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Azbil dcp551 mark II User Manual

Azbil dcp551 mark II
220 pages
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DCP551 Mark
ΙΙ
DIGITRONIK
Digital Control Programmer
User's Manual
No. CP-SP-1032E
Thank you for purchasing an Azbil
Corporation product.
This manual contains information for
ensuring the correct use of this
product.
It also provides necessary information
for installation, maintenance, and
troubleshooting.
This manual should be read by those
who design and maintain equipment
that uses this product. Be sure to
keep this manual nearby for handy
reference.
(Not for use in Japan)

Table of Contents

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Azbil dcp551 mark II Specifications

General IconGeneral
TypeDigital Indicating Controller
Input TypeThermocouple, RTD, DC voltage, DC current
Control ModePID, ON/OFF
Control OutputCurrent
Power Supply100 to 240 VAC
CommunicationRS-485
Operating Temperature0 to 50°C

Summary

SAFETY REQUIREMENTS

EQUIPMENT RATINGS

Specifies supply voltages, frequency, and power/current ratings for the equipment.

EQUIPMENT CONDITIONS

Details operational environment like temperature, humidity, vibration, and altitude.

EQUIPMENT INSTALLATION

Describes controller mounting requirements for operator access to rear terminals.

STANDARDS COMPLIANCE

Lists compliance with standards like EN61010-1 and EN61326-1 for industrial locations.

SAFETY PRECAUTIONS

About Icons

Explains the meaning of various icons used to indicate safety precautions.

Chapter 1. PRODUCT OUTLINE

1-1 Features

Details the general purpose, patterns, segments, and subfunction limits of the DCP551.

1-2 Basic Function Block Diagram

Illustrates the functional blocks and data flow of the DCP551 controller.

1-3 Data Configuration Overview

Explains the composition of parameters and programs, including patterns and data types.

1-4 System Configuration

Describes network-based configuration and connection examples for CPL communications.

1-5 Model Number

Provides a breakdown of the model number structure and its components.

Chapter 2. NAMES AND FUNCTIONS OF PARTS

2-1 Structure

Details the main unit, console, case, and terminal base components of the DCP551.

2-2 Console

Explains the console displays, LEDs, and how to cycle through different statuses.

2-4 Key pad

Illustrates and describes the function of each key on the DCP551A and DCP551B models.

Chapter 3. INSTALLATION AND MOUNTING

3-1 Before Installation

Lists locations where the DCP551 should not be installed due to environmental factors.

3-2 Installation

Provides the required panel cutout dimensions in millimeters for mounting the DCP551.

Installation procedures

Details the steps for physically mounting the instrument using brackets and ensuring correct orientation.

Chapter 4. WIRING

4-1 Precautions on Wiring

Highlights crucial safety warnings and cautions to follow during the wiring process.

4-3 Making Terminal Connections

Explains how to make terminal connections using appropriate solderless wire connectors and torque.

4-4 Terminal Array

Provides a detailed diagram of the terminal layout for connecting wires to the terminal base.

4-5 Power Supply and Grounding

Details requirements for a suitable instrument-dedicated power supply and interference reduction.

4-6 PV Input (Analog Input) Connection

Shows how to connect sensors for PV input channel 1, detailing thermocouple and RTD connections.

4-7 Control Output Connection

Details the wiring for current output types (4 to 20mAdc) and load resistance.

4-8 Auxiliary Output (Output CH1, CH2) Connection

Details the wiring for auxiliary output CH1 (4 to 20mAdc).

4-11 Communication Connection

Provides handling precautions and connection details for RS-485 communication.

Chapter 5. FUNCTIONS

5-1 Data

Lists and briefly describes the different types of data managed by the DCP551, including parameters and programs.

5-2 Program Pattern

Explains the three systems (RAMP-X, RAMP-T, RAMP-E) for selecting program segments.

Time events

Allows setting On Time or On/Off durations for outputs by event number and segment.

PV deviation rate event

Measures PV deviation per sampling cycle to determine ON/OFF states based on deviation rate.

Code event

Assigns code numbers to event outputs, effectively increasing physical output points for events.

PID group selection

Explains how to select PID groups via segments or automatic switching for control output.

G.SOAK (Guarantee soak)

Details G.SOAK settings for on/off state, type, width, and clearing conditions.

PV shift

Allows setting a PV correction value for each segment to adjust PV input value plus bias.

Repeat

Sets repeat on/off and return destination for segment operations, allowing repetition with a specified count.

PV start

Allows setting a PV start condition where operation begins when PV and SP are equal.

Cycle

Enables repeating operation from segment 1 to the last segment based on a set cycle count.

Pattern link

Links patterns by setting the program number of the destination for sequential or conditional execution.

Mode types

Lists and categorizes the different operational modes of the DCP551, including Program Operation, Constant Value Control, and READY.

Mode transitions

Illustrates mode transitions for program operation, including key, switch, and communication operations.

Controllers and Programmers

Describes the controller function, including PID computations and manual control via keys.

PV input 1 channel model

Details the input process functions for a single PV input channel, including various compensation and scaling settings.

Channel switching (PV input 2 channel model)

Lists provided switching types, including high/low temperature sensors, CH tied, and backup switching.

Output Processing Functions

Explains how the control output is processed when the controller function is used, detailing PID computations and output types.

Chapter 6. OPERATION

6-1 Power Supply On

Details the procedure for powering on the DCP551 and the startup flow.

6-2 Basic Display Selection

Explains the console displays, LEDs, and how to cycle through different statuses.

Program run mode displays

Describes the different display modes (A1-A6) available in program run mode and the DISP key function.

6-3 Selecting Programs

Details the process of selecting program numbers and segments using the operation keys.

6-4 External Switch Operation

Categorizes external switch inputs by function (RUN, HOLD, ADV, etc.) and detection method.

6-5 Manual Operation and Auto-Tuning

Explains how to manually control instrument outputs and SP values using console keys.

Chapter 7. PARAMETER SETUP

7-1 Parameter Setup

Describes how to select parameter groups (Variable, Event, PID, Setup, Constant Value) using specific keys.

Modifying individual items and exiting the setting mode

Explains how to change individual parameter settings, enter values, and exit the setting mode.

Variable parameter setting

Provides a comprehensive list of variable parameters (PA01-PA96), their factory defaults, and user settings.

Event configuration data settings

Lists event configuration data items (E01-E16), their types, auxiliary settings, and factory/user defaults.

PID parameter setting

Lists and describes PID parameters (P, I, d, rE, oL, oH) for nine PID groups and A1-A7.

Setup data setting

Provides a detailed list of setup data items (C01-C21) and their corresponding settings and descriptions.

Chapter 8. PROGRAM SETUP

8-1 Program Setup

Explains how to select program numbers before or during programming using keys or external switches.

Starting programming

Details the key operations and conditions required to start the programming mode.

State transition

Illustrates the state transitions during the programming process, with numbered items described on the next page.

Programming map

Describes the programming map layout, consisting of segment numbers and program setting items.

Setting event items

Explains how to set the event operating point for PV events in the programming map.

When the event is a time event

Details how to set the On Time and Off Time for time events, including range and unit selections.

When the event is a code event

Explains how to set the event output code for code events, including range and subfunction usage.

Setting PID groups and output limiter group number items

Guides on setting PID group numbers and output limiter group numbers for segments.

Setting G.SOAK (Guarantee soak) items

Details how to set the G.SOAK type and width for segments, including its subfunction usage.

Setting PV shift items

Explains how to set the PV shift value for segments, noting its dependency on previous settings.

Setting repeat items

Details how to set the return segment number and repeat times for segments, and its subfunction usage.

Setting PV start items

Explains how to set the PV start value (no PV start, descending, ascending, bi-directional) for segments.

Setting cycle items

Details how to set the cycle value (number of repetitions) for segments.

Setting pattern link items

Explains how to set the pattern link value (destination program number) for segments.

Deleting programs

Details the procedure for deleting entire programs or segments from the programming map.

Inserting and deleting segments

Explains how to insert new segments or delete existing ones on the programming map.

8-2 Copying Programs

Describes the procedure for copying programs within the DCP551 using the READY program run mode.

8-3 General Reset

Explains how to perform a general reset to delete program settings and reset parameters to factory defaults.

Chapter 9. MEMORY CARD OPERATIONS

9-1 Memory Card Type and Functions

Lists compatible memory cards and their basic functions (Save/Load) for DCP551.

9-2 Save Procedures

Provides step-by-step procedures for saving data (programs, setup, parameters) to a memory card.

Procedures for formatting cards

Explains the procedure for formatting memory cards for use with the DCP551.

Procedures for saving single programs

Details the process for saving a single program from the DCP to a memory card.

Procedures for saving all programs

Describes saving all programs from DCP551 to a memory card, including overwrite/skip functions.

Procedures for saving setup data

Details the procedure for saving the DCP551 setup data onto a memory card.

Procedures for saving variable parameters

Explains the process for saving DCP551 variable parameter data onto a memory card.

Procedures for saving PID parameters

Details saving PID parameters and constant value control data onto a memory card.

Procedures for saving event configuration data

Explains saving event configuration data onto a memory card.

Procedures for saving all parameters

Describes saving all parameters, including setup, variable, PID, and event data, to a memory card.

9-3 Load Procedures

Presents the load menu options for retrieving data from a memory card, including individual programs and all data.

Procedures for loading individual programs

Details the procedure for loading single program files from a memory card onto the DCP551.

Procedures for loading all programs

Explains loading all programs from a memory card to the DCP551, including overwrite/skip functions.

Procedures for loading setup data

Details loading setup data from a memory card onto the DCP551.

Procedures for loading variable parameters

Explains loading variable parameter data from a memory card onto the DCP551.

Procedures for loading PID parameters

Details loading PID parameters and constant value control data from a memory card onto the DCP551.

Procedures for loading event configuration data

Explains loading event configuration data from a memory card onto the DCP551.

Procedures for loading all parameters

Describes loading all parameters from a memory card onto the DCP551, noting model compatibility issues.

9-4 Autoload

Details the procedure for starting autoload using the LOAD key and the required conditions.

9-5 Error Message List

Lists memory card error codes, their meanings, and remedial measures for troubleshooting.

Chapter 10. MAINTENANCE AND TROUBLESHOOTING

10-1 Self-Diagnostic Functions and Alarm Code Displays

Describes self-diagnostic routines, alarm codes, and their classification for troubleshooting.

Alarm code display

Explains how alarm codes and normal display items alternate on panel 1 during input or system failures.

Alarm classification

Categorizes alarms into PV range and instrument alarm groups, including battery voltage drop.

Display behavior and alarm code upon input burnout

Details how display behavior and alarm codes differ based on input type during input burnout.

10-2 Key Input Related Problems

Lists problems related to mode changes, PROG key function, RUN/HOLD key, and RESET operations.

10-3 When the BAT LED Flashes

Explains that the BAT LED flashing indicates low battery voltage, potentially affecting data.

Replacing the battery

Provides safety precautions and a step-by-step guide for replacing the internal battery.

Chapter 11. DISPOSAL

Battery removal method

Refers to Chapter 10 for the procedure on removing the battery before product disposal.

Chapter 12. SPECIFICATIONS

12-1 Specifications

Lists specifications related to programs, segments, slopes, subfunctions, and event/PID group settings.

Input section

Details specifications for input types, sampling cycles, bias, impedance, resistance, and allowable input.

External switch input section

Provides specifications for external switch inputs, including number of points and connection types.

Display and setting section

Lists specifications for display panels, message display, profile display, status LEDs, and operating keys.

Mode

Specifies the states and availability of run modes like READY, RUN, HOLD, FAST, END, and READY FAST.

PID control

Lists PID control parameters like Proportional band, Integral time, Derivative time, and limits.

Output section

Specifies details for Voltage output (6D) and Open collector output (8D), including current, voltage, and response times.

Event output section

Details specifications for Event outputs, including types (Time-based, Code-based, Mode-based) and communication protocols.

Communication

Lists specifications for RS-485 communication, including data flow, sync system, speed, and distance.

Memory card (optional)

Lists specifications for optional memory cards, including type, capacity, and number of programs.

General specifications

Covers general specifications like power supply voltage, power consumption, and battery backup RAM.

12-2 External Dimensions

Provides external dimension diagrams for the DCP551A and DCP551B consoles in millimeters.

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