Honeywell DCP200 User Manual

Name: Honeywell DCP200
Brand: Honeywell
SKU: 883072
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DCP200 Profile Controller & Recorder - Product Manual

DCP200 Graphical Profiler Controller

with optional Recorder

51-52-25-150

Issue 1

April 2009

DCP200 Profile Controller & Recorder - Product Manual

This manual supplements the Concise Product manual(s) supplied with each instrument at the time of shipment. Information in this installation, wiring and operation manual is subject to change without notice.

Copyright © Honeywell Inc, April 2009, all rights reserved. No part of this publication may be reproduced, transmitted, transcribed or stored in a retrieval system, or translated into any language in any form by any means without the written permission of Honeywell Inc.

Copies of this manual are available in electronic format on the Honeywell web site www.honeywell.com/ps. Printed versions are available from Honeywell or its representatives.

Note:

It is strongly recommended that applications incorporate a high or low limit protective device, which will shut down the equipment at a preset process condition in order to prevent possible damage to property or products.

WARNING:

THE INTERNATIONAL HAZARD SYMBOL IS INSCRIBED ADJACENT TO THE REAR CONNECTION TERMINALS. IT IS IMPORTANT TO READ THIS MANUAL BEFORE INSTALLING OR COMMISSIONING THE UNIT.

WARNING:

THIS SYMBOL MEANS THE EQUIPMENT IS PROTECTED THROUGHOUT BY DOUBLE INSULATION.

Products covered by this manual are suitable for Indoor use, Installation Category II,

Pollution category 2 environments.

This user guide covers all versions of the Honeywell DCP200 Profile controller & Recorder.

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DCP200 Profile Controller & Recorder - Product Manual

Warranty and Returns Statement

These products are sold by Honeywell Inc under the warranties set forth in the following paragraphs. Such warranties are extended only with respect to a purchase of these products, as new merchandise, directly from Honeywell or from a Honeywell distributor, representative or reseller and are extended only to the first buyer thereof who purchases them other than for the purpose of resale.

Warranty

These products are warranted to be free from functional defects in material and workmanship at the time the products leave the factory and to conform at that time to the specifications set forth in the relevant Honeywell manuals sheet or sheets, for such products for a period of 18 months.

THERE ARE NO EXPRESSED OR IMPLIED WARRANTIES, WHICH EXTEND BEYOND THE WARRANTIES HEREIN AND ABOVE SET FORTH. NO WARRANTY IS MADE OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO THE PRODUCTS.

Limitations

Honeywell shall not be liable for any incidental damages, consequential damages, special damages, or any other damages, costs or expenses excepting only the cost or expense of repair or replacement as described above. Products must be installed and maintained in accordance with Honeywell’s instructions. There is no warranty against damage to the product resulting from corrosion. Users are responsible for the suitability of the products to their application.

For a valid warranty claim, the product must be returned carriage paid to the supplier within the warranty period. The product must be properly packaged to avoid damage from Electrostatic Discharge or other forms of harm during transit.

Contacts

World Wide Web

The following lists Honeywell's World Wide Web sites that will be of interest to our customers. Honeywell Organization WWW Address (URL)

Corporate http://www.honeywell.com

Honeywell Field Solutions http://www.honeywell.com/ps

Technical tips http://content.honeywell.com/ipc/faq

Telephone

Organization Phone Number

United States and Canada Honeywell 1-800-423-9883

Tech. Support 1-800-525-7439 Service

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DCP200 Profile Controller & Recorder - Product Manual

How to use this manual

This manual is structured to give easy access to the information required for all aspects of the installation and use and of the Graphical Controller. The main sections are shown here, followed by a full table of contents.

Section 1: Introduction - A brief description of the product and it’s features.

Section 2: Installation - Unpacking, installing and panel mounting instructions.

Section 3: Field Upgrade Options - Installation of the plug-in option modules.

Section 4: Wiring Instructions - Guidance on good wiring practice, noise avoidance, wiring diagrams and input/output connections.

Section 5: Powering Up - Powering up procedure and descriptions of displays & switches.

Section 6: Messages & Error Indications - Display Messages and fault indications.

Section 7: Configuration & Use - Describes operating and configuration modes available.

These include Operation Mode; the Main and Configuration menus; the Easy Setup Wizard;

Supervisor Mode; Automatic tuning; Product and Service Information. Also available on some models are menus to setup the USB, Data Recorder and Profiler features.

Section 8: The USB Interface Option – Describes uploading or downloading of instrument settings, profiles or recorder logs to a USB memory stick.

Section 9: The Data Recorder Option – Describes the Data recorder feature. This allows process data to be stored in to memory for later download and analysis.

Section 10: Profiler – Describes the Profiler feature. A profile controls the value of the setpoint over time; increasing, decreasing or holding its value as required.

Section 11: Manually Tuning - Advice on manually adjusting the controller to the process characteristics.

Sections 12: Serial Communications - Details the physical layer and message formats used for the RS485 and Ethernet communications options.

Sections 13: Modbus Parameters - Details the parameter addresses and data formats used for the Modbus RTU and TCP communications protocols.

Section 14: Calibration - Step-by-step instructions to calibrate the instrument. This section is intended for use by suitably qualified personnel.

Appendix 1: Glossary - Explanations of the terms used and product features.

Appendix 2: PC Software – Using the software suite.

Appendix 3: Specifications - Technical specifications for all products in the range.

Appendix 4: Product Coding - Product model/ordering codes.

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Contents

DCP200 Profile Controller & Recorder - Product Manual

Page Number:

Warranty and Returns Statement ....................................................................................................		iv
1	Introduction ..........................................................................................................................	14
2	Installation ............................................................................................................................	15
	Unpacking ...........................................................................................................................................	15
	Installation ...........................................................................................................................................	15
	Panel-Mounting ...................................................................................................................................	15
	Cleaning..............................................................................................................................................	16
3	Field Upgrade Options.........................................................................................................	17
	Options Modules and Functions...........................................................................................................	17
	Preparing to Install or Remove Options Modules..................................................................................	18
	Removing/Replacing Option Modules ..................................................................................................	19
	Replacing the Instrument in its Housing ...............................................................................................	20
	Auto Detection of Option Modules........................................................................................................	20
	Replacement of Power Supply or Input Boards ....................................................................................	20
	Data Recorder Board...........................................................................................................................	21
4	Electrical Installation ...........................................................................................................	22
	Installation Considerations ...................................................................................................................	22
	AC Power Wiring - Neutral (for 100 to 240V AC versions) ....................................................................	22
	Wire Isolation.......................................................................................................................................	22
	Use of Shielded Cable .........................................................................................................................	23
	Noise Suppression at Source...............................................................................................................	23
	Sensor Placement (Thermocouple or RTD)..........................................................................................	24
	Thermocouple Wire Identification Chart ...............................................................................................	24
	Connections and Wiring.......................................................................................................................	25
	Power Connections ........................................................................................................................	26
	Universal Input Connections ...........................................................................................................	27
	Option Slot 1 Connections ..............................................................................................................	29
	Option Slot 2 Connections ..............................................................................................................	30
	Option Slot 3 Connections ..............................................................................................................	32
	Option Slot A Connections..............................................................................................................	35
	Option Slot B Connections..............................................................................................................	36
5	Powering Up .........................................................................................................................	37
	Powering Up Procedure.......................................................................................................................	37
	Front Panel Overview ..........................................................................................................................	37
	Display ................................................................................................................................................	37
	LED Functions.....................................................................................................................................	38
	Keypad................................................................................................................................................	38
6	Messages and Error Indications .........................................................................................	39
	Start-up Errors.....................................................................................................................................	39

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	Input Problems ....................................................................................................................................	39
	USB Data Transfer Problems...............................................................................................................	40
	Getting Help ........................................................................................................................................	40
7	Configuration and Use .........................................................................................................	41
	Operation Mode...................................................................................................................................	41
	Base, Trend & Profile Operating Screens.......................................................................................	41
	Adjusting the Local Setpoint(s) ......................................................................................................	43
	Adjusting the Setpoint Ramp Rate .................................................................................................	44
	Selecting Automatic or Manual Mode.............................................................................................	44
	Control Enable or Disable ..............................................................................................................	44
	Main Menu...........................................................................................................................................	45
	Entry into the Main Menu...............................................................................................................	45
	Unlock Codes................................................................................................................................	45
	Setup Wizard.......................................................................................................................................	46
	Manual entry to the Setup Wizard ..................................................................................................	46
	Supervisor Mode .................................................................................................................................	47
	Entry into Supervisor Mode............................................................................................................	47
	Configuration Menu .............................................................................................................................	48
	Entry into the Configuration Menu..................................................................................................	48
	Input Configuration Sub-Menu .............................................................................................................	49
	Control Configuration Sub-Menu..........................................................................................................	50
	Output Configuration Sub-Menu...........................................................................................................	52
	Alarm Configuration Sub-Menu ............................................................................................................	53
	Communications Configuration Sub-Menu ...........................................................................................	53
	Recorder Configuration Sub-Menu.......................................................................................................	54
	Clock Configuration Sub-Menu ............................................................................................................	55
	Display Configuration Sub-Menu..........................................................................................................	55
	Lock Code View...................................................................................................................................	56
	Lost Lock Codes............................................................................................................................	56
	Resetting To Defaults ..........................................................................................................................	57
	Automatic Tuning Menu .......................................................................................................................	57
	Profiler Setup Menu .............................................................................................................................	58
	Profiler Control Menu...........................................................................................................................	61
	USB Menu...........................................................................................................................................	62
	Recorder Menu....................................................................................................................................	63
	Product Information Mode....................................................................................................................	63
	Service Information Mode ....................................................................................................................	64
8	The USB Interface.................................................................................................................	65
	Using the USB Port..............................................................................................................................	65
	USB Memory Stick Folders & Files ................................................................................................	65
9	The Data Recorder Option ...................................................................................................	66

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	DCP200 Profile Controller & Recorder - Product Manual
	Introduction .........................................................................................................................................	66
	Changes To Operation Mode...............................................................................................................	66
10	The Profiler Option...............................................................................................................	67
	Profile Components .............................................................................................................................	67
	Profile Starting & Standard Segments..................................................................................................	68
	Loops Segments..................................................................................................................................	69
	Profile Running / Holding vs. Hold Segments .......................................................................................	69
	The Auto-Hold Feature ........................................................................................................................	70
	Profile Cycles & Repeat Sequences.....................................................................................................	71
	Power/Signal Lost Recovery Actions....................................................................................................	71
	Profile End Actions ..............................................................................................................................	72
	Profile Abort Actions ............................................................................................................................	73
11	Manually Tuning Controllers ...............................................................................................	74
	Single Control Tuning (PID with Primary Output only) ..........................................................................	74
	Dual Control Tuning (PID with Primary and Secondary Outputs) ..........................................................	75
	PI Tuning (Valve, Damper & Speed Controllers) ..................................................................................	75
	Fine Tuning. ........................................................................................................................................	77
12	Serial Communications........................................................................................................	78
	Supported Protocols ............................................................................................................................	78
	RS485 Configuration ...........................................................................................................................	78
	Ethernet Configuration.........................................................................................................................	78
	Supported Modbus Functions ..............................................................................................................	80
	Function Descriptions ..........................................................................................................................	80
	Exception Responses .....................................................................................................................	82
13	Modbus Parameters.............................................................................................................	83
	Example Register Address Calculations .........................................................................................	83
	Universal Process Input Parameters ....................................................................................................	84
	Option Slot A Parameters ....................................................................................................................	86
	Option Slot B Parameters ....................................................................................................................	87
	Option Slot 1 Parameters.....................................................................................................................	88
	Option Slot 2 Parameters.....................................................................................................................	90
	Option Slot 3 Parameters.....................................................................................................................	93
	Option Slot 4 Parameters.....................................................................................................................	96
	Setpoint Parameters..........................................................................................................................	101
	Control Parameters............................................................................................................................	102
	Alarm parameters ..............................................................................................................................	104
	Recorder & Clock Parameters............................................................................................................	106
	Display Parameters ...........................................................................................................................	109
	Profiler Control & Status Parameters .................................................................................................	112
	Profile Setup Via Modbus ..................................................................................................................	114
	Instrument Data.................................................................................................................................	129

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14	Calibration...........................................................................................................................	130
	Calibration Reminder .........................................................................................................................	130
	Equipment Required For Checking or Calibrating The Universal Input................................................	130
	Calibration Check ..............................................................................................................................	130
	Recalibration Procedure ....................................................................................................................	131
15	Appendix 1 – Glossary of Terms Used..............................................................................	132
	Active Setpoint...................................................................................................................................	132
	Actual Setpoint ..................................................................................................................................	132
	Alarm Configuration ...........................................................................................................................	132
	Alarm Operation ................................................................................................................................	134
	Alarm Inhibit ......................................................................................................................................	135
	Alarm Types ......................................................................................................................................	135
	Alternative Setpoint............................................................................................................................	135
	Auto Pre-Tune ...................................................................................................................................	135
	Automatic Reset ................................................................................................................................	135
	Auxiliary Input....................................................................................................................................	136
	Auxiliary Input Lower Limit .................................................................................................................	136
	Auxiliary Input Offset..........................................................................................................................	136
	Auxiliary Input Type ...........................................................................................................................	136
	Auxiliary Input Upper Limit .................................................................................................................	136
	Band Alarm Value..............................................................................................................................	136
	Bar Graphs........................................................................................................................................	137
	Bias (Manual Reset) ..........................................................................................................................	137
	Bumpless Transfer.............................................................................................................................	137
	Cascade Control ................................................................................................................................	137
	Clock Configuration ...........................................................................................................................	138
	Communications Write Enable ...........................................................................................................	138
	Configuration Menu ...........................................................................................................................	138
	Contactor...........................................................................................................................................	138
	Control Configuration.........................................................................................................................	138
	Control Deviation ...............................................................................................................................	139
	Control Action....................................................................................................................................	139
	Control Enable/Disable ......................................................................................................................	139
	Control Type......................................................................................................................................	139
	Controller...........................................................................................................................................	139
	Controller Mode .................................................................................................................................	139
	Correcting Variable ............................................................................................................................	139
	CPU ..................................................................................................................................................	140
	Current Proportioning Control ............................................................................................................	140
	Custom Display Mode........................................................................................................................	140
	Cycle Time ........................................................................................................................................	140

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DCP200 Profile Controller & Recorder - Product Manual

Data Recorder ...................................................................................................................................	140
Deadband..........................................................................................................................................	140
Derivative Action................................................................................................................................	140
Deviation Alarm Value .......................................................................................................................	141
Digital Input .......................................................................................................................................	141
Direct Acting Control..........................................................................................................................	141
Display Configuration.........................................................................................................................	141
Display Languages ............................................................................................................................	141
Display Resolution.............................................................................................................................	142
Effective Setpoint...............................................................................................................................	142
Engineering Units ..............................................................................................................................	142
Ethernet.............................................................................................................................................	142
Indicator ............................................................................................................................................	142
Input Configuration ............................................................................................................................	142
Input Filter Time Constant..................................................................................................................	142
Input Range.......................................................................................................................................	143
Input Span.........................................................................................................................................	143
Integral Time Constant.......................................................................................................................	143
Latching Relay...................................................................................................................................	143
LED...................................................................................................................................................	143
Linear Input .......................................................................................................................................	143
Linear Output.....................................................................................................................................	144
Limit Controller ..................................................................................................................................	144
Local Setpoints..................................................................................................................................	144
Lock Codes .......................................................................................................................................	144
Logical Combination of Alarms...........................................................................................................	144
Loop Alarm ........................................................................................................................................	145
LSD...................................................................................................................................................	145
mADC ...............................................................................................................................................	145
Main Menu ........................................................................................................................................	146
Manual Loop Alarm Time...................................................................................................................	146
Manual Mode.....................................................................................................................................	146
Master & Slave Controllers ................................................................................................................	146
Minimum Duration Of Change............................................................................................................	147
Modbus RTU .....................................................................................................................................	147
Modbus TCP .....................................................................................................................................	147
Modulating Valve...............................................................................................................................	148
Multi-Point Scaling.............................................................................................................................	148
mVDC ...............................................................................................................................................	148
On-Off Control ...................................................................................................................................	148
On-Off Differential (On-Off Hysteresis)...............................................................................................	148

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Operation Mode.................................................................................................................................	149
Output Configuration..........................................................................................................................	149
Overlap/Deadband.............................................................................................................................	149
PD Control.........................................................................................................................................	151
PI Control ..........................................................................................................................................	151
PID Control........................................................................................................................................	151
PLC ...................................................................................................................................................	151
Pre-Tune ...........................................................................................................................................	151
Power Output Limits ..........................................................................................................................	152
Primary Proportional Band .................................................................................................................	153
Process High Alarm n Value ..............................................................................................................	153
Process Input ....................................................................................................................................	153
Process Low Alarm n Value ...............................................................................................................	153
Process Variable (PV)........................................................................................................................	153
Process Variable Offset .....................................................................................................................	154
Profile Control Menu ..........................................................................................................................	154
Profile Events ....................................................................................................................................	154
Profile Header....................................................................................................................................	154
Profile Segments ...............................................................................................................................	154
Profile Setup Menu ............................................................................................................................	154
Profiler...............................................................................................................................................	155
Profiler Mode .....................................................................................................................................	155
Proportional Control...........................................................................................................................	155
Rate ..................................................................................................................................................	155
Rate Of Change Alarm.......................................................................................................................	155
Recorder Configuration......................................................................................................................	155
Recorder Option ................................................................................................................................	156
Recorder Menu..................................................................................................................................	156
Relay.................................................................................................................................................	156
Remote Setpoint (RSP) .....................................................................................................................	156
Retransmit Output..............................................................................................................................	156
Retransmit Output n Scale Maximum .................................................................................................	156
Retransmit Output n Scale Minimum ..................................................................................................	157
Reset To Defaults..............................................................................................................................	157
Reverse Acting Control ......................................................................................................................	157
RS485 ...............................................................................................................................................	157
RTD...................................................................................................................................................	158
Scale Range Upper Limit ...................................................................................................................	158
Scale Range Lower Limit ...................................................................................................................	158
Secondary Proportional Band ............................................................................................................	158
Self-Tune...........................................................................................................................................	159

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	DCP200 Profile Controller & Recorder - Product Manual
	Sensor Break Pre-Set Power .............................................................................................................	159
	Serial Communications Configuration ................................................................................................	160
	Serial Communications Option...........................................................................................................	160
	Setpoint.............................................................................................................................................	160
	Setpoint Upper Limit ..........................................................................................................................	160
	Setpoint Lower Limit ..........................................................................................................................	160
	Setpoint Ramp Editing .......................................................................................................................	160
	Setpoint Ramp Rate ..........................................................................................................................	161
	Setpoint Selection..............................................................................................................................	161
	Setup Wizard.....................................................................................................................................	161
	Solid State Relay (SSR).....................................................................................................................	161
	Solenoid Valve ..................................................................................................................................	162
	Supervisor Mode ...............................................................................................................................	162
	Thermocouple ...................................................................................................................................	162
	Three Point Stepping Control.............................................................................................................	162
	Time Proportioning Control ................................................................................................................	163
	Trend Display ....................................................................................................................................	163
	Tuning ...............................................................................................................................................	163
	Tuning Menu .....................................................................................................................................	163
	Triac..................................................................................................................................................	164
	USB Menu.........................................................................................................................................	164
	Valve Motor Drive Control (VMD).......................................................................................................	164
	VDC ..................................................................................................................................................	164
	VMD..................................................................................................................................................	164
16	PC SOFTWARE...................................................................................................................	165
	Using The Software ...........................................................................................................................	165
	Instrument Configuration....................................................................................................................	166
	Profile Creation And Editing ...............................................................................................................	167
	Changing the Start-up Splash Screen ................................................................................................	169
	Changing the Alternate Display Language .........................................................................................	169
	Instrument Simulation ........................................................................................................................	169
	Configuring The Connection ..............................................................................................................	169
	Network Configuration For Modbus TCP Options...............................................................................	171
17	Appendix 2 - Specifications...............................................................................................	173
	Universal Process Input .....................................................................................................................	173
	General Input Specifications .........................................................................................................	173
	Thermocouple Input......................................................................................................................	173
	Resistance Temperature Detector (RTD) Input .............................................................................	174
	DC Linear Input ............................................................................................................................	175
	Auxiliary Inputs ..................................................................................................................................	175
	Digital Inputs......................................................................................................................................	176

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	Output Specifications.........................................................................................................................	177
	Communications................................................................................................................................	179
	Display ..............................................................................................................................................	180
	Control Loop......................................................................................................................................	180
	Data Recorder Option........................................................................................................................	180
	Profiler Option....................................................................................................................................	181
	Alarms...............................................................................................................................................	181
	Conditions For Use ............................................................................................................................	182
	Standards..........................................................................................................................................	182
	Dimensions........................................................................................................................................	182
18	Appendix 3 - Product Coding.............................................................................................	183

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DCP200 Profile Controller & Recorder - Product Manual

1 Introduction

This product is a 1/4 DIN size (96 x 96mm front) microprocessor based graphical process controller, featuring a 160 x 80 pixel, monochrome LCD with a dual colour (red/green) backlight. It can control process variables from a variety of sources such as temperature, pressure, flow and level.

The operating voltage is either 100-240V at 50/60 Hz or 24V-48V AC/DC depending on the model purchased. Optional features include a USB interface, RS485 or Ethernet communications, profile controlling and data recording. Non-volatile memory protects against data or configuration loss during power outages. If the unit is left un-powered, a lithium battery powers the data recorder’s real-time clock for a minimum of one year.

The USB Interface option allows uploading or downloading instrument configuration settings to/from a USB memory stick, for easy configuration of multiple instruments or transfer to/from the PC configuration software. If the Data Recorder of Profiler options are fitted, recordings and profile information can also be transferred via the memory stick.

The Data Recorder option allows the user to make recordings of the process over time. Recordings can be transferred to a memory stick using the USB Port or downloaded using one of the communications options.

The Profiler option allows the user to predefine up 255 segments, shared amongst up to 64

Setpoint Profiles. These control the setpoint level over time, increasing, decreasing or holding its value as required. When combined with the real-time clock of the Data Recorder option, the profiling capabilities are expanded to allow automatic program start at a defined time and day.

Inputs are user configurable for thermocouple and RTD probes, as well as linear process signal types such as mVDC, VDC or mADC. Multipoint scaling can compensate for nonlinear signals. Output options include relays, SSR drivers, triacs or linear mV/voltage modules. These can be used for process control, alarms or retransmission of the process variable or setpoint to external devices. Transmitter Power Supply options can provide an unregulated 24V DC (22mA) auxiliary output voltage, or a 0 to 10VDC stabilised excitation for external signal transmitters.

Alarm indication is standard on all instruments; up to five alarms can be defined. Alarms may be set as process high or low, deviation (active above or below controller setpoint), band (active both above and below setpoint), rate of input change, control loop or signal break types. Alarm status can be indicated by lighting an LED, changing the display backlight colour or viewing the alarm status screen. These alarms can be linked to any suitable output.

The controller can be programmed for on-off, time proportioning, or current proportioning control implementations, depending on the output modules fitted, and feature manual or automatic tuning of the PID parameters. A secondary control output is available when additional output modules are fitted. Optional analogue Remote Setpoint inputs can be included. Configuration of the major settings is made easy by a Setup Wizard that runs automatically at first ever power-up or whenever option modules have been changed. Access to the full range of parameters is via a simple menu driven front panel interface, or the PC based configuration software.

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Introduction

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2 Installation

Unpacking

1.Remove the product from its packing. Retain the packing for future use, in case it is necessary to transport the instrument to a different site or to return it to the supplier for repair/testing.

2.The instrument is supplied with a panel gasket and push-fit fixing strap. Concise manual(s) are supplied with the instrument, in one or more languages. Examine the delivered items for damage or defects. If any are found, contact your supplier immediately.

Installation

CAUTION:

Installation should only be performed by technically competent personnel. It is the responsibility of the installing engineer to ensure that the configuration is safe. Local Regulations regarding electrical installation & safety must be observed (e.g. US National Electrical Code (NEC) or Canadian Electrical Code).

Figure 1. Main dimensions

Panel-Mounting

The mounting panel must be rigid and may be up to 6.0mm (0.25 inches) thick. The cut-out size is:

92mm x 92mm (+0.5mm / -0.0mm).

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DCP200 Profile Controller & Recorder - Product Manual

Instruments may be mounted side-by-side in a multiple installation, but instrument to panel moisture and dust sealing will be compromised. Allow a 20mm gap above, below and behind the instrument for ventilation. The cut-out width (for n instruments) is:

(96n - 4) mm or (3.78n - 0.16) inches

If panel sealing must be maintained, mount each instrument into an individual cut-out with

6mm or more clearance between the edges of the holes.

Note:

The mounting clamp tongues may engage the ratchets either on the sides or the top/bottom faces of the Instrument housing. When installing several Instruments side-by- side in one cut-out, use the ratchets on the top/bottom faces.

CAUTION:

Ensure the inside of the panel remains within the instrument operating temperature and that there is adequate airflow to prevent overheating.

Gasket

Mounting Panel

Clamp

Ratchets

Instrument

Housing

Slide mounting clamp over the instrument housing towards rear face of mounting panel until the tongues engage in ratchets and instrument is clamped in position.

Hold instrument firmly in position (apply pressure to bezel only)

Figure 2. Panel-Mounting the instrument

CAUTION:

Do not remove the panel gasket, as this may result in inadequate clamping and sealing of the instrument to the panel.

Once the instrument is installed in its mounting panel, it may be subsequently removed from it’s housing, if necessary, as described in the Fitting and Removing Option Modules section.

Cleaning

Clean the front panel by washing with warm soapy water and dry immediately If the USB option is fitted, close the USB port cover before cleaning.

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3 Field Upgrade Options

Options Modules and Functions

The available plug-in modules, options and accessories are shown in below:

Table 1. Options & Accessories

	PART			BOARD
	PART	DESCRIPTION		IDENTIFICATION
	NUMBER	DESCRIPTION		IDENTIFICATION
	NUMBER			NUMBER
				NUMBER
	OPTION SLOT 1

51453391-517		Single Relay Output for option slot 1	716/01
51453391-502		Single SSR Driver Output for option slot 1	716/02
51453391-503		Triac Output for option slot 1	716/03
51453391-504		Linear mA / Voltage Output module for option slot 1	639/01
	OPTION SLOT 2 or 3

51453391-518		Single Relay Output for option slot 2 or 3	717/01
51453391-510		Dual Relay Output for option slot 2 or 3	644/01
51453391-507		Single SSR Driver Output for option slot 2 or 3	717/02
51453391-519		Dual SSR Driver Output for option slot 2 or 3	644/02
51453391-508		Triac module Output for slot 2 or 3	647/01
51453391-509		Linear mA / Voltage Output for option slot 2 or 3	640/01
51453391-111		24VDC Transmitter Power Supply for option slot 2 or 3	642/01
	OPTION SLOT A

51453391-513		Digital Input for option slot A	641/02
51453391-515		Basic Auxiliary Input for option slot A	653/01
51453391-512		RS485 Serial Communications for option slot A	680/01
51453391-521		Ethernet Communications for option slot A	707/01
	OPTION SLOT B

51453391-516		Full Auxiliary Input (inc digital input B) for option slot B	641/01
	OPTION SLOT 4

51453391-520		4-Relay Output for option slot 4	703/01
	ACCESSORIES

51453391-522		Blue Control PC Configuration Software & Lead

Note:

Modules can be either pre-installed at the time of manufacture, or retrofitted in the field.

CAUTION:

Plastic pegs prevent fitting of older non-reinforced single relay modules (Board Identification Numbers 637/01 and 638/01). Fitting the older relay modules reduces the isolation rating to Basic 240V Isolation and is therefore not recommended. Remove this peg when fitting Dual Relay Modules.

Note:

All dual relay modules have reinforced isolation.

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Board Positions

Board Mounting Struts

Option 4 Module

Option A Module

Option 3 Module

Universal Input Board

Power Supply Board

Option B Module

Option 1 Module

(hidden below B)

Option 2 Module

Option C Module

Figure 3. Rear view (uncased) & board positions

Preparing to Install or Remove Options Modules

CAUTION:

Before removing the instrument from it’s housing, ensure that all power has been removed from the rear terminals. Modules / boards should only be replaced by a trained technician.

1.Remove the instrument from its housing by gripping the edges of the front panel (there is a finger grip on each edge) and pull the instrument forwards. This will release the instrument from the rear connectors in the housing and will give access to the boards.

2.Take note of the orientation of the instrument for subsequent replacement into the housing. The positions of the boards in the instrument are shown above.

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		DCP200 Profile Controller & Recorder - Product Manual

	Main Board Connectors

	POWER SUPPLY	Option 3 Slot
	BOARD	Connector PL4B
	Transformer Colour
	Code	Option Slot A
	100-240V (Yellow)	Option Slot A
	100-240V (Yellow)	Connectors PL5, & PL6
	24-48V(Blue)	Connectors PL5, & PL6
	24-48V(Blue)
		Option 1 Slot
		Connectors PL7 & PL8
	Display Board	PC Configurator
	Connections	Socket SK1
		Option 2 Slot
	UNIVERSAL INPUT	Connector PL4A
	UNIVERSAL INPUT
	BOARD	Option Slot B
		Option Slot B
		Connectors PL2A, PL2B &
		PL2C

Figure 4. Main board connectors

Removing/Replacing Option Modules

1.To remove or replace modules in Option Slots 1, 2, 3, A or B, it is necessary to detach the Power Supply and Input boards from the front panel by lifting first the upper and then lower mounting struts.

2.Remove or fit the modules to the connectors on the Power Supply and Input boards. The location of the connectors is shown below. Plastic pegs prevent fitting of older nonreinforced single relay modules – Remove the peg to fit dual relay modules

3.Assemble the Power Supply and Input boards together. Tongues on each option module locate into a slots cut into the main boards, opposite each of the connectors. Hold the Power and Input boards together and relocate them back on their mounting struts.

4.Remove or replace the Slot C and 4 modules as required.

5.Push the boards forward to ensure correct connection to the front Display/CPU board.

CAUTION:

Check for correct orientation of the modules and that all pins are located correctly.

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Replacing the Instrument in its Housing

CAUTION:

Before replacing the instrument in it’s housing, ensure that all power has been removed from the rear terminals.

With the required option modules correctly located into their respective positions the instrument can be replaced into it’s housing as follows:

1.Hold the Power Supply and Input boards together.

2.Align the boards with the guides in the housing.

3.Slowly and firmly, push the instrument in position.

CAUTION:

Ensure that the instrument is correctly orientated. A mechanical stop will operate if an attempt is made to insert the instrument in the wrong orientation, this stop MUST NOT be over-ridden.

Auto Detection of Option Modules

The instrument automatically detects which option modules have been fitted into each slot. The menus and screens change to reflect the options compatible with the hardware fitted. The modules fitted can be viewed in the products information menu, as detailed in the Product Information Mode section of this manual.

Replacement of Power Supply or Input Boards

It is recommended that users only change these boards if it is unavoidable..

1.Remove the instrument from it’s housing as detailed above.

2.Remove all option modules.

3.Replace the Power Supply or Input board as required. Carefully observe the transformer colour and the case labelling to check the supply voltage when replacing the power supply board.

4.Reassemble the unit in it’s case.

5.If the input board has to be replaced, a full recalibration must be carried out before the instrument is used. Refer to the calibration section of this manual for instructions.

CAUTION:

Replacement of boards must be carried out by a trained technician.

If the Power Supply board does not match the labelling, users may apply incorrect voltage resulting in irreparable damage.

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Data Recorder Board

If installed, the Data Recorder memory and Real Time Clock (RTC) components are located on a plug-in daughter board attached to the front Display/CPU board.

CAUTION:

Servicing of the Data Recorder/RTC circuit and replacement of the lithium battery should only be carried out by a trained technician.

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4 Electrical Installation

CAUTION:

Installation should be only performed by technically competent personnel. It is the responsibility of the installing engineer to ensure that the configuration is safe. Local Regulations regarding electrical installation & safety must be observed (e.g. US National Electrical Code (NEC) or Canadian Electrical Code).

Installation Considerations

Ignition transformers, arc welders, motor drives, mechanical contact relays and solenoids are examples of devices that generate electrical noise in typical industrial environments. The following guidelines MUST be followed to minimise their effects.

1.If the instrument is being installed in existing equipment, the wiring in the area should be checked to ensure that good wiring practices have been followed.

2.Noise-generating devices such as those listed should be mounted in a separate enclosure. If this is not possible, separate them from the instrument, by the largest distance possible.

3.If possible, eliminate mechanical contact relays and replace with solid-state relays. If a mechanical relay being powered by an output of this instrument cannot be replaced, a solid-state relay can be used to isolate the instrument.

4.A separate isolation transformer to feed only the instrumentation should be considered. The transformer can isolate the instrument from noise found on the AC power input.

AC Power Wiring - Neutral (for 100 to 240V AC versions)

It is good practice to ensure that the AC neutral is at or near ground (earth) potential. A proper neutral will help ensure maximum performance from the instrument.

Wire Isolation

Four voltage levels of input and output wiring may be used with the unit:

1.Analogue input or output (for example thermocouple, RTD, VDC, mVDC or mADC)

2.Relays & Triac outputs

3.SSR Driver outputs

4.AC power

CAUTION:

The only wires that should run together are those of the same category.

If any wires need to run parallel with any other lines, maintain a minimum space of 150mm between them.

If wires MUST cross each other, ensure they do so at 90 degrees to minimise interference.

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Use of Shielded Cable

All analogue signals must use shielded cable. This will help eliminate electrical noise induction on the wires. Connection lead length must be kept as short as possible keeping the wires protected by the shielding. The shield should be grounded at one end only. The preferred grounding location is at the sensor, transmitter or transducer.

Noise Suppression at Source

Usually when good wiring practices are followed, no further noise protection is necessary. Sometimes in severe electrical environments, the amount of noise is so great that it has to be suppressed at source. Many manufacturers of relays, contactors etc supply 'surge suppressors' which mount on the noise source. For those devices that do not have surge suppressors supplied, Resistance-Capacitance (RC) networks and/or Metal Oxide Varistors

(MOV) may be added.

Inductive coils:- MOVs are recommended for transient suppression in inductive coils, connected in parallel and as close as possible to the coil. Additional protection may be provided by adding an RC network across the MOV.

Figure 5. Transient suppression with inductive coils

Contacts:- Arcing may occur across contacts when they open and close. This results in electrical noise as well as damage to the contacts. Connecting a properly sized RC network can eliminate this arc.

For circuits up to 3 amps, a combination of a 47 ohm resistor and 0.1 microfarad capacitor

(1000 volts) is recommended. For circuits from 3 to 5 amps, connect two of these in parallel.

Figure 6. Contact noise suppression

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Sensor Placement (Thermocouple or RTD)

If the temperature probe is to be subjected to corrosive or abrasive conditions, it must be protected by an appropriate thermowell. The probe must be positioned to reflect true process temperature:

1.In a liquid media - the most agitated area

2.In air - the best circulated area

CAUTION:

The placement of probes into pipe work some distance from the heating vessel leads to transport delay, which results in poor control.

For a two wire RTD, a wire link should be used in place of the third wire (see the wiring section for details). Two wire RTDs should only be used with lead lengths less than 3 metres.

Use of three wire RTDs is strongly recommended to reduce errors do to lead resistance.

Thermocouple Wire Identification Chart

The different thermocouple types are identified by their wires colour, and where possible, the outer insulation as well. There are several standards in use throughout the world.

The table below shows the wire and sheath colours used for most common thermocouple types. The format used in this table is:

	+ Wire	Sheath
	- Wire	Sheath
	- Wire

Table 2. Thermocouple Extension Wire Colours

Type

International

USA ANSI

British

French

German

IEC584-3

MC 96.1

BS1843

NFC 42-324

DIN 43710

Black

White

Yellow

Red

Black

Blue

White

Red

Blue

Black

Blue

Brown

Blue

White

Yellow

Red

Brown

Blue

Brown

White

Red

Blue

Brown

Green

Yellow

Brown

Red

Yellow

Red

Green

White

Red

Blue

Purple

Green

Pink

Orange

Pink

White

Red

Blue

Grey

Red

Grey

White

Red

Grey

R & S

Orange

Black

White

Yellow

Red

Orange

Green

White

Red

Blue

Green

White

C (W5)

White

Red

Note:

* = Wire is magnetic

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Connections and Wiring

This symbol means the equipment is protected throughout by double insulation.

CAUTION:

All external circuits connected must provide double insulation. Failure to comply with the installation instructions may impact the protection provided by the unit.

WARNING:

TO AVOID ELECTRICAL SHOCK, AC POWER WIRING MUST NOT BE CONNECTED TO THE SOURCE DISTRIBUTION PANEL UNTIL ALL WIRING PROCEDURES ARE COMPLETED. CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY.

Note:

The wiring diagram below shows all possible combinations to the main connections

(numbered 1 to 24) in the centre of the case rear. The actual connections required depend upon the features available on the model and the modules and options fitted.

Figure 7. Main Rear terminals

Note:

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The wiring diagram below shows the additional connections (numbered 25 to 42) at the sides of the case rear. These are required for Options Slots 4 and C if fitted.

Figure 8. Additional Option terminals

Note:

Use single strand (1.2mm / AWG18 max size) copper wire throughout, except for the thermocouple input, where the correct thermocouple or compensating cable and connectors must be used.

Power Connections

Power Connections - Mains Powered Instruments

Mains powered instruments operate from a 100 to 240V (±10%) 50/60Hz supply. Power consumption is 24VA. Connect the line voltage (live and neutral) as illustrated via a two-pole IEC60947-1 & IEC60947-3 compliant isolation switch / circuit breaker and a UL listed fuse type: 250V AC 1Amp anti-surge. If the instrument has relay outputs with contacts carrying mains voltage, it is recommended that the relay contacts supply should be switched and fused in a similar manner, but should be separate from the instruments mains supply.

13	L

14	N

Figure 9. Mains Power Connections

WARNING:

CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY.

CAUTION:

This equipment is designed for installation in an enclosure that provides adequate protection against electric shock. The isolation switch should be located in close proximity to the unit, in easy reach of the operator and appropriately marked.

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Power Connections - 24/48V AC/DC Powered Instruments

24/48V AD/DC powered instruments will operate from a 20 to 48V AC or 22 to 55V DC supply. AC power consumption is 15VA max, DC power consumption is 12 watts max. Connection should be via a two-pole IEC60947-1 & IEC60947-3 compliant isolation switch / circuit breaker and a UL listed fuse type: 65v dc 1Aamp anti-surge.

Figure 10. 24/48V AC/DC Power Connections

WARNING:

CHECK THE INFORMATION LABEL ON THE CASE TO DETERMINE THE CORRECT VOLTAGE BEFORE CONNECTING TO A LIVE SUPPLY.

CAUTION:

Universal Input Connections

Universal Input Connections - Thermocouple (T/C)

Use only the correct thermocouple wire or compensating cable from the probe to the instrument terminals avoiding joints in the cable if possible. Where joints are made, special thermocouple connectors must be used. Failure to use the correct wire type and connectors will lead to inaccurate readings. Ensure correct polarity of the wires by cross-referencing the colours with a thermocouple reference table.

3 _

2 +

Figure 11. Thermocouple Input Connections

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Universal Input Connections – PT100 / NI120 (RTD) input

For three wire RTDs, connect the resistive leg and the common legs of the RTD as illustrated. For a two wire RTD a wire link should be used in place of the third wire (shown by dotted line). Two wire RTDs should only be used when the leads are less than 3 metres long.

Avoid cable joints.

RTD 1

Figure 12. RTD Input Connections

Four wire RTDs can be used, provided that the fourth wire is left unconnected. This wire should be cut short or tied back so that it cannot contact any of the terminals on the rear of the instrument.

Universal Input Connections - Linear Volt, mV or mA input

Linear DC voltage, millivolt or milliamp input connections are made as illustrated. Carefully observe the polarity of the connections.

3		_	+
3		_



2
2	+
	+
			_
1		mV/V
1
			mA
			mA

Figure 13. DC Volt, mV & mA Input Connections

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Option Slot 1 Connections

Option Slot 1 – Single Relay Output Module

If option slot 1 is fitted with a single relay output module, make connections as illustrated.

The relay contacts are SPDT and rated at 2 amps resistive, 240 VAC.

19 N/C

20 COM

21 N/O

Figure 14. Option Slot 1 – Single Relay Module

Option Slot 1 – Single SSR Driver Output Module

If option slot 1 is fitted with a single SSR driver output module, make connections as illustrated. The solid-state relay driver is a 0-10V DC signal, load impedance must be no less than 500 ohms. SSR driver outputs are not isolated from the signal input or other SSR driver outputs.

19 _

21 +

Figure 15. Option Slot 1 – Single SSR Driver Module

Option Slot 1 - Triac Output Module

If option slot 1 is fitted with a Triac output module, make connections as shown. This output is rated at 0.01 to 1 amp @ 280V AC 50/60Hz. A snubber should be fitted across inductive loads to ensure reliable switch off the Triac.

Figure 16. Option Slot 1 - Triac Module

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Option Slot 1 - Linear Voltage or mADC Output module

If option slot 1 is fitted with a DC linear output module, make connections as illustrated.

19 _

21 +

Figure 17. Option Slot 1 - Linear Voltage & mADC Module

Option Slot 2 Connections

Option Slot 2 – Single Relay Output Module

If option slot 2 is fitted with a single relay output module, make connections as illustrated. The relay contacts are SPDT, and rated at 2 amps resistive, 240 VAC.

22 N/C

23 COM

24 N/O

Figure 18. Option Slot 2 – Single Relay Module

Option Slot 2 - Dual Relay Output Module

If option slot 2 is fitted with a dual relay output module, make connections as illustrated. This module has two independent SPST relays, which share a common connection terminal. The contacts are rated at 2 amp resistive 240 VAC.

22		N/O OUTPUT 2B
22		N/O OUTPUT 2B

23 COMMON

24		N/O OUTPUT 2A
24		N/O OUTPUT 2A

Figure 19. Option Slot 2 - Dual Relay Module

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