Yamatake DCP32 User Manual

DigitroniK

Digital Program Controller

DCP32

User’s Manual

No. CP-SP-1042E

Thank you for purchasing the DigitroniK Digital Program Controller DCP32. This manual contains information for ensuring correct use of the DCP32. It also provides necessary information for installation, maintenance, and troubleshooting. This manual should be read by those who design and maintain devices that use the DCP32. Be sure to keep this manual nearby for handy reference.

When using this product in applications that require particular safety or when using this product in important facilities, pay attention to the safety of the overall system and equipment. For example, install fail-safe mechanisms, carry out redundancy checks and periodic inspections, and adopt other appropriate safety measures as required.

RESTRICTIONS ON USE

DigitroniK®is a registered trademark of Yamatake Corporation. DCP31, DCP32, SDC20, SDC21, SDC30, SDC31, SDC40, MA500 and MX200 are registered trademarks of Yamatake Corporation.

Make sure that this Instruction Manual is handed over to the user before the product is used.

Copying or duplicating this Instruction Manual in part or in whole is forbidden. The information and specifications in this Instruction Manual are subject to change without notice.

Considerable effort has been made to ensure that this Instruction Manual is free from inaccuracies and omissions. If you should find any inaccuracies or omissions, please contact Yamatake Corporation.

In no event is Yamatake Corporation liable to anyone for any indirect, special or consequential damages as a result of using this product.

REQUEST

■ 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 electrical 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.

WARNING

CAUTION

Use the DCP32 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.

Do not allow lead clippings, chips or water to enter the DCP32 case. Doing so might cause fire or faulty operation.

Wire the DCP32 properly according to predetermined standards. Also wire the DCP32 using designed power leads according to recognized installation methods. Failure to do so might cause electric shock, fire or faulty operation.

Inputs to the current input terminals and on the DCP32 should be within the current and voltage ranges listed in the specifications. Failure to do so might cause fire 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 DCP32 as relay terminals. Doing so might cause electric shock, fire or faulty operation.

We recommend attaching the terminal cover (sold separately) after wiring the DCP32. Failure to do so might cause electric shock.



Before removing or mounting the DCP32, be sure to turn the power OFF. Failure to do so might cause electric shock.

Do not disassemble the DCP32. Doing so might cause electric shock or faulty operation.

Before connecting the DCP32 to the measurement target or external control circuits, make sure that the FG terminal is properly grounded (100

Ω max.).

Failure to do so might cause electric shock or fire. Turn the DCP32 OFF before starting wiring.

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.

iii

CAUTION

Use Yamatake Corporation's SurgeNon 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 leak. 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.

Do not throw used batteries into fires or dispose at the user site. Return used batteries to Yamatake Corporation or your dealer.

If you touch components inside the DCP32, touch a grounded metal object to discharge any static electricity from your body. Otherwise, static electricity might damage the components.

Handling Precautions

After turning the power ON, do not operate the DCP32 for at least 15 seconds to allow the DCP32 to stabilize.

To reduce of electrical shock which could cause personal injury, all safety notices in this documentation.

This symbol warns the user of a potential shock hazardous live voltages may be accessible.

・ If the equipment is used in a manner not specified by the manufacturer, the protection

provided by the equipment must be impaired.

・ Do not replace any component (or part) not explicity specified as replaceable by your

supplier.

・ All wiring must be in accordance with local norms and carried out by authorized

experienced personnel.

・ The ground terminal must be connected before any other wiring (and disconnected last).

・ A switch in the main supply is required near the equipment. ・ In the case of AC power supply models, the main power supply wiring requires a (T) 1.0 A,

250 V fuse(s).(IEC127)

EQUIPMENT RATINGS

Supply voltages 100 to 240 Vac (operation power voltages 90 to 264 Vac) Frequency 50/60 Hz Power or current ratings 30 VA maximum

EQUIPMENT CONDITIONS

Do not operate the instrument in the presence of flammable liquids or vapors. Operation of any electrical instrument in such an environment constitutes a safety hazard. Temperature 0 to 50

℃

Humidity 10 to 90%RH Vibration Frequency 10 to 60 Hz

Acceleration 1.96 m/s

maximum Installation category Category II (IEC664-1, EN61010-1) Pollution degree 2

EQUIPMENT INSTALLATION

The controller must be mounted into a panel to limit operator access to the rear terminal. Specification of common mode voltage; The common mode voltages of all I/O except for main supply and relay outputs are less than 30 Vrms, 42.4 V peak and 60 Vdc .

APPLICABLE STANDARDS

EN61010-1, EN50081-2, EN50082-2

CAUTION

Danger of explosion if battery is incorrectly replaced.

Replace only with the same or equivalent type recommended by the manufacturer.

Dispose of used batterries according to the manufacturer’s instructions.

SAFETY REQUIREMENTS

Request

The Role of This Manual

The filter on the front of the DCP32 is covered with a protective film to protect the surface of the DCP32. When you have finished mounting and wiring the DCP32, fix cellophane adhesive tape on the corners of the filter, and pull in the direction of the arrow to peel off the protective film.

Pull towards you.

Handling Precautions

Peeling off the protective film with your fingernail might scratch the surface of the DCP32.

DigitroniK CPL Communications DCP31/32 Version

Manual No. CP-UM-1760E

This manual is required reading for those using the CPL communications functions of the DCP32.

This manual describes an outline of CPL communications, wiring, communications procedures and DCP communications data, how to remedy trouble, and communications specifications.

XXXXX

XXXXXX

ser's anua

XXXXX

No.CP-UM-XXXXE

XXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX

Product Manual Manual No. CP-SP1042E

This manual This manual is provided with the DCP32 (single-loop model). It is required reading for those in charge of designing, producing and

maintaining control systems incorporating the DCP32, and for those using the DCP32 in other applications.

It describes mounting onto control panels, wiring, parameter setup, program setup, operation methods, maintenance and inspection, troubleshooting and specifications.

XXXXX

XXXXXX

ser's anua

XXXXX

No.CP-UM-XXXXE

XXXXXXXXXXXXXX

XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX

The following two manuals have been prepared for the DCP32. The following gives a brief outline of the manual. If you do not have the required manual, contact Yamatake Corporation or your dealer.

Organization of This User’s Manual

This user's manual comprises the following ten chapters.

Chapter 1. GENERAL

This chapter describes DCP32 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 DCP32 parts, input types and range Nos.

Chapter 3. INSTALLATION & MOUNTING

This chapter describes how to mount the DCP32 on control panels. This chapter is required reading for designers of control systems using the DCP32.

Chapter 4. WIRING

This chapter describes the precautions when wiring the DCP32 to a control system and how to wire the DCP32. 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 DCP32. This chapter is required reading for designers of control systems using the DCP32.

Chapter 6. OPERATION

This chapter describes how to switch the basic display states of the DCP32, and select and run programs. This chapter is required reading for designers of control systems using the DCP32 and users of control systems.

Chapter 7. PARAMETER SETUP

This chapter describes how to set up parameters on the DCP32 and the meaning of settings.

Chapter 8. PROGRAM SETUP

This chapter describes how to set up programs on the DCP32 and the meanings of settings.

Chapter 9. MAINTENANCE & TROUBLESHOOTING

This chapter describes points to check when the DCP32 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 DCP32.

Contents

vii

SAFETY PRECAUTIONS SAFETY REQUIREMENT Request The Role of This Manual Organization Used in This Manual Contents Conventions Used inThis 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

Chapter 2. NAMES & FUNCTIONS OF PARTS

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

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

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

■ Displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

■ Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

■ Combined key operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

■ Loader jack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2-3 Input Type and Range No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

■ Inputs 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

■ Inputs 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Chapter 3. INSTALLATION & MOUNTING

3-1 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

■ Mounting locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

■ Noise generating sources and countermeasures . . . . . . . . . . . . . . . . . . 3-2

■ Dust-proof cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

■ Panel cutout dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

■ Mounting method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

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

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

■ Connecting input 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-8 Connecting Control Outputs (outputs 1, 2, 3) . . . . . . . . . . . . . . . . . . . . . . . 4-10

■ Relay output (0D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

■ Current output (5G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

■ Position-proportional output (2G). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

■ Heat/cool output (3D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

■ Heat/cool output (5K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-9 Connecting Auxiliary Outputs (output 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

■ 0D, 5G auxiliary outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-10 Connecting Event Output (relay output). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-11 Connecting Time Event Output (open-collector). . . . . . . . . . . . . . . . . . . . . 4-16

4-12 Connecting External Switch (RSW) Input. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-13 Connecting for Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

■ RS-485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-14 Isolating Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

■ Control outputs 0D, 5G, 3D, 5K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

■ Control output 2G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

■ PV start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

■ Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

■ Pattern link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

■ Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

5-3 Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

■ Mode type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

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

■ Mode transition operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

■ Mode transition limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-4 Controller and Programmer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-5 Input Processing Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5-6 Output Processing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

■ Exchanging MV1/MV2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

■ Control output CH1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

■ SP output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

■ Auxiliary output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

viii

Chapter 6. OPERATION

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

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

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

■ Display in constant-value operation mode . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-3 Program Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

■ How to select the program No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-4 External Switch (RSW) Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

■ External switch (RSW) input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

■ Program selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

■ Read timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-5 Manual Operation and Auto-tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

■ Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

■ Auto-tuning (AT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

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 PARA Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

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

7-3 Parameter Setup List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

■ Variable parameter settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

■ Description of variable parameter settings . . . . . . . . . . . . . . . . . . . . . . . 7-9

■ Variable parameter 2 settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

■ Description of variable parameter 2 settings. . . . . . . . . . . . . . . . . . . . . 7-17

■ Event configuration data settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

■ Description of event configuration data. . . . . . . . . . . . . . . . . . . . . . . . . 7-24

■ PID parameter 1 settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25

■ PID parameter 2 settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28

■ Setup data settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

■ Description of setup data settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38

■ Table data settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

■ Description of table data settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47

■ Constant-value operation data settings . . . . . . . . . . . . . . . . . . . . . . . . . 7-48

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 SP 2 items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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

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

■ Setting up PID set No. items (CH1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

■ Setting up PID set No. items (CH2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

■ Setting up G.Soak (guarantee soak) items (CH1) . . . . . . . . . . . . . . . . . 8-11

■ Setting up G.Soak (guarantee soak) items (CH2) . . . . . . . . . . . . . . . . . 8-12

■ Setting up PV start items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

■ Setting up cycle items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14

■ Setting up pattern link items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-15

■ Deleting programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

■ Inserting and deleting segments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17

8-2 Copying Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

■ Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19

8-3 General Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

■ Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

Chapter 9. MAINTENANCE & TROUBLESHOOTING

9-1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

9-2 Self-diagnostics and Alarm Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

■ Self-diagnostics at power ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

■ Self-diagnostics at each sampling cycle . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

■ Intermittent self-diagnostics during operation . . . . . . . . . . . . . . . . . . . . 9-3

■ Self-diagnostics only when certain functions are operating . . . . . . . . . 9-3

■ Alarm code display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

■ Alarm categories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

9-3 Trouble during Key Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

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

■ Trouble in the parameter setup state . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

■ Trouble in the program setup state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8

9-4 Motor Adjustment is Impossible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

■ Normal wiring for direct motor rotation . . . . . . . . . . . . . . . . . . . . . . . . . 9-12

■ Normal wiring for reverse motor rotation. . . . . . . . . . . . . . . . . . . . . . . . 9-12

■ Alarm display caused by wrong wiring and causes . . . . . . . . . . . . . . . 9-12

9-5 When BAT LED Blinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

■ BAT LED blinking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

■ Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13

Chapter 10.

SPECIFICATIONS

10-1

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

■ Accessories/option list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8

10-2

External Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

■ DCP32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9

■ Soft dust-proof cover (sold separately) . . . . . . . . . . . . . . . . . . . . . . . . 10-10

■ Hard dust-proof cover (sold separately) . . . . . . . . . . . . . . . . . . . . . . . 10-10

■ Terminal cover set (sold separately) . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10

Index

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 DCP32.

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

knowing.

: Circled numbers indicate steps in a sequence or indicate corresponding

parts in an explanation.

» : Indicates the DCP32 state after an operation.

DISP + ↑ keys : These icons represent keys on the DCP32's console.

FUNC + PROG keys : Key combinations like these indicate keys that must be pressed while

being held down together.

PA01, C21

: These represent indications on the upper and lower 7-segment

displays.

1-1

Chapter 1. GENERAL

1 - 1 Features

The DCP32 is:

• a general-purpose double-loop program controller for controlling temperature, pressure, flow rate and other inputs

• a 2-loop program controller for controlling temperature and relative humidity.

On the DCP32, you can set up to 19 program patterns, and set up to 30 segments to each program pattern.

● 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 (±0.2%FS±1 digit for Input 2 only) and a sampling cycle of 0.1 seconds ensures consistently high-precision control.

● Wide range of control output types

A wide range of models supporting various control output types are available: relay time-proportional 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 netbased auto-tuning and smart-tuning for inhibiting overshoot, in addition to 2 degrees of freedom PID.

● Enhanced compatibility with PLCs

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, facilitating recall of item setups.

1-2

Chapter 1. GENERAL

1 - 2 Basic Function Blocks

4 External Switch Inputs

• RUN

• HOLD

• RESET

• ADV

* indicates options.

Inputs 1/2

• Thermocouple

• Resistance

• DC current

• DC voltage

8 External Switch Inputs

• Program No.

• FAST

• PV start

• AUTO/MANUAL

• AT start/stop

• G.Soak cancel

• Direct/reverse action

Key Operation

• Display selection

• Program No.

• RUN/HOLD

• RESET

• ADV

• FAST

• AUTO/MANUAL

• AT start/stop

• 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

• Exchanging MV1/MV2

Outputs 1/ 2/ 3

• 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 (input 1 only)

Linearization table approximation

( ) indicates output for

one loop only.

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 DCP32.

● Total of 19 program patterns

Up to 19 program patterns can be set.

1-3

Chapter 1. GENERAL

● Parameters

Parameters are provided for six types of data: variable parameters, event configuration data, PID parameters, setup data, table data and constant-value operation data.

Note

Variable parameters contain common parameters regardless of channels CH1 and CH2.

Program No. = 19 Number of segments = 8

Time

Program No. = 3 Number of segments = 15

Time

Program No. = 2 Number of segments = 19

Time

Program No. = 1 Number of segments = 6

Time

SP1

SP2

Variable parameters Variable parameters 2 Event configuration data PID parameter 1 PID parameter 2 Setup data Table data Constant-value operation data

1 - 3 Data Structure

1-4

Chapter 1. GENERAL

■ System configuration by CPL communications

On DCP32 models supporting RS-485 communications (optional), DigitroniK series controllers can be connected as slave stations on the CPL communications* network. Yamatake Corporation’s MA500 FA controller or MX200 machine controller can be used as the host station in this case.

* “CPL communications” refers to standard host communications defined in

Yamatake CPD.

Handling Precautions

On a 3-lead wire RS-485 configuration, the Yamatake CMA50A105 cannot be used as the converter for the master or slave station.

MA500 or MX200

RS-485

DCP32 (slave station)

Personal computer

DCP32 (slave station)

RS-232C

CMA50A105 or CMC410A102 (master station)

RS-485

1 - 4 System Configuration

1-5

Chapter 1. GENERAL

Basic

Model Output Function Power Option 1 Option 2 Additions Description

No.

P32A Digital Program Controller (2-loop

model) 0D Relay outputs + current output 2G Position-proportional output + current

output 5G Current output + current output 3D Heat-cool output (relay output + relay

output) + current output 5K Heat-cool output (current output +

current output) + current output

1 Input 2 channel 2 Temperature/humidity calculation

AS Free power supply (90 to 264 Vac)

00 No auxiliary output 01 1 auxiliary output

0 External switch inputs (4), time events

not supported, communications 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

communications supported

00 Additional treatment not supported T0 Tropical treatment K0 Antisulfide treatment D0 Inspection Certificate provided B0 Tropical treatment + Inspection

Certificate provided

L0 Antisulfide treatment + Inspection

Certificate provided

Y0 Traceability Certificate

Basic Model No. : P32A AS

Handling Precautions

• On 2G, 3D and 5K output models, only 00 (auxiliary output OFF) can be designated for option 1.

• On current output models other than heat/cool output, you can choose between use of the DCP32 as a controller or a programmer.

• Current output can be changed to voltage output (with current value adjustment function).

• Relay output on 0D output models is time-proportional output.

• Relay output on 3D output models is either time-proportional output or 3-position control output.

• Voltage output is time-proportional output.

1 - 5 Model Numbers

2-1

Chapter 2. NAMES & FUNCTIONS OF PARTS

2 - 1 Structure

The DCP32 comprises a body, console, case, standard terminal base and add-on terminal base.

Case

Console

Body

Standard terminal base

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

Contains console and electrical circuits.

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

Add-on terminal base

Terminal for connecting external switch inputs (8 options), time event outputs (options) and CPL communications (options). This base is not provided on models not supporting external switch inputs (8) and time event outputs.

Key lock screw Fixes the case to the body.

Key cover Cover for preventing erroneous operation.

2-2

Chapter 2. NAMES & FUNCTIONS OF PARTS

2 - 2 Console

The console comprises keys for operating the DCP32, and displays and LEDs.

■ Basic display state

The “basic display state” is the state in which the DCP32 operating state is displayed on the console. When the power is turned ON, the DCP32 is in this state. Key operation changes the DCP32 from the basic display state to one of the parameter setup, program setup, program copy or general reset states. Key operation also returns the DCP32 to the basic display state.

■ 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 “AL” 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.

Power ON

Parameter setup state

Program setup state Program copy state

General reset state

Basic display state

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

Chapter 2. NAMES & FUNCTIONS OF PARTS

● Mode indicator LEDs

RUN, HLD : Display the READY, RUN, HOLD, FAST and END modes. (See

following table.)

MAN : Lights when the displayed channel (CH1 or CH2 whose LED is lit)

is in the MANUAL mode, blinks when the displayed channel is in the AUTO mode or the undisplayed channel is in the MANUAL mode, and goes out when both channels are 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 : The channel currently displayed in the upper or lower displays

(

CH1 or CH2 whose LED is lit) 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 open-side 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 closed-side relay is ON and goes out when the relay is OFF. Lights when current output is assigned to output 2.

OT3 : Lights when voltage output assigned to output 3 is ON, and goes

out when voltage output is OFF. Lights when current output is assigned to output 3, and goes out when output 3 is auxiliary output.

● 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 : Lights when CH1 data is displayed, blinks when CH1 data is

displayed with

CH2 data. Otherwise, this LED is out.

CH2 : Lights when CH2 data is displayed, blinks when CH2 data is

displayed with

CH1 data. Otherwise, this LED is out.

Mode

LED

READY RUN HOLD FAST END

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

2-3

2-4

Chapter 2. NAMES & FUNCTIONS OF PARTS

● Event LEDs

EV1, EV2, : ･ In the basic display state or parameter setup state, these LEDs EV3 light when each of EV3 events 1 to 3 are ON, and go out when

OFF.

･ In the program setup (programming) state, these LEDs light

when each of the items for events 1 to 3 are displayed. Otherwise, these LEDs are out.

T1, T2, T3, : ･ These LEDs light when each of time events 1 to 5 are ON, and T4, T5 go out when OFF.

･ In the program setup (programming) state, these LEDs 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 of the displayed channel (CH1 or CH2 whose LED is lit) in the upper/lower display. Blinks during G.Soak standby, and light successively after the power is turned ON.

2-5

Chapter 2. NAMES & FUNCTIONS OF PARTS

■ Keys

Handling Precautions

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

Function key (FUNC key)

Auto/Manual key (A/M key)

Parameter key (PARA key)

Program key (PROG key)

Run/Hold key (RUN/HOLD key)

Display key (DISP key)

Clear key (CLR key)

Up arrow key (↑ key)

Enter key (ENT key)

Auto-tuning key (AT key)

Down arrow key (↓ key)

Left arrow key (← key)

Right arrow key (→ key)

Loader jack

RUN/HOLD

PROG

PARA

FUNC

ENT

DISP

CLR

A/M

2-6

Chapter 2. NAMES & FUNCTIONS OF PARTS

Yamatake DCP32 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual