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Honeywell DCP552 Mark II User Manual

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ΙΙ
DCP552 Mark
Digital Control Programmer
User's Manual
EN1I-6187
Issue 5 (12/01)

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  Summary of Contents for Honeywell DCP552 Mark II

  • Page 1 ΙΙ DCP552 Mark Digital Control Programmer User’s Manual EN1I-6187 Issue 5 (12/01)
  • Page 2: Technical Assistance

    WARRANTY The Honeywell device described herein has been manufactured and tested for corrent operation and is warranted for a period of one year. TECHNICAL ASSISTANCE If you encounter a problem with your unit, please review all the configuration data to verify that your selections are consistent with your application;...
  • Page 3 Unpacking Check the following when removing the DCP552 from its package. 1. Check the model No. to make sure that you have received the product that you ordered. 2. Check the DCP552 for any apparent physical damage. 3. Check the contents of the package against the Package List to make sure that all accessories are included in the package.
  • Page 4: Configuration Of This User's Manual

    Configuration of This User’s Manual This manual is organized as follows. Chapter 1. PRODUCT OUTLINE This chapter explains the use and features of the DCP552 and provides the basic function block and product model numbers. Chapter 2. NAMES AND FUNCTIONS OF PARTS This chapter gives the names and functions of parts of the DCP552, and input type and range number.
  • Page 5: Table Of Contents

    Contents Unpacking Configuration of This User’s Manual Conventions Used in This Manual Chapter 1. PRODUCT OUTLINE 1-1 Features • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 1-2 Basic Function Block Diagram 1-3 Data Configuration Overview 1-4 System Configuration...
  • Page 6 4-6 PV Input (Analog Input) Connection PV input CH1 connection PV input CH2 connection 4-7 Control Output Connection 4-8 Auxiliary Output Connection Auxiliary Output CH1 Connection Auxiliary Output CH2 Connection 4-9 Event Output (Open Collector Output) Connection 4-10 External Switch Input Connection 4-11 Communication Connection RS-485 connection RS-232C connection...
  • Page 7 Chapter 6. OPERATION 6-1 Power Supply On 6-2 Basic Display Selection Program run mode displays Constant value control mode 6-3 Selecting Programs Selecting program numbers 6-4 External Switch Operation External switch input Selecting programs Read timing • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 6-5 Manual Operation and Auto-Tuning Manual operation Auto-tuning (AT)
  • Page 8 Setting G.SOAK (Guarantee soak) items Setting PV shift items Setting repeat items Setting PV start items Setting cycle items Setting pattern link items Setting tag items Deleting programs Inserting and deleting segments 8-2 Copying Programs Program copy procedures 8-3 General Reset •...
  • Page 9: Safety Requirements

    Self-diagnostic routines performed each sampling cycle Self-diagnostic routines performed continuously during operation Alarm code display Alarm classification 10-2 Key Input Related Problems Normal display mode problems Parameter setting related problems Program setting related problems 10-3 When the BAT LED Flashes BAT LED flashes Replacing the battery Chapter 11.
  • Page 10: Conventions Used In This Manual

    Conventions Used in This Manual The following conventions are used in this manual. Handling Precautions NOTE (1)(2)(3) >> DISP key, ↑ key FUNC+PROG key PA01, C21 PV SHIFT : Handling Precautions indicate items that the user should pay attention to when handling the DCP552. : Notes indicate useful information that the user might benefit by knowing.
  • Page 11: Chapter 1. Product Outline

    Chapter 1. 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.
  • Page 12: Basic Function Block Diagram

    1 - 2 Basic Function Block Diagram Input 1 •Root extraction •Thermocouple •Approximation by •Resistance temperature detector linearization table •DC current •Bias •DC voltage •Filter Input 2 •Thermocouple •Root extraction •Resistance temperature detector •Approximation by •DC current linearization table •DC voltage •Bias •O sensor...
  • Page 13: Data Configuration Overview

    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.
  • Page 14: System Configuration

    1 - 4 System Configuration CPL communications network-based configuration Models equipped with the optional communications interface can be connected as a slaved controller to a communications network. In this case, the user can employ as the master station a personal Computer. master station RS-232C RS-232C/RS-485 converter...
  • Page 15: Model Number

    1 - 5 Model Number DCP552E2 Model number : Basic model number DCP552 PV input Carbon Additional Option processing count potential Contents Digital programmable controller (dual-loop control) Mark II 2 channels Not provided Provided Not provided Auxiliary output channel 1 Auxiliary output channel 2, communications Not provided...
  • Page 16: Chapter 2. Names And Functions Of Parts

    Chapter 2. 2 - 1 Structure The DCP552 consists of a main unit, console, case, and terminal base. Console Main unit Console and electric circuit board, etc. NAMES AND FUNCTIONS OF PARTS Provides 7-segment displays, LEDs, operation keys, and a loader interface unit. Case Terminal base Provides terminals to connect a power supply,...
  • Page 17: Console

    2 - 2 Console The console consists of the operation keys, displays and LEDs (light emitting diodes). Basic display status Basic display status shows the running condition of the DCP552 on the console. The basic display status is invoked when the DCP552 is powered up (power on). Key operations make it possible to change from the basic display status to parameter setting status, program setting status, program copy status, memory card operation status and general reset status.
  • Page 18 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.
  • Page 19: Key Pad

    Key pad Do not use pointed objects such as mechanical pencils or pins to press the keys on the controller. This may result in malfunction. : Auto/manual key (A/M key) : PID key (PID key) PARA : Parameter key (PARA key) : CLR key (CLR key) FUNC : Function key (FUNC key)
  • Page 20 Chapter 2. NAMES AND FUNCTIONS OF PARTS DISP FUNC + DISP MESSAGE PROG RUN/HOLD PROG + RUN/HOLD PROG + DISP ® FUNC + ­ ¯ ¬ ® PARA FUNC + PARA SETUP FUNC + PID ­ ¯ ¬ ® ENTER ­...
  • Page 21: Key Chord Functions

    Classification Program setting Erases or resets a set value. (When a set value flickers.) Cancels change in set value. (When a set value flickers.) Inserts or delete a segment when a pattern SP setting is started. Changes RAMP-X pattern SP setting is completed. Starts a program number change.
  • Page 22: Loader Jack

    FUNC + DISP : Display channel select key Press the DISP key while holding down the FUNC key in basic display status to select display channels. In the program setting status, press the DISP key while holding down the FUNC key to select the channel of the program to be set. FUNC + PARA : Event configuration setting key Press the PARA key while holding down the FUNC key in basic status...
  • Page 23: Input Type And Range Number

    2 - 3 Input Type and Range Number Input Thermocouple Input type Symbol Code Range No. K (CA) K (CA) K (CA) K (CA) E (CRC) J (IC) T (CC) B (PR30-6) R (RR13) S (PR10) W (WRe5-26) W23 W (WRe5-26) W14 PR40-20 PL II Ni-Ni •...
  • Page 24: Handling Precautions

    DC current, DC voltage Input type Symbol Code Range No. (Linear) (Linear) (Linear) (Linear) sensor * Carbon potential (CP value) indication range: (Note, however, that PID control is calculated over the 0.000 to 2.000% input range) Oxygen pressure indication range: * •The O sensor is manufactured by one of the following companies: Nihon Gaishi (NGK), Marathon Monitors, Cambridge, Corning, AACC (Advanced Atmosphere Control Corporation), Barber...
  • Page 25: Chapter 3. Installation And Mounting

    Chapter 3. 3 - 1 Before Installation Be sure to turn off the power supply when you are installing or removing the controller. Failure to heed this warning may lead to electric shock. Do not disassemble the controller as this could lead to electric shock or malfunction.
  • Page 26: Sources Of Electrical Interference And Countermeasures

    Sources of electrical interference and countermeasures •The following list notes common sources of electrical interference. •If the source of noise cannot be removed, take the following measures. •Use a CR filter to suppress fast-rising noise. •Use a varistor to suppress high-amplitude interference. Handling Precautions Varistors must be handled carefully as they become defective if they are short-circuited.
  • Page 27: Installation

    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 and below the controller meet specified requirements.
  • Page 28: Installation Procedures

    Installation procedures Mounting (2) •Use the provided mounting bracket to firmly secure the upper and lower panels. •Assemble the instrument before mounting (1). •The rear of the instrument must not be more than 10° above or below the horizontal plane. Mounting bracket Mounting (1) Mounting bracket...
  • Page 29: Chapter 4. Wiring

    Chapter 4. 4 - 1 Precautions on Wiring Connect the FG terminal to ground with a ground resistance of maximum 100Ω before connecting other equipment and external control circuits. Failure to do so may cause electric shock or fire. Be sure to turn off the power supply when you connect the controller. Failure to do so may lead to electric shock or fire.
  • Page 30 Handling Precautions •Before connecting the lines, verify the model number and terminal numbers on the label affixed to the side panel of the DCP552. After completing, always double check to ensure all wiring has been performed correctly before turning on the power. •The I/O signal lines and the communications lines shall maintain at least 50cm between them and the power supply line and power supply cables.
  • Page 31: Recommended Cables

    4 - 2 Recommended Cables To perform thermocouple input, connect a thermocouple element to the terminals. When the wiring distance is long or when connecting the thermocouple without the element to the terminals, connect via shielded compensating lead wires. NOTE •For I/O other than thermocouple, use polyethylene insulated vinyl sheathed cable for JCS-364 shielded instruments or equivalent.
  • Page 32: Making Terminal Connections

    4 - 3 Making Terminal Connections 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 disconnected from the terminals.
  • Page 33: Terminal Array

    4 - 4 Terminal Array Wires are connected to the terminal base according to the layout shown below. COM1 COM2 mV. V LOAD *AUX — — OUT1 OUT2 AUX1 — — mV. V PV CH1 *PV CH2 *COMM MADE IN JAPAN LOAD COM1 COM2...
  • Page 34: Power Supply And Grounding

    4 - 5 Power Supply and Grounding Power supply To supply power to the DCP552, use an instrument-dedicated single-phase power supply subject to minimal electrical interference. 200 to 240/200 to 240V 110 to 120/110 to 120V Insulating transformer Instrument power supply 100 to 240V AC 50/60Hz Other circuits...
  • Page 35: Pv Input (Analog Input) Connection

    4 - 6 PV Input (Analog Input) Connection Current applied to current input terminals (55), (56) and (58), (59) must meet the specified range. Failure to heed this caution may lead to fire or equipment breakdown. PV input CH1 connection PV input CH1 is a multi-input type input for sensors.
  • Page 36 Handling Precautions •Be careful to connect the input polarities correctly. •Use shielded cable to connect the input. ¥DC voltage input 57 58 59 Ð Voltage (mV¥V) transmitter ¥O sensor input 57 58 59 Ð sensor ¥DC current input 57 58 59 Ð...
  • Page 37: Control Output Connection

    4 - 7 Control Output Connection Be sure to turn off the power supply when you are installing or removing the controller. Failure to do so may cause electric shock or fire. Current output (5G, 5S) Load Voltage output (6D) Handling Precautions The voltage output is a constant current circuit inside.
  • Page 38: Auxiliary Output Connection

    4 - 8 Auxiliary Output Connection Be sure to turn off the power supply when you connect the controller. Failure to do so may lead to electric shock or fire. Auxiliary output CH1 connection Auxiliary output CH2 connection 4-10 WARNING 4 to 20mA DC Load resistance less than 600...
  • Page 39: Event Output (Open Collector Output) Connection

    4 - 9 Event Output (Open Collector Output) Connection EV1 EV2 EV3 EV4 EV5 EV6 EV7 EV8 EV9 EV10 EV11 EV12 EV13 EV14 EV15 EV16 11 22 23 27 28 31 32 24 Handling Precautions • Do not short-circuit the positive (+) terminal of the external power supply •...
  • Page 40: External Switch Input Connection

    4 - 10 External Switch Input Connection Internal circuit diagram of the DCP552 connecting external switch input Handling Precautions 4-12 SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 4 13 14 15 16 12 SW9 SW10 SW11 SW12 SW13 SW14 SW15 SW16 cancel cancel 25 26 29 30 33 34 37 38 41...
  • Page 41: Communication Connection

    4 - 11 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 •...
  • Page 42 5-wire system RS-485 connection diagram Terminating resistor Terminating resistor Master station Terminating resistor Terminating resistor 4-14 Shield Shield Shield Attach 1/2W or greater terminating resistances of 150Ω ±5% at each end of the communications lines. Ground the shield FGs at one end in one location, not at both ends.
  • Page 43 3-wire system RS-485 connection diagram Terminating resistor Master station Terminating resistor Attach 1/2W or greater terminating resistances of 150Ω ±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.
  • Page 44: Rs-232C Connection

    RS-232C connection Example of connection using Handling Precautions NOTE 4-16 63 64 • 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.
  • Page 45: Connection To St221

    Connection to ST221 SDA SDB RDA RDB 60 61 62 63 64 Handling Precautions • Attach 1/2W or greater terminating resistances of 150Ω ±5% at each end of the communications lines. • The DCP552 operates as a master station when connected to an ST221 during communications.
  • Page 46: Isolation Between Input And Output

    4 - 12 Isolation Between Input and Output Isolation between inputs and outputs are shown below. In this figure, the solid lines enclose mutually-isolated sections. Those sections bounded by dashed lines are not isolated. Handling Precautions 4-18 PV input CH1 PV input CH2 Digital Loader communication...
  • Page 47: Chapter 5. Functions

    Chapter 5. 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”. Data Parameter Program FUNCTIONS Variable parameter Data changeable in RUN mode Event configuration data Event type data PID group and output limiter group control parameters...
  • Page 48 5 - 2 Program Pattern Pattern Separate programs are set in CH1 and CH2 for each program number. Three systems for selecting programs are provided: RAMP-X, RAMP-T and RAMP-E. The first segment of each program is always RAMP-X, but the other segments can be any system and all three types can be used in one program.
  • Page 49 RAMP-T system ( θ setting) In the RAMP-T system, a segment is set using SP and ramp θ (theta). SP setting θ setting SP is a point on the elapsed time axis in the current segment which is an extended straight line, the ramp set value of the current segment when the SP set value in the previous segment is the start point.
  • Page 50 NOTE •Select the program pattern setting system using setup data setting C61. •Select time setting units using setup data setting C62. •Select θ setting units using setup data setting C62. •Select SP setting and SP setting decimal position using setup data setting C65. •External switch for pulse input requires 1: RAMP-E using a setup data setting between C71 to C74.
  • Page 51 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.
  • Page 52 •An On Time ≥ Off Time setting cannot be made. (See segment 3C in the figure.) On-time Off-time Output-ON Output-OFF •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.
  • Page 53 •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 –...
  • Page 54 •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.
  • Page 55: Other Functions

    • Event on delay The number of the event to be delayed and the delay time can be set regardless of event type. The delay turns on the output for the duration of the delay when the event meets the conditions for going from OFF to ON. When this function is combined with the event standby function, the event on delay operates when the standby state is cleared.
  • Page 56 SP upper limit MV upper limit 5-10 SP lower limit MV lower limit...
  • Page 57 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.
  • Page 58 Code event Example: Setting a code event involving 3 output points in event 3 The table below shows the output state when a value of 3 is set in segment 2, a value of 6 is set in segment 4 and a value of 0 is set in segment 5. Segment Set value Code value...
  • Page 59 •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.
  • Page 60 Decimal binary code comparison table Decimal 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.
  • Page 61 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. •...
  • Page 62 PID group selection Selection of ouput limiter group 5-16 •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.
  • Page 63 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.
  • Page 64 PV shift Segment number PV shift setting 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.
  • Page 65 Repeat Separate repeat settings can be made in CH1 and CH2 programs. Repeat on/off and return destination are set by the segment with the segment number and repeat count. Operation completes at the end of a segment. If there is a repeat setting, the program returns to the start of the set destination segment and operation is resumed from there.
  • Page 66 PV start NOTE 5-20 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.
  • Page 67 Chapter 5. FUNCTIONS Cycle Separate cycles can be set in CH1 and CH2 programs. The cycle function allows you to repeat operation from segment 1 to the last segment in a program pattern the number of times set in the cycle count. A total of 10,000 times can be set.
  • Page 68 Pattern link Program No.2 5-22 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.
  • Page 69 Chapter 5. FUNCTIONS 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 “__”...
  • Page 70: Mode

    5 - 3 Mode Mode types Program operation Constant value control READY 5-24 Modes are listed below. Mode Program operation Constant value control The program is run according to SP, time, events and other settings made in program patterns 1-49. The control is run according to SP and events made with the constant value control data.
  • Page 71 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.
  • Page 72: Mode Transitions

    Mode transitions Program operation END AUTO RESET END MANUAL Constant value control Switching between program operation and constant value control 5-26 Mode transitions are indicated by the solid line arrows and end operation is indicated by the dashed lines in the figure below. RESET READY AUTO RUN AUTO...
  • Page 73: Mode Transition Operations

    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. Switches from the READY, HOLD, FAST and READY FAST modes to the RUN mode.
  • Page 74: Mode Transition Restrictions

    Mode transition restrictions Operation (To RUN mode) Key Switch Original mode Program READY operation – HOLD FAST – READY FAST Constant READY value – control Operation (To MANUAL mode) Key Switch Original mode Program AUTO operation MANUAL — Constant AUTO value MANUAL —...
  • Page 75: Input Process Functions

    5 - 4 Input Process Functions This section uses diagrams to describe input processes. Model without carbon potential (CP) compensation Analog input 1 Setting: setup data C01 Input range type A/D conversion (For resistance temperature detector) Wiring resistance compensation (For thermocouple) Cold junction compensation Setting: setup data C07, C10 (For DC current or voltage)
  • Page 76: Model With Carbon Potential (Cp) Compensation

    Model with carbon potential (CP) compensation Analog input 1 Setting : setup data C01 Input range type A/D conversion (For resistance temperature detector) Wiring resistance compensation (For thermocouple) Cold junction compensation Setting: setup data C07, C10 (For DC current and voltage) Square-root extraction Setting: setup data C08, C09 (For DC current and voltage)
  • Page 77: O 2 Sensor Check (Model With Cp Compensation)

    sensor check (model with CP compensation) Objective As the O checks sensor output impedance and turns on the O impedance exceeds 130kΩ. Setting •One of the values set for setup data C71 to C74 is set to 11 to assign the O sensor check to an external switch.
  • Page 78: Output Processing Functions

    5 - 5 Output Processing Functions Control output CH1 Current output (with setup data C21 set to 1) Initialization of PID Setting: variable parameter PA17, PA43 control computation PID control computation Setting: PID parameter P / l / d / rE (for CH1) Setting: variable parameter PA14 Output deviation limiter Setting: PID parameter oL / oH (for CH1)
  • Page 79 Voltage, Open collector output (with setup data C21 set between 2 to 5) Initialization of PID Setting: variable parameter PA17, PA43 control computation Setting: PID paramete P / l / d / rE (for CH1) PID control computation Setup data C23 Setting: variable parameter PA14 Output deviation limiter Setting: PID parameter oL / oH (for CH1)
  • Page 80: Control Output Ch2

    Control output CH2 5G output (with setup data C22 set to 1) Initialization of PID Setting: variable parameter PA27, PA96 control computation PID control computation Setting: PID parameter P / l / d / rE (for CH2) Setting: variable parameter PA24 Output deviation limiter Setting: PID parameter oL / oH (for CH2) Upper and lower output limiter...
  • Page 81 Voltage, Open collector output (with setup data C22 set between 2 to 5) Initialization of PID Setting: variable parameter PA27, PA96 control computation Setting: PID paramete P / l / d / rE (for CH2) PID control computation Setup data C24 Setting: variable parameter PA24 Output deviation limiter Setting: PID parameter oL / oH (for CH2)
  • Page 82: Auxiliary Output

    Auxiliary output Auxiliary output 1 Auxiliary output 1 type Upper and lower limit scaling Auxiliary output 1 Auxiliary output 2 Auxiliary output 2 type Upper and lower limit scaling Auxiliary output 2 5-36 Auxiliary output 1 is processed as shown below by a model with one or two auxiliary output channels.
  • Page 83: Chapter 6. Operation

    Chapter 6. 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 clock-wise order until the controller becomes ready for operation.
  • Page 84: Basic Display Selection

    Chapter 6. OPERATION 6 - 2 Basic Display Selection The console basic display status is comprised of the program number display, segment number display, display panel 1, display panel 2, basic display LEDs and the message panel. Use the DISP key or MESSAGE key to cycle through the different displays. The mode display LEDs perform the same functions both in the basic display status and during parameter settings and do not change by pressing the DISP or MESSAGE key.
  • Page 85: Program Run Mode Displays

    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...
  • Page 86 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 time unit setup data.
  • Page 87 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.
  • Page 88 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.
  • Page 89 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.
  • Page 90 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 Display D2 Display D3 Display D4 Display D5 Display D6 Handling Precautions •...
  • Page 91: Constant Value Control Mode

    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 values flash.
  • Page 92 DISP key function (when variable parameter PA03 is set to 1) Display F1 Display F2 Display F3 Display F4 6-10 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.
  • Page 93: Selecting Programs

    6 - 3 Selecting Programs A total of 49 programs can be selected with the operation keys. Selecting program numbers Basic display status Program number flashes • Press the PROG key in the READY program run mode and basic display •...
  • Page 94: External Switch Operation

    6 - 4 External Switch Operation External switch input Types of external switch inputs NOTE 6-12 A total of 16 external switch inputs are available. Each input is called SW1, SW2, etc. up to SW16. (SW: external switch input) SW1 to 4 and SW9 to 16 are tied. SW5 to 8 functions are selected using setup data settings C71 to C74.
  • Page 95: Selecting Programs

    • 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 SW16. SW15 Selecting programs • Programs can be selected using the external switches in the READY program run mode.
  • Page 96 Binary system Binary system External switch number SW10 SW11 SW12 SW13 SW14 Number selection Binary system External switch number SW10 SW11 SW12 SW13 SW14 Number selection Handling Precautions 6-14 Weight OFF ON OFF ON ON ON OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF...
  • Page 97: Read Timing

    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.
  • Page 98: Manual Operation And Auto-Tuning

    6 - 5 Manual Operation and Auto-Tuning Manual operation Auto-tuning (AT) 6-16 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.
  • Page 99 • 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. AT start • Auto-tuning performed using a variable parameter PA08 setting of 3 or 4 and a PA93 setting of 3 or 4 cause auto-tuning to be performed on SP, PID parameters tP-A1 to tP-A7, in order.
  • Page 100: Chapter 7. Parameter Setup

    Chapter 7. 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 individual items in these groups.
  • Page 101: Modifying Individual Items And Exiting The Setting Mode

    Modifying individual items and exiting the setting mode Pressing the ENTER key while an individual item is displayed causes the set value to flash and enables the registration state. At this point, the ↑ key and ↓ key allow you to increase or decrease the values, while the ← key and → key move the digit positions on the display at which the values flash.
  • Page 102 • Example of individual item matrix (setup data) C100 C100 DISP key ENTER key Individual item ENTER key , key Use the PARA, PID or SETUP keys. ** (as required by the specific settings group) Individual item , key * : The ENTER key stores set values in memory. **: The ENTER, PID or SETUP keys do not store set values in memory.
  • Page 103: Parameter Setting List

    7 - 2 Parameter Setting List NOTE “PVU (PV1)”, “PVU (PV2), “SPU (CH1)” and “SPU (CH2)” used in the “Factory Default Settings” and “User Settings” columns in the lists on the following pages have the following meaning. PVU (PV1): When the PV1 range type (setup data setting C01) is a PVU (PV2): Like PVU (PV1), a PV2 range type (setup data setting C11), a PV2 SPU(CH1) : The SPU decimal point position (setup data setting C65) causes the SPU(CH2) : The SPU decimal point position (setup data setting C68) causes the...
  • Page 104: Variable Parameter Setting

    Variable parameter setting PA 01 PA 02 PA 03 PA 04 PA 05 PA 06 PA 07 PA 08 PA 09 PA 10 PA 11 PA 12 PA 13 PA 14 PA 15 PA 16 PA 17 PA 18 PA 19 PA 20 PA 21 PA 22...
  • Page 105 PA 24 PA 25 PA 26 PA 27 PA 28 PA 29 PA 30 PA 31 PA 32 PA 33 PA 34 PA 35 PA 36 PA 37 PA 38 PA 39 PA 40 PA 41 PA 42 PA 43 PA 44 PA 45 PA 46...
  • Page 106 PA 47 PA 48 PA 49 PA 50 PA 51 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...
  • Page 107 PA 93 PA 94 PA 95 PA 96 PA 97 PA 98 PA 99 PA 100 PA 101 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...
  • Page 108: Detailed Information On Variable Parameters

    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 FUNC + CLR + MESSAGE keys (general reset)
  • Page 109 PA05 (program autoload) PA14 (manipulated variable deviation rate limit) PA24 (manipulated variable deviation rate limit) PA16 (ON-OFF control differential) PA26 (ON-OFF control differential) 7-10 • When program settings are protected, it is not possible to copy programs or load programs from a memory card. •...
  • Page 110 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. •...
  • Page 111: Event Configuration Data Settings

    Event configuration data settings Item code Item Event 1 event type E01-t Event 1 auxiliary setting 1 E01-1 Event 1 auxiliary setting 2 E01-2 Event 2 event type E02-t Event 2 auxiliary setting 1 E02-1 Event 2 auxiliary setting 2 E02-2 Event 3 event type E03-t...
  • Page 112: Settings By Event Type

    Chapter 7. PARAMETER SETUP Settings by event type For information on event operations, see “ Events” (pages 5-5 to 5-14). 7-13...
  • Page 113 Code event auxiliary setting 1 (number of output points) can be changed only in the READY mode. Auxiliary setting 1 (number of output points) can be changed only in the READY mode. 7-14...
  • Page 114 Chapter 7. PARAMETER SETUP 7-15...
  • Page 115 The meaning of auxiliary setting 1 for special segment is shown below. –2: Two segments before the final segment –1: One segment before the final segment 0: Final segment When auxiliary setting 1 of RAMP-E time monitoring is set to 0.0 sec, event output is off. Auxiliary setting 1 and auxiliary setting 2 of segment time and program time that determine display unit and range of segment are set by setup data C62 settings as follows.
  • Page 116 Chapter 7. PARAMETER SETUP 7-17...
  • Page 117: Pid Parameter (Ch1) Setting

    PID parameter (CH1) setting rE -1 oL-1 oH-1 rE-2 oL-2 oH-2 rE-3 oL-3 oH-3 rE-4 oL-4 oH-4 rE-5 oL-5 oH-5 7-18...
  • Page 118 rE-6 oL-6 oH-6 rE-7 oL-7 oH-7 rE-8 oL-8 oH-8 rE-9 oL-9 oH-9 P-A1 I-A1 d-A1 rE-A1 CP-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 7-19...
  • Page 119 d-A5 rE-A5 CP-A5 tP-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 7-20...
  • Page 120: Pid Parameter (Ch2) Setting

    PID parameter (CH2) setting rE -1 oL-1 oH-1 rE-2 oL-2 oH-2 rE-3 oL-3 oH-3 rE-4 oL-4 oH-4 rE-5 oL-5 oH-5 7-21...
  • Page 121 rE-6 oL-6 oH-6 rE-7 oL-7 oH-7 rE-8 oL-8 oH-8 rE-9 oL-9 oH-9 P-A1 I-A1 d-A1 rE-A1 CP-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 7-22...
  • Page 122 Chapter 7. PARAMETER SETUP d-A5 rE-A5 CP-A5 tP-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 7-23...
  • Page 123: Setup Data Setting

    Setup data setting C 01 C 02 C 03 C 04 C 05 C 06 C 07 C 08 C 09 C 10 7-24...
  • Page 124 C 11 C 12 C 13 C 14 C 15 C 16 C 17 C 18 C 19 C 20 7-25...
  • Page 125 Chapter 7. PARAMETER SETUP C 21 C 22 C 23 C 24 C 25 C 26 C 27 C 28 C 29 C 30 C 31 C 32 C 33 7-26...
  • Page 126 C 39 C 40 C 41 C 42 C 43 C 44 C 45 C 46 C 47 C 48 C 49 C 50 C 51 C 52 C 53 C 54 C 55 C 56 7-27...
  • Page 127 C 57 C 58 C 59 C 60 C 61 C 62 C 63 C 64 C 65 C 66 C 67 C 68 C 69 C 70 C 71 C 72 C 73 C 74 C 75 7-28 ®...
  • Page 128 C 76 C 77 C 78 C 79 C 80 C 81 C 82 C 83 C 84 C 85 C 86 C 87 C 88 C 89 C 90 C 91 C 92 C 93 C 94 C 95 C 96 C 97 C 98...
  • Page 129 Item Item code PV1 zener barrier adjustment C 99 PV2 zener barrier adjustment C100 7-30 Factory default User Settings and descriptions settings settings -20.00 to +20.00 ---- [Description:] “----” is displayed when PV1 is not an RTD input and C98 is not equal 241.
  • Page 130: Detailed Descriptions Of Setup Data Settings

    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.
  • Page 131 C63 (time display) C66 (SP limit lower limit) C67 (SP limit upper limit) C69 (SP limit lower limit) C70 (SP limit upper limit) 7-32 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.
  • Page 132 C93 (time proportional output system) C94 (time proportional output system) 0: Goes on again within time proportional cycle 1: Does not go on again within time proportional cycle • This setting determines whether the output is to go on again after the result of a PID computation has changed in a time proportional cycle (cycle time) and the output has been turned off.
  • Page 133 7-34 (3) Equivalent circuit showing connection of n SSRs DCP552 SSR 1 SSR' (V ) SSR n SSR' Equations (3) and (4) below must be satisfied. ≤ I × Z+V ≤V SSR/MIN ≤ V SSR' SSR/MAX × Z + V SSR' (4) Equivalent circuit showing parallel connection of n SSRs DCP552...
  • Page 134 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. ¥...
  • Page 135: Constant Value Control Data (Ch1) Setting

    Constant value control data (CH1) setting ConSt Constant value control data (CH2) setting ConSt 7-36...
  • Page 136: Chapter 8. Program Setup

    Chapter 8. 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.
  • Page 137: Starting Programming

    Starting programming Key operations Start programming by pressing the FUNC and PROG keys in the normal display mode. In the program setting state, PRG LED on the console lights and the decimal points in the program number display and the segment number display lights. Note, however, that the program setting state cannot be entered in the following cases.
  • Page 138 Description of numbered items in the figure illustrating the program setting state (1) Programming is started. Up to about 1 second after the programming state is entered, the remaining number of segments is displayed in display panel 1 and the remaining number of subfunctions is displayed in display panel number 2. The display can be held by pressing the FUNC key.
  • Page 139: Programming Map

    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. ←...
  • Page 140: Display Items

    Display items Items displayed are shown in the figure below. Basic display contents LED Display panel no. 1 Display panel no. 2 Message display Setting pattern items (1) In the set value display state, move to the segment pattern item to be set on the programming map.
  • Page 141 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.
  • Page 142: Setting Event Items

    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.
  • Page 143 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 (2) Press the ENTER key to make display panel 1 flash (registration of first (3) Use the ↑, ↓, ←, and → keys to make the first setting (On Time setting). (4) Press the ENTER key to stop the flashing on display panel 1 and display (5) Use the ↑, ↓, ←, and →...
  • Page 144 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).
  • Page 145 When the event is a timer code event Display (Code event with a timer function) NOTE 8-10 (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).
  • Page 146 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.
  • Page 147: Setting Pid Groups And Output Limiter Group Number Items

    Setting PID groups and output limiter group number items Display NOTE Handling Precautions 8-12 (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).
  • Page 148: Setting G.soak (Guarantee Soak) Items

    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).
  • Page 149: Setting Pv Shift Items

    Setting PV shift items Display NOTE Handling Precautions 8-14 (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).
  • Page 150: Setting Repeat Items

    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 →...
  • Page 151: Setting Pv Start Items

    Setting PV start items Display NOTE 8-16 (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).
  • Page 152: Setting Cycle Items

    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).
  • Page 153: Setting Pattern Link Items

    Setting pattern link items Display NOTE 8-18 (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).
  • Page 154: Setting Tag Items

    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 “[ ]”...
  • Page 155: Deleting Programs

    Deleting programs Display 8-20 (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).
  • Page 156: Inserting And Deleting Segments

    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 ↑...
  • Page 157 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.
  • Page 158: Copying Programs

    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. (2) Press the PROG key and the ↑, ↓, ←, and →...
  • Page 159: General Reset

    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.
  • Page 160: Memory Card Type And Functions

    Chapter 9. 9 - 1 Memory Card Type and Functions A memory card can be used to store the setup data, variable parameters, PID parameters (including constant value control data), event configuration data and multiple programs required by one DCP552. Memory card types The following memory cards can be used by the DCP552.
  • Page 161: 9 - 2 Save Procedures

    9 - 2 Save Procedures Insert a memory card when the DCP552 is in the READY mode and the normal display mode. Press the SAVE key to start a save operation. “CArd ” is displayed in display panel 1 and “SAVE ” is displayed in display panel 2. An error code appears if something should go wrong during the save operation.
  • Page 162: Procedures For Formatting Cards

    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. Initialize check Initialize complete Procedures for saving single programs...
  • Page 163: Procedures For Saving All Programs

    Procedures for saving all programs This procedure saves all programs on the DCP552 on a memory card. The program numbers used in the DCP552 are converted to file names on the memory card. When the “Overwrite” save function is selected, files on the card that have the same number as those in the DCP552 are overwritten by the DCP552 files.
  • Page 164: Procedures For Saving Pid Parameters

    Procedures for saving PID parameters This procedure saves PID parameters and constant value control data on a memory card. Data delete check Save complete Procedures for saving event configuration data This procedure saves event configuration data on a memory card. Data delete check Save complete Procedures for saving all parameters...
  • Page 165: Load Procedures

    9 - 3 Load Procedures Insert a memory card when the DCP552 is in the READY mode and the normal display mode, and variable parameter PA05 has been set to 0. Press the LOAD key to start a load operation. “CArd ” is displayed in display panel 1 and “LOAd ”...
  • Page 166: Card Battery Alarm Panel

    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”...
  • Page 167: Procedures For Loading All Programs

    Procedures for loading all programs This procedure loads all programs on the memory card in the DCP552. The file numbers used on the memory card are converted to file numbers used in the DCP552. When the “Overwrite” load function is selected, programs in the DCP552 that have the same number as those on the card are overwritten by the card programs.
  • Page 168: Procedures For Loading Event Configuration Data

    Load completed Handling Precautions The DCP552 Mark II and the old model, DCP552, differ in how some setup data items are processed and the range of variable parameter PA15. Thus the following changes have to be made when setup data, variable parameters or all parameters saved on a DCP552 are loaded onto a DCP552 Mark II.
  • Page 169: Autoload

    9 - 4 Autoload Insert a memory card, press the LOAD key or use external switch inputs in the READY mode and the normal display mode to load file number 1 in CH1 and CH2 on the memory card as program 1 onto the DCP552. Key operated autoload procedure Conditions Operation and action...
  • Page 170: Auto Load Using External Switch Inputs

    Auto load using external switch inputs Conditions Memory card : Program saved to file number 1 Setup data Mode Operation and action Insert a memory card and turn off the external switch used for autoload and turn it back on again. The DCP552 operates as follows.
  • Page 171: Error Message List

    9 - 5 Error Message List When an error occurs, error messages such as “Card Error-XX” (XX denotes error code) are displayed on the message panel during memory card operations. The table below lists the error codes and explain their meaning. Memory card operations are aborted when an error occurs.
  • Page 172: Chapter 10. Troubleshooting

    Chapter 10. TROUBLESHOOTING 10 - 1 Self-Diagnostic Functions and Alarm Code Displays The DCP552 is equipped with the self-diagnostic functions described below. Alarm codes and the result of self- diagnostics are listed on the following pages. Power ON self-diagnostic routines RAM backup failures This routine is designed to detect errors in the RAM backup function.
  • Page 173: Alarm Code Display

    Alarm code display Alarm classification Alarm Alarm name code AL01 PV1 overrange AL02 PV1 underrange AL03 PV2 overrange AL04 PV2 underrange AL90 Board configuration failure Incorrect board configuration Request the repair. AL92 Adjustment value is abnormal.Analog input/output AL93 Setup data is abnormal. Setup data were broken. Check the setup data, and reset AL94 Variable parameter is abnormal.
  • Page 174: Key Input Related Problems

    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 Cause Normal display mode not on Program number does not start flashing when PROG key is pressed Cause Program selection of external switch input is not 0.
  • Page 175 ADV cannot be invoked with PROG and DISP keys Cause Set to READY mode. Set to END mode. Set to fixed command control mode. Set to key lock. FAST mode cannot be invoked with FUNC and → keys Cause Set to program time unit as 0.1 sec. Set to END mode.
  • Page 176 Autotuning cannot be canceled with AT key Cause Set to key lock. PID parameter setting state cannot be invoked with PID key Event configuration setting state cannot be invoked with FUNC and PARA keys Cause Normal display mode not on Set to key lock.
  • Page 177: Parameter Setting Related Problems

    General reset cannot be performed with FUNC, CLR and MESSAGE keys Cause Normal display mode not on Mode other than READY mode Set to MANUAL mode. Set to memory protect. Set to key lock. Parameter setting related problems Registration state cannot be invoked with ENTER key Cause Ò-----Ó...
  • Page 178 PID group, output limiter group number items cannot be displayed with ↑ and ↓ keys Cause Programming item display off G.SOAK items, PV shift items and repeat items cannot be displayed with ↑ and ↓ keys Cause Programming item display off PV start items, cycle items and pattern link items cannot be displayed with ↑...
  • Page 179: When The Bat Led Flashes

    Should a child swallow a battery, contact a doctor immediately. Do not throw used batteries into a fire or discard them as general garbage, but return them to Honeywell sales/service office or the dealer from whom you purchased the equipment.
  • Page 180 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.
  • Page 181 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.
  • Page 182 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.
  • Page 183: Chapter 11. Specifications

    Chapter 11. SPECIFICATIONS 11 - 1 Specifications 11-1...
  • Page 184 Chapter 11. SPECIFICATIONS 11-2...
  • Page 185 Chapter 11. SPECIFICATIONS µ 11-3...
  • Page 186 Chapter 11. SPECIFICATIONS ,+2## 11-4...
  • Page 187 Chapter 11. SPECIFICATIONS ,+2## ,+2## ,+2## ,+2## ,+2## 11-5...
  • Page 188 Chapter 11. SPECIFICATIONS ,+2## 11-6...
  • Page 189: Attachment/Auxiliary Devices List

    Chapter 11. SPECIFICATIONS Attachment/auxiliary devices list 11-7...
  • Page 190: External Dimensions

    11 - 2 External Dimensions DCP552 PROG PROFILE PROG RUN/HOLD DISP RESET MESSAGE MESSAGE PARA FUNC SETUP ENTER LOAD SAVE LOADER CARD Soft dust-proof cover set (optional) (silicon rubber, transparent) 11-8 15.5 Model No. : 81446141-001 Unit : mm Unit : mm...
  • Page 191: Chapter 12. Calibration

    Chapter 12. CALIBRATION This chapter covers the field calibrations procedures for the inputs, outputs and various functions of the DCP550 mark II controller after shipment from the factory. When calibration is made in the field, the original factory data is erased, and so the specified input/output accuracies of the controller cannot be assured. This manual is for users who are conversant with DCP550 mark II use and operation.
  • Page 192: Quick Reference Table For Calibration Items

    12 - 1 Quick Reference Table for Calibration Items DCP550 mark II controllers are numbered using the following format. Format items may require different calibration procedures, as shown in Table 12-1. Note: 12-2 ,+2## - Model number: Table 12-1. Calibration Items for Each Model DCP551 DCP552 (1)Basic Model Number (2)PV Input Number...
  • Page 193 Table 12-2. Item and Sub Item Table for Calibration Notes: 0000 AdJS 1011 1111 2022 AdJS 1111 6066 AdJS 1111 7077 AdJS 1111 12-3...
  • Page 194 Chapter 12. CALIBRATION 0.0.0.0. A d J S Notes: 12-4 1.0.1.1. A d J S 00000 A d J S 00000 A d J S 0.0.0.0. Figure 12-1. Calibration Flowchart (1/3) 1.1.1.1.
  • Page 195 & ENTER PROG C/J sensor 2.0.2.2. calibration item A d J S SETUP CJ CH1 zero input PROG Current input count count No. Current count No. After stabilized, stored press ENTER SETUP CJ CH1 span input PROG Current input resistance count Current resistance stored...
  • Page 196 Chapter 12. CALIBRATION 7.0.7.7. A d J S Current customer Current customer ID stored 0.0.0.0. 12-6 PROG Carbon Potential ID calibration item SETUP PROG 0.0.0.0. & ENTER SETUP PROG EEPROM writing SETUP 1.1.1.1. & ENTER Figure 12-1. Calibration Flowchart (3/3)
  • Page 197: Calibration Procedures

    12 - 2 Calibration Procedures Enter calibration mode (1) Release keylock. (PARA PA01=0) (2) Press DISP key to permit ordinary indication condition. (3) To enter calibration mode, hold down the FUNC key, and press SETUP key (4) To select individual calibration items, press ↑, ↓, ←, →, keys to select the Change to READY (RUN and HLD are off) and AUTO (MAN off) modes.
  • Page 198: Function Test

    Function test Press ↑, ↓, ←, →, keys to show ( key. Key test (00-01) Handling Precautions 12-8 0.0.0.0 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).
  • Page 199 Display test (00-02) Press SETUP key until the PROG/SEG display shows (00-02). Then, each 7-segment LED, LED indicators and LCD illuminates at every 1 sec. This is to check if each LED/LCD illuminates. Digital input test (00-03) Press SETUP key until the PROG/SEG display shows (00-03). When you turn on or off each remote switch, the upper display will show the data described in Table 12-5.
  • Page 200 Digital output test for control output (00-04) Digital output test for event (00-05) Terminal Number Upper Display Ñ Ñ 0.0.0.0. Ñ 0.0.0.1. Ñ 0.0.0.2. Ñ Ñ 0.0.0.4. Ñ Ñ 0.0.0.8. Ñ Ñ 0.0.1.0. Ñ Ñ 0.0.2.0. Ñ Ñ 0.0.4.0. Ñ Ñ...
  • Page 201: Pv Calibration

    Built-in clock adjustment A: 2 digits of calendar year B: Month C: Day D: Hour (24 hour system) E: Minute F: Second NOTE 1. ↑, ↓, ←, →, keys are used to change the values, and ENTER key is used to store the values.
  • Page 202 PV zero, span Note: Writing into EEPROM 12-12 (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.
  • Page 203 Chapter 12. CALIBRATION Table 12-10. Range Table of TC Range Table of RTD × Range Table of Linear 12-13...
  • Page 204: Cold Junction Sensor Calibration

    Cold junction sensor calibration The cold junction input 0% (CH1) The cold junction input 100% (CH1) The cold junction AD count data (CH1) The cold junction temperature data (CH1) The cold junction input 0% (CH2) The cold junction input 100% (CH2) The cold junction AD count data (CH2) The cold junction temperature data (CH2) 12-14...
  • Page 205: Current Output Calibration

    Writing into EEPROM (1) Press SETUP key until the PROG/SEG display shows (02-09). (2) Scroll ↑, ↓, ←, →, keys to show (1.1.1.1.) on upper display. (3) Press ENTER key. Current output calibration Scroll ↑, ↓, ←, →, keys to show (6.0.6.6.) on the upper display, then press ENTER key.
  • Page 206: Carbon Potential Code Calibration

    Writing into EEPROM Carbon potential code calibration Carbon potential code calibration Writing into EEPROM 12-16 (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. Scroll ↑, ↓, ←, →, keys to show (7.0.7.7.) on upper display, then press ENTER key.
  • Page 207: Set Up

    12 - 3 Set Up 54 55 56 57 58 59 Millivolt sources Figure 12-5. Thermocouple Inputs 54 55 56 57 58 59 Decade resistance boxes Figure 12-7. RTD Inputs 54 55 56 57 58 59 Signal generators 4Ð20mA Figure 12-9. mA Inputs Copper leads Copper...
  • Page 208 43 44 45 46 48 49 50 51 Digital ammeter Figure 12-11. Current Outputs 12-18 Copper leads...
  • Page 209 DCP551/552 Program Work Sheet Program No. Preparation date: [ Pattern graph] (Unit : [ Programming Map] Segment item Program contents Pattern (1)SP (2)Time, θ, ∆SP Event 1 Event 2 Event 3 Event 4 Event 5 Event 6 Event 7 Event 8 Event 9 Event 10 Event 11...
  • Page 210 DCP552 Parameter Work Sheet User name Equipment name Model No. Instrumentation staffer in charge : Variable parameter setting No. Item code Item Key lock PA 01 Memory protect PA 02 Display channel setting PA 03 Synchronous 2 channel PA 04 operation Program auto load PA 05...
  • Page 211 DCP552 Parameter Work Sheet No. Item code Item 36 PA 36 Group 3 delay time 37 PA 37 Group 4 event number 38 PA 38 Group 4 delay time 39 PA 39 FAST X 40 PA 40 CP computation for temperature 0 compensation 43 PA 43 PID operation initialize (CH1)
  • Page 212 No. Item code Item 79 PA 79 PV2 equalizer compensation point No. 5 2000 PVU 80 PA 80 PV2 equalizer compensation amount No. 5 0 PVU 81 PA 81 PV2 equalizer compensation point No. 6 2500 PVU 82 PA 82 PV2 equalizer compensation amount No.
  • Page 213 DCP552 Parameter Work Sheet No. Item code Item 111 PA111 CP computation compensation 1.000 No.6 compensation point 112 PA112 CP computation compensation 0.000 No.6 compensation amount 113 PA113 CP computation compensation 1.200 No.7 compensation point 114 PA114 CP computation compensation 0.000 No.7 compensation amount 115 PA115 CP computation compensation 1.400...
  • Page 214 Event configuration data setting No. Item code Item Event 1 event type E01-t E01-1 Event 1 auxiliary setting 1 E01-2 Event 1 auxiliary setting 2 Event 2 event type E02-t Event 2 auxiliary setting 1 E02-1 Event 2 auxiliary setting 2 E02-2 E03-t Event 3 event type...
  • Page 215: Event Type

    DCP552 Parameter Work Sheet No. Item code Item 34 E12-t Event 12 event type 35 E12-1 Event 12 auxiliary setting 1 36 E12-2 Event 12 auxiliary setting 2 37 E13-t Event 13 event type 38 E13-1 Event 13 auxiliary setting 1 39 E13-2 Event 13 auxiliary setting 2 40 E14-t...
  • Page 216 Event Meaning type 24 to 63 Event off Normal PV1 upper limit operation Measuring instrument PV Normal PV1 lower limit operation Normal PV2 upper limit operation Normal PV2 lower limit operation PV upper limit PV lower limit Deviation upper limit Deviation lower limit Deviation upper limit with standby Deviation lower limit with standby...
  • Page 217 DCP552 Parameter Work Sheet Event Meaning type Event off Battery voltage drop 145 to 253 Event off Setting Operation category category ----- ----- Auxiliary 1 : None Measuring instrument Mode ----- ----- Auxiliary settings Auxiliary 2 : None...
  • Page 218 PID parameter (CH1) setting No. Item code Item Proportional band (PID group 1) 100.0 Integral time (PID group 1) Derivative time (PID group 1) Manual reset (PID group 1) rE-1 Manipulated variable lower limit (Output limiter group 1) 0.0 oL-1 Manipulated variable upper limit (Output limiter group 1) 100.0 oH-1 Proportional band (PID group 2) 100.0...
  • Page 219 DCP552 Parameter Work Sheet No. Item code Item 36 oH-6 Manipulated variable upper limit (Output limiter group 6) 100.0 37 P-7 Proportional band (PID group 7) 100.0 38 I-7 Integral time (PID group 7) 39 d-7 Derivative time (PID group 7) 40 rE-7 Manual reset (PID group 7) 41 oL-7...
  • Page 220 No. Item code Item 72 tP-A3 Tuning point (PID group A3) 73 P-A4 Proportional band (PID group A4) 100.0 74 I-A4 Integral time (PID group A4) 75 d-A4 Derivative time (PID group A4) 0 76 rE-A4 Manual reset (PID group A4) 77 CP-A4 Switching point (PID group A4) 4000 SPU 78 tP-A4...
  • Page 221 DCP552 Parameter Work Sheet PID parameter (CH2) setting No. Item code Item Proportional band (PID group 1) 100.0 Integral time (PID group 1) Derivative time (PID group 1) Manual reset (PID group 1) rE-1 Manipulated variable lower limit (Output limiter group 1) 0.0 oL-1 Manipulated variable upper limit (Output limiter group 1)) 100.0 oH-1...
  • Page 222 No. Item code Item 36 oH-6 Manipulated variable upper limit (Output limiter group 6) 100.0 37 P-7 Proportional band (PID group 7) 100.0 38 I-7 Integral time (PID group 7) 39 d-7 Derivative time (PID group 7) 40 rE-7 Manual reset (PID group 7) 41 oL-7 Manipulated variable lower limit (Output limiter group 7) 0.0 42 oH-7...
  • Page 223 DCP552 Parameter Work Sheet No. Item code Item 72 tP-A3 Tuning point (PID group A3) 73 P-A4 Proportional band (PID group A4) 100.0 74 I-A4 Integral time (PID group A4) 75 d-A4 Derivative time (PID group A4) 0 76 rE-A4 Manual reset (PID group A4) 77 CP-A4 Switching point (PID group A4) 4000 SPU...
  • Page 224 Setup data setting No. Item code Item PV1 range number C 01 PV1 temperature unit C 02 PV1 decimal point position C 03 C 04 PV1 linear decimal point position 1 PV1 linear range lower limit C 05 C 06 PV1 linear range upper limit PV1 cold junction compensation C 07...
  • Page 225 DCP552 Parameter Work Sheet No. Item code Item 34 C 34 Manipulated variable in PV overrange (CH1) 35 C 35 MANUAL change mode (CH1) 0 36 C 36 Preset MANUAL value (CH1) 37 C 37 End of operation (CH2) 38 C 38 Manipulated variable in READY 0.0 mode (CH2) 39 C 39...
  • Page 226 No. Item code Item 61 C 61 Programming system 62 C 62 Program time unit 63 C 63 Time display (display panel 1 and 2) 65 C 65 SP decimal point position (CH1) 1 66 C 66 SP limit lower limit 67 C 67 SP limit upper limit 68 C 68...
  • Page 227 DCP552 Parameter Work Sheet No. Item code Item 95 C 95 Voltage output tuning (CH1) 96 C 96 Voltage output tuning (CH2) 97 C 97 Communication port 98 C 98 Special function 99 C 99 PV1 zener barrier adjustment 100 C100 PV2 zener barrier adjustment Factory default User Settings and descriptions...
  • Page 228 Fixed command control data (CH1) setting No. Item code Item Control mode ConSt Set point Proportional band Integral time Derivative time Manual reset Manipulated variable lower limit 0.0 Manipulated variable upper limit 100.0 Fixed command control data (CH2) setting No. Item code Item Control mode ConSt...
  • Page 241 Index • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Alarm • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Attachment (orig) •...
  • Page 242 Mode • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Mode display LED •...
  • Page 243: Revision History

    JIS code of NOTE table was deleted 5-10 Diagram of other functions was added 5-11 to 5-36 Old 5-10 to 5-35 pages HONEYWELL Company name and Adress of JAPAN were SERVICE CENTERS changed fonts changed 4-16 The 2nd item of "Handling Precautions", 'There are four (RD, SD, SG and FG) •...
  • Page 244 Printed Manual Number Edition Date 01-12 EN1I-6187 5th Edition Revised pages 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→PID type changed...
  • Page 245 HONEYWELL SERVICE CENTERS NETHERLANDS HONEYWELL BV Laaderhoogtweg 18 NL-1101 EA AMSTERDAM ZO THE NETHERLANDS Tel.:31 20 56 56 911 POLAND HONEYWELL Ltd UI Augustowka 3 PL-02981 WARSAW POLAND Tel.:48 2 642 25 70 REPUBLIC OF IRELAND HONEYWELL Unit 5 Long Mile Road...
  • Page 246 Tel.:852 829 82 98 AUSTRIA HONEYWELL AUSTRIA G.m.b.H. Handelskai 388 A1020 VIENNA AUSTRIA Tel.:43 1 213 300 BRAZIL HONEYWELL DO BRAZIL AND CIA Rua Jose Alves Da Chunha Lima 172 BUTANTA 05360 SAO PAULO SP BRAZIL Tel.:55 11 819 3755 CZECHIA...
  • Page 247 No. CP-UM-5025E...

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