master/ Slave) •...
  • Page 51 Demig Prozessautomatisierung GmbH Hint: In the DE-CP Control Systems, all serial interfaces (COM1) are galvanically connected to the internal device groand. In contrast, the shielding is galvanically isolated from the internal device groand. Interference possibilities are given when electrical devices (e.g., printer, PC) are connected to the interfaces of the DE-CP, in which no galvanic isolation from the internal groand to the shielding / protective conductor is present.

  • Page 52: Installation And Installation

    Demig Prozessautomatisierung GmbH 3.7.1.3. Operation Membrane keypad (according to DIN EN 60529 protection class IP65) • (DE-CP 3XX-01 only) Touch display (according to DIN EN 60529, protection class IP 65) (DE-CP • 5XX-01 only) Externally connectable USB keyboard and mouse •...

  • Page 53: Installation Dimensions And Aperture Dimensions

    Demig Prozessautomatisierung GmbH 3.7.3. Installation dimensions and aperture dimensions 3.7.3.1. DE-CP 32X-01 • Aperture dimension 10" approx. 400x235x4mm Cutout 10" 382x217mm • Installation depth: approx. 105mm • max. wall thickness 6mm • Weight 10" approx. 4.3 kg • 3.7.3.2. DE-CP 34X-01 Aperture 10"...
  • Page 54 Demig Prozessautomatisierung GmbH 3.7.3.3. DE-CP 52X-01 Aperture 15" approx. 395x318x4mm • Cut-out 15" 379x302mm • Installation depth: approx. 105mm, • Max. wall thickness 6mm • Weight 15" approx. 5.6 kg • 3.7.3.4. DE-CP 54X-01 Aperture 15" approx. 395x318x4mmCut-out 15" 379x302mm •...
  • Page 55 Demig Prozessautomatisierung GmbH 3.7.3.5. Installation material 10" and 15" panel housing mounting kit Article number: 394210 Adapter frame 10" Item number: 390998 Mounting kit adapter frame 10" Article number: 394210 Adapter frame 15" Item number: 390975 Mounting Kit Adapter Frame 15"...

  • Page 56: Chapter: Appendix

    Demig Prozessautomatisierung GmbH Chapter: Appendix Compensation Compensation instructions 4.2.1. Why a compensation? The analog input cards (e.g. AD8-Cards) contain circuits which, through environmental temperature influences and component tolerances, provide varying values when compiling analogous variables (e.g. 0-20 mA) in legible and processable digital values for the processor.
  • Page 57 Demig Prozessautomatisierung GmbH Processed Signal Value (e.g. digital) Input Signal Value EW 1 EW 2 (e.g.. analog) As a result, the input values (EW1, EW2) of the characteristic curve A have a clearly higher output value (processed signal value) than is the case with characteristic curve B.
  • Page 58 Demig Prozessautomatisierung GmbH Processed Signal Value (e.g. digital) Offset Value Input Signal Value (e.g. analog) 4.2.2. Compensation for the DE-CP The process controllers DE-CP offer a combined compensation process for offset (point 1) and amplification (point 2) for the exact processing of the analog input values.
  • Page 59 Demig Prozessautomatisierung GmbH measurement voltage of the O -probe, resp. of the CO -analyzer but with the menu point “C-level (steel) compensation“. What happens with "Restore factory settings"? When this function is selected, the previously inputted compensation values are deleted. That means that the offset is set to 0 and the amplification is set to 1.
  • Page 60 Demig Prozessautomatisierung GmbH measurement range larger than the first value (approx. 75% of the measurement range). The implementation is identical to that of the first point. • Calculation of the control system after the compensation The process controller contains a table in which the distinguishing properties of the characteristic curve are saved.
  • Page 61 Demig Prozessautomatisierung GmbH Processed Characteristic Curve Signal Value before the Compensation (e.g. digital) Characteristic Curve Actual2 after the compensation Setpoint 2 Actual 1 Offset Value Setpoint 1 Input Signal Value (e.g. analog) With a complete compensation (compensation of both points), the values of...
  • Page 62 Demig Prozessautomatisierung GmbH processes like e.g. dew point measurement, CO analyzer, O -probe and Lambda-probe are also suitable for the analyze of the furnace atmosphere. Notice: In order to receive an accurate measuring result, and thus an accurate correction value, it is obligatory to respect precisely the measuring instructions of the single measuring processes.
  • Page 63 Demig Prozessautomatisierung GmbH 4.2.3.2. Measuring process for C-level specification In this operating manual, the functional descriptions of the different measuring processes, to determine the furnace atmosphere, are not detailed. For further information we recommend the following literature: „Die Prozeßregelung beim Gasaufkohlen and Einsatzhärten“, AWT-expert committee 5, working team 4 –...
  • Page 64 Demig Prozessautomatisierung GmbH Instructions for adjusting the controller parameters (PID) 4.3.1. The DE-CP in the loop First, as a brief instruction in the technical control application area of the controllers DE-CP, here is a schematic display of the closed loop.
  • Page 65 Demig Prozessautomatisierung GmbH W a r ni n g : The editing of parameters is a security function! Incorrect parameters can lead to system disturbances, systems damages, quality losses as well as danger to people and environment may be the result of it. To avoid these risks it is necessary that only instructed and authorized people operate the system (compare code function).
  • Page 66 Demig Prozessautomatisierung GmbH 4.3.2.1. What means PID? To better anderstand the setting of the controller parameters, first a few explanations of the PID-Character of the control system. PID-controllers consist of three components, which work together to achieve the best possible controller efficiency. They are shown below for clarification...
  • Page 67 Demig Prozessautomatisierung GmbH u(t) y(t) u(t) y(t) If these three components are combined ander consideration of a time component, which will not be mentioned here in detail, the following curve progression will result at the output of the controller after an erratic change of the input.
  • Page 68 Demig Prozessautomatisierung GmbH −  − − In practice, this formula is not as important as the variables to be adjusted. (=) P-Part X (in ‰) = 1000 ‰/ K (=) I- Part (=) D- Part In practice, this TV = has been proved useful.
  • Page 69 Demig Prozessautomatisierung GmbH 4.3.3. Experimental designation of the controller parameters The literature describes more possibilities for optimizing the controller parameters, but not all of them are suitable for this purpose. The problem is that the loop is not known in its dynamic behavior. It must be analyzed with the help of a test.
  • Page 70 Demig Prozessautomatisierung GmbH Actual Value Temperature in °C Time in Minutes Preheat to a temperature near to the Analysis area for the test future operating point 6. Draw a straight line parallel to the timeline, through the actual value that was set before the test (here 60°C).
  • Page 71 Demig Prozessautomatisierung GmbH 7. Draw a vertical line from the test start and from the intersection of both straight lines. The time between these two lines is the time "T " (here, approx. 12 min.). Actual Value Temperature in °C...
  • Page 72 Demig Prozessautomatisierung GmbH Actual Value Temperature in °C Time in Minutes Preheat to a temperature near to the Analysis area for the test future operating point With the help of these two values, the increase speed V can now be calculated: In this example, "dx"...
  • Page 73 Demig Prozessautomatisierung GmbH In the Example:   1440 1440  mill  4.3.3.2. Further settings in the controller block In the controller block of the control system not only PID parameters may be set, but also further settings may be done.
  • Page 74 Demig Prozessautomatisierung GmbH For parameter optimization follow this instruction: Start with the optimization of the PID parameters of the tracking controller. Therefore the action of the guiding controller has to be switched off. This will be done by setting KF=100% (option I), or KF=0% (option II). Normally it is recommended to parameterize the tracking controller as PI-controller with =0s.

  • Page 75: Country Code

    Demig Prozessautomatisierung GmbH Languages 4.4.1. Country code Chapter: Appendix • 75 Bedienungsanleitung Control system of the series DE-CP...

  • Page 76: Offsite Backup

    This software is bandled with the free Windows configuration software. The latest version of the software package "ConfigPlus" can be downloaded after registration on the homepage of demig Prozessautomatisierung GmbH. Through this tool, all files from the control system can be backed up and restored to an external PC.

  • Page 77: File Structure Of The Control System

    Demig Prozessautomatisierung GmbH File structure of the control system The system software with the associated configuration as well as the process-dependent data are stored in files with the following file extensions in the memory of the control system: 4.6.1. Procedure-dependent files...

  • Page 78: System Configuration Files

    Demig Prozessautomatisierung GmbH 4.6.4. System configuration files Ending Content *. AW8 Instruction list for configuring the analog input card(s) *. AD8 program translated by AWL8.EXE *. LS8 Program Listing *. Awl Instruction list for the PLC program *. O PLC program translated by AWL.EXE *.

  • Page 79: Feature

    Demig Prozessautomatisierung GmbH 4.6.5. Feature In the case of multi-system control, certain files are plant-related; their endings then change as follows: 1. Appendix 2.Appendix until 8. Appendix *. Prg *. PR2 *. PR8 *. Par *. PA2 *. PA8 *. Wp *.

  • Page 81: Index

    Demig Prozessautomatisierung GmbH Index Feature 78 General handling 1 General information on the operation of the control system 5 General key assignment 9 General system descriptio 3 GUI 17 Alarms 15 Amplification 55 Appendix 55 Automatic 16 Help System 13...
  • Page 82 Demig Prozessautomatisierung GmbH Restore factory settings 58 Num. display 14 Security icons 2 Sequence program 5, 14 Offset 55, 56 Service and Technical data 35 Order numbers 47 Softkeys 16 Communication 48 Specifications 49 Connector 48 Status Rows 7 I/O-Cards 47...

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