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Honeywell DCP301 User Manual

Honeywell DCP301
187 pages
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EN1I-6197
Issue 7 (02/04)
DCP301
Digital Program Controller
Users Manual

Table of Contents

Questions and Answers:

Honeywell DCP301 Specifications

General IconGeneral
TypeDigital Controller
Operating Temperature0 to 50°C (32 to 122°F)
Enclosure RatingIP65 (front panel)
Control ModesPID, On/Off
DisplayDual 4-digit LED
CommunicationRS-485 Modbus RTU
Power Supply100-240 VAC

Summary

DCP301 Digital Program Controller User's Manual

WARRANTY

Details the one-year manufacturer's warranty for the Honeywell device.

TECHNICAL ASSISTANCE

Provides contact information and troubleshooting advice for technical assistance.

SAFETY PRECAUTIONS

Explains safety precautions and the meaning of various warning and caution icons.

Unpacking

Instructions for checking and handling the product after removing it from its package.

Organization of This User's Manual

Describes how the manual is structured into chapters for user guidance.

Conventions Used in This Manual

Explains the symbols, notes, and conventions used throughout the manual.

Chapter 1. GENERAL

1-1 Features

Details the DCP301's capabilities, including high accuracy, wide control output types, PLC compatibility, and easy operation.

1-2 Basic Function Blocks

Illustrates the controller's basic function blocks, inputs, outputs, and operational parameters.

1-3 Data Structure

Explains the structure of data, comprising parameters for setting functions and programs for operation.

1-4 System Configuration

Describes system configuration, particularly for models supporting RS-485 communications via a network.

1-5 Model Numbers

Provides a guide for selecting model numbers based on output, function, power, options, and additions.

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-1 Structure

Details the controller's main components: body, console, case, standard terminal base, and add-on terminal base.

2-2 Console

Describes the console, including basic display state, display elements, and indicator LEDs.

Keys

Explains the various keys on the console and their functions for operating the controller.

Functions using two or more keys

Details key combinations for performing specific functions like reset, advance, fast operation, and program setup.

2-3 Input Type and Range No.

Lists available input types, range numbers, and their corresponding temperature ranges in °C and °F.

Chapter 3. MOUNTING

3-1 External Dimensions

Provides detailed external dimensions and mounting bracket information in millimeters.

3-2 Panel Cutout Dimensions

Specifies panel cutout dimensions for single and multiple unit mounting, including recommendations.

3-3 Mounting

Covers mounting locations, noise countermeasures, dust-proof covers, and essential warnings.

Mounting method

Details how to securely mount the controller using brackets, including securing steps and angle considerations.

Chapter 4. WIRING

4-1 Wiring Precautions

Outlines essential safety warnings and precautions to follow before and during wiring.

Compensating Lead

Explains the use and types of compensating leads required for thermocouple inputs and other I/O.

Terminal Connections

Describes the type of crimped terminals and recommended tightening torque for M3.5 screws.

Layout of Terminals and Recommended Lead Draw-out Direction

Shows the layout of terminals on the standard and add-on bases with recommended lead draw-out directions.

Connecting the Ground and Power Supply

Details how to properly connect the ground and power supply, including anti-noise measures.

Wiring of Standard and Add-on Terminal Base

Provides detailed wiring layouts for both standard and add-on terminal bases.

Connecting Inputs (analog inputs)

Explains how to connect analog inputs, including thermocouple, RTD, DC voltage, and DC current.

Connecting control outputs (outputs 1, 2)

Details wiring for various control output types like relay, current, and position-proportional outputs.

Connecting auxiliary outputs (outputs 2, 3)

Explains how to connect optional auxiliary outputs for different model types.

Connecting Event Output (relay output)

Details wiring for event outputs EV1, EV2 (1a contact), and EV3 (1a1b).

Connecting Time Event Output (open-collector)

Explains how to connect optional time event outputs T1 to T5.

Connecting External Switch (RSW) Input

Details how to wire external switch inputs, both standard and optional.

Internal circuit for controller components for connecting external switch inputs

Illustrates the internal circuitry for connecting external switch inputs on terminal bases.

Connecting for Communications

Explains how to connect for communications, specifically the RS-485 interface.

Isolating Inputs and Outputs

Shows isolation between inputs and outputs for different control output types.

Chapter 5. FUNCTIONS

5-1 Data

Outlines the various data types supported by the DCP301, including parameters and program data.

Program Patterns

Explains program patterns, segments, SP setting, and how segments are categorized (ramp, soak).

Events 1 to 3

Details event configuration data, including PV type, controller status, and time events.

Time events 1 to 5

Explains how to set time events, including ON/OFF times and segment No. events.

PID set selection

Describes PID set selection methods, including segment designation and auto-switching.

G.Soak (guarantee soak)

Explains the G.Soak function for ensuring segment execution time with PV close to SP.

PV start

Details the PV start function, which initiates operation from a point where PV matches SP in the program pattern.

Cycle

Explains the cycle function for repeating program operation a preset number of times.

Pattern link

Describes the pattern link function for connecting patterns together sequentially.

Modes

Details the available modes: Program operation, Constant-value operation, READY, RUN, HOLD, FAST, END, AUTO, MANUAL.

Mode transition operations

Explains how to transition between different operational modes like RUN, HOLD, RESET, ADV, FAST, AUTO, MANUAL.

Controller and Programmer

Explains the roles of the DCP301 as either a controller or a programmer, depending on model and setup.

Input Processing Functions

Describes the sequence of input processing, including range type, compensation, scaling, and filtering.

Output Processing Functions

Details how control output, SP output, and auxiliary output are processed based on model type.

Chapter 6. OPERATION

6-1 Turning the Power ON

Guides the user on powering on the DCP301 and the startup sequence of operations.

6-2 Switching the Basic Display

Explains how to switch between different display states on the controller's console using the DISP key.

Display in program operation mode

Details the various display modes available when the controller is operating in program mode, shown via DISP key.

Display in constant-value operation mode

Details the various display modes available when the controller is operating in constant-value mode.

6-3 Program Selection

Explains how to select program numbers for operation using console keys or external switch inputs.

6-4 External Switch (RSW) Operations

Details the functions of external switch inputs (RSW1-RSW12) and their assignment types.

Read timing

Specifies the read timing for external switch inputs and program selection operations.

6-5 Manual Operation and Auto-tuning

Explains manual operation of outputs/SP and the process of auto-tuning (AT) for PID parameter optimization.

Chapter 7. PARAMETER SETUP

7-1 Parameter Setup

Guides on entering parameter setup, selecting setting groups (major items), and individual items (minor items).

How to Use PARA

Explains how to use the PARA key for registering and calling up frequently used parameters.

Parameter Setup List

A comprehensive list of all parameters, their codes, factory/user settings, and descriptions.

Description of variable parameter settings

Provides detailed explanations for key parameters like L O C (key lock) and P R T C (program protect).

Event configuration data settings “E v”

Details the settings for event type, standby, hysteresis, and ON delay time for events 1, 2, and 3.

PID parameter settings “P I d”

Lists PID parameters for sets 1 through 8, including proportional band, reset time, and rate time.

Setup data settings “S E t”

Details setup data settings for control action, input units, range types, and limits.

Description of setup data settings

Provides detailed explanations for setup data settings such as square root extraction and SP limits.

Table data settings “T B L”

Explains settings for input linearization table approximation (A-axis and B-axis).

Constant-value operation data settings “C N S t”

Details settings for constant-value operation mode, SP, events, and PID parameters.

Chapter 8. PROGRAM SETUP

8-1 Program Setup

Guides on entering program setup, selecting program numbers, and understanding display start items.

Mode transition

Illustrates the mode transitions within the program setup state using a diagram and descriptions.

Programming map

Shows the programming map matrix, detailing setup items and segments for program creation.

Setting up pattern items

Explains how to set up pattern items, including SP and time settings for No.1 and No.2 setups.

Setting up events 1 to 3 items

Details setting up events (PV type, time, controller status) for segments in the programming map.

Setting up time events 1 to 5

Explains how to set up time events, including ON/OFF times and their display.

Setting up PID set No. items

Describes how to set the PID set number for each segment in the programming map.

Setting up G.Soak (guarantee soak) items

Explains how to set G.Soak width and G.Soak time-out items for segments.

Setting up PV start items

Details how to set PV start items, enabling or disabling PV start for programs.

Setting up cycle items

Explains how to set cycle items to repeat program operation a specified number of times.

Setting up pattern link items

Details how to set pattern link items to link one program to another.

Deleting programs

Guides on how to delete entire programs from the controller.

Inserting and deleting segments

Explains the process of inserting or deleting segments within a program.

8-2 Copying Programs

Details the procedure for copying programs between the controller and other sources.

8-3 General Reset

Explains how to perform a general reset to clear programs and return parameters to factory settings.

Chapter 9. TROUBLESHOOTING

9-1 Self-diagnostics and Alarm Code Display

Explains self-diagnostics functions, alarm codes, and categories for identifying issues.

9-2 Trouble during Key Entry

Addresses common problems related to key entry and mode changes, providing causes and remedies.

9-3 Motor Adjustment is Impossible

Discusses issues with motor adjustment, wiring, and alarm displays related to motor control.

9-4 Replacing the Battery

Provides instructions and precautions for replacing the controller's internal lithium battery.

Chapter 10. SPECIFICATIONS

10-1 Specifications

Lists detailed specifications for programs, inputs, outputs, conditions, standards, and installation.

External Dimensions

Provides detailed drawings and dimensions of the controller and its external parts.

Accessories/option list

Lists standard accessories and optional parts available for the DCP301.

Chapter 11. CALIBRATION

Precautions before calibration

Advises on warming up the controller and ensuring stabilized test equipment before calibration.

Equipment needed

Lists the necessary equipment and their required accuracy for performing calibration.

11-1 Quick Reference Table for Calibration Items

Provides a table summarizing calibration items for different controller models and options.

11-2 Calibration Procedures

Details the procedures for entering calibration mode and selecting calibration items using keys.

Function test

Explains how to perform a function test, including key tests and display checks.

PV calibration

Guides on performing PV zero and span adjustments using calibration devices and gain number selection.

Cold junction sensor calibration

Details the procedure for calibrating the cold junction sensor, including input and temperature data.

Current output calibration

Explains how to calibrate the current outputs (CH1, CH2, CH3) by adjusting to specific mA values.

11-3 Set Up

Provides diagrams showing how to connect calibration devices for various gain numbers and PV inputs.

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