Honeywell DCP 50 User manual

Sensing and Control
DCP 50
Digital Controller Programmer
Product Manual
57-77-25-17
3/00

Copyright, Notices, and Trademarks
Printed in U.S.A. – © Copyright 2000 by Honeywell
Revision – 3/00
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Honeywell warrants goods of its manufacture as being free of defective materials and faulty
workmanship. Contact your local sales office for warranty information. If warranted goods are
returned to Honeywell during the period of coverage, Honeywell will repair or replace without
charge those items it finds defective. The foregoing is Buyer’s sole remedy and is in lieu of all
other warranties, expressed or implied, including those of merchantability and fitness for a
particular purpose. Specifications may change without notice. The information we supply is
believed to be accurate and reliable as of this printing. However, we assume no responsibility for
its use.
While we provide application assistance personally, through our literature and the Honeywell
web site, it is up to the customer to determine the suitability of the product in the application.
Sensing and Control
Honeywell
11 West Spring Street
Freeport, Illinois 61032

About This Document
Abstract
The purpose of this manual is to support the installation, configuration, and operation of the DCP 50
Digital Controller Programmer.
Contacts
World Wide Web
The following lists Honeywell’s World Wide Web sites that will be of interest to our customers.
Honeywell Organization WWW Address (URL)
Corporate http://www.honeywell.com
Sensing and Control http://www.honeywell.com/sensing
International http://www.honeywell.com/Business/global.asp
Telephone
Contact us by telephone at the numbers listed below.
Organization Phone Number
United States and Canada Honeywell 1-800-423-9883 Tech. Support
1-888-423-9883 Faxback
1-800-525-7439 Service
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Hong Kong (852) 2829-8298
Europe Honeywell PACE, Brussels, Belgium [32-2] 728-2111
Latin America Honeywell, Sunrise, Florida U.S.A. [phone]

HONEYWELL DCP 50
DIGITAL CONTROLLER/PROGRAMMER
PRODUCT MANUAL
CONTENTS
1BASE MODE1-1
1.1DISPLAY SEQUENCE - NO PROGRAM RUNNING1-1
1.2STARTING A PROGRAM1-2
1.3 PUTTING A PROGRAM IN HOLD1-2
1.4RELEASING A PROGRAM FROM HOLD1-2
1.5ABORTING A PROGRAM1-2
1.6DISPLAY SEQUENCE - PROGRAM RUNNING1-3
1.7RaPID CONTROL FEATURE1-4
1.8 PRE-TUNE FEATURE 1-4
1.9 ENGAGING BOTH PRE-TUNE AND RaPID FEATURES1-5
1.10 INDICATION OF PRE-TUNE AND RaPID STATUS1-5
1.11VIEWING THE HARDWARE DEFINITION CODE1-6
1.12MANUAL CONTROL1-7
2INSTALLATION2-1
2.1UNPACKING PROCEDURE 2-1
2.2 PANEL-MOUNTING THE CONTROLLER2-1
(v)

2.3CONNECTIONS AND WIRING2-2
3PROGRAM DEFINITION MODE
- CREATING/EDITING A PROGRAM3-1
3.1ENTRY3-1
3.2CREATING A PROGRAM 3-2
3.3 DEFAULT VALUES AND ADJUSTMENT RANGES3-9
3.4EXIT FROM PROGRAM DEFINE MODE3-9
4CONTROLLER SET-UP MODE4-1
4.1PARAMETER DETAILS4-3
4.2 EXIT FROM CONTROLLER SET-UP MODE4-9
5MODBUS COMMUNICATIONS5-1
5.1INTRODUCTION5-1
5.2MODBUS FUNCTIONS SUPPORTED5-1
5.3MESSAGE FORMATS5-1
5.4PARAMETER NUMBERS5-7
5.5 PROFILER STATUS BYTE 5-11
5.6 PROFILER COMMANDS 5-11
6CONFIGURATION MODE6-1
6.1ENTRY INTO CONFIGURATION MODE6-1
6.2HARDWARE DEFINITION CODE6-1
6.3 OPTION SELECTION6-3
6.4CONFIGURATION MODE PARAMETERS6-4
6.5EXIT FROM CONFIGURATION MODE 6-9
(vi)

7INTERNAL LINKS AND SWITCHES 7-1
7.1REMOVING THE CONTROLLER PROGRAMMER FROM ITS HOUSING7-1
7.2REMOVING/REPLACING THE OUTPUT 2/OUTPUT 3 OPTION PCBs7-3
7.3REMOVING/REPLACING THE RS485 COMMUNICATIONS OPTION PCB
OR REMOTE RUN/HOLD OPTION PCB7-3
7.4REPLACING THE INSTRUMENT IN ITS HOUSING7-3
7.5 SELECTION OF INPUT TYPE AND OUTPUT 1 TYPE7-4
7.6OUTPUT 2 TYPE/OUTPUT 3 TYPE7-6
APRODUCT CODESA-1
BPRODUCT SPECIFICATIONB-1
CSUMMARY OF DISPLAYSC-1
(vii)

1BASE MODE
1.1DIS PL AYSEQUENCE - NO PROGRAM RUNNING
1-1

1.2 STARTING A PROGRAM
To start a program running:
1.3PUTTING A PROGRAM IN HOLD
A program can be put in Hold (i.e. frozen) at any time whilst it is running. The program
setpoint will stay at its value at the instant the program entered Hold until the
program is released (see Subsection 1.4) or aborted (see Subsection 1.5). To put a
program in hold, momentarily press the RUNkey. The RUNindicator will flash whilst
the program is in hold.
1.4RELEASING A PROGRAM FROM HOLD
To release a program currently in Hold, momentarily press the RUNkey. The RUN
indicator will then go ON continuously.
1 -2

1.5ABORTING A PROGRAM
To abort the current-running (or held) program, hold down the RUNkey for 5
seconds. The program will be aborted, the RUNindicator will go OFF and the
normal Controller functions will be resumed.
NOTE: When a program is aborted, the instrument returns to the Controller
setpont value. If a program is successfully completed, the Controller setpoint is
automatically set to the final setpoint value of the program. If it is desired to
restore the initial Controller setpoint value after the program is completed,
theis value should be used as the program's Final Setpoint Value.
1.6DISPLAY SEQ UENCE - PROGRAM RUNNING
1-3

1.7RaPID CONTROL FEATURE
The RaPID control feature may be used when extra fast responses and minimum
overshoot are required. The RaPID feature works best when PID terms are well-tuned;
therefore, it is recommended that the Pre-Tune feature (see Subsection 1.8) is run
before the RaPID feature is engaged.
To dis-engage RaPID control, use the same key actions. NOTE: The RaPID feature
cannot be engaged if Proportional Band 1 or Proportional Band 2 is set to 0.
1.8PRE-TUNE FEATURE
This facility may be used to provide initial tuning of the Controller’s PID parameters.
Pre-Tune may be engaged (and subsequently dis-engaged) as follows:
1-4

NOTE: The Pre-Tune facility will not engage if (a) a program is currently running,
(b) the process variable is within 5% of input span of the setpoint, or (c) an
erroneous key sequence is used. Pre-Tune is a single-shot process which
automatically dis-engages itself when completed.
1.9ENGAGING BOTH PRE-TUNE AND RaPID FEATURES
The Pre-Tune and RaPID features can be
engaged in one key action sequence
(see right). Pre-Tune will operate first. When
it is completed it will dis-engage itself and
the RaPID feature will then operate
automatically.
1.10INDICATION OF PRE-TUNE AND RaPID STATUS
The responses to the RaPID feature being engaged are:
The responses to the RaPID feature being dis-engaged are:
The responses to Pre-Tune being engaged are:
1-5
Pre-Tune Status Response Indication
Not operational.RaPID activated.AT indicator goes ON.
Operational.Pre-Tune completes routine,
then RaPID activated.
ATindicator flashes at double
rate then comes ON.
Pre-Tune Status Response Indication
Not operational. RaPID de-activated. AT indicator goes OFF.
Operational.Pre-Tune completes routine,
then RaPID de-activated -
return to normal control.
ATindicator flashes at
double rate then goes OFF.
RaPID status ResponseIndication
Not operational.Pre-Tune activated and
routine completed
ATindicator flashes at
normal rate the goes OFF.
Operational. RaPID interrupted, Pre-Tune
activated. Pre-Tune completes
routine, then RaPID control
resumed.
ATindicator flashes at
double rate then goes ON.

The responses to Pre-Tune being dis-engaged (manually or automatically) are:
1.11VIEWING THE HARDWARE DEFINITION CODE
NOTE: An automatic return is made to the normal Base Mode display after 30
seconds.
The Hardware Definition Code has the following significance:
1-6
RaPID StatusResponseIndication
Not operational.Pre-Tune dis-engaged, normal
control resumed.
ATindicator goes OFF.
Operational.Pre-Tune dis-engaged, RaPID
control resumed.
ATindicator goes ON.
Value0 1 2 3 4 5 7 8
Input RTD/
Linear
DC
mV
Thermo-
couple
Linear
DC mA
Linear
DC V
Output
1
Relay SSR
Drive
DC
0 - 10V
DC
0 - 20mA
DC
0 - 5V
DC
4 - 20mA
Solid
State
Output
2
Not
fitted
RelaySSR
Drive
DC
0 - 10V
DC
0 - 20mA
DC
0 - 5V
DC
4 - 20mA
Solid
State
Output
3
Not
fitted
RelaySSR
Drive
DC
0 - 10V
DC
0 - 20mA
DC
0 - 5V
DC
4 - 20mA

1.12MANUAL CONTROL
In Base Mode, with no program running or held, Manual Control may be selected as
follows:
The lower display shows the output power in the form Pxxx (xxx is in the range 000% to
100% of maximum output power). This may be adjusted using the Up and Down keys.
To return to automatic control:
1-7

2INSTALLATION
2.1UNPACKING PROCEDURE
1. Remove the Controller from its packing. The Controller is supplied
with a panel gasket and push-fit fixing strap. Retain the packing for
future use, should it be necessary to transport the Controller to a
different site or to return it to the supplier for repair/testing.
2. Examine the delivered items for damage or deficiencies. If any is
found, notify the carrier immediately.
2.2PANEL-MOUNTING THE
CONTROLLER
The panel on which the Controller is to be
mounted must be rigid and may be up to 6.0mm
(0.25 inches) thick. The cut-outrequired for a
single Controller is as shown in Figure 2-1.
Several controllers may be installed in a single
cut-out, side-by-side. For n Controllers mounted
side-by-side, the width of the cut-out would be:
(48n - 4) millimetres or (3.78n - 0.16) inches.
The Controller Programmer is 110mm deep (measured from the rear face of the front
panel). The front panel is 48mm high and 48mm wide. When panel-mounted, the
front panel projects 10mm from the mounting panel. The main dimensions of the
Controller are shown in Figure 2-2.
2-1
45mm +0.5 -0.0
Figure 2-1Cut-out Dimensions
Figure 2-2Main Dimensions

The procedure to panel-mount the Controller Programmer is shown in Figure 2-3.
CAUTION:Do not remove the panel gasket, as this may result in
inadequate clamping of the instrument in the panel.
NOTE: When installing several Programmer Controllers side-by-side in
one cut-out, use the ratchets on the top/bottom faces.
Once the Controller is installed in its mounting panel, it may be subsequently
removed from its housing, if necessary, as described in Subsection 7.1.
2.3CONNECTIONS AND WIRING
The rear terminal connections are illustrated in Figure 2-4.
WARNING! This instrument is designed for installation in an
enclosure which provides adequate protection aganist electric
shock. All pertinent local regulations should be rigidly observed.
Consideration should be given to prevention of access to the
rear terminals by unauthorised personnel. Disregard for these
instructions may cause injury or death!
2 -2
Figure 2-3Panel-Mounting the Controller Programmer

2-3
Figure 2-4Rear Terminal Connections

2.3.1Mains(Line) Input
The Controller will operate on 96 - 264V AC 50/60Hz mains (line) supply. The power
consumption is approximately 4 VA. Power should be connected via a two-pole
isolating switch (preferably situated near the equipment) and a 1A fuse.
If the Controller has relay outputs in which the contacts are to carry mains (line)
voltage, it is recommended that the relay contact mains (line) supply should be
switched and fused in a similar manner but should be separate from the Controller
mains (line) supply.
2.3.224V (Nominal) AC/DC Supply
The supply connections for the 24V AC/DC option of the Controller are as shown in
Figure 2-4. Power should be connected via a two-pole isolating switch and a 315mA
slow-blow (anti-surge Type T) fuse.
With the 24V AC/DC supply option fitted, these terminals will accept the following
supply voltage ranges:
24V (nominal) AC 50/60Hz - 20 - 50V
24V (nominal) DC -22 - 65V
2.3.3Thermocouple Input
The correct type of thermocouple extension leadwire or compensating cable must
be used for the entire distance between the Controller and the thermocouple,
ensuring that the correct polarity is observed throughout. Joints in the cable should
be avoided, if possible. The Controller’s CJC facility must be enabled (normal
conditions) for this input (see Subsection 6.4).
NOTE: Do not run thermocouple cables adjacent to power-carrying
conductors. If the wiring is run in a conduit, use a separate conduit for the
thermocouple wiring. If the thermocouple is grounded, this must be done at
one point only. If the thermocouple extension lead is shielded, the shield must
be grounded at one point only.
2.3.4RTD Inputs
The compensating lead should be connected to Terminal 4. For two-wire RTD inputs,
Terminals 4 and 5 should be linked. The extension leads should be of copper and the
resistance of the wires connecting the resistance element should not exceed 5 ohms
per lead (the leads should be of equal resistance).
2-4

2.3.5Linear Inputs
For linear mA input ranges, connection is made to Terminals 4 and 6 in the polarity
shown in Figure 2-4. For linear mV and V ranges, connection is made to Terminals 4
and 5 in the polarity shown in Figure 2-4. For details of the linear input ranges
available, refer to Appendix A.
2.3.6Remote Run/Hold Input
With this option fitted, Terminals 11 and 12 are used for external Run/Hold control of
the currently-selected program; this has an effect identical to that of the front panel
RUNkey. These terminals may be connected to (a) the voltage-free contacts of a
switch or relay, or (b) a TTL-compatible voltage. This is an edge-sensitive input for
which the following convention has been adopted:
For TTL input, OFF = logic 1 and ON = logic 0
Fot a voltage=free input, OFF = open and ON = closed
Program control is as follows:
OFF-ON transition:The currently-selected program will run (or will
resume running if it is currently held).
ON-OFF transition: The currently-running program will be held.
NOTE: When this input is used, the front panel RUNkey can be used
only to abort a program. Powering-up the Controller Programmer whilst
this input is ON will not cause a program to run. The RS485 Serial
Communications option and the Remote Run/Hold option are mutually
exclusive.
2.3.7Relay Outputs
The contacts are rated at 2A resistive at 120/240V AC.
2.3.8DC Pulse Outputs
These outputs produce a time-proportioned non-isolated DC signal (0 - 4.2V nominal
into 1kΩminimum).
2 -5

2.3.9AC SSR Outputs
These outputs provide up to 1A AC drive with a longer lifetime than an
electromechanical relay. For further details, refer to Appendix A.
2.3.10DC Outputs
See Appendix A.
2.3.11RS485 Serial Communications Link
The cable used should be suitable for data transfer at the selected rate (1200, 2400,
4800 or 9600 Baud) over the required distance. Transmitters/receivers conform to the
recommendations in the EIA Standard RS485.
The “A” terminal (Terminal 11) on the Controller should be connected to the “A”
terminal on the master device; the “B” terminal (Terminal 12) on the Controller should
be connected to the “B” terminal on the master device. Where several Controllers
are connected to one master port, the master port transceiver in the active state
should be capable of driving a load of 12kΩper Controller; the master port
transceiver in the passive state must have pull-up/pull-down resistors of sufficiently low
impedance to ensure that it remains in the quiescent state whilst supplying up to
± 100µA each to the Controller transceivers in the high impedance state.
NOTE: The RS485 Serial Communications option and the Remote
Run/Hold option are mutually exclusive.
2-6