PROGRAMMABLE CONTROLLER PCD-33A INSTRUCTION MANUAL
Preface Thank you for purchasing our Programmable Controller PCD-33A. This manual contains instructions for the mounting, functions, operation and notes when operating the PCD-33A. To prevent accidents arising from the misuse of this controller, please ensure the operator receives this manual. Notes • This instrument should be used in accordance with the specifications described in the manual. If it is not used according to the specifications, it may malfunction or cause a fire.
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Abbreviations used in this manual Symbol Term PV Process variable SV Desired value MV Output manipulated variable OUT Control output AT Auto-tuning --- CONTENTS --- 1. Model 1.1 Model ------------------------------------------------------------------------------------ 5 1.2 Rated input ----------------------------------------------------------------------------- 6 1.3 How to read the model label ------------------------------------------------------- 6 2. Name and functions of sections 2.
1. Model 1.1 Model Fill in the squares with the alphanumeric characters to represent the function or type.
1.2 Rated input (Table 1.2-1) Input type K Thermocouple J R S B E T N PLC (W/Re5-26) Pt100 RTD JPt100 DC current DC voltage 4 to 20mA DC 0 to 20mA DC 0 to 1V DC 0 to 5V DC 1 to 5V DC 0 to 10V DC Input range -200 to 1370 -320 to 2500 -199.9 to 400.0 -199.9 to 750.0 -200 to 1000 -320 to 1800 0 to 1760 0 to 3200 0 to 1760 0 to 3200 0 to 1820 0 to 3300 -200 to 800 -320 to 1500 -199.9 to 400.0 -199.9 to 750.0 -200 to 1300 -320 to 2300 0 to 1390 0 to 2500 0 to 2315 0 to 4200 -199.9 to 850.0 -199.9 to 999.
2 Name and functions of sections 2.1 Displays and indicators (2) (1) (3) (11) (4) (10) (5) (9) (6) (8) (7) (Fig. 2.1-1) (1) PV display (Red) Indicates the PV (Process variable), or setting characters in the setting mode. (2) SV display (Green) Indicates the SV (desired value) or step SV, or each set value in the setting mode. (3) PTN display (Green) Indicates the Pattern number. (4) STEP display (Green) Indicates the step number. While Wait function is working, the related step number flashes.
2.2 Keys (18) (17) (12) (16) (13) (15) (14) (Fig. 2.2-1) (Increase Key) : Increases the numeric value on the SV display or switches to the next item. (13) (Decrease Key) : Decreases the numeric value on the SV display or switches to the next item. (14) PTN (Pattern Key) : Selects a program pattern number. (15) STOP (STOP Key) : Cancels the program control or the pattern end output.
1 106.2 3.2 External dimensions and Panel cutout (Scale: mm) 11.5 96 98.5 104.5 (for TC option) 130 92 ＋0.8 0 (Fig. 3.2-1) nX96-3 ＋ 0.5 0 Lateral close mounting n: Number of units mounted 92 ＋0.8 0 (Fig. 3.2-2) If lateral close mounting is used for the controller, IP66 specification (Drip-proof/Dust-proof) may be compromised, and all warranties will be invalidated. 3.3 Mounting Mountable panel thickness is 1 to 8mm. Insert the PCD-33A from the front of the control panel.
4. Wiring Warning Turn the power supply to the instrument off before wiring or checking. Working on or touching the terminal with the power switched on may result in severe injury or death due to Electric Shock. Moreover, the instrument must be grounded before the power supply to the instrument is turned on. Caution • Do not leave wire remnants in the instrument, because they could cause a fire or malfunction. • For the ground terminal of the PCD-33A, use 2mm2 or more of thick wire.
Communication (RS-485) C5 or Set value digital transmission SVTC 4.1 Terminal arrangement 1 11 2 12 3 13 H 4 14 5 Relay contact C 5 15 6 L 6 16 7 17 8 18 9 19 Ground Power supply + 2 24V DC - 3 100 to 240V AC or 24V AC Control output + Non-contact voltage DC current - Alarm 1 (A1) + 9 Insulated power output P24 - 10 Alarm 2 (A2) 10 YA(-) 14 YB(+) Event output (EVT) External operation input SG 17 + - 18 19 20 20 TC (Fig. 4.
External operation function Program control run/stop can be performed externally. See (Fig. 4.1-3) and (Fig. 4.1-4). • External operation input terminals External operation comprises 2 input types as follows. Open collector input Contact (pulse) input 14 14 15 15 16 16 17 17 (Fig. 4.1-3) • Program control run As soon as terminals 14 and 17 change from Open to Closed, program control is performed. • Program control stop As soon as terminals 14 and 17 change from Closed to Open, program control stops.
[PCD-33A-S/M] Single phase 100 to 240V AC or 24V AC/DC 2 3 1 4 Solid-state relay SA-300 1 11 2 12 3 13 4 14 5 15 6 16 7 17 8 18 9 19 10 20 + - Alarm unit Alarm unit Heater Electric furnace Thermocouple (Fig.4.2-2) [PCD-33A-A/M] 3-phase 100 to 240V AC or 24V AC/DC 1 2 3 4 U V W u v w Alarm unit Phase control Power controller Alarm unit PA-215-H3 Heater Electric furnace Thermocouple (Fig. 4.
5. Setup 5.1 Setup Setup should occur before using this controller, to set the Input type, Program control start type, Alarm type, Control action, etc. according to the users’ conditions. If the users’ specification is the same as the default value of the PCD-33A, it is not necessary to set up the controller. Proceed to “6. Operation” (p.21). Set up the controller after connecting terminals 2 and 3 for the power supply to this instrument, referring to “4. Wiring” (p.10, 11).
(19) Alarm 2 (A2) action delay timer Sets Alarm 2 (A2) action delay timer. Event output function Selects an Event output type. Pattern end output time Sets pattern end output time. Direct/Reverse control action Selects Direct(Cooling) or Reverse(Heating) control action. (20) (21) (22) 0 seconds Time signal output 0sec(Continuous output) Reverse (Heating) control 5.2 Basic operation for setup The following shows how to enter and set Auxiliary function setting mode 2.
5.3 Setting items in Auxiliary function setting mode 2 (1) : Input type Selects a sensor type and temperature unit. When changing the input from DC voltage to other inputs, remove the sensor connected to this controller, then change the input. If the input is changed while the sensor is connected, the input circuit may break. Set the same sensor type as the users’. Selecting item: Refer to (Table 5.3-1) below. Default value: (K, -200 to 1370 ) (Table 5.
• Selecting item: No decimal point 1 digit after the decimal point 2-digit after the decimal point 3-digit after the decimal point • Default value: (No decimal point) (5) : PV filter time constant Sets the PV filter time constant. This reduces input fluctuation caused by noise. If the input changes in a step, set the time that reaches 63% of the step. However, if the set value is set too high, it affects control result due to delay of response. • Setting range: 0.0 to 10.0 seconds • Default value: 0.
(12) Alarm 1 (A1) type Selects Alarm 1 (A1) type, referring to 8.5 Alarm 1 (A1) action (pages 48, 49). Note: If an alarm type is changed, the alarm set value becomes 0 (0.0).
(20) Event output function Selects an Event output type from Time signal output, Pattern end output and Run output. When Event output is turned ON, EVT indicator is turned on, and terminals 12 and 13 are used for the Event output. • Selecting item: Time signal output Pattern end output Run output. • Default value: Time signal output Event output [Time signal output] (Fig. 5.3-1) Sets the amount of time for Time signal output OFF time and ON time within 1 pattern time.
[Run output] (Fig. 5.3-3) This is outputted during the program control. (Fig. 5.3-3) Temperature C Step 1 Step 2 Step 3 Time Program control end Run output OFF Run output ON Run output OFF (Fig. 5.3-3) (21) Pattern end output time Sets pattern end output time after pattern end output has been selected during Event output function selection. When 0 seconds are set, the output remains ON until the Key is pressed. Available only when pattern end output is selected during Event output function selection.
6. Operation Key operation for setup Key : Selects a program pattern number. , key : Increases or decreases the numeric value or switches the selecting item. , Key : Registers the set value (numeric value) or selected item. By pressing the Key, the controller reverts to the Program standby mode or Program control run mode. This key is very convenient as the user can revert to the Program standby mode or Program control run mode from any setting mode. Key operation on the Operation flowchart : Press the Key.
6.1 Operation flowchart Power ON Data clearing PTN PV STEP SV Automatically reverts to the Program standby mode after data is cleared. + + (Approx. 3 sec) (*2) (*1) Program standby mode Each time the key is pressed, the pattern number on the PTN display changes. Program control run mode (Approx. 1sec) + (Approx.
• BY pressing the Key, the controller reverts to (*1) or (*2) from any mode. • The setting items with dotted lines are optional, and they appear only when the options are added.
6.2 Operation (1) Turn the power supply to the controller ON. The sensor input characters and temperature unit are indicated on the PV display, and the input range high limit value is indicated on the SV display for approx. 3 seconds after the power is turned ON. See (Table 6.2-1). For DC input, Scaling high limit value is indicated on the SV display for approx. 3 seconds after the power is turned ON. During this time, all outputs and the LED indicators are in OFF status.
PTN PV STEP SV PTN PV STEP SV PTN PV STEP SV PTN PV STEP SV Actual temp. Program pattern 1 is selected. Actual temp. Program pattern 2 is selected. Actual temp. Program pattern 3 is selected. Actual temp. Program pattern 9 is selected. (4) Pattern (step SV/Time) setting mode This mode is available for the currently selected program pattern number. The following is an example of program pattern setting and its procedures.
PTN PV STEP SV PTN PV STEP SV Press the Key. Step 1 SV is registered, and Step 1 time setting mode appears. , PTN PV STEP SV PTN PV STEP SV Press the Key. Step 1 time is registered, and Step 2 SV setting mode appears. , PTN PV STEP SV PTN PV STEP SV PV STEP SV PTN PV STEP SV Step 2 SV Set the step SV to 200 using or key. • Setting range: SV low limit to SV high limit • Default value: 0 Press the Key. Step 2 SV is registered, and Step 2 time setting mode appears.
(5) Alarm/Time signal setting mode Alarm/Time signal setting mode is available for the currently selected program pattern number. Settings are available only for the pattern which is now running during program control. Note: To go to the Alarm/Time signal setting mode, select an alarm type except for No alarm action from Alarm 1 (A1) and Alarm 2 (A2) type selection in “5. Setup”, or select Time signal output from Event output function selection.
PTN PV STEP SV PTN PV STEP SV Pattern 1 Time signal output OFF time Sets Time signal output OFF time after running program control. Available only when Time signal output is selected during Event output function selection. • Setting range: 00:00 to 99.59 (Hour:Minute or Minute:Second) • Default value: 00:00 (Hour:Minute) Pattern 1 Time signal output ON time Sets Time signal output ON time following the Time signal output OFF time.
PTN PV STEP SV PTN PV STEP SV PTN PV STEP SV PTN PV STEP SV Integral time Sets the integral time. Off when set to 0. Not available for ON/OFF control. • Setting range: 0 to 1000 seconds • Default value: 200 seconds Derivative time Sets the derivative time. Off when set to 0. Not available for ON/OFF control. • Setting range: 0 to 300 seconds • Default value: 50 seconds ARW (Anti-reset windup) Sets the ARW. Available only for PID control. This prevents overshoot caused by the integral action.
[Program standby mode or Program control run mode] Press the key for 3 seconds while PTN PV Actual temp. holding down the key. STEP SV Wait parameter setting mode appears, and + (3 sec) Wait value setting item is indicated. [Wait parameter setting mode] PTN PV STEP SV PTN PV STEP SV PTN PV STEP SV PTN PV STEP SV Wait value Sets Pattern 1 Wait value.
[Program standby mode or Program control run mode] PTN PV Actual temp. STEP SV (8) Auxiliary function setting mode 1 Settings/Selections in Auxiliary function setting mode 1 are common to all program pattern numbers. [Program standby mode or Program control run mode] PTN PV Press the Key for 3 seconds while holding Actual temp. down the key. STEP SV Auxiliary function setting mode 1 appears, and + (3 sec) Set value lock selection item is indicated.
PTN PV STEP SV PTN PV STEP SV PTN PV STEP SV PTN PV STEP SV PTN PV STEP SV Communication protocol Selects the communication protocol. Available only when C5/SVTC (option) is added. • Selecting item: Shinko protocol Set value digital transmission (Shinko protocol) Set value digital reception (Shinko protocol) Modbus protocol ASCII mode Modbus protocol RTU mode • Default value: Shinko protocol Instrument number Selects the instrument number.
[Program standby mode or Program control run mode] PTN PV Actual temp. STEP SV (9) Auxiliary function setting mode 2 The settings in Auxiliary function setting mode 2 have already been completed in Section “5. Setup” (p.14). (10) Data clearing function This function returns all set values to the default values (See pages 58, 59). This function can only be used during Program standby mode. This function can not be used during Program control run mode.
7. Running [Before running] Before running the controller, check the mounting and wiring carefully, referring to “3. Mounting to the control panel” (p.8) and “4. Wiring” (p.10). Check that settings are applicable for the users’ conditions, referring to “5. Setup” (p.14). 7.1 How to set the program Set the following items, referring to “6. Operation” (p.21) (1) Program pattern number (p.24) (2) Pattern (Step SV/Time) setting mode (p.25) Set the following items as needed.
[Control action when the program control starts] Program control type selected during the selection phase will initiate. PV start: When the program control starts, step SV and step time are advanced to the PV, then the program control is performed. However, if a value set during “Step SV for control start” and the step SV are equal, or if the value set during “Step SV for control start” is higher than PV, PV start is cancelled, and SV start is adopted.
[Action after power is restored] (1) If power failure occurs during the program control run, the control resumes from the point at which power failure occurred. (2) If power failure occurs during Program standby mode, the control resumes from the Program standby mode. [Indication during Wait action] PTN PV Actual temp. SV Step SV STEP Flashes during WAIT action. PTN display : Selected program pattern number PV display : Current actual temperature STEP display : Flashes during Wait action.
When the program pattern is falling [The Wait function is cancelled at PV (Step SV + Wait value)] Temperature C T Wait cancellation range The control proceeds to the next step at PV 510 C . The step at which the Wait funtion was set 510 T Step SV=500 Wait value 10 C Time T : Program pattern : PV : Program pattern which is delayed by T due to the Wait function : Wait time (Fig. 7.
[Indication during Time signal action] If Time signal output is selected during the [Event output function selection], Event output is turned on during time signal output ON time. Time signal output ON time follows time signal output OFF time after the program control starts. If Time signal output ON time has elapsed, Event output is turned off. The following shows the indication during time signal action. PTN display : Selected program pattern number PTN PV Actual temp.
The following shows the indication during Run output. PTN display : Selected program pattern number PTN PV Actual temp. PV display : Current actual temperature STEP SV Step SV STEP display : Step number of the program control which is running SV display : Current step SV RUN indicator : Lit EVT indicator : Lit while Run output is ON Other indicators: Lit or unlit according to the controller status 7.3 Stopping program control Pressing the Key for 1 second or longer stops the program control.
Temperature C Step 1 1000 Step 2 Step 3 Advance 500 01.00 (1 hour) Time signal ON OFF Program control run 01.00 (1 hour) Turned ON after 1 hour and 20 minutes Setting 00.40(40min.) Time Turned OFF after 1 hour and 50 minutes Time signal OFF time: 1 hour and 20 minutes, Time signal ON time: 30 minutes (Fig. 7.4-1) 7.
[Time signal action during fixed value control] During the fixed value control, step time of the step at which the Hold function was set is regarded as (00:00). Time signal time measurement is carried out ignoring this step. Step number Temperature C 1 2 3 4 5 Advance Step SV=500 The step at which Hold function was set Time Usual time signal output ON OFF Time signal output at which the Advance function is used ON (when advanced to Step 2) OFF (Fig. 7.
[Auxiliary function setting mode 1] PTN PV Press the Key 3 times. Sensor correction setting item is indicated. STEP SV Selection (Press 3 times) PTN PV STEP SV , PTN PV STEP SV Set value Set the sensor correction value with the or key. Setting range: -100.0 to 100.0 ( ) DC input: -1000 to 1000 (The placement of the decimal point follows the selection.) Press the Key. The controller reverts to the Program standby mode or Program control run mode.
[Auto-tuning performing conditions] (A) When processing temperature is lower than [SV –20 (40 )] The AT process will fluctuate at the temperature 20 (40 ) lower than the SV. Temperature 20 (40 ) lower than the SV (1) Calculating PID constant (2) PID constant calculated (3) Controlled by the PID constant set by auto-tuning. SV Temperature Time AT starting point (1) (2) (3) (Fig. 7.
[If P, I, D, ARW values cannot be changed] • If auto-tuning does not finish in 4 hours after it has started, it will be cancelled automatically, and P, I, D, ARW values return to the value set before the auto-tuning was performed. In this case, set P, I, D, ARW values manually. • If auto-tuning is cancelled during the process, P, I, D, ARW values return to the value set before the auto-tuning was performed. [How to perform auto-tuning] Auto-tuning can be performed only during Program control run mode.
[How to cancel auto-tuning] Available only during AT Perform [AT is performing] PTN STEP PV Actual temp. SV Step SV + Press the Key while holding down the key. The unit enters the PID parameter setting mode, and AT Perform/Cancel item is indicated. [PID parameter setting mode] PTN PV STEP SV PTN PV STEP SV AT Perform/Cancel selection Press the key. Press the Key. Auto-tuning is cancelled, and the controller reverts to the Program control run mode.
(3) Derivative time (D) Derivative action is used to restore the change in the processing temperature (PV) according to the rate-of-change. It reduces the amplitude of overshoot and undershoot width. If the derivative time is shortened, the restoring value becomes smaller, and if the derivative time is extended longer, an excessive returning phenomenon may occur and the control system may oscillate. (4) ARW (Anti-reset windup) ARW (Anti-reset windup) prevents overshoot caused by the integral action.
8.3 ON/OFF control action Heating (reverse) control action Cooling (direct) control action Hysteresis Hysteresis ON ON Control action OFF OFF SV Relay contact output R/ Non-contact voltage output S/ DC current output A/ SV H4 H4 H 4 H 4 C 5 C5 C 5 C 5 L 6 L 6 L 6 L 6 + 5 + 5 + 5 6 6 6 6 + 5 + 5 + 5 + 5 6 6 6 6 12V DC 0V DC 20mA DC 4mA DC + 5 0V DC 12V DC 20mA DC 4mA DC Indicator (OUT1) Green Lit Unlit Unlit Lit 8.
8.
High/Low limits alarm with standby A1 hysteresis ON Alarm action OFF A1 value SV A1 value Alarm output : A1 output terminals 7 and 8 are connected (ON). : A1 output terminals 7 and 8 are connected (ON) or disconnected (OFF). : A1 output terminals 7 and 8 are disconnected (OFF). : Standby functions. Alarm indicator and Alarm output For A2 output, use terminals 12 and 13. A1 and A2 indicators light when their terminals are connected, and go off when their terminals are disconnected.
Automatic cold junction temperature compensation (Only thermocouple input type) This detects the temperature at the connecting terminal between the thermocouple and the instrument, and always maintains it at the same status as if the reference junction location temperature was at 0 (32 ). Burnout When the thermocouple or RTD input is burnt out, PV display flashes “ ” (For DC current output, OUT low limit value) with control output (OUT) being turned off.
10. Specifications 10.1 Standard specifications Model : Programmable controller Name : PCD-33A Mounting : Flush Setting : Input system using membrane sheet key Display PV display : Red LED display 4 digits, character size, 18(H) x 8(W)mm SV display : Green LED display 4 digits, character size, 12.6(H) x6(W)mm PTN display : Green LED display 1 digit, character size, 12.6(H) x 6(W) mm STEP display : Green LED display 1 digit, character size, 12.
Setting resolution Step SV : Refer to Section “1.2 Rated input” (p. 6). Step time : 1 minute or 1 second Status after power is restored: The control resumes from the point at which power failure occurred. (Progressing time error after power is restored: Max.
Alarm output action: One alarm can be selected by the front keypad from 9 types of alarm and no alarm action: High limit alarm, Low limit alarm, High/Low limits alarm, High/Low limit range alarm, Process high alarm and Process low alarm, High limit alarm with the standby function, Low limit alarm with the standby function, High/Low limits alarm with the standby function and No alarm action.
Circuit insulation configuration 1 2 3 Power supply 4 5 6 Control output (OUT) 7 8 Alarm 1 (A1) output 9 Alarm 2 (A2) output or Insulated power output (P24) 10 Event output 12 13 External operation 14 17 Input 18 19 20 Communication C 10 14 17 Insulated A B When the control output (OUT) is non-contact voltage or DC current, A is not electrically insulated from B, and A is not electrically insulated from C.
Communication interface : EIA RS-485 Communication method : Half-duplex communication Synchronization method : Start-stop synchronization Communication protocol : Shinko protocol, Set value digital transmission (Shinko protocol), Set value digital reception (Shinko protocol), Modbus ASCII, Modbus RTU (Default: Shinko protocol) Communication speed : 2400, 4800, 9600, 19200bps, (Default: 9600bps) Selectable by keypad Parity : Even, Odd, No parity (Selectable by keypad) (Default: Even) Stop bit : 1, 2 (Selecta
Problem [ ] is flashing on the PV display. [ ] is flashing on the PV display. The indication of PV display is irregular or unstable. [ ] is indicated on the PV display. Problem It is impossible to select a program pattern number. Settings or selections are impossible. Presumed cause and solution • Thermocouple or RTD is burnt out.
Problem The setting indication does not change in the input range even if the , keys are pressed, and new values are unable to be set. Presumed cause and solution • SV high limit or low limit in Auxiliary function setting mode 1 may be set at the point where the value does not change. Set it to a suitable value ( , or ) while in Auxiliary function setting mode 1. (p.31) Problem If process variable (temperature) does not rise. If the control output (OUT) remains in an ON status.
12. Character table Photocopiable material Step No. PV display Setting item Default value Step 1 SV 0 Step 1 time 00.00 (H:M) Step 2 SV 0 Step 2 time 00.00 (H:M) Step 3 SV 0 Step 3 time 00.00 (H:M) Step 4 SV 0 Step 4 time 00.00 (H:M) Step 5 SV 0 Step 5 time 00.00 (H:M) Step 6 SV 0 Step 6 time 00.00 (H:M) Step 7 SV 0 Step 7 time 00.00 (H:M) Step 8 SV 0 Step 8 time 00.00 (H:M) Step 9 SV 0 Step 9 time 00.00 (H:M) Step No.
Step 5 Wait function Used/Not used Step 6 Wait function Used/Not used Step 7 Wait function Used/Not used Step 8 Wait function Used/Not used Step 9 Wait function Used/Not used Step No. PV display Setting item Set value lock SV high limit SV low limit Sensor correction Communication protocol Instrument number Communication speed Parity Stop bit Step No.
13. Program pattern graphing Before setting the program, graph a program pattern and data table. Copy the program pattern table, and follow the procedures below. (1) Write down the program pattern number. (2) From Step 1, write down the step SV and step time of each step in sequence. (3) Write down Alarm 1 (A1) and Alarm 2 (A2) values and Time signal output time. (4) Write down the P, I, D, ARW and proportional cycle values. (5) Write down the Wait value and Wait function Used/Not used of each step.
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Program pattern (Pattern number) Step number 1 2 SV (Desired value) Step SV ( C ) Step time (Hour:Minute) Wait function Used/Not used Wait value P (Proportional band) I (Integral time) D (Derivative time) ARW Proportional cycle Time signal output ON OFF 62 3 4
5 6 7 8 63 9
***** Inquiry ***** For any inquiries about this unit, please contact the vendor where you purchased the unit after checking the following. [Example] • Model --------------------------- PCD-33A-R/M • Option --------------------------- C5 • Serial number ----------------- No. xxxxxx In addition to the above, please let us know the details of the malfunction, if any, and the operating conditions. SHINKO TECHNOS CO., LTD. OVERSEAS DIVISION Reg.
