Honeywell DCP301 User Manual

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EN1I-6197 Issue 7 (02/04)

DCP301

Digital Program Controller

User’s Manual

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WARRANTY

The Honeywell device described herein has been manufactured and tested for corrent operation and is warranted for a period of one year.

TECHNICAL ASSISTANCE

If you encounter a problem with your unit, please review all the configuration data to verify that your selections are consistent with your application; (i.e. Inputs, Outputs, Alarms, Limits, etc.). If the problem persists after checking the above parameters, you can get technical assistance by calling the following:

In the U.S.A.

・・・・・

1-800-423-9883

In Europe

・・・・・・・

Your local branch office

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■ About Icons

Safety precautions are for ensuring safe and correct use of this product, and for preventing injury to the operator and other people or damage to property. You must observe these safety precautions. The safety precautions described in this manual are indicated by various icons. The following describes the icons and their meanings. Be sure to read and understand the following descriptions before reading this manual.

■ Examples

Triangles warn the user of a possible danger that may be caused by wrongful operation or misuse of this product. These icons graphically represent the actual danger. (The example on the left warns the user of the danger of electric shock.)

White circles with a diagonal bar notify the user that specific actions are prohibited to prevent possible danger. These icons graphically represent the actual prohibited action. (The example on the left notifies the user that disassembly is prohibited.)

Black filled-in circles instruct the user to carry out a specific obligatory action to prevent possible danger. These icons graphically represent the actual action to be carried out. (The example on the left instructs the user to remove the plug from the outlet.)

SAFETY PRECAUTIONS

WARNING

Warnings are indicated when mishandling this product might result in death or serious injury to the user.

CAUTION

Cautions are indicated when mishandling this product might result in minor injury to the user, or only physical damage to this product.

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WARNING

CAUTION

Use the DCP301 within the operating ranges recommended in the specifications (temperature, humidity, voltage, vibration, shock, mounting direction, atmosphere, etc.). Failure to do so might cause fire or faulty operation.

Do not block ventilation holes. Doing so might cause fire or faulty operation.

Wire the DCP301 properly according to predetermined standards. Also wire the DCP301 using designed power leads according to recognized installation methods. Failure to do so might cause electric shock, fire or faulty operation.

Do not allow lead clippings, chips or water to enter the controller case. Doing so might cause fire or faulty operation.

Inputs to the current input terminals (

31) and (33) on the DCP301 should be

within the current and voltage ranges listed in the specifications. Firmly tighten the terminal screws at the torque listed in the specifications.

Insufficient tightening of terminal screws might cause electric shock or fire. Do not use unused terminals on the DCP301 as relay terminals.

Doing so might cause electric shock, fire or faulty operation. We recommend attaching the terminal cover (sold separately) after wiring

the DCP301. Failure to do so might cause electric shock, fire or faulty operation.

Use the relays on the DCP301 within the service life listed in the specifications. Continued use of the relays after the recommended service life might cause fire or faulty operation.

Before connecting the DCP301 to the measurement target or external control circuits, make sure that the FG terminal is properly grounded (100Ω max.). Failure to do so might cause electric shock or fire.

Before wiring, or removing/mounting the DCP301, be sure to turn the power OFF. Failure to do so might cause electric shock.

Do not touch electrically charged parts such as the power terminals. Doing so might cause electric shock.

Do not disassemble the DCP301. Doing so might cause electric shock or faulty operation.

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CAUTION

Use induced lighting surge preventive device if there is the risk of power surges caused by lightning. Failure to do might cause fire or faulty operation.

Before replacing the battery, be sure to turn the power OFF. Failure to do so might cause electric shock.

Do not touch internal components immediately after turning the power OFF to replace the battery. Doing so might cause burns.

･ Do not insert the battery with the polarities (+,-) reversed. ･Do not use damaged (broken battery skin, leaking battery fluid) batteries. ･Do not throw batteries into fires, or charge, short-circuit, disassemble or

heat batteries. ･Store batteries in low-temperature, dry locations. Failure to observe the above cautions may cause batteries to emit heat or split, or battery fluid to lead.

Store batteries out of the reach of small children. Batteries are small and are easy to swallow. If a child swallows a battery, consult a physician immediately.

Return used batteries to Honeywell sales/service office or your dealer. When disposing of used batteries at the user site, observe local by laws.

Handling Precautions

After turning the power ON, do not operate the DCP301 for at least 15s to allow the DCP301 to stabilize.

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ser

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Unpacking

Check the following when removing the DCP301 from its package.

1. Check the model No. to make sure that you have received the product that you ordered.

2. Check the DCP301 for any apparent physical damage.

3. Check the contents of the package against the Package List to make sure that all accessories are included in the package.

After unpacking, handle the DCP301 and its accessories taking care to prevent damage or loss of parts. If an inconsistency is found or the package contents are not in order, immediately contact your dealer.

Name Model No. Q’ty Remarks

See 1-5 How Model Nos. Are Configured, page 1-5.

Mounting bracket

81405411-001

1 set (2)

User's Manual EN1I-6197

This manual

Unit indicator label (SI units)

N-3132

Request

The filter on the front of the controller is Covered with a protective film to protect the surface of the controller. When you have finished mounting and wiring the controller, fix cellophane adhesive tape on the corners of the filter, and pull in the direction of the arrow to peel off the protective film.

The Model No. is the parts No. for two installation tools.

Product List

Pull towards you.

Handling Precautions

Peeling off the protective film with your fingernail might scratch the surface of the controller.

Body

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Organization of This User’s Manual

This manual is organized as follows.

Chapter 1. GENERAL

This chapter describes DCP301 applications, features and basic function blocks. It also gives a list of model numbers.

Chapter 2. NAMES & FUNCTIONS OF PARTS

This chapter describes the names and functions of DCP301 parts, input types and range Nos.

Chapter 3. MOUNTING

This chapter describes how to mount the DCP301 on control panels. This chapter is required reading for designers of control systems using the DCP301.

Chapter 4. WIRING

This chapter describes the precautions when wiring the DCP301 to a control system and how to wire the DCP301. This chapter is required reading for designers of control systems and supervisors of wiring work.

Chapter 5. FUNCTIONS

This chapter describes the functions of the controller. This chapter is required reading for designers of control systems using the DCP301.

Chapter 6. OPERATION

This chapter describes how to switch the basic display states of the DCP301, and select and run programs. This chapter is required reading for designers of control systems using the DCP301 and users of the DCP301.

Chapter 7. PARAMETER SETUP

This chapter describes how to set up parameters on the controller and the meaning of settings.

Chapter 8. PROGRAM SETUP

This chapter describes how to set up programs on the controller and the meanings of settings.

Chapter 9. TROUBLESHOOTING

This chapter describes points to check when the DCP301 is not working properly or how to remedy trouble that might occur.

Chapter 10. SPECIFICATIONS

This chapter describes the general specifications, performance specifications and external dimensions of the DCP301.

Chapter 11. CALIBRATION

This chapter describes calibration procedures for the functions of the DCP301.

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Contents

Safety Precautions Unpacking Request Organization of the Product Manual Conventions Used in This Manual

Chapter 1. GENERAL

1-1 Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2 Basic Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-3 Data Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-4 System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

■ System configuration by CPL communications . . . . . . . . . . . . . . . . . . . 1-4

1-5 Model Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

■ Model selection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

■ Basic display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

■ Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

■ Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

■ Functions using two or more keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

■ Loader jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2-3 Input Type and Range No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

■ Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Chapter 3. MOUNTING

3-1 External Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2 Panel Cutout Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

■ Mounting locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

■ Noise generating sources and countermeasures . . . . . . . . . . . . . . . . . . 3-4

■ Dust-proof cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

■ Mounting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Chapter 4. WIRING

4-1 Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 Compensating Lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-3 Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-4 Layout of Terminals and Recommended Lead Draw-out Direction. . . . . . . 4-5

4-5 Connecting the Ground and Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

■ Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

■ Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-6 Wiring of Standard and Add-on Terminal Base . . . . . . . . . . . . . . . . . . . . . . . 4-7

■ Standard terminal layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

■ Add-on terminal layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

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4-7 Connecting Inputs (analog inputs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

■ Connecting input 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-8 Connecting control outputs (outputs 1, 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

■ Relay output (0D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

■ Current output (5G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

■ Position-proportional output (2G). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

■ Voltage output (6D). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

■ Heat/cool output (3D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

■ Heat/cool output (5K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4-9 Connecting auxiliary outputs (outputs 2, 3). . . . . . . . . . . . . . . . . . . . . . . . . 4-11

■ 0D, 5G, 6D auxiliary outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

■ 2G, 3D, 5K auxiliary outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-10 Connecting Event Output (relay output). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-11 Connecting Time Event Output (open-collector). . . . . . . . . . . . . . . . . . . . . 4-13

4-12 Connecting External Switch (RSW) Input. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-13 Connecting for Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

■ RS-485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-14 Isolating Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

■ Control outputs 0D, 5G, 6D, 3D, 5K. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

■ Control output 2G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Chapter 5. FUNCTIONS

5-1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

■ Data types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5-2 Program Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

■ Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

■ Events 1 to 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

■ Time events 1 to 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

■ PID set selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

■ G.Soak (guarantee soak) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

■ PV start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

■ Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

■ Pattern link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5-3 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

■ Mode type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

■ Mode transition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

■ Mode transition operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

■ Mode transition limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-4 Controller and Programmer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-5 Input Processing Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-6 Output Processing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

■ Control output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

■ SP output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

■ Auxiliary output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Chapter 6. OPERATION

6-1 Turning the Power ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 Switching the Basic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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■ Display in program operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

■ Display in constant-value operation mode . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-3 Program Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

■ How to select the program No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-4 External Switch (RSW) Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

■ External switch (RSW) inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

■ Program selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

■ Read timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-5 Manual Operation and Auto-tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

■ Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

■ Auto-tuning (AT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Chapter 7. PARAMETER SETUP

7-1 Parameter Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

■ Selecting the setting group in the parameter setup . . . . . . . . . . . . . . . . 7-1

■ Moving individual items in the parameter setup . . . . . . . . . . . . . . . . . . 7-2

■ Changing individual items and how to return from the setup state . . . 7-2

7-2 How to Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

■ How to register functions to keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-3 Parameter Setup List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

■ Variable parameter settings “paRa” . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

■ Description of variable parameter settings . . . . . . . . . . . . . . . . . . . . . . 7-10

■ Event configuration data settings “ev”. . . . . . . . . . . . . . . . . . . . . . . . . 7-18

■ Description of event configuration data. . . . . . . . . . . . . . . . . . . . . . . . . 7-22

■ PID parameter settings “pi d” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

■ Setup data settings “Set” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

■ Description of setup data settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

■ Table data settings “TBL” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

■ Description of table data settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41

■ Constant-value operation data settings “CNST” . . . . . . . . . . . . . . . . . 7-42

Chapter 8. PROGRAM SETUP

8-1 Program Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

■ How to enter program setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

■ Selecting the program No. to set up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

■ Mode transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

■ Programming map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

■ Display details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

■ Setting up pattern items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

■ Setting up events 1 to 3 items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

■ Setting up time events 1 to 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

■ Setting up PID set No. items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

■ Setting up G.Soak (guarantee soak) items. . . . . . . . . . . . . . . . . . . . . . . 8-10

■ Setting up G.Soak time-out items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

■ Setting up PV start items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

■ Setting up cycle items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

■ Setting up pattern link items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

■ Deleting programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

■ Inserting and deleting segments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

PARA

Page 11

8-2 Copying Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

■ Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

8-3 General Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

■ Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

Chapter 9. TROUBLESHOOTING

9-1 Self-diagnostics and Alarm Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

■ Self-diagnostics at power ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

■ Self-diagnostics at each sampling cycle . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

■ Intermittent self-diagnostics during operation . . . . . . . . . . . . . . . . . . . . 9-1

■ Self-diagnostics only when certain functions are operating . . . . . . . . . 9-2

■ Alarm code display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

■ Alarm categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9-2 Trouble during Key Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

■ The program No. does not change by pressing in basic display

state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

■ The program No. does not change by pressing in the basic

display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

■ The controller does not change to RUN mode by pressing in

the basic display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

■ The controller does not change to HOLD mode by pressing in

the basic display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

■ The controller cannot be reset by pressing + in the basic

display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

■ The program is not advanced by pressing + in the basic

display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

■ The controller does not change to FAST mode by pressing +

in the basic display state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

■ The controller does not change to MANUAL mode by pressing

in the basic display state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

■ The controller does not change to AUTO mode by pressing in

the basic display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

■ Auto-tuning (AT) is not started by pressing in the basic display

state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

■ Auto-tuning (AT) is not canceled by pressing in the basic display

state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

■ Setting group other than “paRa” is not displayed by pressing

by selecting the setting group in parameter set state . . . . . . . . . . . . . . 9-5

■ Setting group other than “Set” is not displayed by pressing by

selecting the setting group in parameter set state . . . . . . . . . . . . . . . . . 9-5

■ The controller does not enter the setting entry state by pressing

in the parameter setup state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

■ The controller does not change to setup group selection state and setting entry state continues by pressing in parameter setting

entry state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

■ The controller does not change to program setup state by pressing

+ in the basic display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

■ The controller does not change to the setting entry state by pressing

in the basic display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

ENT

PROG

FUNC

PARA

ENT

PARA

ATATA/M

A/M

FUNC

DISP

PROG

RUN/HOLD

PROG

RUN/HOLD

PROG

Page 12

■ Items cannot be changed by pressing , in program setup

state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

■ Event items cannot be changed by repeatedly pressing , in

program setup state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

■ Time events cannot be changed by repeatedly pressing , in

program setup state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

■ PID set items cannot be changed by repeatedly pressing , in

program setup state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

■ G.Soak items cannot be changed by repeatedly pressing , in

program setup state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

■ PV start items, cycle items and pattern link items cannot be displayed

by repeatedly pressing , in program setup state . . . . . . . . . . . 9-6

■ Insertion/deletion of segments cannot be confirmed by pressing

+ in program setup state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

■ Program deletion cannot be confirmed by pressing + while

entering pattern items in program setup state . . . . . . . . . . . . . . . . . . . . 9-7

■ The program cannot be copied by pressing + in the basic

display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

■ General reset is not applied by pressing + + in the basic

display state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

9-3 Motor Adjustment is Impossible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

■ Normal wiring for direct motor rotation . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

■ Normal wiring for reverse motor rotation. . . . . . . . . . . . . . . . . . . . . . . . . 9-9

■ Alarm display caused by wrong wiring and causes . . . . . . . . . . . . . . . . 9-9

9-4 Replacing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

■ BAT LED blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

■ Items to prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

■ Replacement procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

Chapter 10.

SPECIFICATIONS

10-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

■ Accessories/option list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7

10-2 External Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

■ Soft dust-proof cover set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

■ Hard dust-proof cover set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

■ Terminal cover set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

Chapter 11. CALIBRATION

■ Precautions before calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

■ Equipment needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11-1 Quick Reference Table for Calibration Items. . . . . . . . . . . . . . . . . . . . . . . . 11-2

11-2 Calibration Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

■ Enter calibration mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

■ Function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-7

■ PV calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10

■ Cold junction sensor calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

■ Current output calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12

Index

DISP

CLR

FUNC

PROG

CLR

FUNC

ENT

FUNC

Page 13

Conventions Used in This Manual

The following conventions are used in this manual.

Handling Precautions

Handling Precautions indicate items that the user should pay attention to when handling the DCP301.

Note : Notes indicate useful information that the user might benefit by

knowing.

: These icons represent keys on the DCP301’s console.

+ : Combinations of icons like these indicate that must be pressed

while holding down.

(1) (2) (3) :The numbers with the parenthesis indicate steps in a sequence or

indicate corresponding parts in an explanation.

>> :Indicates the controller state after an operation.

PROG

RUN/HOLD

PROG

DISP

Page 14

Chapter 1. GENERAL

1-1

Chapter 1. GENERAL

1-1 Features

The DCP301 is a general-purpose single-loop program controller for controlling temperature, pressure, flow rate and other inputs.

● High accuracy achieved by multi-range input

Multi-range input allows you to choose between the following input types: thermocouple, resistance temperature detector (RTD), dc voltage and dc current. Accuracy of ±0.1%FS±1 digit and a sampling cycle of 0.1s ensures consistently high-precision control.

● Wide range of control output types

A wide range of models supporting various control output types are available: relay timeproportional output, position-proportional output, current output, voltage time-proportional output, and heat/cool output.

On models other than heat-cool control output, you can also choose neural net-based auto-tuning and smart-tuning for inhibiting overshoot, in addition 2 degrees of freedom PID.

● Enhanced compatibility with PLC

12 external switch inputs (eight optional), three event outputs and five time event outputs (optional) ensure compatibility with automating systems designed around a PLC core.

● Easy operation

Up to eight frequently changed parameter setups can be registered to the

PARA

key, facili-

tating recall of item setups. If the Smart Loader Package (sold separately) is used together with the DCP301, pro-

grams and parameters can be set up on a personal computer.

Page 15

Chapter 1. GENERAL

1-2

4 external switch inputs

• RUN

• HOLD

• RESET

• ADV

* indicates options.

Input

• Thermocouple

• Resistance

• dc current

• dc voltage

8 external switch inputs

• Program No.

• FAST

• PV start

• AUTO/MANUAL

• AT

• G.Soak cancel

• Direct/reverse action

Key operation

• Display selection

• Program No.

• RUN/HOLD

• RESET

• ADV

• FAST

• AUTO/MANUAL

• AT

• Program setup

• Parameter setup

MFB input

• Square root extraction

•

• Bias

• Filter

Control Operation Block

• Mode transition

• PID control

• Auto-tuning

• Neuro & Fuzzy

• Forward/reverse action

• ON-OFF control

• SP limit

• SP bias

• Output change limitter

• Upper/lower limitter

• SP output

Outputs

• Current

• Relay

• Voltage

• Position-proportional

• Heat-cool

Event Outputs

• PV

• SP

• Deviation

• MV

• MFB

• Modes

• Alarm

Time Event Outputs

• Time event

• Segment code

Auxiliary Outputs

• PV

• SP

• Deviation

• MV

• MFB

CPL communications I/O

Loader communications I/O

Program

• 19 patterns x 30 segments

• Events

• Time events

• PID sets

• G.Soak

• PV start

• Cycle

• Pattern link

Parameters

• Variable parameters

• Event configuration

• PID parameters (8 sets)

• Setup

• Tables

• Constant-value operation

temperature detector

Linearization table approximation

1-2 Basic Function Blocks

Page 16

Chapter 1. GENERAL

1-3

1-3 Data Structure

Data is made up of “parameters” that are used mainly for setting controller functions and “programs” that are used for setting operation during program operation of the controller.

• Total of 19 program patterns

Time

Program No.=19 Number of segments=8

Time

Program No.=3 Number of segments=15

Time

Program No.=2 Number of segments=19

(5)

(6)

Time

Program No.=1 Number of segments=6

(18)

(19)

(1)

(2)

(3)

(4)

(12)

(13)

(14)

(15)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

• Parameters

Variable parameters

Event configuration data

PID parameters

Setup data

Table data

Constant-value operation data

Page 17

Chapter 1. GENERAL

1-4

1-4 System Configuration

■ System configuration by CPL communications

On DCP301 models supporting RS-485 communications (optional), controllers can be connected as slave stations on a communications network.

Personal computer (master station)

DCP301 (slave station)

RS-485

RS-232C

RS-232C/RS-485 converter

Page 18

Chapter 1. GENERAL

1-5

1-5 Model Numbers

■ Model selection guide

P301 Digital Program Controller (single-

loop model)

0D Relay outputs (on-off, or time-

proportional) 2G Position-proportional output 5G Current output

(controller/programmer selectable)

(changeable to 6D output) 6D Voltage output (current value

adjustment function supported, on-

off, or time-proportional)

(changeable to 5D output) 3D Heat-cool output, relay output +

relay output (PID control or 3-

position-proportional) 5K Heat-cool output, current output +

current output (changeable be-

tween current output and voltage

output)

0 One input channel

ES Free power supply (90 to 264Vac)

00 No auxiliary output 01 1 auxiliary output 02 2 auxiliary outputs

0 External switch inputs (4), time

events not supported, communica-

tions not supported

1 External switch inputs (12), 5 time

events supported, communications

not supported

2 External switch inputs (12), 5 time

events supported, RS-485 commu-

nications supported

00 Additional treatment not supported T0 Tropical treatment

K0 Antisulfide treatment D0 Inspection Certificate supplied B0 Additional treatment + Inspection

Certificate provided

L0 Antisulfide treatment + Inspection

Certificate provided

Y0 Traceability Certificate

Basic

Model Output Function Power Option Option Additions Description

No.

Handling Precautions

On 2G, 3D and 5K output models, 2 auxiliary output (option 1) cannot be designated.

Page 19

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-1

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-1 Structure

This controller comprises a body, console, case, standard terminal base and add-on terminal base.

Key cover Cover for preventing erroneous operation.

Lock screw Fixes the case to the body.

Case

Console

Body Contains console and electrical circuits.

Standard terminal base

Add-on terminal base

Contains 7-segment display, LEDs, operation keys and loader connector.

Connectors for connecting power, input, output, event outputs, external switch inputs (4) and auxiliary outputs (options)

Terminal for connecting external switch inputs (8 options), time event outputs (options) and CPL communications (options). The add-on terminal base is provided only on models that support optional external switch inputs (8) and time event outputs.

Page 20

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-2

2-2 Console

The console comprises keys for operating the controller, displays and LEDs.

■ Basic display state

The “basic display state” is the state in which the controller operating state is displayed on the console.

When the power is turned ON, the controller is in this state. Key operation changes the controller from the basic display state to one of the parameter

setup, program setup, program copy or general reset states. Key operation also returns the controller to the basic display state.

Parameter setups

Program setups

Program copy

General reset

Power ON

Basic display states

■ Display

Program No. display

Mode indicator LED lamps

Event LEDs

Segment No. display

Basic indicator LED lamps

Upper display

Lower display

Low battery voltage LED (BAT) Control/output state LED

Profile display

• Program No. display In the basic display state, this display indicates the currently selected program No.

In the program setup state, this display indicates the program No. currently being set up. During constant-value operation, this display goes out in the basic display state. When an alarm occurs in the basic display state, alarm code “A L” is displayed.

• Segment No. display In the basic display state, this display indicates the currently selected segment No.

In the program setup state, this display indicates the segment No. currently being set up. During constant-value operation, this display goes out in the basic display state. In the parameter setup state, this display indicates the item No. When an alarm occurs in the basic display state, the alarm code No. is displayed.

Page 21

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-3

• Mode indicator LEDs RUN, HLD: Display the READY, RUN, HOLD, FAST and END modes. (See follow-

ing table.)

READY RUN HOLD FAST EN D

RUN Out Lit Out Blinking Out HLD Out Out Lit Out Blinking

Mode

LED

MAN : Lights in the MANUAL mode, and goes out in the AUTO mode. PRG : Lights in the program setup state. Otherwise, this LED is out.

• Upper display In the basic display state, displays PV and other values. In the parameter setup state, displays the item code.

• Lower display In the basic display state, displays SP, time, output and other values. In the parameter setup state, displays the item setting value.

• Low battery voltage LED BAT: Blinks when the battery voltage is low. Otherwise, this LED is out.

• Control/output state LED

AT: Blinks during auto-tuning, and lights during smart-tuning. Otherwise, this LED is

out.

OT1: When relay or voltage are assigned to output 1, lights when output is ON and goes

out when output is OFF. In the case of 2G output models, lights when the openside relay is ON and goes out when the relay is OFF.

Lights when current output is assigned to output 1.

OT2: When relay or voltage are assigned to output 2, lights when output is ON and goes

out when output is OFF. In the case of 2G output models, lights when the closedside relay is ON and goes out when the relay is OFF. Lights when current output is assigned to output 2, and goes out when auxiliary output is assigned to output 2.

OT3: Out

• Basic indicator LEDs

PV: Lights during PV display. Otherwise, this LED is out. SP: Lights during SP display. Otherwise, this LED is out. OUT: Lights during output display. Otherwise, this LED is out. TM: Lights during time display. Otherwise, this LED is out. CYC: Lights during cycle display. Otherwise, this LED is out. CH1: Out CH2: Out

• Event LEDs

EV1, EV2, : • In the basic display state or parameter setup state, light when each of EV3 events1 to 3 are ON, and go out when OFF.

• In the program setup (programming) state, light when each of the items for events 1 to 3 are displayed. Otherwise, these LEDs are out.

T1, T2, T3, : • Light when each of time events 1 to 5 are ON, and go out when OFF. T4, T5 • In the program setup (programming) state, light when each of the items

for time events 1 to 5 are displayed. Otherwise, these LEDs are out.

• Profile display Displays the tendencies (rise, soak, fall) of the program pattern. Blinks during G.soak standby, and lights successively after the power is turned ON.

Page 22

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-4

FUNC

DISP

PROG

A/M

: Program key

: Function key

Loader jack

: Auto/Manual key

: Auto-tuning key

: Parameter key

PROG

FUNC

A/M

PARA

: Enter key

ENT

: Clear key

CLR

: Run/Hold key

RUN/HOLD

: Display key

DISP

: Left arrow key, right arrow key : Up arrow key, down arrow key

To change the display To change the program No. in ascending order

(in READY mode) To execute running of program

(in READY mode) To run the program

(in READY, HOLD, FAST modes) To hold the program

(in RUN mode) To reset the program

(in READY, HOLD, FAST, END modes) To advance the program

(in RUN, HOLD, FAST modes) To run the program fast

(in RUN, HOLD modes) To execute manual operation

(in AUTO mode) To execute automatic operation

(in MANUAL mode) To start auto-tuning

(when not executing auto-tuning) To cancel auto-tuning

(when executing auto-tuning) To change values during manual operation

(when MV or SP is blinking)

DISP

RUN/HOLD

Category Function Key operation

Basic display state

■ Keys

Page 23

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-5

Starts parameter setup. So the controller enters selection of setup group (major item). (in basic display state)

To change the setup group (major item)

To fix the setup group To moves between individual items (minor items) To start changing individual item setting values

(while setting value is blinking) To end changing individual item setting values

(while setting value is blinking) To change individual item setting values

(while setting value is blinking) To cancel changing individual item setting values

(in basic display state) To selects setup group To end parameter setup To start changing assignment item setting values

(in basic display state) To move to next item by assignment item, and start

changing setting values To change assignment item setting values

(while setting value is blinking) To end changing assignment item setting values

(while setting value is blinking)

To start changing assignment item setting values To end assignment item setup To start program setup (programming)

(in basic display state) To move between program items and segment Nos.

To start changing item setting values (while setting value is blinking)

To end changing item setting values (while setting value is blinking)

To change item setting values (while setting value is blinking)

To clear item setting (while setting value is blinking)

To cancel changing item setting values (while setting value is blinking)

To insert/delete segments To change the program No. in ascending order

To change the program No. in descending order To end program setup (programming)

PARA

ENT

FUNC

PARA

ENT

PARA

DISP

FUNC

PROG

FUNC

ENT

DISP

FUNC+CLR

ENT

FUNC

PROG

DISP

PARA

ENT

Category Function Key operation

Parameter setup

key Assignment item setup

Program setup

Page 24

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-6

Category Function Key operation

Program copy

General reset

Do not operate the console keys using a sharp-pointed object such as a propelling pencil or needle. Doing so might damage the console.

To start program copy +

PROG

(in basic display state) To change the copy destination program No. To execute program copy

ENT

(while setting value is blinking) To end program copy

DISP

To check general reset

FUNC

CLR

DISP

(in basic display state) To execute general reset

ENT

To cancel general reset

DISP

Handling Precautions

Page 25

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-7

■ Functions using two or more keys

PROG

RUN/HOLD

: Reset keys

Press

RUN/HOLD

with

PROG

held down in the basic display state to reset the controller. The controller enters the READY mode in the RUN, HOLD, FAST or END modes. The controller cannot be reset in the READY mode by key operation.

PROG

DISP

: Advance keys

Press

DISP

with

PROG

held down in the program operation mode in the basic display state to advance the program. In the RUN, HOLD or FAST modes, the program advances to the next segment. The controller cannot advance in the READY mode by key operation.

FUNC

+ : Fast keys

Press with

FUNC

held down in the program operation mode in the basic display state to fast-operate the program. The controller enters the FAST mode from the RUN or HOLD modes.

FUNC

PARA

: Parameter setup keys

Press

PARA

with

FUNC

held down in the basic display state to move to selection of the setting

group (major items) in the parameter setup state.

FUNC

PROG

: Program setup (programming) keys

Press

PROG

with

FUNC

held down in the program operation mode in the basic display state to move to the program setup (programming) state. Press

PROG

with

FUNC

held down in the program setup state to change the No. of the program to be set up in ascending order.

FUNC

+ : Program No. change keys

Press with

FUNC

held down in the program setup state to change the No. of the program to

be set up in descending order.

FUNC+CLR

: Program item delete keys

Press

CLR

with

FUNC

held down during entry of settings in the program setup state to clear the

setting.

FUNC

ENT

: Segment insert/delete keys

Press

ENT

with

FUNC

held down at SP or time item in the program setup state to move to the

segment insert/delete screen.

PROG

: Program copy keys

Press

PROG

with held down in the program operation READY mode in the basic display

state to move to the program copy screen.

FUNC+CLR

DISP

: General reset keys

Press

CLR

and

DISP

with

FUNC

held down in the READY AUTO mode in the basic display

state to move to the general reset confirmation screen.

■ Loader jack

This jack is for connecting the loader. Objects other than the loader plug should not be inserted into this jack.

The loader jack is not isolated from internal digital circuits. Be sure to cap the loader jack when it is not in use.

Page 26

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-8

Input Format Range No. Code Temp. Range (°C) Temp. Range (°F)

K (CA) 0 K09 0 to 1200 0 to 2400 K (CA) 1 K08 0.0 to 800.0 0 to 1600 K (CA) 2 K04 0.0 to 400.0 0 to 750 K (CA) 3 K29 -200 to 1200 -300 to 2400 K (CA) 4 K44 -200.0 to 300.0 -300 to 700 K (CA) 5 K46 -200.0 to 200.0 -300 to 400 E (CRC) 6 E08 0.0 to 800.0 0 to 1800 J ( IC) 7 J08 0.0 to 800.0 0 to 1600 T (CC) 8 T44 -200.0 to 300.0 -300 to 700 B (PR30-6) 9 B18 0 to 1800 0 to 3300 R (PR13) 10 R16 0 to 1600 0 to 3100 S (PR10) 11 S16 0 to 1600 0 to 3100 W (WRe5-26) 12 W23 0 to 2300 o to 4200 W (WRe5-26) 13 W14 0 to 1400 0 to 2552 PR40-20 14 D19 0 to 1900 0 to 3400 Ni-Ni-Mo 15 Z13 0 to 1300 32 to 2372 N 16 U13 0 to 1300 32 to 2372 PL II 17 Y13 0 to 1300 32 to 2372 DIN U 18 Z08 -200.0 to +400.0 -300 to +750 DIN L 19 Z07 -200.0 to +800.0 -300 to +1600 Golden iron 20 Z06 0.0 to +300.0K —

chromel

Input Format Range No. Code Temp. Range (°C) Temp. Range (°F)

JIS’89 Pt100 32 F50 -200.0 to 500.0 -300 to 900 (IEC Pt100Ω) 33 F46 -200.0 to 200.0 -300 to 400

34 F32 -100.0 to 150.0 -150.0 to 300.0 35 F36 -50.0 to 200.0 -50.0 to 400.0 36 F38 -60.0 to 40.0 -76.0 to 104.0 37 F33 -40.0 to 60.0 -40.0 to 140.0 38 F05 0.0 to 500.0 0.0 to 900.0 39 F03 0.0 to 300.0 0.0 to 500.0 40 F01 0.00 to 100.00 0.0 to 200.0

JIS’89 J Pt100 48 P50 -200.0 to 500.0 -300 to 900

49 P46 -200.0 to 200.0 -300 to 400 50 P32 -100.0 to 150.0 -150.0 to 300.0 51 P36 -50.0 to 200.0 -50.0 to 400.0 52 P38 -60.0 to 40.0 -76.0 to 104.0 53 P33 -40.0 to 60.0 -40.0 to 140.0 54 P05 0.0 to 500.0 0.0 to 900.0 55 P03 0.0 to 300.0 0.0 to 500.0 56 P01 0.00 to 100.00 0.0 to 200.0

2-3 Input Type and Range No.

■ Inputs

● Thermocouple

● Resistance temperature detector (RTD)

Page 27

Chapter 2. NAMES & FUNCTIONS OF PARTS

2-9

● dc current, dc voltage

Input Format Range No. Code Range (programmable)

4 to 20mA 64 C01 0 to 20mA 65 C08 0 to 10mA 66 M01

-10 to +10mV 67 L02 0 to 100mV 68 L01 -1999 to 9999 0 to 1V 69 L04

-1 to +1V 70 L08 1 to 5V 71 V01 0 to 5V 72 L05 0 to 10V 73 L07

• The unit of code Z06 is Kelvin (K)

• The lower limit readout of code B18 is 20°C (68°F). The lower limit readout (°C) of codes K44, K46, T44, Z08 and Z07 is -199.9°C.

• The lower limit readout (°C) of codes F50, F46, P50 and P46 is -199.9°C.

• The upper limit readout (°C) of codes F01 and P01.

• The PV lower limit alarm does not occur with code F50. However, note that the PV lower limit alarm occurs at a disconnection when

input has been downscaled when input is disconnected during setup.

• The number of digits past the decimal point for dc current and dc voltage is programmable within the range 0 to 3.

Handling Precautions

Page 28

Chapter 3. MOUNTING

3-1

Chapter 3. MOUNTING

3-1 External Dimensions

B-B

78.4

110.5

A-A

90.2

91.5

Back plate

Add-on terminal base

Terminal screw

(106x104)

(18)

159.5 137

Unit: mm

Mounting bracket 81405411-001

Soft dust-proof cover set (sold separately) 81446087-001

Hard dust-proof cover set (sold separately) 81446083-001

Terminal cover set (sold separately) 81446084-001

Page 29

Chapter 3. MOUNTING

3-2

+0.8

46 4696 x (N - 1)

96 x N - 4

+0.8

N=number of units installed

Panel cutout dimensions

Panel cutout dimensions during multiple mounted

(recommended)

Unit: mm

150min.(when vertically mounted)

99 min. (when horizontally mounted)

(107 min. when hard dust-prevention cover is used)

Panel cutout dimensions when mounting units horizontally and vertically (recommended)

3-2 Panel Cutout Dimensions

Use a steel panel of at least 2mm in thickness for mounting the controller.

When mounting the controller, take care to prevent the temperature at the lower surface of the controller’s case from exceeding the operating temperature range (0 to 50°C), particularly when mounting vertically or during multiple mounting.

Handling Precautions

Page 30

Chapter 3. MOUNTING

3-3

Do not block ventilation holes. Doing so might cause fire or faulty operation.

Do not allow lead clippings, chips or water to enter the controller case. Doing so might cause fire or faulty operation.

Before wiring, or removing/mounting the DCP301, be sure to turn the power OFF. Failure to do so might cause electric shock.

Do not disassemble the DCP301. Doing so might cause electric shock or faulty operation.

WARNING

3-3 Mounting

CAUTION

■ Mounting locations

Avoid installing the DCP301 in the following locations:

• Locations outside of the operating temperature range (0 to 50°C) and operating humid-

ity range (10 to 90%RH)

• Locations subject to sulfide gas or other flammable gases

• Locations subject to dust or oil smoke

• Locations subject to the direction sunlight, wind or rain

• Locations that directly subject the body to vibration or impact

• Locations under high-voltage lines, near welders or near sources of electrical noise

• Locations near (within 15m) of high-voltage ignition equipment such as boilers

• Locations where magnetic fields are generated

• Locations subject to flammable liquids or moisture

Page 31

Chapter 3. MOUNTING

3-4

indicates that a function can be used.

The varister may become short-circuited when trouble occurs. Pay attention to this when providing a varister on a controller.

■ Dust-proof cover

Use the dust-proof cover when using the controller in a dusty or dirty location, and to prevent inadvertent operation.

Two dust proof-covers are provided, hard or soft, each with the following differing functions.

Type Confirmation on Display Operation

Hard x

Soft

■ Noise generating sources and countermeasures

• Generally, the following generate electrical noise: (1) Relays and contacts (2) Solenoid coils, solenoid valves (3) Power lines (in particular, 90Vac min.) (4) Induction loads (5) Inverters (6) Motor commutators (7) Phase angle control SCR (8) Wireless communications equipment (9) Welding equipment (10) High-voltage ignition equipment

• If the influence of electrical noise cannot be eliminated, we recommend taking the following countermeasures:

- Provision of a CR filters for fast-rising noise

Recommended CR filter: Model No. 81446365-001

- Provision of a varister for noise with a high wave height

Recommended varister: Model No.81446366-001 (100V)

81446367-001 (200V)

Handling Precautions

Page 32

Chapter 3. MOUNTING

3-5

Mounting bracket 81405411-001Panel

Mounting bracket

■ Mounting method

• Firmly secure the top and bottom of the controller by the mounting brackets.

• When mounting the controller, secure by lower mounting bracket (1) first.

(1)

Panel

Mounting bracket

(2)

To secure the controller, tighten the screw on the mounting bracket (supplied) until there is no more play and then tighten a further full turn. Take care not to overtighten the screw. Doing so might deform the case.

• Keep the mounting angle to within 10° from the horizontal at both the controller rear

top and bottom.

Lift up from rear by 10° max.

Pull down from rear by 10° max.

Handling Precautions

Page 33

Chapter 4. WIRING

4-1

Chapter 4. WIRING

4-1 Wiring Precautions

Do not allow lead clippings, chips or water to enter the DCP301 case. Doing so might cause fire or faulty operation.

Inputs to the current input terminals (31) and (33) on the DCP301 should be within the current and voltage ranges listed in the specifications. Failure to do so might cause electric shock or faulty operation.

Firmly tighten the terminal screws at the torque listed in the specifications. Insufficient tightening of terminal screws might cause electric shock or fire.

Do not use unused terminals on the DCP301 as relay terminals. Failure to do so might cause electric shock, fire or faulty operation.

We recommend attaching the terminal cover (sold separately) after wiring the DCP301. Failure to do so might cause electric shock, fire or faulty operation.

Use the relays on the DCP301 within the service life listed in the specifications. Continued use of the relays after the recommended service life might cause fire or faulty operation.

Use induced lighting surge preventive device if there is the risk of power surges caused by lightning. Failure to do might cause fire or faulty operation.

WARNING

Before connecting the DCP301 to the measurement target or external control circuits, make sure that the FG terminal is properly grounded (100Ω max.).

Failure to do so might cause electric shock or fire. Before wiring, or removing/mounting the DCP301, be sure to turn the power

OFF. Failure to do so might cause electric shock. Do not touch electrically charged parts such as the power terminals. Doing

so might cause electric shock.

CAUTION

Page 34

Handling Precautions

• Before wiring the DCP301, check the controller catalog No. and terminal Nos. on the label on the rear of the body. After wiring the DCP301, be sure to check the wiring for any mistakes.

• Maintain a distance of at least 50cm between I/O leads or communications leads and the power lead. Also, do not pass these leads through the same piping or wiring duct.

• When wiring with crimped terminals, take care to prevent contact with adjacent terminals.

• When connecting the DCP301’s thermocouples in parallel to other controllers, make sure that the total input impedance of the other controller is at least 1MΩ.

If the input impedance is less than 1MΩ, the DCP301 may not be able to detect sensor disconnection.

• When inputting the DCP301’s I/O (parallel connection in case of input) to an A/ D converter or analog scanner, read data may fluctuate.

To prevent this, adopt one of the following measures.

(1) Use a low-speed, integrating type A/D converter.

(2) Insert an isolator without a switching power supply between the DCP301

and A/D converter.

(3) Average data on a personal computer when reading data.

(4) If possible, set a filter for the input.

• Provide the wiring for the instrument power supply with a mains power shutoff switch within reach of the instrument operator.

• Provide the wiring for the instrument power supply with a delayed operation type (T) 1A current rating, 250V voltage rating fuse. (IEC 127)

• Devices and systems to be connected to this unit must have the basic insulation sufficient to withstand the maximum operating voltage levels of the power supply and input/output parts.

4-2

Page 35

Chapter 4. WIRING

4-3

4-2 Compensating Lead

In the case of thermocouple input, connect the bare thermocouple lead to the terminal. If the thermocouple is located a long way from the DCP301 or the thermocouple is connected to a terminal, extend the connection using a compensating lead and then connect to the terminal. Use shielded compensating leads only.

• For I/O other than thermocouples, use JCS-364 shielded instrument polyethylene insulated vinyl sheath cable or equivalent product. (This is generally referred to “twisted shielded cable for instruments.”) The following cables are recommended.

Fujikura Ltd. 2-core IPEV-S-0.9mm

x 1P

3-core ITEV-S-0.9mm

x 1T

Hitachi Cable Co. 2-core KPEV 0.9mm

x 1P

3-core KTEV-S-0.9mm

x 1T

• Shielded, multi-core microphone cord (MVVS) can be used if there is little electromagnetic induction.

Page 36

Chapter 4. WIRING

4-4

4-3 Terminal Connections

Use crimped terminals that fit onto M3.5 screws.

7.4

7.3 max.

6.6 max.

3.7dia.

Unit: mm

• When installing the DCP301 in locations subject to vibration or impact, be sure to use round crimped terminals to prevent the lead from coming loose from the terminal.

• When wiring with crimped terminals, take care to prevent contact with adjacent terminals.

• The recommended tightening torque for the terminal screws is 0.78 to

0.98N•m.

Handling Precautions

Page 37

Chapter 4. WIRING

4-5

4-4 Layout of Terminals and Recommended Lead Draw-out

Direction

Wiring is carried out on the standard terminal base or add-on terminal base. The following diagram shows the recommended draw-out directions for the leads on the standard terminal base.

The lead draw-out directions are the same when using the add-on terminal base.

Standard terminal base

Lead draw-out direction

(11) to (20) to left ( )

(1) to (10) to left ( )

(21) to (26) to left ( )

(26) to (34) to right ( )

Page 38

Chapter 4. WIRING

4-6

4-5 Connecting the Ground and Power Supply

■ Power supply

Connect the DCP301 to a single-phase power supply for controllers, and take measures to prevent the influence of electrical noise.

GND

Instrument power supply

Other circuits

GND GND

Recommended

line filter

81446364-001

DCP301

200/200V,

100/100V

insulated transformer

• If the power supply generates a lot of electrical noise, we recommend inserting an insulating transformer in the power circuit and using a line filter.

Recommended line filter: Model No. 81446364-001

• After providing anti-noise measures, do not bundle primary and secondary power leads together, or pass them through the same piping or wiring duct.

■ Ground

When it is difficult to ground shielded cable, prepare a separate ground terminal (earth bar).

Ground type: 100Ω max. Ground cable: 2mm sq. min soft-copper wire (AWG14) Cable length: Max. 20m

FG terminal

DCP301

GND terminal plate

GND (100Ω max.)

Shielded cable

Use only the FG terminal (3) on the DCP301 for grounding. Do not ground across other terminals.

Handling Precautions

Page 39

Chapter 4. WIRING

4-7

* On 2G, 3D or 5K models, (17) and (18) are the auxiliary outputs.

On 0D, 5G or 6D models, (14) and (15), and (17) and (18) are the auxiliary outputs.

4-6 Wiring of Standard and Add-on Terminal Base

■ Standard terminal layout

■ Add-on terminal layout

RSW1

RSW2

RSW3

RSW4

mAdc

COM

V, mV

EV1

EV2

EV3

90 to 264Vac 50/60Hz

Instrument power supply

FG (Frame GND)

Event outputs

2G output

OD output 3D output

5G output 6D output 5K output Auxiliary output

Relay

4 to 20mA voltage

4 to 20mA

Output 1 Output 2

Auxiliary output 1

Auxiliary output 2

External switch input (RSW)

Current input

Input

Resistance temperature detector

Voltage input

Thermocouple input

Auxiliary output 4 to 20mA Recorder, etc.

RSW5

SDA

SDB

RDA

RDB

RSW6

RSW7

RSW8

RSW9

RSW10

RSW11

RSW12

External switch inputs

To terminals

Time event outputs

Load

External

10 to 29Vdc power supply

Bias circuit

RS-485 communications

Page 40

Chapter 4. WIRING

4-8

V, mV

4-7 Connecting Inputs (analog inputs)

■ Connecting input 1

Multiple input 1 supports various sensor inputs. Connect as follows according to the sensor being used.

• Thermocouple input • RTD input

• dc voltage input • dc current input

• Applying voltage across dc current input terminals (31) and (33) may cause

faulty operation.

• Take care of polarities (+,-) when wiring inputs.

• Use only shielded cable for wiring inputs.

• When using a thermocouple input, prevent air blasts from coming into contact

with the terminal. Doing so might cause a reading error.

Handling Precautions

Page 41

Chapter 4. WIRING

4-9

WARNING

4-8 Connecting control outputs (outputs 1, 2)

Before wiring, or removing/mounting the DCP301, be sure to turn the power OFF. Failure to do so might cause electric shock.

■ Relay output (0D)

Connect as follows.

Load

Power supply

Contact rating, resistive load 5A (30Vdc/120Vac) 4A (240Vac)

Minimum switching current: 100mA

When switching small currents, connect a bleeder resistor to allow current flow of the minimum relay switching input (100mA min.).

■ Current output (5G)

Connect as follows.

Actuator

4 to 20/0 to 20mAdc Resistive load 600Ω max.

Open side

Power supply

Closed side

Open

Closed

Contact rating 4A (120Vac, cosø=0.4) 2A (240Vac, cosø=0.4)

Feedback resistance 100 to 2500Ω

Load

• The life of internal relays is limited. Avoid setting the PID constant in such a way that results in excessive repeated ON/OFF switching.

• When using a 100/200Vac motor, pay attention to rush current and the contact rating. If necessary, provide an external auxiliary relay.

• Separate the wiring for motor terminals (11) (12) (13) and feedback resistor terminals (14) (15) (16). (Do not wire the leads in the same duct or use 6-core cable. Doing so might result in faulty controller operation caused by electrical noise when the motor is started up.)

• When controlling without motor feedback with variable parameter M .-Cset to “2”, terminals (14) (15) (16) need not be connected.

4 to 20mAdc and 0 to 20mAdc can be selected in setup data C 9 0.

■ Position-proportional output (2G)

Connect as follows paying attention to the switching direction.

Handling Precautions

Page 42

Chapter 4. WIRING

4-10

SSR

2 to 22mAdc With current adjustment function (setup: C78)

Voltage output is reliant on an internal fixed-current circuit. Set the current value in the setup data so that the optimum voltage is obtained

matched to the conditions of the SSR in use and load. Factory setting: general-purpose SSR voltage value.

■ Heat/cool output (3D)

Connect as follows.

Load

Power supply

Load

Power supply

Output 1 Contact rating, resistive load 5A (30Vdc/120Vac) 4A (240Vac)

Minimum switching current: 100mA

Output 2 Contact rating, resistive load 5A (30Vdc/120Vac) 4A (240Vac)

Minimum switching current: 100mA

When switching small currents, connect a bleeder resistor to allow current flow of the minimum relay switching input (100mA min.).

■ Heat/cool output (5K)

Connect as follows.

(SSR)

Load

Output 2

•

Output 1

•

Voltage output: 2 to 22mAdc With current adjustment function (setup: C78)

Current output: 4 to 20/0 to 20mAdc Load resistance 600Ω max.

Voltage output: 2 to 22mAdc With current adjustment function (setup: C79)

Current output: 4 to 20/0 to 20mAdc Load resistance 600Ω max.

■ Voltage output (6D)

Connect as follows.

Current output and voltage output can be selected by setups C 7 5 and C 7 6. Voltage output is reliant on an internal fixed-current circuit. Set the current value in the setup data so that the optimum voltage is obtained

matched to the conditions of the SSR in use and load. Factory setting: general-purpose SSR voltage value.

Handling Precautions

Page 43

Chapter 4. WIRING

4-11

Before wiring, or removing/mounting the DCP301, be sure to turn the power OFF. Failure to do so might cause electric shock.

4-9 Connecting auxiliary outputs (outputs 2, 3)

Optional auxiliary outputs can be added on.

■ 0D, 5G, 6D auxiliary outputs

WARNING

Receiver

Auxiliary output 1 (output 2) 4 to 20/0 to 20mAdc Resistive load 600Ω max.

Auxiliary output 2 (output 3) 4 to 20/0 to 20mAdc Resistive load 600Ω max.

• 4 to 20mAdc and 0 to 20mAdc can be selected in setup data C 9 0.

• Use shielded cable only.

■ 2G, 3D, 5K auxiliary outputs

Receiver

Auxiliary output 2 (output 3) 4 to 20/0 to 20mAdc Resistive load 600Ω max.

Auxiliary output 1 is not provided for 2G, 3D and 5K outputs.

• 4 to 20mAdc and 0 to 20mAdc can be selected in setup data C 9 0.

• Use shielded cable only.

Handling Precautions

Page 44

Chapter 4. WIRING

4-12

4-10 Connecting Event Output (relay output)

Event outputs EV1 and EV2 are 1a contact, and event output EV3 is 1a1b. Event outputs are connected on the standard terminal base.

EV1 1a

EV2 1a

EV3 1a1b

Load

Power supply

Load

Power supply

Load

Power supply

Standard terminal base

Contact rating, resistive load 1A (30/250Vdc)

Contact rating, resistive load 2A (30/250Vdc)

Minimum switching current: 10mA

When switching small currents, connect a bleeder resistor to allow current flow of the minimum relay switching input (10mA min.).

Handling Precautions

Page 45

Chapter 4. WIRING

4-13

4-11 Connecting Time Event Output (open-collector)

Optional time event outputs T1 to T5 (open-collector outputs) can be added on. Time event outputs are connected on the add-on terminal base.

10 to 29Vdc

Load

External power supply

Add-on terminal base

Bias circuit

Maximum load current: OFF leakage current:

70mA/load

0.1mA max.

• Be sure to connect terminal (55) to the + terminal of the external power supply. Otherwise, open-collector output will not function.

• Do not short-circuit the + terminal of the external power supply and terminals (49) to (53) on the DCP301. Doing so will cause faulty open-collector output.

(The DCP301 does not contain a short-circuit prevention circuit.)

• When connecting to a semiconductor load such as a programmable controller (sequencer), select a module whose current directions are matching.

Use a module that does not operate by leakage current when the open-collector output of the DCP301 is OFF.

Handling Precautions

Page 46

Chapter 4. WIRING

4-14

4-12 Connecting External Switch (RSW) Input

The DCP301 is provided with four external switch inputs as standard (eight optional). The optional eight inputs are located on the add-on terminal base. Wire the external switch inputs across the standard and add-on terminal bases.

RSW1

RSW2

RSW3

RSW4

COM

RSW5

RSW6

RSW7

RSW8

RSW10

RSW11

RSW12

RSW9

Add-on terminal base

Standard terminal base

Contact

• The external switch inputs on the DCP301 have built-in power supplies (open voltage 12Vdc). Be sure to use no-voltage contacts for external contacts.

• Use no-voltage contacts such as gold contacts whose small current can be switched ON/OFF. On some relay contacts, the small current cannot be switched ON/OFF. Use no-voltage contacts having a sufficient minimum switching capability with respect to the contact current and open voltage of the DCP301.

• When using a semiconductor (e.g. open-collector) as a no-voltage contact, use a semiconductor whose contact terminal voltages at contact ON are 3V max., and whose leakage current at contact OFF is 0.1mA.

• External switch inputs on the DCP301/302 can be connected in parallel. When connecting in parallel with other controllers, thoroughly check the condi-

tions of the other controller before configuring the control system.

Handling Precautions

Page 47

Chapter 4. WIRING

4-15

● Internal circuit for controller components for connecting external switch inputs

12Vdc

Standard terminal base

External switch input

Internal circuit Internal circuit

Add-on terminal base

Page 48

Chapter 4. WIRING

4-16

4-13 Connecting for Communications

Some controller models support the RS-485 communications interface. Select the RS-485 communications models by selected the required catalog No.

Connect as follows.

The DCP301 operates as a slave station.

■ RS-485 interface

SDA

SDB

RDA RDB

Add-on terminal base

• Multi-drop connection of slave stations is possible.

• Make sure that different addresses are set for each slave station.

• Provide terminating resistor (total of 4 in the case of a 5-wire system connec-

tion) on both ends of the communications path. Use terminating resistor of 150Ω±5%, 1/2W min.

• In the case of a 3-wire system connection, short-circuit terminals (57) and (59), (58) and (60) on the DCP301.

• Do not short-circuit the RDA and RDB, or SDA and SDB terminals. Doing so might damage the DCP301.

Handling Precautions

Page 49

Chapter 4. WIRING

4-17

● 5-wire system RS-485 mutual connection

SDA

SDB

RDA RDB

SG FG

SDA

SDB

RDA RDB

SDA SDB

SG FG

SDA

SDB

RDA RDB

SG FG

Terminating resistor

Slave station DCP301

Shielded cable

Master station

Slave station DCP301

Provide terminating resistor of 150Ω±5%, 1/2W min. at both ends of the communications path. Grounding of the shielded FG terminal should be carried out at only one end and not both ends.

Be sure to connect SG terminals each others. Failure to do so might cause unstable communications.

Handling Precautions

Page 50

Chapter 4. WIRING

4-18

● 3-wire system RS-485 mutual connection

Provide terminating resistor of 150Ω±5%, 1/2W min. at both ends of the communications path. Grounding of the shielded FG terminal should be carried out at only one end and not both ends. When there are only three RS-485 terminals, terminals marked * are wired internally.

SDA

SDB

RDA RDB

SG FG

SDA

SDB

RDA RDB

SDA SDB

SG FG

SDA

SDB

RDA RDB

SG FG

Terminating resistor

Slave station DCP301

Shielded cable

Master station

Shielded cable

Be sure to connect SG terminals each others. Failure to do so might cause unstable communications.

Handling Precautions

Page 51

Chapter 4. WIRING

4-19

4-14 Isolating Inputs and Outputs

The following figures show isolation between inputs and outputs. Solid lines show isolated items, and dotted lines show non-isolated items.

■ Control outputs 0D, 5G, 6D, 3D, 5K

11 12

14 15

17 18

4 5

6 7 8 9

10 49

32 33 34

25 41

48 57

Input 1 (full multiple-input PV supported)

Output 1

(relay, current, voltage output)

Output 2

(relay, current, voltage output, auxiliary output)

Output 3 (auxiliary output)

Event output 1 (relay output 1a)

Event output 2 (relay output 1a)

Event output 3 (relay output 1a1b)

Time event outputs 1 to 5 (open-collector output)

Loader communications I/O

Loader jack

12 external switch inputs

Communications I/O (RS-485)

Digital circuit

11 12 13 14 15 16 17 18

4 5

6 7 8 9

10 49

32 33 34

25 41

48 57

Input 1 (full multiple-input PV supported)

Output 1 (control output 1a relay x 2)

Motor feedback input

Output 3 (auxiliary output)

Event output 1 (relay output 1a)

Event output 2 (relay output 1a)

Event output 3 (relay output 1a1b)

Time event outputs 1 to 5 (open-collector output)

Loader communications I/O

Loader jack

12 external switch inputs

Communications I/O (RS-485)

Digital circuit

The loader jack is not isolated from internal digital circuits. Be sure to cap the loader jack when it is not in use.

■ Control output 2G

Handling Precautions

The loader jack is not isolated from internal digital circuits. Be sure to cap the loader jack when it is not in use.

Page 52

Chapter 5. FUNCTIONS

5-1

Chapter 5. FUNCTIONS

5-1 Data

■ Data types

The DCP301 supports the following data types. For further details, see Chapter 7, Parameter Setup and Chapter 8, Program Setup.

Data that can be changed even in RUN mode

Data Parameters

Program

Data (e.g. event type)

Control parameters of PID sets 1 to 8

Basic data that can be changed only in READY mode

Linearization table data

Data (e.g. SP, PID) of constant-value operation

SP and time data

Events 1 to 3 data

Time events 1 to 5 time data

PID set No. data for use in control

G.Soak ON/OFF data

PV START ON/OFF data

Cycle count data

Pattern link destination program No. data

Variable parameters

Event configuration data

PID parameters

Setup data

Table data

Constant-value operation data

Pattern

Event

Time event

PID set No.

G.Soak

PV start

Cycle

Pattern link

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5-2 Program Patterns

■ Patterns

SP and time comprise the settings for a single segment in a pattern. Up to 30 segments can be linked to create a broken-line whose vertical axis is SP and horizontal axis is time. This system is called the “RAMP-X” system.

SP setting: Within range of SP limitter upper and lower limits Timesetting: 0 to 99h, 59min or 0 to 99min, 59s

(Select the time unit in setup data C 6 4.)

SP is the point that corresponds to the time elapsed in the current segment on a straight line made by jointing the start point (SP setting value of the previous segment) to an end point (SP setting value of the current segment).

Accordingly, segments are categorized as follows:

• Rising ramp (rising ramp, rising tendency) Previous segment SP setting value < current segment SP setting value

• Falling ramp (falling ramp, falling tendency) Previous segment SP setting value > current segment SP setting value

• Soak (soak) Previous segment SP setting value = current segment SP setting value

In the case of the No.1 segment, both the start and end points become the soak segment of the No.1 segment SP setting values.

SP (other than No.1 segment) is calculated as by the following formula: SP = (current segment SP setting value - previous segment SP setting value) x (current

segment elapsed time ÷ current segment time setting) + previous segment SP setting

Time setting of current segment

SP setting value of current segment

SP setting value of previous segment

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■ Events 1 to 3

Events 1 to 3 are event configuration data. These are used after setting the event type, event standby, hysteresis and ON delay time.

A total of three event types are available: PV type events, controller status events, and

time events.

● PV type events

• Basic specifications The following page shows event type PV, deviation, absolute value deviation, SP, MV

and MFB. In the figures, the thick lines show ON-OFF changes in state. The upper line expresses the ON state, and the lower line the OFF state.

EV and H stand for event setting value and hysteresis, respectively. Output in the READY state is OFF.

• Event standby Events function as follows when event standby has been set to ON.

- If the controller is in the state in the figure when changing from the READY to

the RUN mode and after restoring the power, operation is the same as when event standby is set to OFF. The up-facing arrow in the figure indicates a change to ON, and a down-facing arrow indicates a change to OFF.

- If the controller is outside the state in the figure when changing from the READY

to the RUN mode and after restoring the power, the state is OFF. After entering the

state, the up-facing arrow in the figure indicates a change to ON, and a down-

facing arrow indicates a change to OFF.

• Event ON delay The event No. to apply the delay to and the delay time can be set regardless of event

type. “Delay” functions to turn output ON when the event is continuously ON for the preset delay time after the event OFF→ON condition is satisfied.

When event ON delay is combined with event standby, event standby must first be canceled before event ON delay functions.

• Segment progression

- Output is OFF until the program progresses to the segment containing the event

setting.

- When the program progresses to the segment containing the event setting, event ON/

OFF operation is carried out according to the event setting value.

- The previous setting is valid until the program progresses to a segment containing a

new event setting. For this reason, set as follows to disable the event set in the previous segment from a

certain segment onwards:

Direct action events: Upper limit value of event setting Reverse action events: Lower limit value of event setting

Note, however, that some types of event turn ON even if events are set as shown above.

- When the program has progressed to the No.1 segment by the cycle or pattern link

functions, the previous setting is disabled. Output is OFF unless the No.1 segment contains an event setting.

• Other On 5G output models, when setup data C 1 8 is set to 1, and SP output (programmer

functions) is selected, the MV direct/reverse event does not function.

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5-4

PV reverse

SP+EV

Deviation reverse

SP reverse

MV reverse

MFB

MFB reverse

SP+EV

Deviation direct

H H

EVEV

Absolute value deviation direct

SP direct

MV direct

MFB

MFB direct

H H

EVEV

Absolute value deviation reverse

OFF

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5-5

● Controller status events

Controller status events are turned ON and OFF according to the controller mode, alarm status and other statuses.

Though the event standby function does not function, the ON delay function does. Event setting values (operating point), hysteresis and event standby are not set.

• Basic operations The following basic operation types are provided:

RUN+HOLD+FAST+END READY RUN HOLD FAST END G.Soak standby MANUAL Auto-tuning executing Constant-value operation MFB estimated position control, sum of all alarms PV range alarm Controller alarms Low battery voltage Console setup in progress Loader setup in progress ADV

When the DCP301 reaches the state designated by the event type, the event is turned ON. Otherwise, the event is OFF.

• Alarms Alarms are divided into PV range alarm groups (alarm code Nos. 01 to 16) and control-

ler alarm groups (alarm code Nos. 70 to 99, and low battery voltage). When the event type is set to the sum of all alarms, the alarm turns ON even if at least

one of the alarms occurs. When the event type is set to PV range alarm, the alarm turns ON even if at least one of

the alarms in the PV range alarm group occurs. When the event type is set to controller alarm, the alarm turns ON even if at least one

of the alarms in the controller alarm group occurs.

• ADV This is ON for 1s after executing program advance. The event ON delay is disabled

and a delay is not applied.

● Time events

When the event 1 to 3 type is set to time event, the event can be used in the same way as time events 1 to 5. However, note that events 1 to 3 do not have segment No. event functions.

Though the event standby function does not function, the ON delay function does.

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■ Time events 1 to 5

Either of time events or segment No. events can be selected by the time event type item in the event configuration data setup.

● Time events

Segment 1

ON time OFF time Output ON Output OFF

ON<OFF

Segment 2 3

ON time OFF time Output ON Output OFF

Output turns OFF at end of segment even if OFF time is not set.

Segment 5 6

ON time OFF time Output ON Output OFF

ON continued

Segment 3B 3C

ON time OFF time Output ON Output OFF

No ON

ON=OFF ON>OFF

Segment 4

Segment time

ON time OFF time Output ON Output OFF

G.Soak standby

ON-OFF time is invalid even if set in excess of segment 4 time.

Advance to segment 5

ON=0

Segment 7

ON time OFF time Output ON Output OFF

Segment time start

The ON and OFF times or only the ON time can be set for each event No. and segment. The following describes ON/OFF of output.

• When the ON time is smaller than the OFF time, output is ON for the duration from the ON time to the OFF time. (See segments 1, 6 and 7 in the figure.)

• When only the ON time is set, output is ON for the during from the ON time to the segment end point. (See segments 2 and 5 in the figure.)

• When both the ON time and OFF time are not set, output is OFF. (See segment 3 in the figure.)

• Setting only the OFF time without an ON time is not possible. (See segment 3B in the figure.)

• Setting an ON time to be greater to or equal than the OFF time is not possible. (See segment 3C in the figure.)

• Only ON and OFF times set within the segment time are valid. Times straddling the next segment are invalid. The ON and OFF times set in the next segment are valid. (See segments 4 and 5 in the figure.)

Accordingly, the ON and OFF times settings at the segment end point are ignored.

However, ON and OFF times set for segment end points when the END mode is shifted to are valid. (See segment 9 in the figure, and compare with segment 10 in the END mode.)

• When the ON time is set to 0 (no OFF time setting, or OFF time is greater than 0), output becomes OFF at time 0.

If output at the previous segment end point was ON at this time, the output status at the segment switching point does not momentarily become OFF. (See segments 5 and 6 in the figure.)

• The G.Soak standby time is not included in the ON and OFF times. (See segment 7 in the figure.)

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5-7

Segment 8

ON time OFF time Output ON Output OFF

G.Soak standby

Segment 9

ON time OFF time Output ON Output OFF

ON=segment time

Segment 10

Segment time

ON time OFF time Output ON Output OFF

END mode

ON=segment time

Segment 8 time start

When 0N=0, output turns ON when there is input to segment 8.

• If the ON time is set to 0 in the case of G.Soak standby, output becomes ON from the G.Soak standby state, and the ON time is started at completion of the G.Soak standby time.

The output time = G.Soak time + OFF time (See segment 8 in the figure.)

• ON and OFF time settings the same time as the segment end point are valid in the case of the final segment END mode. (See segment 10 in the figure.)

● Segment No. events

The current segment No. is output as binary code. When all of T1 to T5 are selected as segment No. events in the time event type setup, all

ON-OFF operations are as shown in the following table. When T1 to T4 are assigned in part to segment No. events, only the assigned time events

operate as shown in the following table, and the remaining events operate as regular time events.

123456789101112131415

T1 ON OFF O N OFF ON OFF ON OFF ON OFF ON OFF O N OFF ON T2 OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF O N ON T3 OFF OFF OFF ON O N ON O N OFF OFF OFF OFF ON ON ON ON T4 OFF OFF OFF OFF OFF OFF OFF ON ON ON O N ON O N ON ON T5 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

T1 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF T2 OFF OFF ON ON OFF OFF O N ON OFF OFF ON ON OFF OFF O N T3 OFF OFF OFF OFF ON ON O N ON OFF OFF OFF OFF ON ON O N T4 OFF OFF OFF OFF OFF OFF OFF OFF ON O N ON O N ON ON ON T5 ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON

Event No.

Segment

No.

Event No.

Segment

No.

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5-8

12 43

PID set No.

PID set segment designation

Zone 8

Zone 7

Zone 6

Zone 5

Zone 4

Zone 3

Zone 2

Zone 1

All SP ranges are divided to eight zones.

PID set automatic switching

C P. 1 7

P. 1

• Eight sets of PID parameters, PID1 to PID8, are used for control operation. When the PID set No. is set to each segment by designating the PID set segment, control output is calculated by each of the PID parameters.

• There are two ways of selecting PID sets: by designating the PID set segment and PID set auto-switching. The method can be selected by setting setup data C 1 1.

C 1 1 set to 0: Designation of PID set segment C 1 1 set to 1: PID set auto-switching

These two methods cannot be set simultaneously.

When setup data C 1 1 is set to 1, PID items in the program setup are not displayed.

• By designation of PID set segment, the PID set No. is set for each segment, and control output is calculated by each of the PID parameters.

• By PID set auto-switching, the SP full-scale is divided into eight zones according to the settings of C P . 1 1 to C P . 1 7, and the PID constant to be used according to the SP value is automatically selected to calculate the control output.

■ PID set selection

■ G.Soak (guarantee soak)

G.Soak ON/OFF and G.Soak width can be set for each segment. The G.Soak time can also be set by the variable parameter G S . t item.

The G.Soak function ensures a segment execution time with PV close to SP. G.Soak functions not only in soak segments but also in ramp segments.

At the segment start point, PV and SP are compared, and the absolute value of the resulting deviation continues for the G.Soak time or longer. When the absolute value is smaller than the G.Soak width, operation of that segment is started.

The controller is in the G.Soak standby state until this condition is satisfied, and the linear lamp on the left of the profile display blinks. The operation state is the same as hold at the segment start point (time is set to 0). However, note that in the FAST mode, the controller does not enter the G.Soak standby state even if G.Soak is set to ON. The G.Soak standby state can also be canceled by external switch output. The following cancel conditions can be selected by the setup date C 5 2 to C 5 4 settings.

(1) G.Soak cancel when external switch input contact is ON or

PV satisfies the G.Soak cancel conditions

(2) G.Soak cancel when external switch input contact is ON

and PV satisfies the G.Soak cancel conditions

G.Soak width

Segment execution time

G.Soak standby time

Time count start

Segment set time

Time

G.Soak at segment start point

Note

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SP pattern

Start point

Current

PV value

Start point

(1)

(1)'

(1)"

■ PV start

If PV start is set in the program setup, PV is started by regular RUN operation.

The first point where PV matches the SP in the program pattern (including bias for both PV and SP) is searched for, and operation is started from that point.

However, note that if a matching point is not found, operation is started from the beginning of segment 1.

When PV has started, event operating points and the time of time events are automatically corrected. If the PV start function is selected by setup data C 5 2 to C 5 4 settings relating to external switch input, PV start can be executed without setting PV start in the program setup.

PV start is valid for segments in the currently selected program, and invalid for the segment at the pattern link destination.

■ Cycle

The cycle function is for repeating operation from the No.1 segment of the program pattern to the final set segment for a preset number of cycles. The number of cycles can be set up to 9999.

When a number of cycles “n” is set, the operation count becomes “n+1”.

When executing cycle operation, operation at the end point of the final segment is not carried out, and operation is restarted with the settings of events 1 to 3 and time events 1 to 5 cleared. At this time, PV is not started and operation starts from the No.1 segment even if PV start is set.

If the SPs at the pattern start and end points do not match, the SP changes in a stepped manner during cycle operation.

Cycle 1

Time

(1)

(2)

(3)

(4)

(5)

(6)

PV start points (1) PV starts at point A where the PV value first

crosses the SP pattern.

(1)' PV starts at point B where the PV value first

crosses the SP pattern.

(1)'' Point C of segment 1 is the PV start point

since there is no point where the PV value crosses the SP value.

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Program No.2 pattern-linked to program No.1

Program No.1

Program No.2

Time

Program No.1 Program No.2

■ Pattern link

“pattern link” is a function for linking patterns together. The link destination program No. is set by the pattern link item.

When the pattern link item is set to 0 (initial setting), patterns are not linked. When the No. of the current program itself is set to the pattern link item, this creates an endless loop.

If the SPs at the link source end point and the link destination start point do not match, the SP changes in a stepped manner during link operation.

When cycle operation has been set, the pattern link function works after cycle operation has ended. After pattern link operation ends, operation begins from the No.1 segment of the link destination pattern, so operation is restarted with the settings of events 1 to 3 and time events 1 to 5 cleared.

If PV start is programmed to the link destination pattern, the PV start function operates after the link is made.

After the link has been made, PID operation is not initialized, and is continued.

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5-11

5-3 Modes

■ Mode types

The following modes are available on the DCP301.

READY

AUTO

MANUAL

AUTO

MANUAL

AUTO

MANUAL

AUTO

MANUAL

AUTO

MANUAL

AUTO

MANUAL

AUTO

MANUAL

RUN

HOLD

END

FAST

READY

Program operationMode

Constant-value operation

RUN

● Program operation

Operation is carried out according to SP, times, events, etc. set to program patterns No.1 to 19.

● Constant-value operation

Operation is carried out according to SP or events set in the constant-value operation data. Time events 1 to 5 turn OFF.

● READY

In this mode, the DCP301 is ready for operation. MV output is fixed, and events to be operated according to event setting values turn OFF.

However, events to be operated according to controller states are active. Parameters for all of the setup data, some event configuration data and some constant-

value operation data can be set or changed in the READY mode. During program operation, program pattern Nos.1 to 19 can be selected.

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● RUN

In this mode, the program is running. MV outputs are active in PID control or ON-OFF control, and events and time events are

active. In the program operation mode, program operation progresses according to the elapsed

time. However, note that progress of program operation stops in the same way as the HOLD

mode when the controller is in the G.Soak (Guarantee Soak) standby state.

● HOLD

In this mode, the program is held. Progress of program operation stops. However, note that MV outputs are active in PID

control or ON-OFF control, and events and time events are active in the same way as in the RUN mode. The HOLD mode is not available during constant-value operation.

● FAST

In this mode, the program is fast-forwarded. This mode is like the RUN mode except that progress of the program operation time is

speeded up. The time scale is selected by the variable parameter F A S T setting. MV outputs are active in PID control or ON-OFF control, and events and time events are

active. The controller does not enter the G.Soak standby state even if G.Soak (Guarantee Soak)

is set. The FAST mode is not available during constant-value operation.

● END

In this mode, operation of the program has ended. MV outputs are active in PID control or ON-OFF control, and events and time events are

active with program operation stopped at the program end point. The END mode is not available during constant-value operation.

● AUTO

In this mode, program operation is automatic. MV output is active according to controller control. (However, note that when programmer functions are selected on 5G output models, SP

output is active according to controller control.)

● MANUAL

In this mode, program operation is manual. MV output can be changed by , , , on the console or communications. (However, note that when programmer functions are selected on 5G output models, SP

output can be changed by , , , on the console or communications.)

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5-13

READY AUTO READY MANUAL

RUN AUTO RUN MANUAL

RUN

RESET

■ Mode transition

● During program operation

The solid lines in the following diagram show mode transition operations. The broken lines show end of operation.

END AUTO END MANUAL

READY AUTO READY MANUAL

RUN AUTO RUN MANUAL

HOLD AUTO HOLD MANUAL

FAST AUTO FAST MANUAL

RESET

HOLD

RUN

FAST FAST

RUN

RESET

RUN

RESET

HOLD

ADV

ADVADVADV

RESET

Mode changes to READY or END at end of operation.

• When shifting between the AUTO and MANUAL modes, the modes in the square frames can be shifted between.

• Selection of the READY or END modes at end of operation is set up in the setup data.

● During constant-value operation

The solid lines in the following diagram shows mode transition operation.

When shifting between the AUTO and MANUAL modes, the modes in the square frames can be shifted between.

● Switching between program operation and constant-value operation

In the READY mode, select operation by the constant-value operation data “M .O D E” operation mode item.

0: Program operation 1: Constant-value operation

Note

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■ Mode transition operations

The following describes mode transition operations. Though “program end” is not an operation, it is described below as it is a factor in mode

transition.

● RUN

This operation involves shifting to the RUN mode from the READY, HOLD or FAST modes. To shift from the READY mode to the RUN mode, the DCP301 must be in the basic display state even in key, external switch input or communication operations.

● HOLD

This operation involves shifting to the HOLD mode from the RUN or FAST modes. The HOLD mode is not available in the constant-value operation mode.

● RESET

This operation involves shifting to the READY mode from the RUN, HOLD, FAST or END modes.

In the program operation mode, this mode includes returning to the No.1 segment.

● ADV

This operation involves advancing one segment in the READY, RUN, HOLD or FAST modes.

The ADV mode is not available in the constant-value operation mode.

● FAST

This operation involves shifting to the FAST mode from the RUN or HOLD modes. The FAST mode is not available in the constant-value operation mode.

● AUTO

This operation involves shifting to the AUTO mode from the MANUAL mode.

● MANUAL

This operation involves shifting to the MANUAL mode from the AUTO mode. When the DCP301 enters the MANUAL mode, the basic display state changes as fol-

lows.

- When controller functions are selected, PV and output value (%) are displayed.

- When programmer functions are selected, PV and SP are displayed. When the DCP301 enters the MANUAL mode from the AUTO mode by external switch

inputs or communications, the display changes to the basic display state even in the parameter setup or program setup states.

● Program end

When operation progresses in the RUN or FAST modes in the program operation mode, or when the segment has been advanced in the ADV mode, the program ends when all end points in the program setup including cycles and pattern links have been reached.

You can select in the setup setting in which of the READY or END modes program operation ends.

The program does not end in the constant-value operation mode.

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■ Mode transition limitations

Mode transition can be carried out operating the console keys, external switching input and communications. The following table shows which operations are enabled in each of the modes.

Operation RUN HOLD RESET ADV * FAST

(to RUN mode) (to HOLD mode) (to READY mode) (to FAST mode)

(to next segment mode)

Communications

Key

Switch

Key

Switch

Communications

Key

Switch

Key

Switch

Communications

Key

Switch

Original mode

READY

—— ——∆∆— ❍ ————

RUN — — —

❍❍ ❍❍ ❍❍ ❍❍

HOLD

❍❍—— — ❍❍ ❍❍ ❍❍

FAST

❍❍— ❍❍ ❍❍ ❍❍———

END ——————

❍❍——————

READY

❍❍————————————

RUN ——————

❍❍——————

Operation MANUAL AUTO

(to MANUAL mode) (to AUTO mode)

Original mode

AUTO

❍❍———

MANUAL — — —

❍❍

AUTO

❍❍———

MANUAL — — —

❍❍

Communications

Key

Switch

Key

Communications

Switch

Constantvalue operation

Program operation

Constantvalue operation

❍ : Operation is enabled.

: Operation is enabled if in basic display state.

∆ : No.1 segment is returned to if controller is still in READY mode.

— : Operation is disabled.

* With ADV by communications, mode transition is not limited to the next segment; the

mode advances to the segment specified in the communications message.

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5-4 Controller and Programmer

On 5G output models (output catalog No. appended with 5G), you can choose between use as a controller or a programmer. Set this in setup data C 1 8. You can also choose between controller or programmer functions even if the DCP301 is used for program operation or constant-value operation.

The DCP301 is limited to use as a controller at all times on other models.

● Controller

When the DCP301 is used as a controller, PID control operation is carried out according to PV, SP AND PID setting values, and the resulting manipulated variable (MV) is output as an analog output.

ON-OFF control, heat/cool PID control and 3-position-proportional is also possible depending on the type of output supported by the model of DCP301.

In the MANUAL mode, the MV can be incremented or decremented in the basic display state by the console keys.

DCP301 controller

Controlled system

● Programmer

When the DCP301 is used as a programmer, PID control operation is not carried out, and the SP is output in the scaled 4 to 20mA range.

In the MANUAL mode, the SP can be incremented or decremented in the basic display state by the console keys.

4 to 20mA

DCP301 programmer

SP output

RSP input

Controller Controller Controller

Controlled system Controlled system Controlled system

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5-5 Input Processing Functions

Input processing is carried out in the order shown below.

(resistance temperature detector)

(thermocouple)

Input range type

Wiring resistance compensation

Analog input 1

A/D conversion

Cold junction compensation

Upper/lower limit value scaling

Upper/lower limit alarm

Square-root extraction

Temperature unit range

Linearization approximation

Digital filter

Bias

PV1

(DC current and voltage)

Setting: Setup data

C03

Setting: Setup data

C72

Setting: Setup data

C0 7

(thermocouple and resistance temperature detector) Setting: Setup data

C02

(DC current and voltage) Setting: Setup data

C0 4

C06

Setting: Setup data

C08

Table data

T-A. 1

T-B.B

Setting: Variable parameter

PBi

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Chapter 5. FUNCTIONS

5-18

5-6 Output Processing Functions

Three outputs are provided as output processing functions: control output, SP output and auxiliary output.

■ Control output

When the DCP301 is selected for use as a controller, control output is operational. How outputs are processed varies according to the output type supported on the model.

● 5G output

Over-range

READY mode

MANUAL mode

Current output 4 to 20mA (0 to 20mA)

Initialization of PID control

operation

PID control operation

Output change limitter

Output upper/lower limit limitter

Manipulated variable (MV1)

Output 1

AT execution

MV in READY mode

Preset manual value

Manual MV

MV at over-range

AT operation

Setting: Variable parameters 1 OUT/rpi d

Setting: PID parameters p/ 1 / d/8E PID parameters dP/di /dd PID parameters br

Setting: Variable parameters OTL

Setting: Variable parameter AT

Setting: PID parameters OL/OH

Setting: Setup data C 12/C 13

Setting: Setup data C 14/C 15

Setting: Setup data C 16

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● 0D, 6D output

AT execution

Over-range

MANUAL mode

PID control operation

Initialization of PID control operation

Output change limitter

Output upper/lower limit limitter

Voltage output 1 adjustment

Time-proportional relay output Time-proportional voltage output

Output 1

Manipulated variable (MV1)

Output 1 time-proportional output cycle

ON/OFF control

MV at over-range

READY mode

MV in READY mode

Preset manual value

Manual MV

AT operation

ON/OFF control operation

Setting: PID parameters p/ 1 / d/RE PID parameters dP/di /dd PID parameters br

Setting: Variable parameters OTL

Setting: PID parameters OL/OH

Setting: Variable parameter AT

Setting: Setup data C 12/C 13

Setting: Setup data C 14/C 15

Setting: Variable parameter DI FF

Setting: Setup data C 16

(6D output) Setting: Setup data C78

Setting: Variable parameter Cy. 1

Setting: Variable parameters 1 OUT/rpi d

In ON-OFF control, the DCP301 cannot be set to the MANUAL mode. (The DCP301 can be set to the MANUAL mode as ON-OFF control is not possible in the READY mode.)

Handling Precautions

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● 2G output

Over-range

READY mode

MFB automatic adjustment execution

PID control operation

Initialization of PID control operation

Output change limitter

Output upper/lower limit limitter

MFB operation

Motor control operation

Manipulated variable (MV1)

Motor control method selection

AT execution

MV in READY mode

MANUAL mode

Manual MV

Preset manual value

MFB automatic adjustment

MV at over-range

AT operation

Output 1

open-side relay

Output 1

closed-side relay

Setting: Variable parameters 1 OUT/rpi d

Setting: PID parameters p/ 1 / d/RE PID parameters dP/di /dd PID parameters br

Setting: Variable parameters OTL

Setting: Variable parameter AT

Setting: PID parameters OL/OH

Setting: Setup data C 12/C 13

Setting: Setup data C 14/C 15

Setting: Setup data C 16

Setting: Variable parameter DI FF

Setting: Variable parameter M.-AT

Setting: Variable parameter M.-C

Setting: Variable parameters M.-CL/M.-OP/M.-T

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5-21

READY mode

MANUAL mode

READY/AUTO modes READY/AUTO modes

Time-proportional relay output Current output 4 to 20mA (0 to 20mA) Time-proportional voltage output

PID control operation

Initialization of PID control operation

Output change limitter

(odd-numbered PID sets)

Output upper/lower limit limitter

(even-numbered PID sets)

Heat-side Cool-side

Output upper/lower limit limitter

MV (heat)

Output 1 time-proportional output cycle

Voltage output 1 adjustment

Output 1

Time-proportional relay output Current output 4 to 20mA (0 to 20mA) Time-proportional voltage output

MV (cool)

Output 2 time-proportional output cycle

Voltage output 2 adjustment

Output 2

Manipulated variable (MV1)

Heat-cool MV operation

Over-range

Manual MV

3-position control

3-position control operation

Preset manual value

MV in READY mode (heat)

3-position control

MV in READY mode (cool)

3-position control operation

50%

MV at over-range

Setting: Variable parameters 1 OUT/rpi d

Setting: PID parameters p/ 1 / d/RE

Setting: Variable parameters OTL

Setting: Setup data C 12/C 13

Setting: Setup data C 14/C 15

Setting: Variable parameter DI FF

Setting: PID parameters OL/OH

Setting: Setup data C 16

Setting: Setup data C 17

(relay/voltage output) Setting: Variable parameter CY. 1

(relay/voltage output) Setting: Variable parameter CY.2

(voltage output) Setting: Setup data C78

(voltage output) Setting: Setup data C79

Setting: PID parameters OL/OH

Setting: Setup data

Variable parameters

C45

Dv-L/HY-L

Setting: Setup data

Variable parameters

C45

Dv-H/HY-H

● 3D, 5K outputs

In 3-position control, the DCP301 cannot be set to the MANUAL mode

Handling Precautions

Page 73

Chapter 5. FUNCTIONS

5-22

■ SP output

When the DCP301 is selected for use as a programmer, control output is operational. On 5G output models, SP output is processed is as follows.

■ Auxiliary output

● Auxiliary output 1

When auxiliary output 1 or 2 are supported on 0D, 5G or 6D output models, auxiliary output 1 is processed as follows.

● Auxiliary output 2

When auxiliary output 2 is supported on 0D, 5G or 6D output models, auxiliary output 2 is processed as follows.

When auxiliary output 1 is supported on 2G, 3D or 5K output models, auxiliary output 2 is processed as follows.

MANUAL mode

Main output types

Upper/lower limit scaling

SP1 output

Output 1

READY mode

Upper/lower limit scaling

Manual SP1

MV in READY mode

Current output 4 to 20mA (0 to 20mA)

Setting: Setup data C 16

Setting: Setup data C 18

Setting: Setup data C 19/C20

Auxiliary output 1 type

Upper/lower limit scaling

Output 2

4mA (0mA)

Current output 4 to 20mA (0 to 20mA)

When READY mode is entered at auxiliary output type SP and deviation

When auxiliary output type is NOP When auxiliary output type is set to MFB on non-

2G output models When auxiliary output type is set to MV by program-

mer function on 5G output models

Setting: Setup data C46

Setting: Setup data C47 /C48

Auxiliary output 2 type

Upper/lower limit scaling

Output 3

4mA (0mA)

Current output 4 to 20mA (0 to 20mA)

When READY mode is entered at auxiliary output type SP and deviation

When auxiliary output type is NOP When auxiliary output type is set to MFB on non-2G

output models When auxiliary output type is set to MV by program-

mer function on 5G output models When auxiliary output type is set to MV by 3-positionproportional control on 3D output models

Setting: Setup data C49

Setting: Setup data C50/C5 1

Page 74

Chapter 6. OPERATION

6-1

Chapter 6. OPERATION

6-1 Turning the Power ON

The DCP301 is not equipped with a power switch or protective fuses. If necessary, prepare these externally. When a voltage of 90 to 264Vac is applied across terminals (1) and (2) on the DCP301, display appears for about 10s

after which control and other operations are started. During controller startup until start of operations, the LEDs on the profile display light successively at uneven intervals clockwise from top right. The following diagram shows the flow of operations at startup.

● Startup flow

Power ON

YES

Start of operations

Check start of general reset

Press key.

RAM backup normal?

ENT

Continuation of program operation/constant-value operation modes

Continuation of READY/RUN/HOLD/FAST/END modes Continuation of AUTO/MANUAL modes (Continuation of manual value if in MANUAL mode) Continuation of program No./segment No. Continuation of segment progress time Continuation of display No. of basic display state in

AUTO mode

Parameter=factory shipment setting Delete entire program. Program operation mode READY mode AUTO mode Program No.1=1/segment No.=1 Segment progress time=0

Cancellation of auto-tuning/smart-tuning Cancellation of MFB automatic adjustment by 2G output Initialization of G.Soak standby time Initialization of PID operation Initialization of event output state Setting display state → Basic display state Display No. of basic display state in MANUAL mode

With the following modes and items, the state when the power is turned OFF continues when the power is turned back ON.

• READY, RUN, HOLD, FAST, END modes

• AUTO, MANUAL modes

• MANUAL values in MANUAL mode

• Program No., segment No.

• Progress time in segment

• Display No. if in basic display state in AUTO mode

Handling Precautions

Page 75

Chapter 6. OPERATION

6-2

6-2 Switching the Basic Display

The “basic display state” of the controller collectively refers to the display state of the program No. display, segment No. display, upper display, lower display, basic indicator LED lamps and event LEDs.

Each press of

DISP

successively switches the basic display state. Operation of other displays and LEDs is carried out

in the same way even when setting up parameters, for example. However, switching by

DISP

is not possible.

The following figure shows the conventions used for displays in this manual.

PROFILE

(2)

(1)

(3)

(4)

(5)

(6)

Current segment Next segment

Falling ramp

Soak

Rising ramp

Soak

Falling ramp

: LED lit

: LED blinking

PV SP

Program/segment No. Display

Basic indicator LED lamps

Program No. Segment No.

Pattern

tendency

Upper display

Lower display

Event LEDs

Output states of events 1 to 3, time events 1 to 5

Supplementary explanation

In the program operation mode, READY indicates the currently selected program/segment No. Displays other than READY indicate the currently operating program/seg-

ment No. In the constant-value operation mode, nothing is displayed and this dis-

play is blank.

In the program operation mode, the profile is displayed only when the program has been set up. The profile is not displayed when the program is not set up.

When there is no subsequent segment even if the program is set up, the three LEDs on the right do not light. In the constant-value operation mode, nothing is displayed and this display is blank.

Profile Display

Page 76

Chapter 6. OPERATION

6-3

■ Display in program operation mode

●

DISP

functions

Output Model No. Display

0D, 5G, 6D Display 1 → Display 2 → Display 5 → Display 6 → Display 7 →

Display 1 (repeated)

2G Display 1 → Display 2 → Display 3 → Display 5 → Display 6 →

Display 7 → Display 1 (repeated)

3D, 5K Display 1 → Display 2 → Display 4 → Display 5 → Display 6 →

Display 7 → Display 1 (repeated)

● Display 1

PV SP

Program No. Segment No.

Pattern

tendency

Output states of events 1 to 3, time events 1 to 5

The digit to which SP values can be entered blinks in the MANUAL mode when programmer functions are selected.

● Display 2

OUT

Output value (%)

Program No. Segment No.

Pattern

tendency

Output states of events 1 to 3, time events 1 to 5

The digit to which SP values can be entered blinks in the MANUAL mode when controller functions are selected.

● Display 3

Program No. Segment No.

Pattern

tendency

Motor valve opening (%)

Output states of events 1 to 3, time events 1 to 5

F B

This display is exclusive to 2G output models (output catalog No. appended with 2G).

Page 77

Chapter 6. OPERATION

6-4

● Display 4

OUT

Heat-side output (%)

Cool-side output (%)

Program No. Segment No.

Pattern

tendency

Output states of events 1 to 3, time events 1 to 5

This display is exclusive to heat/cool output models (output catalog No. appended with 3D or 5K).

● Display 5

Time

Program No. Segment No.

Pattern

tendency

Output states of events 1 to 3, time events 1 to 5

Either of “h:min” or “min:s” is selected as the time unit in setup settings. Select either “remaining segment time” or “total operating time” in setup settings as the details whose

time is to be displayed.

● Display 6

CYC

Number of remaining cycles

Program No. Segment No.

Pattern

tendency

Output states of events 1 to 3, time events 1 to 5

When the remaining number of cycles is “0”, subsequent cycle operation is not carried out.

Page 78

Chapter 6. OPERATION

6-5

● Display 7

SP TM

Time

Program No. Segment No.

Pattern

tendency

Output states of events 1 to 3, time events 1 to 5

The digit to which SP values can be entered blinks in the MANUAL mode when programmer functions are selected. Either of “h:min” or “min:s” is selected as the time unit in setup settings. Select either “remaining segment time” or “total operating time” in setup settings as the details whose time is to be displayed.

■ Display in constant-value operation mode

●

DISP

functions

Output Model No. Display

0D, 5G, 6D Display 1 → Display 2 → Display 1 (repeated) 2G Display 1 → Display 2 → Display 3 → Display 1 (repeated) 3D, 5K Display 1 → Display 2 → Display 4 → Display 1 (repeated)

● Display 1

PV SP

Output state of events 1 to 3

The digit to which SP values can be entered blinks in the MANUAL mode when controller functions are selected.

● Display 2

OUT

Output value (%)

Output state of events 1 to 3

The digit to which SP values can be entered blinks in the MANUAL mode when programmer functions are selected.

Page 79

Chapter 6. OPERATION

6-6

● Display 3

This display is exclusive to 2G output models (output catalog No. appended with 2G).

● Display 4

OUT

Heat-side output (%)

Cool-side output (%)

Output state of events 1 to 3

This display is exclusive to heat/cool output models (output catalog No. appended with 3D or 5K).

Motor valve opening (%)

Output state of events 1 to 3

F B

Page 80

Chapter 6. OPERATION

6-7

6-3 Program Selection

The program No. can be selected on the console within the range 1 to 19.

■ How to select the program No.

Program No.1

Program No.2

Program No.3

Program No.4

PROG

key

When the controller is in the basic display state in the program operation READY mode:

• Each press of

PROG

increments the program No. The

display reverts to 1 after 19.

• Each press of decrements the program No. The display reverts to 19 after 1.

• Both already set or non-set program Nos. can be selected

• The program No. cannot be selected when selecting the program No. by exter-

nal switch input.

• The program No. cannot be selected during constant-value operation.

• Pressing does not change the program No. when values currently being

entered are displayed in the MANUAL mode.

Handling Precautions

Page 81

Chapter 6. OPERATION

6-8

6-4 External Switch (RSW) Operations

■ External switch (RSW) inputs

In all, the DCP301 is provided with 12 external switch inputs. Each of these inputs are differentiated by RSW1, RSW2 and so forth to RSW12. On models whose option 2 catalog No. is “0”, only inputs RSW1 to RSW4 are mounted.

(RSW: external switch input)

● External switch input types

The functions of RSW1 to 4, and RSW8 to 12 are fixed. The functions of RSW5 to 7 are selected by the setup setting.

External Function Detection Method

Switch No.

RSW1 RUN Rising edge RSW2 HOLD Rising edge RSW3 RESET Rising edge RSW4 ADV Rising edge

Selected by setup from the following functions RSW5 FAST Rising edge RSW6 PV start Rising edge RSW7 AUTO/MANUAL Rising/falling edge

AT start/stop Risi n g / falling edge

G.Soak cancel by OR conditions Status

G.Soak cancel by AND conditions Status

Direct/reverse action switching Status RSW8 Program No. selection Weighting 1 Status RSW9 Program No. selection Weighting 2 Status RSW10 Program No. selection Weighting 4 Status RSW11 Program No. selection Weighting 8 Status RSW12 Program No. selection Weighting 10 Status

• With PV is valid only in the program operation mode and READY mode, and the PV start RUN mode is entered regardless of the PV start setting in the program. Note, however, that RUN mode is entered from the start point of the selected segment in READY mode when there is no SP for the PV start.

• With G.Soak cancel by OR conditions, G.Soak standby is canceled when the external switch turns ON or when the PV enters the G.Soak width.

• With G.Soak cancel by AND conditions, G.Soak standby is canceled when the external switch turns ON or when the PV enters the G.Soak width.

• When the external switch turns ON by direct/reverse action switching, control operation is the opposite to that set in setup parameter C 0 1 . When the external switch turned OFF, control operation is that set in setup parameter C 0 1.

Page 82

Chapter 6. OPERATION

6-9

■ Program selection

The program can be selected in the program operation READY mode. The table below shows program selection by external switch inputs. Two external switch states are provided for selection of programs 10 to 15. When program selection by external switch inputs is set to “0”, the program can be selected by the console keys and by communication with a personal computer.

External Weighting State

Switch No.

RSW8 1 OFF ON OFF ON OFF ON OFF ON OFF ON RSW9 2 OFF OFF ON ON OFF OFF ON ON OFF OFF RSW10 4 OFF OFF OFF OFF ON ON ON ON OFF OFF RSW11 8 OFF OFF OFF OFF OFF OFF OFF OFF ON ON RSW12 10 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

Program No. Selection 0123456789

External Weighting State

Switch No.

RSW8 1 OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON RSW9 2 OFF ON OFF ON ON OFF ON OFF OFF ON OFF ON RSW10 4 OFF OFF OFF OFF OFF ON OFF ON ON ON ON ON RSW11 8 OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON RSW12 10 ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF

Program No. Selection 10 11 12 13 14 15

External Weighting State

Switch No.

RSW8 1 OFF ON OFF ON OFF ON OFF ON OFF ON RSW9 2 ON ON OFF OFF ON ON OFF OFF ON ON RSW10 4 ON ON OFF OFF OFF OFF ON ON ON ON RSW11 8 OFF OFF ON ON ON ON ON ON ON ON RSW12 10 ON ON ON ON ON ON ON ON ON ON

Program No. Selection 16 17 18 19 0

Page 83

Chapter 6. OPERATION

6-10

■ Read timing

● Timing of RSW1 to 7

Inputs RSW1 to RSW7 are read according to the following timing. (1) When input changes state from OFF to ON, the time from the change up to reading is

0.2s max.

(2) When input changes state from ON to OFF, the time from the change up to reading is

0.2s max.

(1) (2)

External switch input state

ON read

OFF read

● Timing of RSW8 to 12, RUN and PV start

The time from the change in input state up to reading when selecting program Nos. by RSW8 to RSW12 is 0.4s max.

Accordingly, due to the relationship with RUN operation, be sure to observe timings ➀ to (4) in the following diagram.

PV start operation also must conform to RUN operation. (1) The time from fixing of the selected No. up to the rising edge of the RUN signal is

0.4s min.

(2) The time from the rising edge of the RUN signal up to holding of the program No. is

0.2s min.

(3) The time from holding of RUN signal OFF up to the rising edge of the RUN signal is

0.2s min.

(4) The time from the rising edge of the RUN signal up to holding of RUN signal ON is

0.2s min.

(5) The time from fixing of the selected No. up to changing of the program No. is 0.4s

max.

(6) The time from the rising edge of the RUN signal up to start of RUN is 0.4s max.

(1) (2)

(5)

(4)(3)

(6)

State of No. different from that selected

State of No. di from that sele

State of selected No.

Program selection No.

(5 inputs)

RUN signal

Program No. No. different from that selected

Selected No.

When operating the controller by external switch inputs, operation can be carried out more reliably if a margin is added to the minimum time for the above read times.

Handling Precautions

Page 84

Chapter 6. OPERATION

6-11

6-5 Manual Operation and Auto-tuning

■ Manual operation

In the MANUAL mode, controller outputs can be manipulated by or on the console.

● Controller functions

When outputs are displayed in the basic display state, only one digit in the output value blinks. If the output value is incremented or decremented by or , actual output also increments or decrements. Output values differ from values being entered to setting items in that

ENT

need not be pressed. The blinking digit can be moved by pressing or . On 2G output models, when only estimated position-proportional control is selected by

variable parameter M .-C setting 2, “——” not the value is displayed as the output display in the MANUAL mode.

Pressing displays “O p e n” , and the open-side relay turns ON. Pressing displays “C l O S” , and the closed-side relay turns ON. Bump-less and preset output changes when shifting from the AUTO to the MANUAL

mode can be selected by setup parameter C 15 setting. When shifting from the MANUAL to the AUTO mode, output is bumpless.

(However, when the total time for the PID parameter of the PID set in use is set to “0”, a sudden change in output occurs.)

● Programmer functions

On 5G output models, when programmer functions are in operation with setup data C 18 setting 1, SP can be manually manipulated. When SP is displayed in the basic display state, only one digit in the SP value being entered blinks. When the SP value is incremented or decremented by or , the actual SP output also increments or decrements. SP values differ from values being entered to setting items in that

ENT

need not be pressed. The blinking digit can be moved by pressing or . Output changes when shifting from the AUTO to the MANUAL mode are bumpless

regardless of setup data C 15 setting. When shifting from the MANUAL to the AUTO mode, the SP becomes the program pattern SP, which results in a sudden change in output.

■ Auto-tuning (AT)

When operating in the AUTO mode in either of the RUN, HOLD, FAST or END modes, setting values can be automatically written to the PID set in use by auto-tuning (AT). The following can be selected by variable parameter A t setting.

0: AT is disabled. 1: General AT is executed. 2: Overshoot-inhibited AT is executed. 3: AT by neural net is executed.

• Auto-tuning does not function when programmer functions are selected on 3D or 5K

heat/cool output models and 5G output models.

• During execution of auto-tuning, progress of program operation time stops. Accord-

ingly, the controller is in a similar state to the HOLD mode even in the RUN or FAST modes.

Page 85

Chapter 6. OPERATION

6-12

• Auto-tuning will not function properly unless the control target is connected.

• The time from start to end of auto-tuning varies according to the control target.

• When auto-tuning is executed, control is stopped, OFF and ON outputs are

switched in the case of relay output and voltage output, and the manipulated variable upper and lower limits of the currently selected PID set are switched several times in the case of current output and position proportional output. If this causes controller trouble, manually set the PID value.

• Sometimes a suitable PID value cannot be obtained depending on the control target. If this happens, manually set the PID value.

• Auto-tuning in all instances involves calculating the downtime and critical sensitivity of the line according to two limit cycles and PID values according to suitable characteristic equations for each, and automatically writing these PID values.

• During execution of auto-tuning, PV fluctuates according to fluctuations in MV. Before executing auto-tuning, make sure that fluctuations in PV will not cause controller trouble.

• Normally, suitable values are written by setting variable parameter At setting to 1 or 3. However, when executing auto-tuning on a line that easily overshoots, either set to 2, or also use smart-tuning for carrying out overshoot inhibit control. Setting to 3 executes AT by neural net so that the suitable value is calculated for wider range applications.

• The point at which output at auto-tuning is inverted (lower limit to upper limit, and vice versa) is determined as follows from SP and PV at start of auto-tuning.

2/3

1/3 1/3

2/3

PV>SP

At start At SP=PV operation

PV<SP

AT start

Normal end AT start Normal end

Time Time

• Auto-tuning can be started byAT, external switch inputs and communications. Dur- ing auto-tuning, the AT LED blinks.

• If one or more of the following conditions occurs during auto-tuning, auto-tuning is canceled without PID constants being written, and the AT LED goes out.

- Cancel by

- Cancel by external switch input

- Cancel by communications

- Change in mode (shift to MANUAL mode or READY mode)

- Execution of automatic motor valve opening adjustment on 2G output models

- When variable parameter A t setting is changed to “0”

- When input 1 becomes out-of-range

Handling Precautions

Page 86

Chapter 7. PARAMETER SETUP

7-1

Chapter 7. PARAMETER SETUP

7-1 Parameter Setup

Parameters can be set up when the DCP301 is in the basic display state. If the DCP301 is not in the basic display state, press

DISP

to set the controller to the basic display state.

■ Selecting the setting group in the parameter setup

Parameter setup is divided into two stages: setting group (major item) and individual item (minor item).

If you press

FUNC

PARA

in the basic display state, the display changes to selection of setting group (major item), the setting group is displayed on the upper display, and the lower display goes out.

If you press

PARA

, or , the setting group display changes in order.

Name Remarks

Variable parameters

Event configuration data

PID parameters

Setup data Table data Constant-value

operation data

Setting group 1 (major items) selection

Basic Display State

Setting group 2 (major items) selection

Setting group n (major items) selection Individual items

Individual items

DISP

key

FUNC

PARA

keys

ENT

key

PARA

key

ENT

key

PARA

key

ENT

key

PARA

key

, , , key

PARA

key key key

PARA

key key key

PARA

key key key

P A R A

E V

P 1 D

S E T T B L C N S T

This parameter is not displayed when variable parameter L O C is 2 or 4

This parameter is not displayed when variable parameter L O C is 2 or 4 This parameter is not displayed when constant-value operation data

M .O D E is 1

This parameter is not displayed when setup data

C 1 8 is 1 by 5G output

This parameter is not displayed when setup data C 4 5 is 1 by 3D output This parameter is not displayed when variable parameter

L O C is 1, 2 or 4

This parameter is not displayed when variable parameter

L O C is 2 or 4

This parameter is not displayed when variable parameter L O C is 2 or 4

Upper

Display

If you press

ENT

when the setup group to be selected is displayed, the display moves to

the individual (minor) item level. The following table shows the setting groups.

Page 87

Chapter 7. PARAMETER SETUP

7-2

■ Moving individual items in the parameter setup

With individual items, item codes are displayed in the upper display and setting values are displayed in the lower display.

The program No. display goes out, and the item No. is displayed in the segment No. display. However, note that the segment No. display also goes out in the case of setup data.

Individual items are arranged in a matrix as shown on the following page, and can be displayed in order by pressing , , or . The size of individual item matrices varies according to the setting group.

■ Changing individual items and how to return from the setup state

If you press

ENT

when an individual item is displayed, the setting value blinks. This state is referred to as the “setting value entry state.” In this state, pressing or can increment or decrement the setting value that is blinking. Also, pressing or moves the position of the digit that is blinking.

If you press

ENT

when the setting value is at the desired value, blinking stops, the display returns to its normally lit state, and the new setting value is stored to internal memory.

To cancel changing of setting values, press

PARA

DISP

. When

PARA

is pressed, the value

stops blinking and the display returns to its normal lit state. If you press

DISP

, the display returns to the basic display state. If “- - - -” is displayed at the lower display when an individual item is displayed, or the controller does not enter the setting value entry state by pressing

ENT

, that item cannot be set nor changed.

Page 88

Chapter 7. PARAMETER SETUP

7-3

• Example of individual item matrix (setup date)

Setting group selection

(major items)

Individual items

(minor items)

Setting value

blinking

Basic Display State

Change setting value.

ENT

key

ENT

key

PARA

key

DISP

key

ENT

key,

PARA

key key key key key

key key key key

DISP

key

key, key, key

Individual items

(minor items)

key stores setting values to memory.

key cancels storage of setting values to memory.

ENT

PARA

ENT

stores setting values to memory.

PARA

does not store setting values to memory.

C0 1

C02

C03

C0 1

C02

C03

C 11

C82

C83

C9 1

C92

C93

C9 1

C92

C93

C99

C00

C09

C10

C20

C 89

C90

C 99

C00

C09

C00

Page 89

Chapter 7. PARAMETER SETUP

7-4

7-2 How to Use

PARA

Use

PARA

for calling up individual items in frequently changed parameters.

■ How to register functions to keys

Up to eight individual items in the parameter setup can be assigned to each

PARA

key. The

assignment item must be registered to use this feature. This feature allows you to call up individual items more easily in the following order:

FUNC

PARA

→ selection of setting group → individual item matrix.

● How to register assignment items

To register an assignment item, add the following base corresponding to the setting group to the item No., and then set the resultant value to setup data C 5 5 to C 6 2 (

PARA

assign-

ment items 1 to 8)).

Base Setting Group

1000 Constant-value operation data 1500 PID parameters 2500 Variable parameters 3500 Event configuration data 4000 Table data 4500 Setup data

Page 90

Chapter 7. PARAMETER SETUP

7-5

● Example

Let’s register four individual items to

PARA

. If you press

PARA

in the basic display state, the 1st to 4th individual items in the table below are displayed successively. In this example, let’s change the setting values.

Order Item to Call by

PARA

1 Setup data C 0 1 2 PID parameter P -2 3 Variable parameter F L 4 Variable parameter F A S T

The settings for registering these individual items are as follows. Setup Data Setting “S E t”

Item Code Setting

No. [auxiliary Item Value Remarks

display]

PARA

assignment

item 1

PARA

assignment

item 2

PARA

assignment

item 3

PARA

assignment

item 4

4501 This is produced by adding item No.1

of C 0 1 to setup data radical 4500.

1511 This is produced by adding item No.11

P -2 to PID parameter radical 1500.

2503 This is produced by adding item No.3

F L to setup data radical 2500.

2520 This is produced by adding item No.20

F A S T to variable parameter

radical 2500.

C 5 5

C 5 6

C 5 7

C 5 8

• For details on item Nos., see 7-3 Parameter Setup List (pages 7-7 to 7-42).

• When the “

PARA

assignment item” setting is set to a value that does not corre-

spond to an existing item, that setting is ignored. For example, though factory setting 1000 corresponds to “constant-value op-

eration data” 0th of base 1000, 0th does not exist, so the setting will be treated an invalid data and will not be registered.

● Operations by

PARA

If you press

PARA

in the basic display state, registered individual items are called up.

Each press of

PARA

successively calls up (up to eight) registered individual items. Only individual items to which valid assignment settings have been registered can be called up.

PARA

operations are not limited by the setting of “variable parameter setup” L O C (key

lock) setting.

PARA

operations are described on the following page.

Handling Precautions

Page 91

Chapter 7. PARAMETER SETUP

7-6

Basic Display State

Max. 8 items

ENT

key

ENT

key

ENT

key

ENT

key

ENT

key

ENT

key

ENT

key

ENT

key

PARA

key

PARA

key

PARA

key

PARA

key

PARA

key

PARA

key

PARA

key

PARA

key

PARA

key

DISP

key

DISP

key

DISP

key

DISP

key

DISP

key

PARA

Display item by key assignment item 1

(blinking)

PARA

Display item by key assignment item 2

(blinking)

PARA

Display item by key assignment item 3

(blinking)

PARA

Display item by key assignment item 8

(blinking)

Display item by key assignment item 1

(normally lit)

PARA

Display item by key assignment item 2

(normally lit)

PARA

Display item by key assignment item 3

(normally lit)

PARA

Display item by key assignment item 8

(normally lit)

PARA

When invalid assignments are registered, that item is

skipped and the next registered item is displayed.

* Items that can be changed: When these items are displayed blinking, the setting

values can be changed by , , and .

ENT

stores data to memory.

Items for reference: These are displayed at all times.

Handling Precautions

Page 92

Chapter 7. PARAMETER SETUP

7-7

No. Item Code Item Factory User Setting

Setting Setting

1 L O C

2 P R T C

3 F L

0.0

4 P B 1

5 S B 1 0U 6 O T L

0.0

7 1 O U T 0.0

(50.0)

8 R P 1 D

9 A T

10 S T

11 2 P 1 D 0

0: Key lock disabled 1: Display of setup data settings disabled 2: Display of parameter settings and program settings

disabled 3: Use of operation keys disabled 4: Display of parameter settings and program settings

displayed, and use of operation keys disabled [Note]

Two or more key lock setting values for actual key lock

items and items assigned to can be displayed

and set.

0: Changing program settings enabled 1: Changing program settings disabled

0.0 to 120.0s [Note]

0.0 disables the filter.

-1000 to 1000U

-1999 to 9999U

0.0 to 10.0% (0.1%s steps) [Note]

0.0 disables the limit.

0.0 to 100% [Note]

On heat/cool models, the factory setting is 50.0. 0: Automatic judgment of initialization is carried out by

advance operation. 1: Initialization is carried out by advance operation. 2: Initialization is not carried out by advance operation. 0: AT is disabled. 1: General AT is executed. 2: Overshoot-inhibited AT is executed. 3: AT by neural net is executed. [Note]

On heat/cool models, “– – – –” is displayed, and

setting is not possible. 0: Smart-tuning is disabled. 1: The brake value is fixed to inhibit overshoot. 2: Overshoot is inhibited while automatically reviewing

the brake value. [Note]

On heat/cool models, “– – – –” is displayed, and

setting is not possible. 0: 2 degrees of freedom PID is disabled. 1: 2 degrees of freedom PID is enabled. [Note]

On heat/cool models, “– – – –” is displayed, and

setting is not possible.

PARA

Key lock

Program protect

Input 1 digital filter

Input 1 bias SP1 bias MV change limitter (CH1)

PID operation initial MV (CH1)

PID operation initialization

Auto-tuning method selection (CH1)

Smart-tuning method selection

(CH1)

Advanced PID selection (CH1)

7-3 Parameter Setup List

“U” and “%FS” used in the “Factory Setting” and “Setting” columns in the table mean the following:

U: The decimal point changes according to the input range type setting. For example,

when one digit past the decimal point is allowed, -1999U becomes 199.9, and 9999U becomes 999.9.

%FS: The numbers and decimal point position changes according to the input range setting.

For example, when the input range is 0.0 to 800.0°C, 0%FS is 0.0 and 100%FS is

800.0.

■ Variable parameter settings “P A R A”

Note

Page 93

Chapter 7. PARAMETER SETUP

7-8

No. Item Code Item Factory User Setting

Setting Setting

12 G 5 .T 2.0 13 C P . 1 1 0U

14 C P . 1 2 200U

C P . 1 3 400U

C P . 1 4 600U

17 C P . 1 5 800U

18 C P . 1 6 1000U

19 C P . 1 7 1200U

20 F A S T 0

21 D 1 F F 5U

5.0

0.0

22 C Y . 1 10

23 C Y . 2 10

24 C Y . 3 –

25 D V -L 5U

26 D V -H 5U

27 H Y -L 5U

28 H Y -H 5U

0.1 to 60.0s

-1999 to 9999U [Note]

When setup data C 1 1 setting is 0 (PID set autoswitching OFF), “– – – –” is displayed and setting is not possible.

-1999 to 9999U [Note]

On heat/cool models, “– – – –” is displayed and setting is not possible. On other models, when setup data C 1 1 setting is 0 (PID set auto-switching OFF), “– – – –” is displayed and setting is not possible.

0: 2X 1: 10X 2: 60X (10X) 3: 120X (10X) [Note]

When setup data C 6 4 setting is 1 (program time

unit:min/s), the FAST factor is 10X for settings 2 and 3. 0 to 1000U [Note]

This setting is displayed on 0D and 6D models.

0.5 to 25.0% [Note]

This setting is displayed on 2G output models.

-100.0 to 50.0% [Note]

This setting is displayed on heat/cool models. [Note]

On 5G output models, “– – – –” is displayed and

setting is not possible. 5 to 120s (relay output) 1 to 60s (voltage output) [Note]

On models whose output 1 is neither relay output nor

voltage output, “– – – –” is displayed and setting is not

possible. 5 to 120s (relay output) 1 to 60s (voltage output) [Note]

On models whose output 2 is neither relay output nor

voltage output, “– – – –” is displayed and setting is not

possible. [Note]

“– – – –” is displayed and setting is not possible. 0 to 1000U [Note]

On models other than 3D output models, “– – – –” is

displayed and setting is not possible.

G.Soak time (CH1) PID auto-switching point 1-1 PID auto-switching point 1-2 PID auto-switching point 1-3 PID auto-switching point 1-4 PID auto-switching point 1-5 PID auto-switching point 1-6 PID auto-switching point 1-7 FAST factor

ON-OFF control differential

Position-proportional dead zone

Heat/cool control dead zone

Output 1 timeproportional output cycle

Output 2 timeproportional output cycle

Unused

3-position control deviation lower limit 3-position control deviation upper limit 3-position control lower limit hysteresis 3-position control upper limit hysteresis

Page 94

Chapter 7. PARAMETER SETUP

7-9

No. Item Code Item Factory User Setting

Setting Setting

29 M .-C 0

30 M .-A T 0

31 M .-C L 1000

32 M .-O P 9000

33 M .-T 30.0

0: MFB control (conventional) + estimated position

control 1: MFB control (conventional) only 2: Estimated position control only [Note]

On models other than 2G output models, “– – – –” is

displayed and setting is not possible. 0: Adjustment disabled 1: Adjustment enabled [Note]

On models other than 2G output models, “– – – –” is

displayed and setting is not possible.

On 2G output models, when M .-C setting is 2, “– – – –

” is displayed and setting is not possible. 0 to (fully open adjustment - 500) [Note]

On models other than 2G output models, “– – – –” is

displayed and setting is not possible.

On 2G output models, when M .-C setting is 2, “– – – –

” is displayed and setting is not possible. (fully closed adjustment + 500) to 9999 [Note]

On models other than 2G output models, “– – – –” is

displayed and setting is not possible.

On 2G output models, when M .-C setting is 2, “– – – –

” is displayed and setting is not possible.

5.0 to 240.0s [Note]

On models other than 2G output models, “– – – –” is

displayed and setting is not possible.

Motor control method selection

Motor valve opening automatic adjustment

Motor valve opening adjustment fully closed position

Motor valve opening adjustment fully open position

Motor valve opening adjustment fully open/closed time

Page 95

Chapter 7. PARAMETER SETUP

7-10

■ Description of variable parameter settings

● L O C (key lock)

0: Key lock disabled 1: Display of setup data settings disabled 2: Display of parameter settings and program settings disabled 3: Use of operation keys disabled 4: Display of parameter settings and program settings displayed, and use of operation

keys disabled

• When L O C is set to 1, the following keys are disabled. Basic display state:

FUNC+CLR

DISP

(general reset)

Only S E T can be selected by setting group selection in the parameter setup state.

• When L O C is set to 2, the following keys are disabled. Basic display state:

FUNC

PROG

(program setup)

PROG

(program copy)

FUNC+CLR

DISP

(general reset) Only P A R A can be selected by setting group selection in the parameter setup state. However, note that items assigned to

PARA

can be called up by

PARA

in the basic dis-

play state.

• When L O C is set to 3, the following keys are disabled. Basic display state:

PROG

(program selection)

RUN/HOLD

(RUN, HOLD)

PROG

RUN/HOLD

(RESET)

PROG

DISP

(ADV)

FUNC

+ (FAST)

A/M

(AUTO, MANUAL)

(AT start, AT cancel)

FUNC+CLR

DISP

(general reset)

However, note that MV (when controller functions are selected) and SP (when programmer functions are selected) can be changed in the basic display state in the MANUAL mode.

• When L O C is set to 4, all keys disabled when L O C is set to 2 and 3 are disabled.

● P R T C (program protect)

0: Changing program settings enabled 1: Changing program settings disabled When P R T C is set to 1, the following keys are disabled. Basic display state: +

PROG

(program copy)

FUNC+CLR

DISP

(general reset)

Program setup state:

ENT

(start of value entry)

FUNC

ENT

(segment insert/delete)

Page 96

Chapter 7. PARAMETER SETUP

7-11

● O T L (MV change limit)

The MV is increased or decreased by the same value so that the output change is taken as the limit setting value when the output change (%) after PID operation is greater than this limit setting.

The following example shows the actual change in MV when the MV changes from 20% to 22% with the change limit setting at 0.5%. MV is output at 0.5% setting value increments every 0.1s, and reaches 22% in 0.4s.

t t + 0.1 t + 0.2 t + 0.3 t + 0.4

● I O U t (PID operation initial MV)

PID operation is started in the following cases using the I O U t setting value:

• When the mode changes from READY AUTO to RUN AUTO

• When the power is turned ON in the RUN AUTO (or HOLD, FAST, END AUTO) mode

• At completion of auto-tuning

As the PV, SP and PID parameters settings bear a relation to PID operation, the first MV resulting from PID operation will not necessarily match the I O U t setting value.

● R P I D (PID operation initialization)

When SP changes suddenly by ADV (advance) operation, rate action in PID operation may cause the MV in the operation to change excessively. For this reason, excessive changes can be suppressed by initializing PID operation.

However, as initialization of PID operation may result in lost continuity, initialization may adversely influence PID operation depending on the circumstances in which the controller is being used.

Initialization ON/OFF and conditions can be selected by the R P I D setting.

Page 97

Chapter 7. PARAMETER SETUP

7-12

● S t (smart-tuning method selection)

0: Smart-tuning is disabled. 1: The brake value is fixed to inhibit overshoot. 2: Overshoot is inhibited while automatically reviewing the brake value.

• When the control direction is set to reverse action, overshoot is inhibited. When set to direct action, undershoot is inhibited. Both functions are referred to collectively as “overshoot inhibit.”

When set to 1, the value of PID parameter setting item B R is used as it is to inhibit overshoot.

When set to 2, the value of B R is reviewed at each rise (reverse action) or fall (direct action, and overshoot is inhibited while the value is automatically rewritten.

Review is executed only in the direction in which the B R value is increased (overshoot inhibit effect becomes more apparent).

When operation is carried out for a long time with this parameter set to 2, overshoot inhibit may function too strongly, and it may take a long time to arrive at SP. So, when overshoot disappears, note down the B R value at that time, set S T to 1, and reset the B R value to the noted down value.

• The AT LED lights while reviewing the B R value when set to 2.

• Do not set to 2 when normal control is not being carried out due to inappropriate tuning of the PID constant, for example.

Also, hunting is more likely to occur when B R is set to a large value on quick-starting lines. Set the B R value to 0 then to 2.

• On heat/cool models, smart-tuning does not function.

● 2 P I D (2 degrees of freedom)

0: 2 degrees of freedom is disabled. 1: 2 degrees of freedom is enabled.

• 2 degrees of freedom is a function for improving the response to disturbance during setup without losing conventional characteristics at rise (or fall).

When set to 1, optimum PID constants can be set individually for inhibiting disturbance in addition to conventional the PID constant.

These constants are set automatically during AT execution, and is memorized. They can also be set and changed independently.

In particular, on 2G output models, suppressing changes in MV to lessen the frequency of motor operation during setup, and manually applying weak PID differential for inhibiting disturbance to lengthen service life, for example, proves effective.

• These PID are switched automatically by applying fuzzy rules on the slope between deviation and PV.

• When I (reset time) is set to 0, control is carried out without integration in all states regardless of the setting value of D I (disturbance inhibit reset time).

• On heat/cool models, 2 degrees of freedom does not function.

Page 98

Chapter 7. PARAMETER SETUP

7-13

● D I F F

• ON-OFF control differential When P is set to 0.0 on both 0D and 6D output models, control is set to ON-OFF control, and operational period at that time is set.

Differential

gap

OFF

Reverse action

Differential

gap

OFF

Direct action

SPSP

• Position-proportional control dead zone On 2G output models, a dead zone between the motor open and motor closed positions is set.

As a general guideline, the minimum value is the value where this dead zone changes to stop motor hunting once a fixed value set to manual output is being output.

If this value is set without any margin, the motor will be operating at all times, which will considerably shorten its service life.

The factory setting is 5%. Use this as a guideline, and take the control results and motor service life into consideration when setting the dead zone.

MFB (%)

Dead zone

Open-side

relay ON

Closed-side

relay ON

Control output (%)

*: Dead zone setting value

• Heat/cool control dead zone On heat/cool models, this sets how the relationship between heat-side output and coolside output should be processed with respect to the MV resulting from PID operation. Heat-cool control is calculated as follows:

Heat-side output

Cool-side output

(PID operation result)

Dead zone

Heat-cool output calculation

PID set selection

(1 of 4 sets)

Heat-side PID set Constants OL, OH

Constants P, I, D, Re

PID operation

(fixed to reverse action)

Cool-side

PID set

Heat-side

PID set

Cool-side PID set Constants OL, OH

Note 2)

Note 4)

Note 3)

Note 1)

Page 99

Chapter 7. PARAMETER SETUP

7-14

Dead

zone

Output

(heat)

Output

(cool)

100%50%

100%

Control output values

Dead zone<0

Dead

zone

Output

(heat)

Output

(cool)

100%50%

100%

Dead zone>0

Output

(heat)

Output

(cool)

100%50%

100%

Dead zone=0

Heat-side output

Cool-side output

100%50%

100%

Cool-side OH

Heat-side OL

Heat-side OH

Cool-side OL

Note 1) On heat/cool models, this sets how the relationship between heat-side output

and cool-side output should be processed with respect to the MV resulting from PID operation.

Note 2) Constants OL and OH function as follows:

Note 3) When MV ≥ 50%, the heat-side PID set is switched to.

When MV < 50%, the cool-side PID set is switched to.

Note 4) PID set selection is carried out by setting value and external switch.

Page 100

Chapter 7. PARAMETER SETUP

7-15

● D v -L (3-position control deviation lower limit)

● D v -H (3-position control deviation upper limit)

● H Y -L (3-position control lower limit hysteresis)

● H Y -H (3-position control upper limit hysteresis)

In 3-position control, control is carried out in the following three states in the RUN, HOLD, FAST and END modes.

State Heat-side Output Cool-side Output MV

1 OFF (0.0%) ON (100.0%) 0.0% 2 OFF (0.0%) OFF (0.0%) 50.0% 3 ON (100.0%) OFF (0.0%) 100.0%

OFF

Output (heat) Output (cool)

HY-L DV-L DV-H HY-H

Even in 3-position control, output is time-proportional in the READY mode. This is set in setup data C 1 6 (MV (heat) in READY mode) and C 1 7 (MV (cool) in READY mode).

When connecting an actuator that may burn by time-proportional output, set setup data C 1 6 and C 1 7 so that output in the READY mode is 0%.

Handling Precautions