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2. Output 1 Control Code ue 0 Mechanical Relay 5 amp 1 Ao mE RR 2 Solid State Relay triac 1 amp 3 I odi eS IVO 4 Output 2 Control Alarm or Retransmission 0 Mechanical Relay 5 1 Ari Less 2 Solid State Relay triac 1 amp 3 DG Logie SS 4 Output 3 Control Alarm Retransmission or Loop Power MA 0 Mechanical Relay 5 1 Amal FEDES e 2 Solid State Relay triac 1 3 DE CNO sss 4 _ ____ 5 Output 4 Alarm Retransmission or Loop Power _ _ _ 0 Mechanical Relay 0 5 amp 24 V 1 Anela MEIN cesse 2 Solid State Relay triac 0 5 amp 24 V 4 3 I SS IUDVOE e 4 5 350 ohm Strain Gage Excitation K Serial Communications RS 485 Serial Communications 5 Note I Up to two outputs may be used for alarms Note 2 outputs are interchangeable modules Note 3 The mechanical relay and solid state relay modules are derated to 0 5 amp at 24 Vac when used as the fourth output DPC 535 User s
3. 48 SH cm M 50 SPECIA M 52 SECURITY 53 SER COMM obe ene edu 54 Parameter Value Charts terrere eene et 57 CHAPTER 6 TUNING E TENA At E EPI ITUR 66 OVEPVIGN Rd a E Lh ma pa Nadu 66 TONING Menu Parameters conieci pet ern pert 67 TUNING Parameter Value Chart cnr 72 Self Tune Messages and Troubleshooting 74 CHAPTER 7 APPLICATIONS 48200 75 A Control A NS MEE Nee x qd 75 nS speed CU S Au kam 77 C Duplex ontrol ur et 81 Duplex with reverse and direct acting outputs 82 Duplex with direct and reverse acting outputs 83 Duplex with 2 reverse acting outputs 83 Duplex with a gap between outputs 83 Duplex with a overlapping outputs and output limits 84 Duplex with various relative gain settings 85 Duplex with one ON OFF output 85 Duplex with two ON OFF 86 E 86 E Retransmission ato tet law 87
4. 5 88 G Multiple Sets of PID Values ste ter o entes 88 Pip POWER DACKS s ee poteet bs vost me I EE 90 L Self Tune POWTERTUHBEG erento rtt tta 90 Pretune caccia te besote potare e 90 Pretune TYPE 1 and Adaptive 93 Pretune TYPE 2 TYPE and Adaptvie Tune 94 Adaptive Tune by se etr std poeta 95 Self Tune with Multiple Sets of PID 5 97 Self Tune with Time Proportioning Outputs 98 Self Tune with Control Valves 98 be unu qu i 98 K Input Linearization aec Rot uec t Gre e Reste ote 99 Thermocouple and RTD Linearization 99 Square Root Linearization ages 99 Custom Linearization 100 101 PIS 102 N Reset 103 Process Variable Reading Correction 103 Serial COMMuUN CAt ONS 104 APPENDIX I MENU FLOWCHARTS 106 APPENDIX 2 TROUBLESHOOTING eere 108 APPENDIX
5. 2 550055000 5050 22 Hardware Input Types eee tierna tut eoruni tata 23 The Process Variable eirca pent eq pi Mas ger 23 Mechanical Relays nate roto pono eoa 24 Accessing and changing 5 552 eene tnter ree ene 25 Adding and Changing output modules eese 26 Special Communications Module eee 28 Chapter 5 SOFTWARE CONFIGURATION 29 Mil eec 30 Paratfiet els cote ated RM E A Lu irs 31 Configuration and Operation 32 Where to e a 32 Text Formatting in This Manual 33 Software Menus and Parameters nece rentrer 33 ee id ru 33 A NUI gr 36 About This Manual Throughout this User s Manual information appears along the margins NOTE CAUTION and WARNING Please heed these safety and good practice notices for the protection of you and your equipment Your Comments We welcome your comments about this user s manual and encourage you to help us improve it Please send your comments to Marketing Communications Dynisco Instruments 38 Forge Parkway Franklin MA 02038 38 CUS Tix LIN 40 CONTROL 42 Np M M 43 5
6. Selects a rate of change alarm D OFF Deactivates the first alarm 45 ALM SRC 2 ALARM SP 2 HIGH SP 2 LOW SP 2 DPC 535 User s Manual 12 ALM SRC 2 Selects the source of the value being monitored by HIGH LOW or HIGH LOW alarm 2 D PV e SP RAMP SP e DEVIATION e OUTPUT PV2 13 ALARM SP 2 Specifies the alarm set point for alarm 2 except HIGH LOW For HIGH or LOW alarms If ALM SRC 2 OUTPUT If ALM SRC 2 any other type R 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 DO For BAND alarms 1099999 0 For DEVIATION or RATE alarms R 9999 to 99999 D 0 14A HIGH SP 2 Specifies the high alarm set point for alarm 2 of type HIGH LOW If ALM SRC 2 OUTPUT If ALM SRC 2 any other type R 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 DO 14B LOW SP 2 Specifies the low alarm set point for alarm 2 of type HIGH LOW If ALM SRC 2 OUTPUT If ALM SRC 2 any other type R 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 DPC 535 User s Manual 15 DEADBAND 2 Defines the deadband for alarm 2 If ALM SRC 2 OUTPUT IfALM SRC 2 any other type R 0 1 to 100 0 I to 99999 D2 D2 16 ALM 2 OUT Selects the output number for alarm 2 D NONE 2 3 4 17 LATCHING 2 Defines the latching sequence of alarm 2 D LATCH e NOLATCH 18 ACK 2 Defines whether alarm 2 may be acknowledged D ENABLED Allows the alarm to be acknowledged e DI
7. DPC 535 User s Manual Hardware Configuration The controller must have analog output modules installed in the first two output sockets Software Configuration 1 Goto the CONFIG menu Set CTRL TYPE to STAGED 2 Goto the CONTROL menu 3 For OUTI STOP specify where the first output reaches 10096 4 For OUT2 START specify where the second output begins E RETRANSMISSION The retransmission feature may be used to transmit a milliamp signal corresponding to the process variable target setpoint control output or actual setpoint to another device A common application is to use it to record one of these variables with a recorder Hardware Configuration There must be an analog module installed in output socket 2 3 or 4 Software Configuration Up to two outputs can be configured for retransmission The menu will scroll through the configuration parameters for specified value X 2 3 or 4 1 Goto the CONFIG menu 2 For OUTPUT 2 OUTPUT 3 and OUTPUT 4 parameters set one or two of them to RETRANS 3 Goto the RETRANS menu 4 Setthe corresponding parameter TYPE X for the first retransmission output to define what is being transmitted the process variable setpoint ramping setpoint or output NOTE For an analog output module for retransmission that was not factory installed calibrate the output for maximum accuracy Refer to Appendix 4 for details on calibration 87 88 DPC 535
8. ANLG RNG 1 ANLG RNG 2 ANLG RNG 3 ANLG RNG 4 LOOP NAME LOOP ONE 35 DPC 535 User s Manual PV INPUT PV1 PVI INPUT J T C PVI TYPE Specifies the particular sensor range or input range for PV1 CAUTION Set parameter values in de ened ada T C RTD VOLTAGE CURRENT mA dependent rE D JT C D DINRTD D I 5V D 4 20mA are dynamically related and changing values of JIS RTD 0 5 V 0 20mA one can alter the value of 4 RTD 4 0 10 mV another e BT C 0 30 For example if SP LO is set to 0 and then M N T C 0 60 thermocouple type is e RT C e 0 100 mV changed to B T C the SP LO LIM value will change e e 25mV to 104 the low limit of 2 a type thermocouple 5 e WTC 3 33 mV V e W5TI C DEG F C K e 2 DEG F C K Selects the PV1 temperature units if using a thermocouple or RTD D FAHR CELSIUS DECIMAL ocn XXXXX 3 DECIMAL Specifies the PV1 decimal point position D XXXXX XXXX X XXX XX XX XXX X XXXX Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Emsb ww P ems mw ww A Lv DPC 535 User s Manual 4 LINEARIZE Specifies if the PV1 input is to be linearized NOTE T C s and RTD s are automatically linearized D NONE e SQR ROOT Square root linearization is activated e CUST
9. All displays are vacuum fluorescent Color is blue green STATUS INDICATORS There are two types of indicators icons and illuminated keys ALM I and ALM 2 icons alarm and alarm 2 status OUT and OUT 2 icons control output and control output 2 status MAN key illuminated controller is in manual control mode ACK key illuminated alarm may be acknowledged SET PT key illuminated setpoint other than primary local setpoint is active MENU key illuminated controller is in configuration mode DIMENSIONS Meets 1 4 DIN designation as specified in DIN standard number 43 700 See diagram for details MOUNTING Panel mounted WIRING CONNECTIONS 29 screw terminals in the rear of the instrument POWER CONSUMPTION 15 VA at 120 VAC 60 Hz typical WEIGHT Approximately kg 2 2 Ibs AMBIENT TEMPERATURE Operative Limits 0 to 50 C 32 to 122 F Storage Limits 40 to 70 C 40 to 158 F RELATIVE HUMIDITY 10 to 90 non condensing VOLTAGE AND FREQUENCY Universal power supply 90 to 250 VAC 48 to 62 Hz 15 16 DPC 535 User s Manual NOISE IMMUNITY Common mode rejection process input gt 120 dB Normal mode rejection process input gt 80 dB AC line is double filtered and transient protected Snubbers are provided for each relay output CONSTRUCTION Case extruded non perforated ABS plastic Bezel black plastic ABS Chassis assembly plug in type Keys silicone rubber wit
10. Dynisco Instruments INSTALLATION AND OPERATING MANUAL DPC 535 PROCESS AND DIFFERENTIAL CONTROLLERS 5 9 Dynisco Instruments DPC535 Quick Start Operating Instructions DIFFERENTIAL PRESSURE CONTROL USING STRAIN GaGE TRANSDUCERS Refer to the full manual for unpacking and mounting instructions and terminal locations When using the DPC535 as a differential pressure controller DPC535 1 1 1 2 K with 350 Ohm Strain Gage pressure transducers such as the Dynisco PT460 series wire as follows NOTE Transducers must be of the same range For PV1 upstream Connect positive signal wire red to terminal 32 Connect negative signal wire black to terminal 31 Connect Excitation green to terminal 10 Connect Excitation white to terminal 11 Connect Calibration 1 blue to terminal 10 Connect Calibration 2 orange to terminal 12 For PV2 downstream Connect positive signal wire red to terminal 29 Connect the negative signal wire black to terminal 28 Connect Excitation green to terminal 10 Connect Excitation white to terminal 11 Connect Calibration 1 blue to terminal 10 Connect Calibration 2 orange to terminal 22 Refer to the full manual for instructions on accessing the following menus IN THE CONFIGURATION MENU Set CTR TYPE to Standard Set LINE FREQ to 60 Set SOURCE to PV1 PV2 Set OUTPUT 2 to ALARM ON Set OUTPUT 3 to ALARM ON Set OUTPUT 4 to RETRANS Set ANLG
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12. Allows user to specify a nine character message to be displayed when the respective alarm is active If both alarms are active or any other diagnostic message is present the messages will alternate FAULT Activates an alarm if the process variable signal is lost Assign this function to either Alarm 1 or Alarm 2 not both This action is in addition the selected alarm type additive alarm function OUTPUT For a RATE alarm selects the output action Use to obtain early indication of a possible break in the process variable signal Select PV BREAK to have rate of change alarm take the same action as Alarm Parameters Reference For Alarm 1 Parameter Description ALM TYPE 1 Type ALM SRC 1 Source ALARM SP 1 Setpoint HIGH SP 1 High setpoint LOW SP 1 Low setpoint DEADBAND 1 Deadband ALM 1 OUT Output number LATCHING 1 Latching sequence ACK 1 Acknowledging POWER UP 1 Status on power up MESSAGE 1 Message For Alarm 2 Parameter Description ALM TYPE 2 Type ALM SRC 2 Source ALARM SP 2 Setpoint HIGH 2 High setpoint LOW SP 2 Low setpoint DEADBAND 2 Deadband ALM 2 OUT Output number LATCHING 2 Latching sequence ACK 2 Acknowledging POWER UP 2 Status on power up MESSAGE 2 Message For either alarm depending on choices Output action for rate Parameter Description FAULT Fault assignment OUTPUT RATE TIME Time base for rate DPC 535 User s Manual a detection of a break in
13. DPC 535 User s Manual TEXT FORMATTING IN THIS MANUAL Feature Format KEYS SET PT DISPLAY or SET PT DISPLAY ICONS OUT ALM MENUS CONFIG TUNING PARAMETERS CYCLE TM 1 MIN OUT2 PARAMETER VALUES OFF SETPOINT LAST OUT DISPLAY MESSAGES TOO HOT OUT SOFTWARE MENUS AND PARAMETERS CONFIG CONFIG l CTRL TYPE Defines the type of control output s D STANDARD Standard control output no special algorithms e POS PROP Position proportioning control output CTRL TYPE Staged outputs STAN DARD DUPLEX Duplex outputs 2 LINE FREQ Defines the power source frequency LINE FREQ A 60Hz D 60HZ Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Esas mw _ mw Caw ww DPC 535 User s Manual 3 PV SOURCE PV SOURCE PV1 Defines how the PV input is derived from PV1 and PV2 D PVI Use PVI e I 2 SWITCH Use until contact com selects PV2 2 BACKUP Use PV2 if PVI is broken NOTE PVI PV2 Use 2 and PV2 can be PVI PV2 Use PVI PV2 of different types and AVG PV Use the average of PVI and PV2 e HI SELECT Use PVI PV2 whichever is greater e LO SELECT Use PVI or 2 whichever is less 4 OUTPUT 2 OUTPUT 2 Defines the function of the second output ALM RLY ON ALM RLY OFF e RETRANS Retransmission e COMM ONLY Output addressable on
14. Please refer to the output state examples in this section to confirm that the configuration is appropriate for the process NOTE Set manual reset load line parameters to 50 when using Duplex control MAN RST X parameter is in the TUNING menu 81 82 DPC 535 User s Manual 6 REL GAIN relative gain changes the gain of Output 2 relative to Output 1 Note that the relative gain can limit the maximum output available for Output 2 when using PID control 7 Goto the CONTROL menu Set LOW OUT and HIGH OUT to limit the maximum or minimum outputs from Output 1 and Output 2 The actual limitation on the outputs is dependent on the offset settings the relative gain setting and the control action Duplex Output State Examples The following Duplex examples represent a variety of ways this function can be set up PID control examples show the PID output percentage on the horizontal axis and On Off control examples show the process variable on the horizontal axis The vertical axes are the output of each physical output Most of these examples use the first output as heating and the second output as cooling When using PID control the DPC 535 controller actually displays the PID output To relate this output to the actual physical output locate the PID output on the horizontal axis Draw a vertical line at that point At the intersection of this vertical line and the respective output line draw a horizontal line
15. engineering units It is not necessary to use all 15 points Whenever the X TH INPUT becomes the high end of the input range that will be the last point in the table Once the various points are defined the values between the points are interpolated using a straight line relationship between the points The only limitation is that the resulting linearization curve must be either ever increasing or ever decreasing L LOAD LINE Load line is a manual reset superimposed on the automatic reset action Adjusting the MAN RST tuning constant shifts the controller proportional band with respect to the setpoint 50 0 20 40 60 80 100 Process Variable Indication of Controller Span 707 Fig 7 170 Load Line Example SEC CODE does not appear unless all functions are unlocked NOTE Lock out CONFIGURE for full security If left unlocked the operator will have access to the security code NOTE The security function is compromised if the security code is left at zero 0 702 DPC 535 User s Manual When used with a proportional only or proportional derivative control algorithm the MAN RST parameter located in the TUNING menu is in effect manual reset However when the automatic reset term is present the reset action gradually shifts the proportional band to eliminate offset between the setpoint and the process In this
16. the low end of the process variable range but this is not required digital input can be set to trip to the second set of PID upon closure which overrides a selection based on trip points Using with Adaptive and Pretune The DPC 535 can be programmed to automatically set the PID values using the Pretune and Adaptive Tuning functions For both functions the tuned set of PID is that which is active upon initiation of the tuning function The controller cannot trip to other PID sets based on trip point or the digital input contact until Adaptive Tuning is disabled However if the PID set is tied to the corresponding local setpoint the active PID set values will change with the local setpoint 90 DPC 535 User s Manual Each PID set has 5 parameters that control its function proportional band reset rate manual reset or loadline and trip point For each set 2 thru 8 these values have to be manually set 1 Press MENU to access the TUNING menu 2 Set values for parameters 1 thru 20 these include the first PID set 3 Press MENU to access these parameters for each additional PID set 2 through 8 PROP BND RESET RATE MAN RST and TRIP H POWERBACK POWERBACK is a proprietary algorithm which when invoked by the user reduces or eliminates setpoint overshoot at power up or after setpoint changes Powerback monitors the process variable to make predictive adjustments to control parameters which in turn h
17. 2 Defines what is be retransmitted for output 2 D PV This refers to the linearized process variable e SETPOINT This is the target setpoint e RAMPSP Thisis the ramping or actual setpoint when the setpoint is ramping e CTRL OUT This is the control output value 2 LOW RANGE Defines the low end of the range for output 2 in engineering units Does not appear for type CTRL OUT 9999 to 99999 D Dependent on the process variable range DPC 535 User s Manual 3 HI RANGE 2 Defines the high end of the range for output 2 in engineering units Does not appear for type CTRL OUT R 9999 to 99999 D Dependent on the process variable range 4 TYPE 3 Defines what is to be retransmitted for output 3 D PV This refers to the linearized process variable e SETPOINT Thisis the target setpoint e RAMPSP Thisis the ramping or actual setpoint when the setpoint is ramping e CTRL OUT This is the control output value 5 LOW RANGE 3 Defines the low end of the range for output 3 in engineering units Does not appear for type CTRL OUT 9999 to 99999 D Dependent on the process variable range 6 HI RANGE 3 Defines the high end of the range for output 3 in engineering units Does not appear for type CTRL OUT R 9999 to 99999 D Dependent on the process variable range 7 TYPE 4 Defines what is to be retransmitted for output 4 D PV This refers to the linearized process variable e SETPOINT Thisis the ta
18. 3 85 5 2208 110 APPENDIX 4 GLOSSARY 50 ur rei e ERR SU 117 List of Figures FIGURE DESCRIPTION PAGE Figure 2 1 Operator Interface ioco eset dri one ges 5 Figure 2 2 Before and After Acknowledging an Alarm 9 Figure 3 1 Instrument Panel amp Cutout Dimensions 10 Figure 3 2 Attaching mounting collar eene 11 Figure 3 3 All 535 Terminal Assignments eee 12 Figure 3 4 AC Power Input Terminals eere 13 Figure 3 5 Process Variable Terminals secas toot 13 Figure 3 6 Differential Pressure Terminal Assignments Using Amplified DRAM SCUCEN ec 14 Figure 3 7 Differential Pressure Terminal Assignments Using Strain Gage 15 Figure 3 8 PV1 and PV2 Wiring for Milliamp and Voltage Inputs 16 Figure 3 9 PV1 and PV2 Wiring for Milliamp Inputs with Internal and External Power Supply 17 Figure 3 10 Interconnect Diagram Dual Strain Gage 1 18 Figure 3 11 Mechanical Relay Output Wiring 19 Figure 3 12 SSR Relay Output Wiring eee 19 Figure 3 13 DC Logic Output Wiring oen ete 20 Figure 3 14 Milliamp Output Wiring toos 20
19. Figure 3 15 Serial Communications Terminals 21 Figure 4 1 Location of Printed Circuit Boards for Hardware On figurat 22 Figure 4 2 The Microcontroller Circuit Board the Option Board and the Power Supply Board 24 Figure 4 3 Representation oflIodule tor tbt 28 Figure 4 4 Install Communications Module onto Microcontroller BOQE dc accensis tuve tren eee ctor t 28 Figure 5 1 Menu Flowchart for Set Up 12 eerte nette 29 Figure 5 2 Independent vs Dependent Parameters 28 Figure 5 3 Configuration Flowchart 31 Figure 6 1 Access the Tuning Menu Block 66 Figure 7 1 Alarm EXaniples eR See ER dh 80 Figure 7 2 Duplex with reverse and direct acting outputs 82 Figure 7 3 Duplex with direct and reverse acting outputs 83 Figure 7 4 Duplex with two reverse acting outputs 83 Figure 7 5 Duplex with a gap between 84 Figure 7 6 Duplex with overlapping outputs and output limits 84 Figure 7 7 Duplex with various relative gain settings 85 Figure 7 8 Duplex with one ON OFF 85 Figure 7 9 Duplex with
20. For duplex applications defines the offset for the second output R 50 0 to 50 0 D 0 0 128 ON OFST 2 For On Off applications defines the offset for the second output R 9999 to 99999 in engineering units 0 13 REL GAIN 2 Defines the adjustment factor for the second output s proportional band It is multiplied by the effective gain of output 1 to obtain the second output s proportional band R 0 1 to 10 0 D 10 14 CYCLE TM 2 Defines the cycle time for control output 2 when using a time proportioning output 0 3 to 120 0 seconds D 15 0 seconds 15 DEADBAND 2 Defines the dead band for control output 2 when using on off control 99999 in engineering units D 2 16 NO OF PID Defines the number of PID sets that will be stored and available for use R Ito8 For numbers PID TRIP defines tripping between the PID sets e SP NUMBER Number of PID sets number of local setpoints specified in NO OF SP Each PID set has a respective SP NUMBER PID OFST 2 ON OFST 2 REL GAIN 2 CYCLE 2 DEADBAND 2 NO OF PID 69 PID TRIP SP VALUE TRIP 1 PROP BND X RESET X 70 DPC 535 User s Manual PV NUMBER PID Set the process variable PVI or PV2 used when PV SOURCE 1 2 SWITCH or PV SOURCE 1 2 D 17 PID TRIP For NO OF PID 1 defines the variable used to select the various PID sets e PV VALUE
21. I any other type R 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 DO 5 DEADBAND I Defines the deadband for alarm 1 If ALM SRC 1 OUTPUT If ALM SRC I any other type R 0 1 to 100 0 to 99999 D2 D2 6 ALM OUT Selects the output number for alarm 1 D NONE 2 3 4 7 LATCHING I Defines the latching sequence of alarm 1 D LATCH e NOLATCH DPC 535 User s Manual 8 1 ACK 1 Defines whether alarm 1 may be acknowledged ENABLED D ENABLED Allows the alarm to be acknowledged e DISABLED Prevents the alarm from being acknowledged while alarm condition 9 POWER UP I POWER UP 1 Defines how alarm 1 will be treated on power up NORMAL D NORMAL Alarm depends on process variable e ALARM Always power up in alarm regardless of PV DELAYED Must leave alarm condition and reenter before activating the alarm 10 55 MESSAGE 1 A 9 character message associated with alarm 1 To enter message The first character of third display will be flashing Press the and W keys to scroll through the character set Press FAST key to advance to subsequent characters Press the MENU to advance to next parameter D ALARM I 11 ALM TYPE 2 Defines the type of alarm for alarm 2 ALM TYPE 2 e HIGH ALRM e LOW ALARM e HIGH LOW Separate High amp Low alarm setpoints in one alarm BAND DEVIATION MANUAL Causes an alarm when in manual control
22. PV2 Wiring for Milliamp Inputs with Internal and External Power Supply NOTE To use loop power there must be a loop power module is installed in the 3rd or 4th output socket Compare the controller product number with the order code in Chapter 1 to determine if the DPC 535 has a loop power module installed To install a loop power module refer to Chapter 4 46 12 Strain Gage 2 DPC 535 User s Manual R Cal Excitation Blue Orange Strain Gage 1 Excitation R Cal Blue Orange Sig Sig Fig 3 10 Interconnect Diagram Dual Strain Gage Input DPC 535 User s Manual OUTPUT MODULES The DPC 535 output modules are used for control alarms and retransmission The four output module types are Mechanical Relay Solid State Relay Triac DC Logic SSR Drive and Analog Milliamp To install these modules plug them into any of the four output sockets on the printed circuit boards refer to Chapter 4 The wiring is the same whether the modules are used for control alarm or retransmission The diagrams on the next two pages are a guide for properly connecting the various outputs To find out which module s have been installed in the controller compare the product number on the controller label with the section Order Code in Chapter 1 This section also includes a diagram of how to wire a position proportioning output a special application using two mechanical or two solid state r
23. Platinel Il RTDs 1000 DIN 100Pt JI 1002Pt SAMA TRANSMITTER SIGNALS Milliamps DC Voltage DC Millivolts DC LINEARIZATION DPC 535 Users Manual 418 to 2500 250 to 1371 328 to 2372 200 to 1300 32 to 3182 0 to 1750 32 to 3182 0 to 1750 328 to 152 200 to 400 32 to 4172 0 to 2300 32 to 4172 0 to 2300 148 to 2550 100 to 1399 RANGE F RANGE C 328 to 1562 200 to 850 328 0 to 545 0 200 0 to 285 0 328 to 1202 200 to 650 328 0 to 545 0 200 0 to 285 0 328 to 1202 200 to 650 328 0 to 545 0 200 0 to 285 0 INPUT RANGE 4 to 20 0 to 20 to 5 0 to 5 0 to 10 0 to 30 0 to 60 0 to 100 25 to 25 STRAIN GAGE 333 Thermocouple and RTD inputs are automatically linearized Transmitter inputs may be linearized with a square root function or user defineable 5 point straight line linearization function INPUT IMPEDANCE Current Input 250 Q Voltage Input MQ Thermocouples 10 RTDs 10 MO DPC 535 User s Manual UPDATE RATE Input is sampled and output updated 10 times per second Display is updated five times per second TRANSMITTER LOOP POWER Isolated 24 Vdc nominal loop power supply is available if a loop power module is installed in an output socket not used for control Capacity is 25 mA INPUT SIGNAL FAILURE PROTECTION When input is lost output is commanded to a predetermined output 5 to 105 Thermocou
24. RANGE OPEN F B ALARMS ALM TYPE 1 ALM 1 OUT CLOSE F B OUT1STOP OUT2STRT ALM SRC 1 ALARM SP 1 LOW SP 1 DEADBAND 1 LATCHING 1 POWER UP 1 ALM TYPE 2 ALM SRC 2 ALARM SP 2 LOW SP 2 LATCHING 2 DEADBAND 2 ALM 2 OUT LATCHING 2 POWER UP 2 FAULT OUTPUT RATE TIME RETRANS TYPE 2 LOW RANGE2 RANGE 2 TYPEX LOW RANGE 3 HIRANGE TYPE 4 LOW RANGE HIRANGE 4 SELF TUNE TYPE PRETUNE TUNE PT OUT STEP LOW LIMIT HI LIMIT TIMEOUT noiseen RESP TIME DEAD TIME SPECIAL AUTO TRIP TRIP DEV DES OUTPT POWER UP PWR UP OUT PWR UP SP SER COMM STATION BAUD SHED TIME SHED MODE SHED OUT DPC 535 User s Manual PRETUNE POWR BACK PROP BND 1 TUNING ADAPTIVE MAN RST 1 RESET 1 RATE 1 PID OFST 1 PID OFST 2 RSP BIAS NO OF PID CYCLE TM 1 DEADBAND 1 P PROP D B REL GAIN 2 CYCLE TM 2 DEADBAND 2 RSP RATIO PID TRIP TRIP 1 PROP BND 2 RESET 2 RATE 2 MAN RST 2 PROP BND 3 RESET 3 RATE 2 MAN RST 3 PROP BND 4 RESET 4 RATE 4 MAN RST 4 PROP BND 5 RESET 5 RATE 5 MAN RST 5 Up to 8 times depending on NO OF PID PROP BND 6 RESET 6 RATE 6 MAN RST 6 PROP BND 7 RESET 7 RATE 7 MAN RST 2 PROP BND 8 RESET 8 RATE 8 MAN RST 8 APPENDIX 2 DPC 535 User s Manual TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Display will not light up Defective power source Check power source and wiring Im
25. RNG 4 to desired output 4 20 0 20 20 4 20 OmA Define LOOP NAME if desired IN THE PV1 MENU Set PV1 TYPE to 0 33 3 mV Set LOW RANGE to match low range of transducer Set HI RANGE to match the full scale range of transducers Set RESTORE to manual IN THE PV2 MENU Set PV2SETUP to same as PV1 IN THE CONTROL MENU Set ALGORITHM to On Off Set SOURCE to PV differential Set ACTION to DIRECT Set PVBREAK to Off IN THE ALARM 1 AND 2 MENUS Set TYPE SOURCE and MODE latching or non latching as appropriate to the process Set Alarm 1 OUTPUT to 2 This will cause its output to be at the output 2 terminals Set Alarm 2 OUTPUT to 3 This will cause its output to be at the output 3 terminals Set POWER UP as desired If set to normal the process will be powered up in the normal mode If there is an alarm condition the alarm will be activated If set to ALARM alarms will be activated on power up If set to delayed alarms will be inhibited regardless of whether or not an alarm condition exists Define MESSAGE if desired IN THE RETRANS MENU Set the TYP 4 To PV differential Set LO RANGE 4 to the desired low end of the range Set HI RANGE 4 to the desired high end of the range Under most conditions LO RANGE and RANGE will encompass the full span setting of the PV s IN THE SPECIAL MENU Set the POWER UP to Manual IN THE SECURITY MENU Set the appropriate Security scheme for your application The above setup w
26. Software configuration does not match hardware Reconfigure software to match hardware Can t switch to auto control PID values not set properly Input sensor signal is not connected or valid Set PID values properly See PV LOST message Erratic display Resetting action due to electrical noise on powerline Filter power line 70 PID values not set properly Retune controller DPC 535 User s Manual Message When does it occur What to do DEFAULTS Whenever the memory is cleared and all Entering the Set Up mode and changing a parameters revert to factory default settings This parameter will clear the message If due to may be done by purposely clearing the memory or something other than the user purposely clearing when the unit is powered for the first time or if the memory call factory for assistance the software version is changed LOST CAL or Indicates that the calibration data has been lost Problem should never happen Must correct the ERROR BAD CAL DATA PV1 UNDER or PV1 OVER or PV2 UNDER or PV2 OVER or LOST PV1 or LOST PV COMM SHED ERROR ROM CHECKSUM OUT1 CONF or OUT2 CONF LOST F B LOST CJC ERROR BAD EEPROM NEEDS CAL ERROR BAD MODEL NUM CAL ERROR SEE MANUAL Occurs if all the memory has been erased When the process variable value travels slightly outside the boundaries of the instrument span Does not apply to thermocouple or RT
27. alarms and monitor conditions SET UP also referred to as configuration Here you set up the basic functions of the instrument such as input and output assignments alarm types and special functions TUNING where you configure control function parameters for Proportional Integral and Derivation PID Use periodically to optimize the control performance of the instrument ORDER CODE PACKAGING INFORMATION Compare the product number to the ordering code on page 3 to determine the outputs and options installed on the DPC 535 The product number is printed on the label on the top of the controller case Included with this DPC 535 are a DPC 535 User s Manual mounting hardware e 1 sheet of Engineering unit adhesive labels WHERE TO GO NEXT become more familiar with the DPC 535 interface continue to Chapter 2 For important hardware installation guidelines see Chapters and 4 e For a detailed description of all the software menus and parameters of the DPC 535 follow through Chapters 5 and 6 Appendix 1 can be used as a basic guideline to these parameters DPC 535 User s Manual TEXT FORMATTING IN THIS MANUAL Feature Format KEYS SET PT DISPLAY or ICONS OUT ALM MENUS CONFIG TUNING PARAMETERS CYCLE TM 1 MIN OUT2 PARAMETER VALUES OFF SETPOINT LAST OUT DISPLAY MESSAGES TOO HOT 097 DPC535 DPC 535 User s Manual
28. anticipate problems before the process variable can reach an undesirable level For example if the alarm setpoint is 10 with a time base of 5 seconds an alarm occurs whenever a change in process variable greater than 10 occurs in 5 seconds ALM SRC 1 and ALM SRC 2 78 DPC 535 User s Manual For HIGH LOW or HIGH LOW alarms specifies the variable source upon which a selected alarm is based Selection includes PV2 SP e RAMP SP e DEVIATION e OUTPUT ALARM 1 and ALARM SP 2 Defines the point at which an alarm occurs For a RATE rate of change alarm it specifies the amount of change per RATE TIME period that must occur before the alarm activates A negative value specifies a negative rate of change Does not apply to HIGH LOW alarms HIGH SP I and HIGH SP 2 For a HIGH LOW alarm defines the high setpoint at which an alarm occurs LOW 5 1 and LOW 5 2 For a HIGH LOW alarm defines the low setpoint at which an alarm occurs DEADBAND and DEADBAND 2 Specifies the range through which the process variable must travel before leaving an alarm condition see alarm examples at the end of this section Prevents frequent alarm oscillation or chattering if the process variable has stabilized around the alarm point ALM I OUT and ALM 2 OUT For any enabled alarm selects the output number to which the selected alarm will be assigned It is possible to assign both alarms to th
29. case load line provides an initial shift at which the reset action begins Load line is adjusted by observing the percent output required to control the process and then adjusting the load line to that value This minimizes the effect of momentary power outages and transients Load line may also be adjusted to give the best response when bringing the load to the desired level from a cold start M SECURITY The DPC 535 security system is easily customized to fit a system s needs Software Configuration 1 Goto the SECURITY menu 2 SEC CODE defines the security password range from 9999 to 99999 The rest of the security parameters can be selectively locked out 3 SP ADJUST prevents the operator from using the and V and keys to change the setpoint value It does not prevent the operator from changing setpoints via the SET PT key 4 AUTO MAN locks out the MANUAL key preventing the operator from transferring between automatic control and manual control 5 SP SELECT locks out the SET PT key This prevents the operator from changing among the various local setpoints or changing to remote setpoint It does not prevent the operator from changing the setpoint value via the and keys 6 ALARM ACK locks out the ACK key preventing an operator from acknowledging any alarms 7 TUNING locks out modification to the parameters in the TUNING menu preventing unauthorized changes to the tuning parameters or the activat
30. end of the input signal range e g 1 volt or 4 mA Example PV range is 1000 Input signal range is 1 5 volts Input signal is 3 volts Therefore PV 0 1000 0 3 1 5 1 1000 5 707 Fig 7 15 Square Root Linearization Formula fashion Then it is a calculated value using the formula in Figure 7 16 Hardware Configuration e A voltage or milliamp input must be installed on the controller Software Configuration 1 Go to the PV INPUT menu 2 Set LINEARIZE to SOR ROOT Custom Linearization Custom linearization allows virtually any nonlinear signal to be linearized using a 15 point straight line approximation curve see Figure 7 17 Typical applications are linearizing signals from nonlinear transducers or controlling volume based on level readings for irregularly shaped vessels To define the function enter data point 15th PV VALUE in engineering units 1st 5th 10th 15th INPUT VALUE in milliamps or voltage Fig 7 16 15 point Linearization Curve DPC 535 User s Manual pairs the engineering units corresponding to a particular voltage or current input Software Configuration 1 Goto the PV INPUT menu 2 Setthe parameter LINEARIZE to CUSTOM 3 Goto the CUST LINR menu 4 Enter values for the IST INPUT and IST PV data points All the input parameters define the actual milliamp or voltage input All the PV parameters define the corresponding process variable value in
31. interconnect the host and field units Belden 9414 foil shield or 8441 braid shield 22 gauge wire are acceptable for most applications The foil shielded wire has superior noise rejection characteristics The braid shielded wire has more flexibility The maximum recommended length of the RS 485 line is 4000 feet Termination resistors are required at the host and the last device on the line Some RS 485 cards converters already have a terminating resistor The communication protocol is asynchronous bidirectional half duplex hence the leads are labelled Comm and Comm DPC 535 Terminals To Comm terminal of next Powers device To Comm terminal of next Powers device Use a 60 to 100 Ohm terminating resistor connected to the two data terminals of the final Powers device on the line CAUTION The shield needs to be connected continuously but only tied to one ground at the host Failure to follow these proper wiring practices could result in transmission errors and other communications problems Fig 3 15 Communications Terminals 21 Hardware configuration of the controller is available at the factory Consult a Dynisco application engineer for details 22 DPC 535 User s Manual 4 HARDWARE Hardware configuration determines the available outputs as well as the type of input signal The DPC 535 controller comes factory set with the following
32. many alarms can be tied to relays Up to two alarm outputs are available if an associated mechanical solid state relay or DC logic module is installed in any output socket not used for control Global Alarm feature allows one or more of the internal software alarms to be tied to the same single physical output The acknowledge key is active for alarms associated with either loop SERIAL COMMUNICATIONS Isolated serial communications is available using an RS 485 interface Baud rates of up to 19 600 are selectable The protocol supports CRC data checking If communications is lost a time out feature will command the controller to a particular control mode and specific setpoint or output if desired Outputs 2 4 and digital inputs can act as host controlled 1 0 independent of the controller s function The PV may be sourced via this interface May be installed in the field DIGITAL DISPLAYS Upper display five digit seven segment Used exclusively for displaying the process variable value Height is 15 mm 0 6 in 2nd display nine character 14 segment alphanumeric Used for displaying setpoint deviation output value slidewire position actual valve position and configuration information Height is DPC 535 User s Manual 6 mm 0 25 in 3rd display nine character 4 segment alphanumeric Used for indicating which loop is displayed and for displaying alarm messages and configuration information Height is 6 mm 0 25 in
33. of the problem s encountered freight prepaid to Dynisco Instruments 38 Forge Parkway Franklin MA 02038 Attention Service Department NOTE Before returning any product for repair please call the Dynisco Service Department at 508 541 9400 or 800 DYNISCO or E mail repair amp mc dynisco com for a Return Authorization number FOR TECHNICAL ASSISTANCE CALL 1 800 221 2201 5 Dynisco Instruments WARRANTY REGISTRATION CARD MODEL NUMBER SERIAL NUMBER DATE PURCHASED PURCHASED FROM NAME COMPANY DIVISION STREET CITY STATE ZIP COUNTRY TELEPHONE FAX My application is Is this your first purchase from Dynisco YES NO How did you first hear of Dynisco ADVERTISING REP PREVIOUS USE COLLEAGUE DIRECTORY need further product information on need application help on Please send complete catalog Tel 508 541 9400 Fax 508 541 9436 E mail www dynisco com PLEASE FOLD AND STAPLE OR TAPE DB Dynisco Instruments DYNISCO INSTRUMENTS 38 FORGE PARKWAY FRANKLIN MA 02038 ATTN MARKETING DEPT 5 Melt Pressure Transducer Quick Start Instructions Important Do not remove protective cap until ready to install Prior to installation verify correct machining of mounting hole When re installing make sure mounting hole is clear of frozen plastic Transducer should be removed when at operating temperature no pressure in system 1 Prepare the Mounting h
34. power up or after setpoint changes D DISABLED ENABLED 4 PROP BND I Defines the proportional band for PID set 1 R 0 1 to 999 0 D 50 0 5 RESET I Defines the integral time for PID set 1 to 9999 seconds D 20 seconds 6 Defines the derivative time for PID set 1 600 seconds D second TUNING ADAPTIVE DISABLED PRETUNE POWR BACK DISABLED PROP BND 1 RESET 1 RATE 1 67 MAN RST 1 CYCLE TM 1 DEADBAND 1 P PROP D B PID OFST 1 ON OFST 1 68 DPC 535 User s Manual 7 MAN RST I or LOADLINE 1 Defines the manual reset for PID set 1 If using automatic reset then this specifies the load line out value R Oto 100 D 0 8 CYCLE TM I Defines the cycle time for control output 1 when using a time proportioning output 0 3 to 120 0 seconds D 15 0 seconds 9 DEADBAND I Defines the dead band for control output 1 when using on off control to 99999 in engineering units D 2 10 P PROP Defines the dead band setting for a slidewire position proportioning output R 0 5 to 10 0 D 2 09 I IA PID 1 For duplex applications defines the offset for the first output 50 0 to 50 0 D 0 0 ON OFST 1 For On Off applications defines the offset for the first output R 9999 to 99999 in engineering units D 0 DPC 535 User s Manual I2A PID OFST 2
35. second noise band measurement B to C is an open loop bump test to determine initial PID values and response time C is Pretune completed so Adaptive PID control begins if ENABLED 70 50 30 CONTROL OUTPUT oy 900 700 500 300 ___ o ADAPTIVE TIME Pretune TYPE 3 Pretune Adaptive Control Ato B is a 5 second noise band measurement Bto is an impulse to determine initial PID values and response time C is Pretune completed so Adaptive PID control begins if ENABLED 70 50 CONTROL OUTPUT 0 900 700 500 300 PV 0 NOISE 7 A B Pretune BUMP ADAPTIVE TIME 7 12 Pretune TYPE 1 2 and 3 with Adaptive Tune DPC 535 User s Manual 7 The next parameter TIMEOUT defines the maximum time in minutes within which pretune must complete its calculations before it is aborted The first time a pretune is performed set TIMEOUT to its maximum value Make note of the length of the pretune cycle Then adjust TIMEOUT to a value about twice the pretune time The purpose of this parameter is to prevent a Pretune cycle from continuing for an excessive time if a problem develops The value has no impact on the PID values being calculated 8 Nextis MODE This defines what mode the controller will enter when pretune is completed Select MANUAL if there will be a need to review PID parameters before attempting to control with them the default AUTOMATIC 9 RE
36. specified module and options installed for details refer to the Order Code in Chapter 1 e Process variable and remote setpoint set to accept a milliamp input Relay outputs set to normally open Alter the factory configuration of the DPC 535 requires accessing the circuit boards and locating the jumpers and output modules see Figure 4 1 1 With the power off loosen the four front screws and remove them 2 Slide chassis out of the case by pulling firmly on the bezel FRONT FACE OPTION BOARD Fig 4 1 Location of Printed Circuit Boards for Hardware Configuration A detailed view of the circuit boards appears in Figure 4 2 After configuring the hardware or if no changes are necessary continued setting up the process as needed DPC 535 User s Manual HARDWARE INPUT TYPES The Process Variable The DPC 535 accepts several different types of process variable signals Set a jumper location to specify the type of input signal Set the signal range in the software see Chapter 5 for software menus or Chapter 7 for applications The jumpers for the process variable are located on the Microcontroller Circuit Board see Figure 4 2 The factory default is Milliamp Locations are marked as follows V Voltage Includes 3 33 mV V Strain Gage MA Milliamp Thermocouple with downscale burnout TCA Thermocouple with upscale burnout RTD RTD NOTE Thermocouple downscale and upscale burnout o
37. the proportional band for PID set 7 47 RESET Defines the integral time for PID set 7 48 RATE 7 Defines the derivative time for PID set 7 49 MAN RST 7 Defines the manual reset or load line for PID set 7 50 TRIP 7 This defines the value that triggers a change to the 7th PID set 51 PROP BND 8 Defines the proportional band for PID set 8 52 RESET 8 Defines the integral time for PID set 8 53 RATE 8 Defines the derivative time for PID set 8 54 MAN RST 8 Defines the manual reset or load line for PID set 8 55 TRIP 8 This defines the value that triggers a change to the 8th PID set DPC 535 User s Manual SELF TUNE MESSAGES AND TROUBLESHOOTING Refer to Chapter 7 for more information on the Self Tune function of the DPC 535 controller When the Pretune function terminates one of the following messages will appear PRETUNE has generated initial PID and the Dead Time values PRETUNE had generated initial PID Response Time Noise Band and the Dead Time values COMPLETED User has aborted PRETUNE before completion The Process variable went beyond the HI LIMIT or Change the HI LIMIT and LOW LIMIT or the HIGH OUT LOW LIMIT and LOW OUT and run Pretune again The Process variable went beyond the HI LIMIT or Change the HI LIMIT and LOW LIMIT or the OUT STEP LOW LIMIT size and run Pretune again The initial process variable was near or beyond the the manual output percentage or t
38. to avoid potential shock hazard and improved noise immunity to your system 72 DPC 535 User s Manual 4 excellent resource about good wiring practices is the IEEE Standard No 518 1982 and is available from IEEE Inc 345 East 47th Street New York NY 10017 212 705 7900 Diagrams on the next three pages serve as guides for wiring different types of process inputs The shaded areas on the diagrams show which rear terminals are used for that type of wiring TOP as viewed from back of controller L1 LINE EARTH 1 89 ov 1 13 Eg 11 OUT 14 112 OUT 6O 313 OUT 2 OUT 3 OUT 3 DIN GND 17E3 Ges COMM COMM 2 PV2 RTD 3RD 1 1 Fig 3 3 DPC Terminal Assignments Actual DPC 535 device only has top and bottom numbers of each column of terminals marked DPC 535 User s Manual AC POWER INPUT Terminals 1 and 2 are for power Terminal 9 is the earth ground Use a 0 5 Amp 250 V fast acting fuse in line with your AC power connection TOP EARTH GROUND Screws must be tight to ensure good electrical connection Fig 3 4 AC Power Input Terminals PROCESS VARIABLE INPUT The DPC 535 accommodates the following types of process variable inputs e Thermocouple Input RTD Input e Voltage Input e Milliamp Input with External Power Supply
39. to stroke at 18 and at 91 it completed its stroke In this case LOW OUT should be set at 18 and HIGH OUT at 91 Note that when output limits are used the full output range from 5 to 105 is available in manual control J RAMP TO SETPOINT The DPC 535 contains a ramp to setpoint function that may be used at the user s discretion This function is especially useful in processes where the rate of change of the setpoint must be limited When the ramping function is activated the controller internally establishes a series of setpoints between the original setpoint and the new target setpoint These interim setpoints are referred to as the actual setpoint Either setpoint may be viewed by the user When the setpoint is ramping RAMPING will be shown in the 3rd display when the actual ramping setpoint is displayed When the target setpoint is being shown RAMPING will not appear Pressing the DISPLAY key will scroll the 2nd display as follows From the target setpoint to the actual ramping setpoint the deviation from setpoint To the output level and e Back to the target setpoint DPC 535 User s Manual Note that when ramping the deviation indication is with respect to the target setpoint The ramp to setpoint function is triggered by one of three conditions 1 Upon power up if the DPC 535 powers up in automatic control then the setpoint will ramp from the process variable value to the setpoint value a
40. 2 GAIN Defines the gain to PV1 R 0 100 to 10 000 D 1 000 13 RESTORE Defines the control mode when a broken PV1 signal is restored D LAST MODE e MANUAL e AUTOMATIC 14 SHUNT Defines Explain this function in your industry s terms R 40 to 100 D 80 15 R CAL Determines whether shunt resistence is used or not D No e Yes 16 SET ZERO Activates set zero function To initiate the Set Zero function press the A or w keys Confirm by pressing ACK within five seconds No 17 SET SPAN Activates set span function To initiate the Set Span function press the A or w keys Confirm by pressing ACK within five seconds No DPC 535 User s Manual PV2 INPUT 1 2 SETUP Defines function of PV2 D SAME AS PVI PV2 parameters are set to the same as PVI no further parameters will appear Note When differential strain gage is selected and PV2 must be the same 2 PV2 TYPE Selects the particular sensor or input range for PV2 T C RTD VOLTAGE CURRENT mA e JT C D DIN RTD D 5 D 4 20 e ET C JIS RTD 0 5V 0 20mA KT C SAMA RTD 0 10 mV 0 30 mV e 0 60 mV RT C 0 100 mV STIC e 25 mV e STRAIN GAGE e WT C W5 TIC 3 33 mV V PLAT II T C 3 DECIMAL Specifies the PV2 decimal point position D XXXXX XXXX X XXX XX XX XXX e 4 LINEARIZE Specifies if the PV2 input is to be
41. ANI gt uonisod jurod TvWIO3 yun einjejeduie 93 0 pesn eq 10 105095 Ad AdALIAd _ 00110112890 1919 DPC 535 User s Manual ALARMS Parameter Description Value 1 ALM TYPE 1 Type of alarm for alarm 1 2 ALM SRC 1 Source of value monitored by HIGH LOW or HIGH LOW alarm 1 3 ALARM SP 1 Alarm setpoint for alarm 1 except for HIGH LOW 4 HIGH SP 1 High alarm setpoint for HIGH LOW alarm 1 4 LOWSP 1 Low alarm setpoint for HIGH LOW alarm 1 5 DEADBAND 1 Deadband for alarm 1 6 ALM 1 OUT Output number for alarm 1 7 LATCHING 1 Latching sequence for alarm 1 8 ACK 1 Whether alarm 1 may be acknowledged 9 POWER UP 1 How alarm 1 will be treated upon power up 10 MESSAGE 1 Nine character message associated with alarm 1 11 ALM TYPE 2 Type of alarm for alarm 2 12 ALM SRC 2 Source of value monitored by HIGH LOW or HIGH LOW alarm 2 13 ALARM SP 2 Alarm setpoint for alarm 2 except for HIGH LOW 14A HIGH SP 2 High alarm setpoint for HIGH LOW alarm 2 148 LOW SP2 Low alarm setpoint for HIGH LOW alarm 2 15 DEADBAND 2 Deadband for alarm 2 16 ALM 2 OUT Output number for alarm 2 17 LATCHING 2 Latching sequence for alarm 2 18 ACK 2 Whether alarm 2 may be acknowledged 19 POWER UP 2 How alarm 2 will be treated upon power up 20 MESSAGE 2 Nine character message associated
42. CKED 6 TUNING Defines lockout status of the tuning parameters D UNLOCKED LOCKED 7 CONFIGURE Defines lockout status of the configuration parameters D UNLOCKED LOCKED SER COMM STATION Defines the unit s station address 1 099 e OFF Disables the communications function D DPC 535 User s Manual 2 BAUD RATE Defines the baud rate e 1200 BPS 2400 BPS 4800 BPS D 9600 BPS e 19200 BPS 3 Defines whether cyclic redundancy check is being calculated D YES NO 4 SHED TIME Defines the time interval between communications activity before the controller determines that communications is lost sheds to 512 seconds D OFF 5 SHED MODE Defines the state of the controller if communications is lost sheds D LAST MODE Remain in automatic or manual control last mode before losing communications MANUAL Trip to manual control AUTOMATIC Trip to automatic control 6 SHED OUT Defines the output if the unit sheds and trips to manual control Choose values based on the process Standard Control On Off Control Velocity Prop Control 5 to 105 ON CW D LAST OUT D OFF e CCW D OUTS OFF BAUD RATE YES SHED TIME SHED MODE LAST MODE SHED OUT SS SHED SP LAST SP DESIG SP 56 DPC 535 User s Manual 7 SHED SP Defines the setpoint status if communications is lost D LAST SP Co
43. CKNOWLEDGE PARAMETER SETTINGS PARAMETER SETTINGS OUTPUT N ALM RLY ON N 2 to 4 OUTPUT N ALMRLY OFF N 2 to 4 ALM HIGH ALRM ALM TYPE 1 BAND ALM 1 OUT N N 2 to 4 OUT N N 2 to 4 LATCHING NO LATCH LATCHING NO LATCH ACK 1 ENABLED ACK 1 DISABLED DEVIATION ALARM POWER UP ALARM IN ALARM C SP CONDITION C SP ALARM UNIT CONDITION POWER RELAY RELAY DE ENERGIZED ENERGIZED Ad ENERGIZED ENERGIZED ENERGIZED ICON OFF ICON ON ICON AND ICON ON ICON ON NO ALARM RS DE ENERGIZE A ICON ON RELAY MAY CANNOT MAY ACKNOWLEDGE ACKNOWLEDGE ACKNOWLEDGE ACKNOWLEDGE PARAMETER SETTINGS PARAMETER SETTINGS OUTPUT N ALM RLY ON 2 to 4 OUTPUT N ALM RLY ON N 2 to 4 ALM TYPE 1 DEVIATION ALM TYPE 1 HIGH ALM ALM 1 OUT N N 2 to 4 ALM 1 OUT N N 2 to 4 LATCHING LATCH LATCHING 1 LATCH ACK 1 ENABLED ACK 1 DISABLED ALARM SP 1 lt 0 POWER UP 1 ALARM Fig 7 1 Alarm Samples DPC 535 User s Manual C DUPLEX CONTROL The Duplex control algorithm enables two discrete control outputs for the control loop Duplex control is commonly used for applications that require both heating and cooling or when 2 control elements are needed to achieve the desired result Hardware Configuration controller must have two output modules assigned to the loop any combination of output modules Software
44. CUST LINR 1ST INPUT 1ST PV XTH INPUT XTH PV 15TH INPT 15TH PV 4 CONTROL ALGORITHM D SOURCE PV ACTION 1 REVERSE LOW OUT PV BREAK HIGH OUT ACTION 2 DIRECT 42 DPC 535 User s Manual CONTROL For configuring the choices for the control algorithm ALGORITHM Defines the type of control algorithm D PID e PI PD ON OFF e PID ON OFF For Duplex applications using for the first output and on off for the second output 2 D SOURCE Selects the variable for the derivative action D PV Derivative term will not react when setpoint changes DEVIATION Derivative term will react when setpoint changes 3 ACTION I Defines the action of the first control output e DIRECT D REVERSE 4 PV BREAK Defines the manual output level if the process variable input is lost Choose values based on the process type On Off Control Standard Control Velocity Prop Control e 5 to 105 ON DO D OFF e CCW D OUTS OFF 5 LOW OUT Defines the lowest output value that can be achieved in automatic control R 0 100 Max is HIGH OUT D 0 6 HIGH OUT Defines the highest output value that can be achieved in automatic control 0 100 Minis LOW OUT D 100 7 ACTION 2 Defines the action of the second control output D DIRECT e REVERSE DPC 535 User s Manual 8 P P TYPE Defines the type of positi
45. Configuration 1 Goto the CONFIG menu Set CTRL TYPE to DUPLEX 2 To use different algorithms for each output PID for the first and On Off for the second Go to the CONTROL menu Set ALGORITHM to PID ON OFF 3 To make the control action for each output independent of the other Go to the CONTROL menu Set ACTION I or ACTION 2 to either DIRECT or REVERSE action based on the diagrams in the output examples section Figures 7 2 through 7 8 4 Goto the TUNING menu Set values for PID OFST I or ON OFST 1 and PID OFST 2 or ON OFST 2 These parameters allow the user to independently offset the point at which output 1 and output 2 become active PID OFSET units are in percent 96 of control output ON OFST is in engineering units The settings can be used to make sure there is a dead band i e no controller output around setpoint They can also be used to overlap output 1 and output 2 so that both are in a small band around setpoint 5 Set MAN RESET manual reset term to 5096 This causes the PID output to be 5096 when there is zero error This term is still active as a load line setting when using automatic reset integral so set it to 5096 whether using automatic reset or not NOTE The duplex output states vary depending upon 1 Control Type PID On Off etc 2 Control Action DA RA 3 Output Limits 4 Output Gap or Overlay and 5 Ouput 2 Relative Gain and PID Output
46. D inputs When the controller senses a lost process variable signal or the input signal travels well beyond the instrument span When the communications is lost for longer than the communications shed time On power up a problem with the EPROM is detected Controller locks up until fixed Upon power up controller senses that the modules needed for control as determined by software configuration are not present Controller locks up until fixed When the controller is powered up with default calibration data input and output accuracy specifications may not be met During power up a discrepancy was found between the EEPROM s and controller s model numbers Controller locks up until fixed During cold junction calibration a discrepancy was found between the controller type and the case type situation and recalibrate Call factory for assistance May not need to do anything May want to check the transmitter accuracy and check to see if range of transmitter matches the range of the controller Check wiring and sensor transmitter Check communications wiring etc To clear message must make an auto manual change This is a fatal error and requires an change Call factory for assistance Must power down and install correct module combination or must reconfigure the controller to match the current module combination Check the slidewire wiring Call factory for assistance This is a fa
47. Manual 2 Basic INTERFACE 1st 2nd ppm ae Location for identification label Fig 2 1 Operator Interface DISPLAYS The display strategy of the DPC 535 Process Controller is the same for all control modes Ist Display five 7 segment digits For the process variable value 2nd Display nine 4 segment digits For the setpoint deviation output level or valve position if available TUNING or SET UP mode for the parameter name e Upon power up indicates the current setpoint 3rd Display nine 14 segment digits e For alarm messages loop name errors etc n TUNING or SET UP mode the value or choice of parameter shown in the 2nd display Q FAST FAST 5 s MANUAL SET PT DISPLAY DPC 535 User s Manual ICONS LIT OUT Indicates either 1 relay output is energized or 2 analog output is greater than 0 ALMI Indicates the respective alarm one is active 2 Indicates the respective alarm two is active OUT OUT OUT 1 2 12 5 FAST Has no independent function Press to modify the function of another key see below MANUAL Press to toggle between manual and automatic control When lit indicates the unit is under manual control SET PT Press to select the active SP When lit indicates that a setpoint other than the primary e g RSP SP2 is active DISPLAY Press to toggle through
48. N 6 peuoqe 10 si Jaye 0J u07 3dOW 8 9J0jeq eunjaJg 104 uonnoex3 INOANIL Z eunjeJg YILI ULI Ad 9 YIII ULI S jueo1ed 9215 0915 11010 seuyaq 2 8 2 AdAL 4315 1nO 7 yo uoruM enje Ad 99 seujeq L 3dAL 1d3Nnl 1ueoJed ejnjosqe ui ezis dejs 2 si ey Buun jas jo adh 3dAL an eA uondisaq ANNL 3135 DPC 535 User s Manual SECURITY Parameter Description Values 1 SEC CODE Security code for temporarily unlocking the instrument 2 SP ADJUST Lockout status for setpoint changes 3 Lockout status of the MANUAL key 4 SPSELECT Lockout status of the SET PT key 5 ALARM Lockout status of the ACK key 6 TUNING Lockout status for adjustment of tuning parameters 7 CONFIGURE Lockout status for Set Up parameters SER COMM Parameter Description Values 1 STATION The unit s station address 2 BAUDRATE Baud rate 3 Whether CRC is being calculated 4 SHED TIME Time between communications before controller sheds 5 SHED MODE State of the controller if communications is lost sheds 6 SHED OUT Output if the unit sheds 7 SHED SP Setpoint statu
49. ND and Response Time RESP TIME will also be calculated In order to run this algorithm the process must fulfill these requirements e The process must be stable with the output the manual mode e For tuning a non integrating process the process must be able to reach a stabilization point after a manual step change and e The process should not be subject to load changes while Pretune operates If these conditions are not fulfilled set the Adaptive Tune to run by itself Adaptive Tune Adaptive Tune continuously monitors the process and natural disturbances and makes adjustments in the tuning parameters to compensate for these changes In order to make accurate calculations Adaptive Tune needs noise band and response time values Pretune TYPE 2 and TYPE 3 automatically calculate these values These values may also be entered or changed manuall in the SELF TUNE menu For Pretune TYPE 1 Noise Band and Response Time parameters must be entered manually Figure 7 12 illustrates the relationship between Pretune and Adaptive Tune Software Configurations Pretune by Itself 1 Goto the SELF TUNE menu pres MENU FAST 2 Setthe TYPE parameter to PRETUNE 3 Set the PRETUNE type to the one that best matches the process see above section 4 The next parameter TUNE PT appears only for TYPE 1 pretune This parameter sets the PV point at which the output will switch off In thermal processes this will help prevent overs
50. NEL 370 95 76 m y 1 180 29 97 3 622 92 00 E 7180 182 37 OVERALL LENGTH 3 653 92 80 MAX ec COOOL x de 71 Aeae Gl Y NIN 00 26 229 3 585 91 06 gt pem 0826 659 BEZEL Auei 6 000 152 40 _____ SIDE CUTOUT Fig 3 1 Instrument Panel amp Cutout Dimensions 2 Figure 3 1 shows the controller and panel dimensions The panel cutout must be precise and the edges free from burrs and waves 9 Place bezel gasket around the controller case starting at the back of controller Then slide the gasket against the back of the bezel 4 With the bezel gasket in place insert the DPC 535 into the panel cutout from the front of the panel Slide the mounting collar over the back of the case as shown in Figure 3 2 The collar clip edges will lock with matching edges on the controller case DPC 535 User s Manual Front Panel LO Mounting Collar Mounting Clip b D N Fig 3 2 Attaching mounting collar Insert the four mounting collar screws from the rear of the collar Gradually tighten the screws using a Phi
51. No 14 SET SPAN Activates set span function To initiate the Set Span function press the A or W keys Confirm by pressing ACK within five seconds No DPC 535 User s Manual CUST LINR Defines a custom linearization curve for PV1 if selected Points 1 and 15 are fixed to the low and high end of the input range and require only setting a corresponding PV value Points 2 through 14 the Xth points require setting both the input and PV values It is not necessary to use all 15 points Whenever the XTH INPUT becomes the high end of the range that will be the last point in the linearization table l IST INPUT Specifies the input signal corresponding to the first point D Thelow end of the appropriate input range e g 4 00 mA 2 IST PV Specifies the engineering unit value corresponding to the first point R 9999 to 99999 D 0 3 XTH INPUT Specifies the input signal corresponding to the XTH point X is 2 to 14 R Any value greater than the first input D Thelow end of the appropriate input range e g 4 00 mA 4 XTH PV Specifies the unit value corresponding to the XTH point X is 2 to 14 R 9999 to 99999 D 0 5 ISTH INPT Specifies the input signal corresponding to the 15th point R 9999 to 99999 Minimum is XTH 1 INPUT D The high end of the appropriate input range e g 20 00 mA 6 15 PV Specifies the engineering unit value corresponding to the 15th point R 9999 to 99999 D 0
52. OM I5 point custom linearization curve is activated 5 LOW RANGE Specifies the engineering unit value corresponding to the lowest PV1 input value e g 4 mA 9999 to 99999 Max is HI RANGE D Dependent on the input selection 6 HI RANGE Specifies the engineering unit value corresponding to the highest PV1 input value e g 20mA R 9999 to 99999 Min is LOW RANGE D Dependent on the input selection 7 SP LOLIM Defines the lowest setpoint value that can be entered from the front panel only 9999 to 99999 Max is SP HI LIM Min is LOW RANGE D Dependent on the LOW RANGE value 8 SP HI LIM Defines the highest setpoint value that can be entered from the front panel only 9999 to 99999 Min is SP LO LIM Maximum is HI RANGE D Dependent on HI RANGE Access Set Up Return to Operation Next menu Next parameter Next value LINEARIZE LOW RANGE RANGE SP LO LIM SP HI LIM Access Tuning Gashi emsk mw ww ww 5 FILTER OFFSET RESTORE LAST MODE SHUNT R CAL SET ZERO SET SPAN Ge DPC 535 User s Manual 9 SP RAMP Defines the rate of change for setpoint changes D OFF Deactivates this function to 99999 units per hour 10 FILTER Specifies the setting for the low pass PV1 input filter Oto 120 seconds D Oseconds 11 OFFSET Defines the offset to PV1 in engineering units R 9999 to 99999 D 0 1
53. PE 1 pretune Helps prevent overshoot Any value in PV input range D AUTOMATIC Controller defines this point low end for Automatic 4 OUT STEP Defines the output step size in absolute percent during a TYPE 2 or TYPE 3 pretune R 50 to 50 0 D 10 0 DPC 535 User s Manual 5 LOW LIMIT Defines the lower most limit the process variable can reach during pretune before aborting Any value in the process variable range D Dependent on the process variable range 6 HI LIMIT Defines the upper most limit the process variable can reach during pretune before aborting Any value in the process variable range D Dependent on the process variable range 7 TIMEOUT This defines the execution time limit for pretune before aborting 8 to 1500 minutes D 1500 minutes 8 MODE Defines the control mode after pretune is completed or aborted e MANUAL D AUTOMATIC 9 NOISE BND Defines the noise band to be used by the adaptive tuning algorithm R 0 1 to 10 of the process variable range D 0 2 10 RESP TIME Defines response time to be used by the adaptive tuning algorithm 10 to 32000 seconds D 7200 seconds LOW LIMIT HI LIMIT TIMEOUT AUTOMATIC NOISE BND RESP TIME 3 DEAD TIME SPECIAL AUTO TRIP TRIP DEV DES OUTPT POWER UP LAST MODE DPC 535 User s Manual DEAD TIME Defines the amount of time required for process to begi
54. PID set selection based on process variable D SP VALUE PID set selection based on setpoint e VALUE PID set selection based on deviation from setpoint 18 TRIP I Defines the value that triggers a change to the primary set 1 of PID values The process variable range D Dependent on the process variable range FOR EACH SET OF PID 2 THROUGH 8 you need to set up the following group of parameters X represents the PID set number Set up the parameters as they appear for each set of PID The controller designates the values for the active PID parameter the third display with an on either side 19 PROP BND X Defines the proportional band for PID set X R 0 1 to 999 0 D 50 0 20 RESET X Defines the integral time for PID set X to 9999 seconds increments of 1 D 20 seconds 21 RATE X Defines the derivative time for PID set X 600 seconds D I seconds DPC 535 User s Manual 22 MAN RST X or LOADLINE X Defines the manual reset or load line for PID set X R 0 0100 D 0 23 TRIP X This defines the value that triggers a change to the Xth set of PID values R process variable range D Dependent on the process variable range MAN RST X 77 DPC 535 User s Manual TUNING Parameter Definition Values 1 ADAPTIVE Activates the self tune algorithm 2 PRE
55. PLAY key until the 2nd display shows OUT followed by the output percentage This value is the PID output n duplex applications this value does not directly refer to the output signal refer to the Chapter 7 section on Duplex Control for details For on off outputs the output value shown is either ON or OFF For duplex applications with two on off outputs the OUT tag is not shown In this case the status of both outputs is shown in the following manner 1 ON 2 OFF 1 and 2 are the respective outputs To display the active PID set 1 Press MENU to reach Tuning Mode 2 In TUNING Mode press MENU to reach the correct Menu parameter 3 The active PID set will have an asterisk on both sides of the value DPC 535 User s Manual ALARM OPERATION Alarms may be used in systems to provide warnings of unsafe conditions All DPC 535 operators must know how the alarms are configured the consequences of acknowledging an alarm and how to react to alarm conditions Alarm Indication elit icons ALM I and or ALM 2 it ACK key e displayed alarm message Acknowledgable alarms meet the first two of these conditions Non acknowledgable alarms only meet the first condition BEFORE AFTER Fig 2 2 Before and Afer Acknowledging an Alarm To acknowledge an alarm s 1 To acknowledge Alarm 1 press ACK once 2 acknowledge Alarm 2 press ACK twice 3 If both alarms are activated pres
56. Recommend use of both MOV and snubber Fig 3 12 SSR Relay Output Wiring NOTE Refer to Figure 4 2 for location of the corresponding jumpers Second input jumper connector on the option board must be in either mA milliamp or V voltage position 19 DPC 535 User s Manual 3 DC Logic SSR Drive Output e Output 1 is always Control 1 Respective jumper J1 J2 or J3 must be set to normally open for DC Logic output Output 4 is always configured for normally open Terminals used Terminals used Terminals used Terminals used with Output with Output with Output with Output Module 1 Module 2 Module 3 Module 4 305 5kD 7KD 150 al 60 sq 16 Fig 3 13 DC Logic Output Wiring 4 Milliamp Output e Output 1 is always Control 1 Respective jumper J1 J2 or J3 must be set to normally open for Milliamp output Terminals used Terminals used Terminals used Terminals used with Output with Output with Output with Output Module 1 Module 2 Module 3 Module 4 1 39 51 78 150 Load 4 8 401 6G 88 meld Fig 3 14 Milliamp Output Wiring DPC 535 User s Manual SERIAL COMMUNICATIONS A twisted shielded pair of wires should be used to
57. Red TRANSDUCER 2 Excitation Green Calibration Blue Excitation White N A Calibration Orange Signal Black Signal Red N A N A For single Strain Gage Transducer input wire as shown under Transducer 1 only 5 NOTE For Typically in the U S negative leads are THERMOCOUPLE INPUT red 2 WIRE RTD Jumper wire 3 WIRE RTD Same color Third leg 4 WIRE RTD Same color Third leg Same color DO NOTconnect 4th leg VOLTAGE INPUT Transmitter DPC 535 Users Manual For PV2 THERMOCOUPLE INPUT 2 WIRE RTD Third leg of RTD 4 WIRE RTD Same color Third leg Do NOT of RTD connect 4th leg VOLTAGE INPUT Transmitter Fig 3 8 PVI and PV2 Wiring for Milliamp RTD and Voltage Inputs DPC 535 User s Manual For PV MILLIAMP INPUT 2 wire transmitter with Separate power supply External Power Supply MILLIAMP INPUT 2 wire transmitter with loop power supply 2 wire E transmitter MILLIAMP INPUT 4 wire transmitter with loop power supply Input power for transmitter 4 20 from transmitter For PV2 MILLIAMP INPUT 2 wire transmitter with separate power supply MILLIAMP INPUT 2 wire transmitter with loop power supply MILLIAMP INPUT 4 wire transmitter with loop power supply Input power for transmitter 4 20 from transmitter Fig 3 9 PVI and
58. SABLED Prevents the alarm from being acknowledged while alarm condition 19 POWER UP 2 Defines how alarm 2 will be treated on power up D NORMAL Alarm depends on process variable e ALARM Always power up in alarm regardless of process variable DELAYED Must leave alarm condition and reenter before activating the alarm 20 MESSAGE 2 A 9 character message associated with alarm 2 To enter message The first character of third display will be flashing Press the and Y keys to scroll through the character set Press FAST key to advance to subsequent characters Press MENU to advance to next parameter D ALARM 2 DEADBAND 2 ALM 2 OUT LATCHING 2 LATCH 2 ENABLED POWER UP 2 NORMAL MESSAGE 2 ALARM 2 FAULT OUTPUT NO ACTION RATE TIME RETRANS TYPE 2 79 LO RANGE 2 48 DPC 535 Users Manual 21 FAULT Defines whether either of the alarm relays will trip if a fault condition lost process variable is detected Only appears if at least one alarm relay is installed D OFF ALARMI e ALARM 2 22 OUTPUT Defines whether a rate of change alarm is interpreted as a lost or broken process variable causing a trip to manual output BREAK D ACTION 23 Defines the time period over which a rate of change alarm condition is determined to 3600 seconds D 5 seconds RETRANS
59. SP TIME defines the amount of damping for the process The choices include FAST results in approximately 2096 overshoot MEDIUM results in approximately 10 overshoot and SLOW lt lt 1 10 Place the controller under manual control 11 Access the TUNING menu press MENU Set the first parameter ADAPTIVE to DISABLED 12 Activate the next parameter PRETUNE 13 Press ACK to begin Pretuning The 3rd display will show the message EXECUTING 14 When Pretune is complete the 3rd display will show COMPLETED for two seconds and then return to the current menu display Pretune TYPE amp Adaptive Tune 1 Goto the SELF TUNE menu 2 Set TYPE to BOTH 3 Set PRETUNE to TYPE 1 4 Seta value for OUTSTEP 5 Set NOISE BND parameter 6 Setthe RESP TIME parameter 93 10 11 DPC 535 User s Manual Make sure that the process is reasonably stable and place the controller under manual control Press MENU to access the TUNING menu Set ADAPTIVE to ENABLED The Adaptive Tuning cycle does not begin the controller is under automatic control Activate the next parameter PRETUNE Press ACK to begin Pretuning The 3rd display will show the message EXECUTING When Pretune is complete the 3rd display will show COMPLETED for two seconds and then return to the current menu display The controller will automatically transfer to automatic control upon completion of Pretune if set to do so or upon manual transfe
60. TUNE Activates the pretune algorithm 3 POWR BACK Reduces setpoint overshoot 4 PROP BND 1 Defines the proportional band for PID set 1 5 RESET Defines the integral time for PID set 1 6 Defines the derivative time for PID set 1 7 MAN RST 1 Defines the manual reset for PID set 1 8 CYCLE TM 1 Defines the cycle time for control output 1 9 DEADBAND 1 Defines the dead band for control output 1 10 P PROP Defines the dead band setting for a slidewire output 11A PID OFST 1 For duplex applications defines the offset for the first output 11B ON OFST 1 For On Off applications defines the offset for the first output 12A PID OFST 2 For duplex applications defines the offset for the 2nd output 12B ON OFST 2 For On Off applications defines the offset for the 2nd output 13 REL GAIN 2 Defines the adjustment factor for the output 2 prop band 14 CYCLE TM 2 Defines the cycle time for control output 2 15 DEADBAND 2 Defines the dead band for control output 2 16 NO OF PID Defines the number of stored and available PID sets 17 PID TRIP Defines the variable used to select the various PID sets 18 TRIP 1 Defines the value that triggers a change to primary PID set 19 PROP BND 2 Defines the proportional band for PID set 2 20 RESET2 Defines the integral time for PID set 2 21 RATE 2 Defines the derivative time for PID set 2 22 RST 2 Defines the manual reset or load line for PID set 2 23 TRIP 2 Defin
61. The physical output is the value where this horizontal line intersects the respective axis The illustrations assumes a manual reset load line term of 5096 Therefore at zero error process variable equals setpoint the PID output is 5096 Duplex with reverse and direct acting outputs A reverse acting output 1 and a direct acting output 2 with no offset no restrictive outputs limits and a neutral relative gain with PID control PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT PID OFST 1 20 PID OFST 2 0 LOW OUT 0 HIGH OUT 100 REL GAIN 1 0 PID OUTPUT Fig 7 2 Duplex with reverse and direct acting outputs DPC 535 User s Manual Duplex with direct and reverse acting outputs A reverse acting output 1 and a direct acting output 2 with no offset no restrictive output limits and a neutral relative gain with PID control PARAMETER SETTINGS ACTION 1 DIRECT ACTION 2 REVERSE PID OFST 1 20 PID OFST 2 0 LOW OUT 0 HIGH OUT 100 REL GAIN 1 0 2 PID OUTPUT Fig 7 3 Duplex with direct and reverse acting outputs Duplex with 2 reverse acting outputs Two reverse acting outputs with no offset no restrictive output limits and a neutral relative gain with PID control PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 REVERSE PID OFST 1 20 PID OFST 2 2 0 LOW OUT 0 HIGH OUT 100 REL GAIN 1 0 PID OUTPUT Fig 7 4 Duplex with two reverse ac
62. User s Manual F MULTIPLE SETPOINTS The DPC 535 can to store up to eight local setpoints and use a remote setpoint One application of this feature is configuring the controller to restrict operators to discrete setpoint choices The DPC 535 can also store multiple sets of PID parameters see next section Software Configuration 1 Goto the SPECIAL menu 2 Set NO OF SP to the number of local setpoints desired 3 Use the SET PT key to scroll to each local setpoint and set it to the desired value with the or W keys 4 Tolink the PID sets to the corresponding local setpoint Go to the TUNING menu Set NO OF PID to SP NUMBER For details on multiple sets of PID refer to the next section in this chapter Basic Operating Procedures To select a set point toggle the SET PT key to scroll through the setpoints The displayed setpoint becomes active after two second of key inactivity The digital inputs can also be used to select the active setpoints A single digital input may be used for selecting the second setpoint SP2 A set of four digital inputs may be used to select up to 8 setpoints see the section in this Chapter in Digital Inputs The SET PT key is lit when a setpoint other than the primary local setpoint is active G MULTIPLE SETS OF PID VALUES The DPC 535 has the ability to store up to eight sets of PID values This can be a valuable feature for operating the controller under conditions which require diff
63. User s Manual display 2nd The middle display of the controller face used to indicate in OPERATION Mode the setpoint deviation or output in TUNING or SET UP Mode the parameter or parameter menu display 3rd The bottom display of the controller face that is used to indicate Operation Mode alarm or error message Tuning of Set up Mode the value or choice of the parameter disturbance An undesired change that takes place in a process that tends to affect adversely the value of a controlled variable duty cycle Percentage of load ON time relative to total cycle time earth ground A terminal used on the 535 to ensure by means of a special connection the grounding earthing of part of the controller engineering unit Terms of data measurement such as degrees Celsius pounds grams etc feedback Process signal used in control as a measure of response to control action the part of a closed loop system which automatically brings back information about the condition under control FM Factory Mutual Research Corporation an organization which sets safety standards gain The ratio of the change in output to the change in input which caused it heat cool control Control method where the temperature of the end product is maintained by controlling two final elements using two of the 535 outputs hysteresis In ON OFF control the temperature change necessary to change the output from ful
64. a signal or variable noise band A measurement of the amount of random process noise affecting the measurement of the process variable offset The difference in temperature between the setpoint and the actual process temperature ON OFF control Control of temperature about a setpoint by turning the output full ON below setpoint and full OFF above setpoint in the heat mode open loop Control system with no sensory feedback optimization The act of controlling a process at its maximum possible level of performance usually as expressed in economic terms DPC 535 User s Manual output modules Plug in devices that provide power handling to enable process control These modules are either binary on off such as a relay or analog continuously variable for current loop control output Action in response to difference between setpoint and process variable overshoot Condition where temperature exceeds setpoint due to initial power up or process changes P control Proportioning control parameter s A user defined variable that specifies how a particular function in the 535 will operate PD control Proportioning control with rate action control Proportioning control with auto reset PID control Proportioning control with auto reset and rate position proportioning A type of control output that utilizes two relays to control an electric motorized actuator pretune algorithm A me
65. al parameter graphics indicate the default factory setting If the default value is dependent on other variables D is shown Fig 5 1 Menu Flowchart for Set Up 2 9 Press MENU to advance to the next parameter this also sets the CAUTION All software changes occur in real time always perform set up functions under manual operation NOTE For information about the Tuning menu mode refer to Chapter 6 For more information about set up parameters and DPC 535 applications refer to Chapter 7 30 MENUS DPC 535 User s Manual In Set Up mode there are 13 sets of options that control different aspects of DPC 535 operation in Tuning mode there is one Each set of options is called a menu When traversing the two modes the menu names appear in the 2nd display CONFIG PVI INPUT PV2INPUT CUST LINR CONTROL ALARMS RETRANS SELF TUNE SPECIAL SECURITY SER COMM and TUNING Mode selection and input output hardware assignments 1st process variable input options 2nd process variable input options Linearization curve options for PV1 input Control options Alarm options Retransmission output options Self tune algorithm options Special feature options Security functions Serial Communications options requires comm board Tuning parameters configuration see Chapter 6 DPC 535 User s Manual PARAMETERS Within each menu are parameters for particular control f
66. alarm setpoint e HIGH LOW Combination of high and low alarms Occurs when the PV exceeds the individually set high or low setpoint BAND Creates a band centered around the control setpoint that is twice the alarm setpoint Alarm occurs when the process variable travels outside of this band The alarm is dependent on the control setpoint As the control setpoint changes the band adjusts accordingly For example if the control setpoint is 500 and the alarm setpoint is 25 then the band extends from 475 to 525 e DEVIATION Similar to the band alarm but creates a band only on one side of the control setpoint Alarm occurs when the process variable deviates from the control setpoint by an amount greater than the alarm setpoint This alarm is dependent on the control setpoint as the control setpoint changes the alarm point changes For example if the control setpoint is 500 and the alarm setpoint is 50 then an alarm occurs when the process variable exceeds 550 In order for an alarm to occur when the process variable drops below 450 select an alarm setpoint of 50 e MANUAL Alarm occurs when the controller is put into manual mode of operation This may be useful for security purposes or to alert the operator that DPC 535 is no longer under automatic control Alarm occurs when the process variable changes at a rate greater than what is specified by the alarm setpoint and time base This alarm helps to
67. an appropriate noise band for each T C type amp RTD 3 Set RESP TIME The response time is the most critical value in Adaptive Tuning Response time represents the time lag from a change in valve position controller output to a specific amount of change in process variable Specifically Response Time is equal to the Deadtime of the process plus one Time Constant The Deadtime is the time between initiation of an input change and the start of an observable response in the process variable The Time Constant is the interval of time between the start of that observable response and the point where the process variable reaches 63 of its final value See Figure 7 15 Example After a stimulus e g valve movement if it takes 300 seconds for a process to reach 63 of its new expected value the response time is 300 seconds If the response time is set too short the process will be unstable and cycle around the setpoint If the Response Time is set too long response to an off setpoint condition will be sluggish It is generally better to use too long a response time than too short Self Tuning with Multiple Sets of PID For both Pretune and Adaptive Tune the tuned set of PID is that which is active upon initiation of the tuning function The controller cannot trip to other PID sets based on trip point or the digital input contact until Adaptive Tuning is disabled However if the PID set is tied to the corresponding local set
68. and in single on off control the deadband effect for output 2 is not illustrated here PARAMETER SETTINGS ACTION 1 REVERSE Out 1 ACTION 2 DIRECT Heat PID OFST 1 0 ON OFST 2 VALUE 100 LOW OUT 0 HIGH OUT 100 Out 1 Out 2 0 100 50 Out2 Offset 0 from Setpoint PID OUTPUT in Engineering Units 6 Fig 7 8 Duplex with one ON OFF output 86 DPC 535 User s Manual Duplex with two ON OFF outputs A reverse acting on off output 1 and a direct acting on off output 2 with a negative offset for output 1 and a positive offset for output 2 Note that here the horizontal axis is expressed in terms of process variable rather than PID output PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT Heat n 2 ON OFST 1 Cool ONOFST 2 VALUE Low Offset1 SP Offset2 High Range PROCESS VARIABLE Range Fig 7 8 Duplex with two ON OFF outputs D STAGED OUTPUTS With staged outputs one analog output can vary its signal e g 4 20 mA over a portion of the PID output range The second analog output then varies its signal over another portion of the PID output range This is an excellent method to stage two control valves or two pumps using standard control signal ranges 20 m 2 esee esee eec 2525 Output 1 4mA 0 33 50 100 PID Output Fig 7 10 Staged Outputs Example OUTI STOP was set to 33 and OUT2 STRT was set to 50
69. and press MENU The MENU key will illuminate and CONFIG will appear in the 2nd display To access the parameters for a particular menu press MENU To select a parameter value use and V Press MENU to advance to the next parameter or FAST MENU to advance to the next menu To advance to the next menu press FAST MENU TUNING mode and the TUNING menu can be accessed from either automatic or manual control To access the tuning menu press MENU To return controller to manual control press DISPLAY or SET PT A key to these functions as shown below appears at the bottom of every page in the menu section of this chapter Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Erast menu ww tiv ww 32 WHERE GO NEXT For information about all the software menus and parameters continue reading this chapter Refer to Appendix D for a quick reference flowchart of all menus and parameters For information about the installed options on the DPC535 compare the product label on top of the controller to the order code in Chapter 1 mount the controller and configure the wiring of the DPC535 for inputs and outputs see Chapter 3 To alter the output module and jumper configuration of the controller see Chapter 4 For more information about applications for the DPC535 see Chapter 6 For more information about the Tuning function of the DPC535 see Chapter 7
70. at could confuse even the most experienced operator The bright crisp display is vacuum fluorescent and offers much better readability than any other display technology Additional operator friendly features include custom programmable alarm messages illuminated keys and an easy to use menu system The DPC 535 is the most accurate instrument in its class With a sampling rate of ten times per second it is ideal for demanding pressure and flow applications The DPC 535 also offers a universal process input and modular field interchangeable outputs that allow more flexibility than ever before The RS 485 serial communications interface allows the controller to utilize sophisticated software routines and high speed hardware to provide exceptionally fast and accurate transmission of data The DPC 535 also offers sophisticated control algorithms including our exclusive Adaptive Tune which constantly analyzes your process and makes modifications to the tuning parameters to ensure you re always under control Thank you for selecting the DPC 535 Process Controller the most sophisticated instrument in its class It will provide you with years of reliable trouble free performance DPC 535 User s Manual DPC 535 MODES There are three operating modes for the DPC 535 controller OPERATION the default mode of the controller When the DPC 535 is operating you can change setpoints select manual control and change output level acknowledge
71. atio 103 Powerback s 88 1 Self Tune POWERTUNE 89 J 10 94 Input 95 A CONTROL TYPE Software Configuration 1 2 Go to the CONTROL menu For the parameter ALGORITHM select the type of DPC 535 control ON OFF Crude control similar to a household thermostat Used primarily on slow stable processes where moderate deviation cycling around setpoint is tolerable Only available with SSR SSR Drive and relay outputs P Proportional only control Provides much better control than on off Used on processes that are less stable or require tighter control but have few load variations and do not require a wide range of setpoints PI Proportional plus integral control In addition to proportional control it compensates for control errors due to wide range of setpoints or load requirements The integral term works to eliminate offsets PD Proportional plus derivative control In addition to proportional 75 control it compensates for control errors due to fast load variations Specifying a variable other than the setpoint SP to HIGH ALARM and LOW ALARM allows for greater flexibility in creating alarm and control strategies 76 DPC 535 User s Manual PID Propo
72. blem Corrective Action RESPONSE Adaptive Tune cannot run if RESPONSE TIME is inaccurate Run TYRE 2 or TYPE 3 Pretune to obtain the correct value TIME or enter it manually Set NOISE BAND large enough to prevent Adaptive Tune from acting on the oscillation If oscillation is not acceptable consider replacing valve Adaptive Tune cannot compensate for PV oscillation due to hysteresis of output device e g a sticky valve Wi t TYPE selected Refer to Chapter 7 th PRETUNE Pretune does not develop optimum PID parameters nds died section on Self Tune DPC 535 User s Manual 7 APPLICATIONS NOTE Controller capabilities The DPC 535 controller provides a variety of user programmable depend upon the control features and capabilities The following topics are included in specified hardware this chapter option A Control Typ e tt 7 L 97 B Alarms s 72 M 2 6 2 6 97 C Duplex Control 76 M Reset Inhibition 98 D Staged 0 83 0 Process Variable Reading Correction 98 Retransmission 83 P Serial Communications 99 Multiple Setpoints 87 0 Cascade 100 6 Multiple Sets of PID Values 87 R R
73. board opening on top Align the circuit boards into the grooves on the top and bottom of the case Press firmly on the front face assembly until the chassis is all the way into the case If it is difficult to slide the chassis in all the way make sure the screws have been removed they can block proper alignment and that the chassis is properly oriented 6 Carefully insert and align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten 5 SOFTWARE CONFIGURATION The software configuration menus of the DPC 535 contain user selected variables that define the action of the controller Read through this section before making any parameter adjustments to the controller When initially setting up the This is a Menu controller cycle through all the Its name will show in the 2nd display parameters in each Menu Press the MENU FAST to advance to the next Menu MENU FAST This is a menu Parameter The name shows in the 3rd display value for the current parameter In this manual independent parameters appear Use arrow keys to selects a value a Press as white text on ME parameters appear as black text on white INDICATOR Use the arrows keys to enter D 4 This is a parameter Value numerical values and or move 9 These values appear in the 3rd display through the selection group press MENU FAST replacing the parameter name Go to next Menu Block In this manu
74. can be manually configured Proper setting of the noise band and response time parameters will yield excellent adaptive control without running the Pretune function 1 Goto the SELF TUNE menu 2 Set NOISE BND The noise band is chosen to distinguish between disturbances which affect the process and process variable noise The controller functions to compensate for disturbances i e load changes but it cannot compensate for process noise Attempting to do this will result in degraded controller performance The Noise Band is the distance 752 norse BAND 4072 402 PROCESS 752 352 VARIABLE 47 406 45 Thermocouple Range 400 328 F TO 752 F 3 X100 5 0 40 80 120 160 200 240 TIME SECONDS Fig 7 12 Noise Band Calculation Example NOTE Adaptive tuning is not available for velocity position proportional control CAUTION If the process conditions are temporarily changed e g during process shutdown draining of a tank etc disable adaptive tuning Otherwise the controller will attempt to adapt its tuning parameters to the temporary process conditions Disable adaptive tuning by 1 Inthe TUNING menu change ADAPTIVE to DISABLED through the keypad or 2 Closing the appropriate digital input see Digital Input section in this chapter 95 DPC 535 User s Manual the process deviates from the setpoint
75. cers Set RESTORE to manual IN THE PV2 MENU Set PV2SETUP to same as PV1 IN THE CONTROL MENU Set ALGORITHM to On Off Set SOURCE to PV differential Set ACTION to DIRECT Set PVBREAK to ON IN THE ALARM 1 AND 2 MENUS Set TYPE SOURCE and MODE latching or non latching as appropriate to the process Set Alarm 1 OUTPUT to 2 This will cause its output to be at the output 2 terminals Set Alarm 2 OUTPUT to 3 This will cause its output to be at the output 3 terminals Set POWER UP as desired If set to normal the process will be powered up in the normal mode If there is an alarm condition the alarm will be activated If set to ALARM alarms will be activated on power up If set to delayed alarms will be inhibited regardless of whether or not an alarm condition exists Define MESSAGE if desired IN THE SPECIAL MENU Set the POWER UP to Manual IN THE SECURITY MENU Set the appropriate Security scheme for your application The above setup will provide a display of the differential pressure with its value controlling the main control output according to the operating setpoint value at terminals 3 and 4 Alarm 1 will output at terminals 5 and 6 Alarm 2 will output at terminals 7 and 8 DPC535 TERMINAL ASSIGNMENTS DIFFERENTIAL PRESSURE CONTROL USING AMPLIFIED TRANSDUCERS TOP EARTH Ele 000 Screws must be tight to ensure good electrical connection TERMINAL NUMBER TRANSDUCER TRANSDUCER 2 16 Signal Red Si
76. citation White 12 Calibration Orange N A 22 N A Calibration Orange 28 N A Signal Black 29 N A Signal Red 31 Signal Black N A 32 Signal Red N A For single Strain Gage Transducer input wire as shown under Transducer 1 only Dynisco Instruments NOTES 5 9 Dynisco Instruments DPC535 Quick Start Operating Instructions DIFFERENTIAL PRESSURE CONTROL USING AMPLIFIED TRANSDUCERS Refer to the full manual for unpacking and mounting instructions and terminal locations When using the DPC535 as a differential pressure controller DPC535 1 1 1 5 with amplified pressure transducers such as the Dynisco PT4624 wire as follows For upstream Connect positive signal wire red to terminal 16 Connect a jumper wire between terminals 15 and 31 Connect the negative signal wire black to terminal 32 For PV2 downstream Connect positive signal wire red to terminal 16 Connect jumper wire between terminals 15 and 28 Connect the negative signal wire black to terminal 29 Refer to the full manual for instructions on accessing the following menus IN THE CONFIGURATION MENU Set CTR TYPE to Standard Set LINE FREQ to 60 Set PV SOURCE to PV1 PV2 Set OUTPUT 2 to ALARM ON Set OUTPUT 3 to ALARM ON Define LOOP NAME if desired IN THE PV1 MENU Set PV1 TYPE to 4 20 mA Set LOW RANGE to match low range of transducer Set HI RANGE to match the full scale range of transdu
77. control algorithm that provides proportional control with the addition of derivative action to compensate for rapid changes in process variable control action proportional plus integral A control algorithm that provides proportional control with the addition of integral action to compensate for offsets between setpoint and process variable control action proportional plus integral plus derivative PID A control algorithm that provides proportional control with both integral and derivative action control adaptive see adaptive control control algorithm A mathematical representation of the control action to be performed control cascade see cascade control control output The end product which is at some desired value that is the result of having been processed or manipulated control mode automatic A user selected method of operation where the controller determines the control output control mode manual A user selected method of operation where the operator determines the control output control parameters User defined values that specify how the process is to be controlled controlled variable A process variable which is to be controlled at some desired value by means of manipulating another process variable DPC 535 User s Manual redundancy check An error checking technique in which a checking number is generated by taking the remainder after dividing all the bit
78. due to noise in percentage of full scale Figure 7 13 shows a typical process variable response in a steady state situation In this example the process noise is within a band of about 0 5 of full scale A noise band that is too small will result in tuning parameter values based on noise rather than the effects of load and setpoint changes If the noise band is set too small then Adaptive Tune will attempt to retune the controller too often This may result in the controller tuning cycling between desirable system tuning and overly sluggish tuning While the result may be better than that achieved with a non adaptive controller this frequent retuning is not desirable If the noise band is set too large the process variable will remain within the noise band and the controller will not retune itself With too large a noise band important disturbances will be ignored INPUT TYPE PLATINEL Peak to Peak Noise F Fig 7 13 Noise Band Values for Temperature Inputs 63 of Final PV Dead Time Time Constant Fig 7 14 Deadtime and Time Constant DPC 535 User s Manual and the controller will be indifferent to sluggish and oscillatory behavior Noise band settings are generally between 0 1 and 1 0 with most common settings of 0 2 or 0 396 Figure 7 14 shows the conversion of peak to peak noise to
79. e Also integral reset term see reset RTD Resistance Temperature Detector Resistive sensing device displaying resistance versus temperature characteristics Displays positive temperature coefficient relative gain An open loop gain determined with all other manipulated variables constant divided by the same gain determined with all other controlled variables constant retransmission a feature on the 535 which allows the transmission of a milliamp signal corresponding to the process variable target setpoint or actual setpoint to another devices typically a chart recorder sample interval The time interval between measurements or observations of a variable secondary loop The inner loop of a cascade system self tune A method of automatically calculating and inserting optimum PID parameters by testing system response and timing serial communications The sending or receiving of binary coded data to a supervisory device such as a personal computer of programmable logic controller setpoint An input variable which sets the desired value of a controlled variable setpoint actual The desired value of a controlled variable that the controller is currently acting upon setpoint deviation from The number of units difference between the current process variable and the setpoint setpoint ramping A setpoint which is determined by the ramp function of the controller where over time the controlle
80. e output of one controller is the setpoint for another controller closed loop Control system that has sensing device for process variable feedback cold junction Point of connection between thermocouple metals and the electronic instrument configuration Also called set up selection of hardware devices and software routines that function together cold junction compensation Electronic means used to compensate for the effect of temperature at the cold junction contact In hardware a set of conductors that can be brought into contact by electromechanical action and thereby produce switching In software a symbolic set of points whose open or closed condition depends on the logic status assigned to them by internal or external conditions control action The slope of the output of the instrument in reference to the input e g direct output increases on rise of input Typical cooling response or reverse output decreases on rise of input typical heating response control action derivative rate D The part of the control algorithm that reacts to rate of change of the process variable control action integral reset I The part of the control algorithm that reacts to offset between setpoint and process variable control action proportional P Control action in which there is a continuous linear relation between the output and the input control action proportional plus derivative PD A
81. e Milliamp Input with Internal Power Supply Differential Strain Gage Input with Internal Power Supply Each type of input can be wired for PV1 terminals 31 and 32 or for PV2 terminals 28 and 29 PV 2 PV 2 3rd pv 1 pi Fig 3 5 Process Variable Terminals When wiring to a 240 V System external fuses are required on L1 and L2 CAUTION Do not run low power sensor input lines in the same bundle as AC power lines Grouping these lines in the same bundle can create electrical noise interference 43 DPC 535 User s Manual Fig 3 6 DPC535 Terminal Assignments Differential Pressure Control Using Amplified Transducers TOP T EARTH Ele Screws must be tight ensure good electrical connection TERMINAL NUMBER TRANSDUCER TRANSDUCER 2 16 Signal Red Signal Red 15 Jumper to 31 Jumper to 28 32 Signal Black N A 29 N A Signal black Note that this wiring configuration applies to any differential measurement done woth 4 20 mA loop powered transducers 4 DPC 535 User s Manual Fig 3 7 DPC535 Terminal Assignments Differential Strain Gage Inputs TOP Ele Screws must be tight to ensure good electrical connection TERMINAL NUMBER 22 28 29 31 32 TRANSDUCER I Excitation Green Calibration Blue Excitation White Calibration Orange N A N A N A Signal Black Signal
82. e same output relay thus creating a global alarm LATCHING I and LATCHING 2 A latching YES alarm will remain active after leaving the alarm condition unless it is acknowledged A non latching NO alarm will return to the non alarm state when leaving the alarm condition without being acknowledged DPC 535 User s Manual ACK 1 and ACK 2 For any enabled alarm enables or disables operator use of the ACK key to acknowledge an alarm at any time even if the control process is still in the alarm condition A latching alarm can always be acknowledged when it is out of the alarm condition When either alarm is available to be acknowledged the ACK key will be illuminated If both alarms are acknowledgeable pressing ACK will first acknowledge alarm 1 Pressing a second time will acknowledge alarm 2 POWER 1 and POWER UP 2 For any enabled alarm selects the alarm condition upon power up Choices are NORMAL Controller will power up in alarm only if it is in alarm condition e ALARM Controller always powers up in alarm regardless of system s alarm condition This is an excellent way to activate an alarm if there has been a power failure e DELAYED Controller will never power up in alarm regardless of system s alarm condition The system must leave and reenter the alarm condition before the alarm will activate This is typically used to avoid alarms during start up 55 MESSAGE 2
83. ead wire resistance etc can cause the display to indicate a value other than the actual process value The PV OFFSET and PV GAIN parameters can be used to compensate for these extraneous conditions NOTE This feature is provided as a convenience only Correcting the cause of the erroneous reading is recommended 1 Goto the PV INPUT menu 2 Set PV OFFSET This parameter either adds or subtracts a set value from the process variable reading in engineering units For example if the thermocouple was always reading 3 too high the parameter could be set to 3 to compensate NOTE Security does not prevent the operation from the digital inputs or serial communications 103 PV GAIN is only available if using a linear voltage or current input 704 DPC 535 User s Manual 3 Set PV GAIN This multiplies the deviation from the low end of the process variable range by the gain factor and then adds it to the value of the low end of the range to arrive at the adjusted process variable value For example if the process variable range is 5O to 650 and the process variable reading is 472 a PV GAIN of 295 would yield an adjusted process variable equal to 472 50 x 995 50 470 With a combination of both offset and gain factors just about any inaccuracy in the sensor or transmitter can be compensated P SERIAL COMMUNICATIONS The serial communications option enables the DPC 535 to communicate w
84. elays 1 Mechanical Relay Output Output 1 is always Control 1 e Outputs 1 2 and 3 are jumper selectable for normally open and normally closed on the power supply circuit board e Output 4 is always configured for normally open and has reduced voltage and current ratings see Specifications Terminals used Terminals used Terminals used Terminals used Line Power with Output with Output with Output with Output Module 1 Module 2 Module 3 Module 4 7 156 48 66 8 16 6 Recommend use of both MOV and snubber Fig 3 11 Mechanical Relay Output wiring 2 Solid State Relay Triac Output e Output 1 is always Control 1 e Respective jumper J1 J2 or J3 must be set to normally open for SSR Triac output e Output 4 is always configured for normally open and has reduced voltage and current ratings see Specifications Terminals used Terminals used Terminals used Terminals used Line Power with Output with Output with Output with Output Module 1 Module 2 Module 3 Module 4 3 9 5 706 15 0 4 0 6 8 0 16 D
85. eliminates setpoint overshoot at power up or after setpoint changes POWERBACK monitors the process variable to make predictive adjustments to the control parameters a feature that helps eliminate overshoot of setpoint ISOLATION Inputs and outputs are grouped into the following blocks Block I process variable Block 2 outputs 2 and 4 Block 3 communications output 3 Earth Ground Each block is electrically isolated from the other blocks to withstand a HIPOT potential of 500 Vac for minute 600 Vac for second with the exception of blocks and 4 which are isolated to withstand a HIPOT potential of 50 volts peak for minute between each other Inputs and outputs are not isolated from other inputs and outputs within the same block CONTROLLER ARCHITECTURE The DPC 535 Controller hardware can be configured as follows Inputs Two univeral process variable inputs are standard Outputs Four outputs are available See Ordering Information RS 485 Communications Available as option with any configuration PROCESS VARIABLE INPUTS 2 PROCESS VARIABLES AVAILABLE Universal input type Any input type may be selected in the field Selection of input type thermocouple RTD voltage or current via jumper Selection of particular sensor or range is via front panel THERMOCOUPLES RANGE F RANGE C B 104 to 3301 40 to 1816 E 454 to 1832 210 to 1000 346 to 1832 210 to 1000 777 112 W5
86. elps to eliminate overshoot of the Setpoint Software Configuration 1 Goto the TUNING menu 2 Set POWR BACK parameter to ENABLED 3 Goto the SELF TUNE menu 4 For DEAD TIME set the value time that the controller should wait before invoking an output change This value is typically the dead time of the process Or let Pretune calculate the dead time then complete just steps 1 and 2 above SELF TUNE The Self Tune function of the DPC 535 consists of two distinct components Pretune and Adaptive Tune These components may be used independently or in conjunction with one another For best results we recommend using them together Pretune This algorithm has three versions Choose the type that most closely matches the process to optimize the calculation of the PID parameters The three Pretune types are Normally used for slow thermal processes e TYPE2 Normally used for fast fluid or pressure processes e Normally used for level control applications DPC 535 User s Manual Pretune is an on demand function Upon initiation there is a five second period during which the controller monitors the activity of the process variable Then the control output is manipulated and the response of the process variable is monitored From this information the initial Proportional Band Reset and Rate P and D values and dead time are calculated When using TYPE 2 or TYPE 3 Pretune the Noise Band NOISE B
87. erent tuning parameters for optimal control There are various methods of selecting which set should be active These methods are explained in this section DPC 535 User s Manual Software Configuration 1 Goto the TUNING menu 2 NO OF PID is the desired number of PID sets to be stored SP VALUE automatically sets this value equal to the number of stored local setpoints each PID set will be active when its respective local setpoint is active 3 PID TRIP determines which variable selects the various PID sets process variable setpoint or deviation from setpoint 4 TRIP X defines the point in the PV range at which that set of PID values become active Basic Operating Procedures A PID set can be selected in one of four ways For NO OF PID PV NUMBER the PID set 1 or 2 is selected when PV1 or PV2 is used For NO OF PID SP NUMBER the active set of PID values is the same as the active setpoint For example if SP3 is active then PID set 3 will be active e When using PID trip values a PID set becomes active when the variable exceeds its trip point For example if PID TRIP SETPOINT and TRIP 2 500 the second set of PID values becomes active when the setpoint exceeds 500 and remains active until the setpoint drops below 500 or exceeds the next highest trip point The PID set with the lowest trip point is also active when the trip variable is less than the trip value The user can set the lowest trip point
88. es the value that triggers a change to the 2nd PID set 24 PROP BND 3 Defines the proportional band for PID set 3 25 RESET 3 Defines the integral time for PID set 3 26 RATE 3 Defines the derivative time for PID set 3 27 MAN RST 3 Defines the manual reset or load line for PID set 3 DPC 535 User s Manual 30 TRIP 3 D D fines the value that triggers a change to the 3rd PID set 31 PROP BND 4 D D fines the proportional band for PID set 4 32 RESET 4 Defines the integral time for PID set 4 33 RATE 4 Defines the derivative time for PID set 4 34 MAN RST 4 Defines the manual reset or load line for PID set 4 35 TRIP 4 This defines the value that triggers a change to the 4th PID set 36 PROP BND 5 Defines the proportional band for PID set 5 37 RESET 5 Defines the integral time for PID set 5 38 RATE 5 Defines the derivative time for PID set 5 39 MAN RST 5 Defines the manual reset or load line for PID set 5 40 TRIP 5 This defines the value that triggers a change to the 5th PID set 41 PROP BND 6 Defines the proportional band for PID set 6 42 RESET 6 Defines the integral time for PID set 6 43 RATE 6 Defines the derivative time for PID set 6 44 MAN RST 6 Defines the manual reset or load line for PID set 6 45 TRIP 6 This defines the value that triggers a change to the 6th PID set 46 PROP 7 Defines
89. etting with PID control PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT PID OFST 1 VALUE PID OFST 2 VALUE LOW OUT 10 HIGH OUT 85 REL GAIN 1 0 Out 1 Out 2 Heat Cool 0 10 100 8 50 0 PID OUTPUT Fig 7 6 Duplex with overlapping outputs and ouput limits DPC 535 User s Manual Duplex with various relative gain settings A reverse acting output 1 and a direct acting output 2 with various relative gain settings assume no offset or restrictive outputs with PID control PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT PID OFST 1 0 Hean PID OFST 2 0 LOW OUT 0 HIGH OUT 100 REL GAIN 2 0 REL GAIN 1 0 REL GAIN 6 0 5 PID OUTPUT Fig 7 7 Duplex with various relative gain settings Notice that the relative gain setting does not affect output 1 In this example a relative gain setting of 2 0 curve 1 results in output 2 reaching its maximum value at a PID output of 25 A relative gain setting of 1 0 results in output 2 reaching its maximum value at a PID output of 0 A relative gain setting of 0 5 results in output 2 reaching a maximum of 50 at a PID output of 0 Duplex with one ON OFF output A reverse acting output 1 and a direct acting on off output 2 with a positive offset Relative gain does not apply when using duplex with an on off output The deadband setting for output 2 works the same as the deadb
90. ffers a choice in which direction the controller would react in the event of thermocouple failure For example in heat applications typically it is desirable to fail upscale TC s so that the system does not apply more heat 23 DPC 535 User s Manual Mechanical Relays Note There are three output module sockets on the Power Supply Circuit Changing the Board and one output module on the Option Board see Figure 4 2 The mechanical relay on the Power Supply Board may be configured for either normally open NO or normally closed NC A jumper located next to each socket determines this configuration relay output are factory set to NO normally open jumpers means moving the jumper connector The jumper connector slips over the pins straddling two rows of pins The printed circuit boards are labeled next to the jumpers 5 Pin Connector 00000 E Remote Setpoint Jumper T Male 22 Pin Male 22 Pin Connector Connector Output 4 Male 34 Pin Connector 5 Pin Connector Retention over Outputs 1 2 3 NO J1 NCNO J2 NCNO J3 NC Fig 4 2 from the top The Microcontroller Circuit Board the Option Board and the Power Supply Board DPC 535 User s Manual ACCESSING AND CHANGING JUMPERS Follow these instruction to change jumpers for the Process Variable CAUTION Remote Setpoint and Digital Inputs Stat
91. gnal Red 15 Jumper to 31 Jumper to 28 32 Signal Black N A 29 N A Signal black Note that this wiring configuration applies to any differential measurement done with 4 20 mA loop powered transducers 9 Dynisco Instruments NOTES Contents CHAPTER I INTRODUCTION 1 DEC 535 entes anos e D a 2 Order Code Packaging lrformation erre 2 Where esie tpe aa 2 Text formatting in this manual 3 CHAPTER 2 55005 5 5 Icons LIE 5 I NEU Rc edu I equ E 6 Basic Operating Procedures euet asa edad 7 Alarm Operations teen eran tite 9 CHAPTER 3 INSTALLATION ntis unii nuire i eto pa oie 10 Mounting eio ebee de 10 Vul Y 11 AC Powet Input oec fo ble 13 Process Variable INpUt eee cerne ene enr oberen Spip epe ss 13 Qutput Modules 19 1 Mechanical Relay Output ccc 19 2 Solid State Relay Triac Output repe 19 3 DC Logic SSR Drive Output sedie teen ttr 20 4 Milliarnp rhe acto eds 20 5 Position Proportioning 20 Serial COMMUNICATIONS 21 4
92. h diffusion printed graphics NEMA rating front panel conforms to NEMA 4X when instrument is properly installed AGENCY APPROVALS 68 LR 84603 Process Conta Heavy Industrial Available as an option MEMORY RETENTION Lithium battery maintains all programming for approximately ten years SECURITY There are two levels of access restricted and full A configurable code is used to enter the full access level Functions not available in the restricted level are configurable DPC 535 User s Manual APPENDIX 4 GLOSSARY adaptive control Control in which automatic means are used to change the type or influence or both of control parameters in such a way as to improve the performance of the control system adaptive tune A component of the 535 self tune function which continuously monitors the process and natural disturbances and makes adjustments in the tuning parameters to compensate for or improve the performance of the control system alarm A condition generated by a controller indicating that the process has exceeded or fallen below the set or limit point alarm band A type of alarm set up where a band is created around the control setpoint alarm deviation An alarm similar to a band alarm except it only creates a band on one side of the alarm setpoint alarm fault An indication that becomes active upon loss of process variable Fault alarm operates in addition to other alarm assign
93. he HI LIMIT and HI LIMIT or LOW LIMIT LOW LIMIT and run Pretune again TIMEOUT limit was reached before Pretune Set a longer TIMEOUT period and or increase the Eliminate the noise source if possible or increase the NOISE ERR Too much PV noise was detected OUT STEP and run Pretune again INPUT ERR PV or Cold Junction break detected during Pretune and makeicorrection or repairs PV HIGH or PV LOW detected during Pretune SLIDEWIRE break detected during Pretune Remote SP Break detected during Pretune The initial trol output i tside the high and I OUT ERROR Tf ge Change the manual output percent and run Pretune again imits defined in the Control menu PV moved too quickly to be analyzed Decrease the OUT STEP size and run Pretune again One or more model parameters are calculated to be zero The initial PV is too close to the TUNE PT Move TUNE PT or the Setpoint if TUNE PT is Automatic farther from the process variable and run Pretune again Check if any PID values were generated and if they are acceptable If not eliminate noise sources if possible and run Pretune again Increase the OUT STEP size and run Pretune again DEV ERROR RETRY The Process variable went beyond the HI LIMIT or LOW LIMIT If Pretune and Adaptive Tune do not generate optimal PID values for control check the following menu entries Message Potential Pro
94. he Option board is also held in place by a tie wrap Snip tie wrap to remove module as shown in Photo 6 Figure 4 3 shows a representation of an output module Inspect the module s to make sure that the pins are straight To install any module align its pins with the holes in the circuit board and carefully insert the module in the socket Press down on the module until it is firmly seated refer to Photo 8 6 Snip Tie Wrap 8 Add Change Module Replace tie wraps for all the modules the Retention Plate and Output Module 4 with new ones before reassembling the controller Failure to use the tie wraps may result in loosening of the module and eventual failure All separately ordered modules come with a tie wrap NOTE For greatest accuracy calibrate all milliamp modules added for retransmission as per the instructions in Appendix 2 Rejoin the circuit boards by aligning the pins of their connectors then squeezing the board s together Make sure that all three printed circuit boards are properly seated against one another check along side edges for gaps Make sure the cable assemblies are not pinched To reattach the board assembly to the front face assembly align the boards with the open area on top into the slots of the font face assembly The clips should snap into place To reassemble the controller properly orient the chassis with board opening on top Align the circuit boards into the grooves on the top and botto
95. he other is constant over an entire range of possibilities linearization custom User definable linearization linearization square root A function the 535 uses to linearize a non linear signal corresponding to the flow being measured by flow transmitters load line out A start up output value which is to bring initial output closer to actual steady state output loop power An internal 24 volt current limited power supply used to power 2 or 4 wire transmitter on the input of the controller load The demand for input to a process low pass input filter A method block fast acting signals typically noise while allowing slow acting signals actual process variable to pass manipulated variable A quantity or condition which is varied so as to change the value of the controlled variable see also control output mechanical relay see relay menu see menu block menu block Groups of parameters arranged in the software microcontroller A large scale integrated circuit that has all the functions of a computer including memory and input output systems NEMA 4X A National Electrical Manufacturers Association standard for specifying a product s resistance to water and corrosion normally open A switched output i e relay etc whose unpowered state has no connection normally closed A switched output i e relay whose unpowered state provides connection noise An unwanted component of
96. hoot The default is AUTOMATIC CAUTION Disable Adative Tuning before altering process conditions e g for shutdown tank draining etc Otherwise the DPC 535 will attempt to adapt the Tuning parameters to the temporary process conditions Adaptive Tune can be disabled via digital input if applicable see Digital Inputs in this chapter or via menus 1 Gotothe TUNING menu 2 Goto parameter ADAPTIVE Change the value to DISABLED 97 DPC 535 User s Manual 5 Setthe value for OUT STEP This parameter defines the size of bump to be used The resulting disturbance must change the process variable by an amount that significantly exceeds the peak to peak process noise but does not travel beyond the normal process variable range 6 The next two parameters LOW LIMIT and HI LIMIT set the process variable boundaries If these boundaries are exceeded during the Pretune the pretune cycle will abort and return to manual control at the output level prior to the initiation of pretune 100 High Out Limit TYPE 1 Pretune Adaptive Control A to B is ON OFF control to determine initial PID values B is Pretune completed so Adaptive PID control beings if ENABLED 70 50 30 CONTROL OUTPUT s 900 Note Noise Band and Resp Time must be entered before Low Out Limit enabling Adaptive TUne 700 500 300 mM o TIME 100 TYPE 2 Pretune Adaptive Control A to B is a 5
97. ic discharge can Equipment needed Needle nose pliers optional cause damage to Sv 9 9 Phillips screwdriver 2 equipment Always use Wrist grounding strap a wrist grounding strap when handling With power off loosen four front screws and remove them electronics to prevent Side the chassis out of the case by pulling firmly on the bezel SEXES SER Use Figure 4 2 to locate the jumper connector to change Using the needle nose pliers or fingers pull straight up on the connector and remove it from its pins as shown in Photo 4 Be careful not to bend the pins Find the new location of the jumper connector again refer to Figure 3 2 Carefully place it over the pins then press connector straight down Make sure it is seated firmly on the pins 4 Remove Jumpers Make any other jumper changes as needed To alter output moduleszl please refer to the next section starting with Step 3 To reassemble the controller properly orient the chassis with board opening on top Align the circuit boards into the grooves on the top and bottom of the case Press firmly on the front face assembly until the chassis is all the way into the case If it is difficult to slide the chassis in all the way make sure the screws have been removed they can block proper alignment and that the chassis is properly oriented Carefully insert and align screws Tighten them until the bezel is 2 seated firmly against the gasket Do not overtigh
98. ill provide a display of the differential pressure with its value controlling the main control output according to the operating setpoint value at terminals 3 and 4 Alarm 1 will output at terminals 5 and 6 Alarm 2 will output at terminals 7 and 8 The retransmission output will be at terminals 15 and 16 CALIBRATION Calibration is to be done with transducers at operating temperature with no pressure applied Return to PV Menu Scroll to SHUNT Set to 8096 for Dynisco transducers For other brands consult the manufacturer for the correct percentage value Set R CAL to yes Set SET ZERO to PRESS ACK Press ACK Button Zero calibration is finished when lower display indicates COMPLETED SET SPAN to PRESS ACK Press ACK Button Span calibration is finished when lower display indicates COMPLETED Go to PV2 Menu Scroll to Shunt Repeat above procedure for PV2 Press DISPLAY button to return to operational mode With no pressure applied Main display should indicate 10 psi Press DISPLAY button to display PV1 on lower display It should indicate 0 10 psi Press DISPLAY to display PV2 on lower display It should indicate 0 10 psi DPC535 TERMINAL ASSIGNMENTS DIFFERENTIAL STRAIN GAGE INPUTS EARTH Elo 000 Screws must be tight to ensure good electrical connection TERMINAL NUMBER TRANSDUCER I TRANSDUCER 2 10 Excitation Green Excitation Green Calibration Blue Calibration Blue 11 Excitation White Ex
99. ion deactivation of the self tuning algorithm 8 CONFIGURE allows access to the configuration menus but prevents any unauthorized changes to the configuration parameters If locked out the security code is not accessible DPC 535 User s Manual Basic Operating Procedures The security feature can be overridden When a locked function is attempted the operator will have the opportunity to enter the security code If the correct security code is entered the operator has full access The security feature is reactivated after one minute of keypad inactivity If the security code is forgtton the security feature can still be overridden e security override code is 62647 Store this number in a secure place and blacken out the code in this manual to limit access N RESET INHIBITION Reset Inhibition is useful in some systems either at the start up of a process or when a sustained offset of process variable from setpoint exists In conditions like these the continuous error signal may cause the process temperature to greatly overshoot setpoint Any of the digital inputs may be set up so that the contact closure disables the reset action sets it to zero Software Configuration 1 Goto the CONFIG menu 2 Set corresponding parameter s CONTACT I to 5 to RST INHBT O PROCESS VARIABLE READING CORRECTION Conditions extraneous to the controller and aging thermocouple out of calibration transmitter l
100. ith a supervisory device such as a personal computer or programmable logic controller The communications standard utilized is RS 485 which provides a multi drop system that communicates at a high rate over long distances Typical limitations are 32 instruments per pair of wires over a distance up to 4000 feet The DPC 535 uses a proprietary protocol which provides an extremely fast and accurate response to any command Cyclic redundancy checking CRC virtually ensures the integrity of any data read by the DPC 535 Through communications there is access to every Set up Tuning and Operating parameter For details on the DPC 535 protocol contact a Dynisco application engineer at 1 800 221 2201 Hardware Configuration This optional features is only available if ordered originally from the factory The circuitry for communications is contained on a modular circuit board that plugs into the Microcontroller Circuit Board Refer to the order code in Chapter 1 for details Software Configuration 1 Access the SER COMM menu 2 STATION specifies the unit s station address It is the only way one DPC 535 can be distinguished from another Each DPC 535 on the same RS 485 interface must have a unique station address 3 Choose a BAUD RATE from 1200 to 19 200 In general select the highest value However every instrument on the RS 485 interface must be set to the same baud rate DPC 535 User s Manual 4 CRC indicates the cyclic
101. l ON to full OFF hunting Oscillation or fluctuation of process temperature between setpoint and process variable icons Indicators on the face of the controller input Process variable information being supplied to the instrument integral Control action that automatically eliminates offset or droop between setpoint and actual process temperature Also reset internal voltage reference A precision voltage source within the 535 controller used to establish internal calibration isolation Electrical separation of sensor from high voltage circuitry Allows for application of grounded or ungrounded sensing element offset Adjustment to actual input temperature and to the temperature values the controller uses tor display and control JIS Japanese Industrial Standards Also Japanese Industrial Standards Committee JISC Establishes standards on equipment and components jumper A wire that connects or bypasses a portion of a circuit on the printed circuit board jumper connectors The connecting device that straddles a jumper to connect or bypass a portion of a circuit a printed circuit board linearization A function the 535 uses to automatically linearize a non linear signal either from thermocouple or RTD temperature sensors through the use of look up tables The relationship that exists between two variables when the ratio of the value of one variable to the corresponding value of t
102. linearized Thermocouples and RTD s are automatically linearized D NONE e SQR ROOT Square root linearization is activated 5 LOW RANGE Specifies the engineering unit value corresponding to the lowest PV2 input value e g 4 mA 9999 to 99999 Max is RANGE D Dependent on the input selection PV2 INPUT PV2 SETUP SAME AS PV1 PV2 TYPE J TC DECIMAL LINEARIZE LOW RANGE J9 RANGE FILTER OFFSET GAIN RESTORE LAST MODE NOTE Menu boxes for PV2 are the same as for 40 DPC 535 User s Manual 6 HI RANGE Specifies the engineering unit value corresponding to the highest PV2 input value e g 20 mA R 9999 to 99999 Min is LOW RANGE D Dependent on the input selection 7 FILTER Setting for the low pass PV2 input filter Oto 120 seconds D 0 seconds 8 OFFSET Defines the offset to PV2 in engineering units 9999 to 99999 D 0 9 GAIN Defines the gain for PV2 R 0 100 to 10 000 D 1 000 10 RESTORE Defines the control mode when a broken PV2 signal is restored D LAST MODE MANUAL AUTOMATIC SHUNT 26 Defines Explain this function in your industry s terms R 40 to 100 D 80 12 R CAL Determines whether shunt resistence is used or not D No Yes 13 SET ZERO Activates set zero function To initiate the Set Zero function press the A or w keys Confirm by pressing ACK within five seconds
103. llips 2 screwdriver to secure the controller against the panel If there is difficulty with any of the mounting requirements apply a bead of caulk or silicone sealant behind the panel around the perimeter of the case WIRING DPC 535 controllers are thoroughly tested calibrated and burned in at the factory so the controller is ready to install Before beginning read this chapter thoroughly and take great care in planning a system A properly designed system can help prevent problems such as electrical noise disturbances and dangerous extreme conditions 1 For improved electrical noise immunity install the DPC 535 as far away as possible from motors relays and other similar noise generators Do not run low power sensor input lines in the same bundle as AC power lines Grouping these lines in the same bundle can create electrical noise interference All wiring and fusing should conform to the National Electric Code and to any locally applicable codes Collar Screws 1 of 4 CAUTION The enclosure into which the DPC 535 Controller is mounted must be grounded according to CSA standard C22 2 No 0 4 WARNING Avoid electrical shock Do not connect AC power wiring at the source distribution panel until all wiring connections are complete 77 WARNING ELECTRIC SHOCK HAZARD Terminals 1 and 2 carry live bower DO NOT touch these terminals when power is on WARNING Terminal 9 must be grounded
104. ly through communication D OFF Completely deactivates the output 5 OUTPUT 3 OUTPUT 3 OFF Defines the function of the third output ALM RLY ON ALM RLY OFF e RETRANS Retransmission e COMM ONLY Output addressable only through communications D OFF Completely deactivates the output Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Eas ose a _ mw La CW DPC 535 User s Manual 6 OUTPUT 4 Defines the function of the fourth output e ALM RLY ON e ALM RLY OFF e RETRANS Retransmission COMM ONLY Output addressable only through communications D OFF Completely deactivates the output 7 ANLG 1 Defines the output signal for the first output D 4 20 mA e 0 20 mA 20 4 mA e 20 0 mA 8 RNG 2 Defines the output signal for the second output D 4 20 e 0 20 mA 4 20 4 mA 4 20 0 mA 9 ANLG RNG 3 Defines the output signal for the third output D 4 20 mA 4 0 20 mA 4 20 4 mA 20 0 mA 10 ANLG RNG 4 Defines the output signal for the fourth output D 4 20 mA 0 20 mA 20 AmA 20 0 mA 11 LOOP NAME A 9 character message associated with the loop The first character of the 3rd display will be flashing To enter message press W keys to scroll through character set Press FAST key to enter the selection and move to next digit Press MENU key to advance to the next parameter D LOOP ONE OUTPUT 4
105. m of the case Press firmly on the front face assembly until the chassis is all the way into the case 27 28 DPC 535 Users Manual If it is difficult to slide the chassis in all the way make sure the screws have been removed they can block proper alignment and that the chassis is properly oriented 13 Carefully insert and align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten Fig 4 3 Representation of Module SPECIAL COMMUNICATIONS MODULE A special communications module is available for the DPC535 see order code in Chapter 1 for details Equipment needed Wrist grounding strap Phillips screwdriver 2 Small flat blade screwdriver 1 Before installing the communications module set up the hardware wiring for the application See Chapter 4 for details 2 With power off loosen two front screws and remove them Insert module onto connectors 000000 Front of controller 4 do circuits boards still attached to front face LAMP Fig 4 4 Install Communications Module onto Microcontroller Board DPC 535 User s Manual 3 Side the chassis out of the case by pulling firmly on the bezel Do not detach the board assembly form the front face of the controller 4 Orient the Communications Module as shown and attach it to Connectors P1 and P2 as shown in Figure 4 4 5 To reassemble the controller properly orient the chassis with
106. ments alarm global The single physical output to which one or more internal software alarms are tied alarm high process variable A type of alarm that is set up to occur when the process variable goes above the alarm setpoint alarm low process variable A type of alarm that is set up to occur when the process variable goes below the alarm setpoint alarm manual A type of alarm set up to occur when the controller is put into manual mode of operation alarm power up A type of alarm that determines alarm condition on power up of the controller alarm rate of change A type of alarm set up to occur when there is an excessive change in the process variable PV value baud rate Any of the standard transmission rates for sending or receiving binary coded data bezel The flat portion surrounding the face of the controller which holds the keys and display bump A sudden increase in the output power initiated by the controller in order to determine the system response during a self tune procedure binary coded decimal BCD A notation in which the individual decimal digits are represented by a group of binary bits e g in the 8 4 2 1 coded decimal notation each decimal digit is represented by four binary bits calibration The act of adjustment or verification of the controller unit by comparison of the unit s reading and standards of known accuracy and stability cascade control Control in which th
107. n to respond to an output change used by POWERBACK algorithm 0 1 seconds to 7200 0 seconds D 0 1 seconds SPECIAL AUTO TRIP Defines the condition under which the DPC535 will automatically trip to automatic control from manual control upon start up D OFF Deactivates this function e RISING Will trip when a rising process variable is within the specified deviation from the setpoint e FALLNG PV Will trip when a falling process variable is within the specified deviation from the setpoint 2 TRIP DEV Defines the deviation from setpoint at which the controller will trip to automatic For AUTO TRIP RISING PV For AUTO TRIP FALLING PV R 99999 to 0 R 0 to 99999 DO 3 DES OUTPT If a digital input is defined to trip the controller to manual mode this designates the output value after the trip LAST OUT means that the output value will be equal to the last output value while in automatic Choose values based on the process Standard Control On Off Control Velocity Prop Control 5 105 ON D LAST OUT D OFF e CCW D OUTS OFF 4 POWER UP Defines the control mode upon power up D LAST MODE Will power up in the same mode prior to power down e PRETUNE Will Pretune on every power up Recommended for TYPE pretune only e MANUAL e AUTOMATIC DPC 535 User s Manual 5 PWR UP OUT Defines the output of the controller if powering up in manual mode LAST OUT means tha
108. ntinues to use setpoint that was active prior to losing communications e DESIG SP Goes to a designated setpoint value if communications is lost 8 DESIG SP Defines the value of the designated setpoint if communications is lost Any value in the process variable range D Dependent on the process variable range DPC 535 User s Manual PARAMETER VALUE CHARTS This section of value charts is provided for logging in the actual parameter values and selections for the process It is recommended that these pages be photocopied so there will always be a master CONFIG Parameter Description Values 1 CTRL TYPE Defines fundamental controller Set Up 2 LINEFREQ Defines the power source frequency 3 PVSOURCE Defines how PV input is derived from PV1 and PV2 4 OUTPUT2 Function of the second output 5 OUTPUT3 Function of the third output 6 OUTPUT4 Function of the fourth output 7 ANLG RNG 1 Output signal for the first output 8 ANLG RNG 2 Output signal for the second output 9 ANLG RNG 3 Output signal for the third output 10 ANLG RNG 4 Output signal for the fourth output 11 LOOP NAME Nine character message associated with control loop DPC 535 User s Manual ueds in sayede n NYdS 135 ueds jo pue 0832 195 l uomneJqueo 5 09 96 1724 JeonpsueJi
109. o 40mA Loop power supply module Current is limited to 25 mA 24V nominally loading Strain Gage Excitation 101 2 into min 175 ohms CONTROL OUTPUTS Up to two output modules may be designated for control Any combination of output modules 2 with the exception of the loop power supply module may be used Duplex control is available if output modules are installed in the first and second output sockets 14 DPC 535 User s Manual Staged split range outputs are available if analog modules are installed in the first and second output sockets This algorithm will allow the output range to be split between the two outputs RETRANSMISSION OUTPUT Based on available outputs any socket not used for control up to two different variables can be simultaneously programmed for retransmission Each precise 6 bit resolution output may be scaled for any range Variable selection includes PV SP RAMP SP and OUTPUT ALARMS The DPC 535 controller has two software alarms High and low alarms may be sourced to the PV SP RAMP SP DEVIATION and OUTPUT If an alarm is tripped the alarm message will show the ACK key will illuminate if acknowledgeable and the ALM icon will light If the alarm is tied to the first available non control output the 1 below the ALM icon will light Similarly if the alarm is tied to the second non control output the 2 below the ALM will light The availability of outputs determines how
110. ole The mounting hole outline drawing for standard 1 2 20 UNF threaded versions is given below Careful attention should be paid to correctly machining the mounting hole A set of mounting hole machining tools Dynisco Part 200925 is included with all the necessary pese drills taps and reamers only in Starter Dynipak When machining to 515 Bas MN i MH the hole pay careful attention to 5 the concentricity between the threads and the 312 314 diame ter Since the pressure seal is on the 45 seating surface this sur face should be examined for good f SNOUT LENGTH 200 MAX e 508 finish free from burrs etc 2 Transducer Installation To prevent galling the transducer threads should be lubricated with the high temperature anti seize compound included In a properly machined mounting hole an adequate seal should be obtained with 100 inch pounds of mounting torque The maximum recommended installation torque is 500 inch pounds When reinstalling the transducer the hole must be free of frozen plastic It is recommended that the barrel manifold be at operating temper ature A mounting hole cleaning tool kit is available Dynisco Part st 200100 to aid in removing material from 312 diameter 45 seat and the threads A gauge plug to check the hole is included with this kit 3 Wiring These transducers are connected to external signal condi
111. on proportioning algorithm Choose values based on the process Feedback option installed Feedback option not installed D SLIDEWIRE SLIDEWIRE e VELOCITY D VELOCITY ALARMS 1 ALM TYPE I Defines the type of alarm for alarm 1 HIGH ALRM e LOW ALARM e HIGH LOW Separate High amp Low alarm setpoints one alarm e BAND e DEVIATION MANUAL Causes an alarm when in manual control RATE Selects a rate of change alarm D OFF Deactivates the first alarm 2 ALM SRC I Selects the source of the value being monitored by HIGH LOW or HIGH LOW alarm 1 D PV SP RAMP SP e DEVIATION e OUTPUT PV2 3 ALARM SP I Specifies the alarm set point for alarm 1 except HIGH LOW For HIGH or LOW alarms If ALM SRC 1 OUTPUT If ALM SRC any other type R 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 DO For BAND alarms 99999 0 For DEVIATION or RATE alarms R 9999 to 99999 D O0 P P TYPE ALARMS ALM TYPE 1 ALM SRC 1 ALARM SP 1 43 HIGH SP 1 LOW SP 1 DEADBAND 1 ALM 1 OUT LATCHING 1 44 DPC 535 User s Manual 4A HIGH SP I Specifies the high alarm set point for alarm 1 of type HIGH LOW lf ALM SRC 1 OUTPUT IfALM SRC I any other type R 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 DO 4B LOW Specifies the low alarm set point for alarm 1 of type HIGH LOW If ALM SRC 1 OUTPUT If ALM SRC
112. output 2 2 LOWRANGE2 Low end of range in eng units for retransmission output 2 3 HI RANGE2 High end of range in eng units for retransmission output 2 4 TYPE3 Whatis to be retransmitted for retransmission output 3 5 LOW RANGE3 Low end of range in eng units for retransmission output 3 6 HI RANGE 3 High end of range in engl units for retransmission output 3 7 Whatis to be retransmitted for retransmission output 4 8 LOW RANGE 4 Low end of range in eng units for retransmission output 4 9 HIRANGE 4 High end of range in eng units for retransmission output 4 DPC 535 User s Manual Ld LAS 10 ndu Aq 10 5 5100495 jog 4530 0 4 dn samod uodn julodjas dS dN Md 9 101 u09 ui dn s 1 94110110110 S dn samod uodn 0007 7 uo 83 ojne oj dui YOIYM 1urodjes c 015011 19 0 02 MOH 2590 1139345 Pem 0 J3NILOV3O eun pasn aq 0 asuodsay J3WIL dS3H 01 Aq pasn eq pueg esioN NS3SIO
113. ple burnout is selectable for upscale or downscale INPUT FILTER Single pole lowpass digital filter with selectable time constant from 0 to 120 seconds CALIBRATION Comes fully calibrated from the factory and continuously calibrates itself for component aging due to temperature and time except for the reference voltage Field calibration can be easily performed in the field with a precision multimeter and thermocouple simulator Process variable offset and gain factors are provided to correct for sensor errors OUTPUT MODULES The controller can have a total of four control outputs alarm outputs and or loop power modules installed There are five types of output modules which can be configured to suit your particular application The modules may be ordered factory installed or they may be installed in the field Analog module Either 0 20 mA or 4 20 mA front panel selectable into a load up to 10000 Accuracy 5pA 25 C Mechanical relay module SPDT electromechanical relay Resistive load rated at 5 amps at 120 240 VAC Normally open or normally closed selection is made by jumper Output 4 is rated at 0 5 amps at 24 VAC and is always normally open Solid state relay triac module Resistive load rated at amp at 120 240 VAC Output 4 is rated at 0 5 amps at 24 VAC These outputs are normally open DC logic SSR drive module ON voltage is 17 Vdc nominal OFF voltage is less than 0 5 Vdc Current limited t
114. point the active PID set values will change with the local setpoint Each PID set has 5 parameters that control its function proportional band reset rate manual reset or loadline and trip point For each set 2 thru 8 these values have to be manually set 1 Press MENU to access the TUNING menu 2 Set values for parameters 1 thru 20 these include the first PID set 3 Press MENU to access these parameters for each additional PID set 2 through 8 PROP BND RESET RATE MAN RST and TRIP 95 DPC 535 User s Manual Self Tune with Time Proportioning Outputs When using either the Pretune or the Adaptive Tune with a time proportioning output use as short of a cycle time as possible within the constraint of maintaining a reasonable life on relays contacts or heating elements Self Tune with Control Valves In many systems utilizing a control valve the point at which the control valve begins to stroke does not coincide with 096 output and the point at which it completes its stroke doesn t coincide with 10096 The parameters LOW OUT and HIGH OUT in the CONTROL menu specify the limits on the output Set these limits to correspond with the starting and stopping point of the valve s stroke This prevents a form of windup and thus provides the adaptive control algorithm with the most accurate information For example in manual the control output was slowly increased and it was noted that the control valve started
115. proper wiring Correct wiring Blown in line fuse Check wiring replace fuse Unit not inserted in case properly or screws have not been tightened Remove unit from case and remove bezel Screws then reinsert unit and properly tighten screws Improper Lost PV reading Voltage current Input jumper selection improperly set Move jumper to proper location Input range improperly selected in software Select proper range Reverse polarity Check and correct sensor wiring If controller powered improperly wired Check and correct wiring Loop power module not installed Install module Defective transmitter Replace transmitter Improper Lost PV reading Thermocouple Transmitter signal out of range Defective thermocouple Select proper range in software Replace thermocouple Input jumper selection improperly set Select Proper input Wrong TC type selected in software Select proper thermocouple type in Improper Lost PV reading RTD software Improper wiring Wire properly Defective RTD Replace RTD Input jumper selection improperly set Move jumper connector to proper location Improper wiring Wire properly No control output Output wiring and module location do not match Check and correct wiring or module location If SSR SSR Drive of Milliamp output jumpers J1 J2 and J3 are not set properly Set jumper connector to proper location
116. r Figure 7 12 illustrates the operation of Pretune TYPE 1 with Adaptive Tune Pretune TYPE 2 or 3 amp Adaptive Tune 1 2 Go to the SELF TUNE menu Set the TYPE parameter to BOTH Set the PRETUNE parameter to TYPE 2 or TYPE 3 DO NOT Enter values for NOISE BND and RESP TIME The Pretune algorithm will calculate these values Make sure that the process is reasonably stable and place the controller under manual control Press MENU to access the TUNING menu Set parameter ADAPTIVE to ENABLED The Adaptive Tuning cycle does not begin the controller is under automatic control Activate the next parameter PRETUNE Press ACK to begin Pretuning The 3rd display will Show the message EXECUTING When Pretune is complete the 3rd display will show COMPLETED for two seconds and then return to the current menu display DPC 535 User s Manual The controller will automatically transfer to automatic control upon completion of Pretune if set to do so or upon manual transfer Figure 7 12 illustrates the operation of Pretunes TYPE 2 and TYPE 3 with Adaptive Tune Adaptive Tune by Itself 1 Goto the SELF TUNE menu 2 Setthe TYPE parameter to ADAPTIVE 3 Press MENU to access the TUNING menu 4 Setthe ADAPTIVE parameter to ENABLED The Adaptive Tuning cycle does not begin the controller is under automatic control If Pretune results are poor or process conditions do not allow Pretune to run the Adaptive Tune parameters
117. r connector should be placed in the TC A position thermocouple downscale burnout V Jumper position that determines whether when a thermocouple fails its output is replaced be a millivoltage which will match the thermocouple s minimum value The jumper connector should be placed in the TC position three mode control See control action PID time proportioning control A control algorithm that expresses output power 0 100 as a function of percent ON versus percent OFF within a preset cycle time time proportioning output A controller output assigned by software to facilitate time proportional control typically a relay SSR or SSR Drive output tracking A function that defines whether the local setpoint will track the remote setpoint When the controller is transferred to a local setpoint that local setpoint value will match the remote process value when the transfer occurs transmitter 2 wire A device used to transmit data via a two wire current loop A two wire transmitter is loop powered transmitter 4 wire A device used to transmit data via a current loop or a DC voltage A 4 wire transmitter uses 2 wires for data and 2 wires for power DPC 535 User s Manual triac Solid state switching device used to switch alternating current signals on and off Triac circuits are sometimes referred to as solid state relays SSR trip point Value which determines when that set of PID values becomes ac
118. r variable reaches a desired value setpoint target The end point of the ramp function set up Also called configuration selection of hardware devices and software routines that function together sheds In serial communications when the signal is lost slidewire position proportioning An output algorithm that utilizes a slidewire feedback signal to determine the actual position of the actuator being controller solid state relay see relay solid state SSR drive A D C on off signal output for controlling a solid state relay staged outputs The set up of two analog outputs where one analog output varies its signal over a portion of the PID output range and the second analog output then varies its signal over the remainder of the PID output range static discharge Undesirable current resulting from the discharge of electrostatic energy station address The unique identifier assigned to a device for communications thermocouple Temperature sensing device that is constructed of two dissimilar metals wherein a measurable predictable voltage is generated corresponding to temperature thermocouple break protection Fail safe operation that assures desired output upon an open thermocouple condition thermocouple upscale burnout Jumper position that determines whether when a thermocouple fails its output is replaced by a millivoltage which will match the thermocouple s maximum value The jumpe
119. redundancy checking feature If the host supports it activating this option is recommended 5 When the DPC535 senses that communications is lost it can go to a predetermined state called shedding The SHED TIME parameter sets the length of time that communications can be interrupted before the controller sheds Since the DPC535 is a stand alone controller it does not depend on communications to operate Therefore if the shed feature is not needed set it to OFF 6 SHED MODE designates the mode to which the controller goes after it shes Setting this to MANUAL brings up the following parameters 7 Use SHED OUT to specify an output level if the unit sheds and trips to manual control 8 To specify a control setpoint in case the host is supervising the setpoint if the DPC 535 sheds Set SHED SP to DESIG SP and then set the parameter DESIG SP to the desired setpoint 105 DPC 535 User s Manual APPENDIX MENU FLOWCHARTS SET UP OUTPUT 4 ANLG RNG 2 ANLG RNG 1 ANLG RNG 3 ANLG RNG 4 LOOP NAME PV1 INPUT PV1 TYPE DEG F C K DECIMAL LINEARIZE LOW RANGE HIRANGE SPLOLIM SPHILIM SP RAMP FILTER OFFSET RESTORE PV2 INPUT PV2 SETUP PV2 TYPE DECIMAL LINEARIZE Low RANGE H HIRANGE CUST LINR 1ST INPUT 1ST PV XTH INPUT XTH PV 15TH INPUT 15TH PV CONTROL ALGORITHM source H action 1 PV BREAK LOW OUT HIGH OUT ACTION 2 P P TYPE CCW TIME CW TIME MIN TIME S W
120. rget setpoint e RAMPSP Thisis the ramping or actual setpoint when the setpoint is ramping e CTRL OUT This is the control output value HI RANGE 2 TYPE 3 U LO RANGE 3 HI RANGE 3 TYPE 4 79 49 LO RANGE 4 HI RANGE 4 SELF TUNE TYPE DISABLED 1 TUNE OUT STEP 50 DPC 535 User s Manual 8 LOW RANGE 4 Defines the low end of the range for output 4 in engineering units Does not appear for type CTRL OUT 9999 to 99999 D Dependent on the process variable range 9 HI RANGE 4 Defines the high end of the range for output 4 in engineering units Does not appear for type CTRL OUT 9999 to 99999 D Dependent on the process variable range SELF TUNE l TYPE Defines the type of self tuning algorithm that is available e PRETUNE Allows the operator to initiate Pretune only e ADAPTIVE Allows the operator to initiate Adaptive Tune only BOTH Allows the operator to initiate both Pretune and Adaptive Tune D DISABLED Both Pretune and Adaptive Tune are disabled 2 PRETUNE Defines the type of pretune algorithm that is available D TYPEI Normally used with slower thermal processes TYPE2 Normally used with faster fluid or pressure processes e Normally used with level control applications 3 Defines the PV value at which the output will switch off during TY
121. ring unit value for the 8th point 19 9th INPUT Input signal for the 9th point of the 15 point curve 20 9thPV Engineering unit value for the 9th point 21 10th INPUT Input signal for the 10th point of the 15 point curve 22 10th PV Engineering unit value for the 10th point 23 11th INPUT Input signal for the 11th point of the 15 point curve 24 11th PV Engineering unit value for the 11th point 25 12th INPUT Input signal for the 12th point of the 15 point curve 26 12thPV Engineering unit value for the 12th point 27 13th INPUT Input signal for the 13th point of the 15 point curve 28 13th PV Engineering unit value for the 13th point 29 14th INPUT Input signal for the 14th point of the 15 point curve 30 14th PV Engineering unit value for the 14th point 31 15th INPUT Input signal for the15th point of the 15 point curve 32 15th PV Engineering unit value for the 15th point DPC 535 User s Manual CONTROL Parameter Description Value 1 ALGORITHM Control algorithm used 2 D SOURCE Variable used to determine the derivative value 3 ACTION 1 Action of the first control output 4 PVBREAK Output level if the process variable input is lost 5 LOWOUT Lowest output value that can be achieved in automatic control 6 HIGHOUT Highest output value that can be achieved in automatic control 7 2 Action of the second control output DPC 535 User s Manual
122. rtional plus integral plus derivative control In addition to proportional control it compensates for changes in setpoint load requirements and process variations e PID ON OFF Only available with Duplex control First output uses the PID algorithm while second output uses on off control 3 For algorithms using the derivative function D choose the conditions for the derivative term Scroll to parameter D SOURCE e For derivative action based on error or deviation from setpoint choose DEVIATION e For derivative action based on process variable changes choose PV B ALARMS The DPC 535 controller has two extremely flexible and powerful software alarms The number of available outputs limits how alarms are linked to relays A Global Alarm feature allows all alarms to be assigned to the same relay The DPC 535 indicates an alarm condition by Lighting up the alarm icon s Displaying a custom message in the 3rd display Illuminating the ACK key if the alarm is acknowledgeable Software Configuration 1 Access the ALARM menu 2 Set values for the following parameters All possible values are shown ALM TYPE I and ALM TYPE 2 Specifies the type of alarm to implement Selection includes e HIGH ALARM High process variable alarm Occurs when the process variable exceeds the alarm setpoint DPC 535 User s Manual e LOW ALARM Low process variable alarm Occurs when the process variable goes below the
123. s ACK once to acknowledge Alarm 1 then again to acknowledge Alarm 2 4 The message and alarm icon dissappear Latching Alarms If an alarm is set up to be latching for details see Chapter 5 then in general it must be acknowledged in order to clear the alarm and release the relay if applicable A non latching alarm will clear itself as soon as the process leaves the alarm condition NOTE All alarms are software alarms unless tied to an output relay in the SET UP mode See Chapters 5 and 7 for details on alarms NOTE Powering down the DPC 535 acknowledges clears all latched alarms When powering up all alarms will be reinitialized 9 95 76 DPC 535 User s Manual Limit Sequence An alarm can be configured to be both latching and non acknowledgeable In this case the alarm is acknowledgeable only after the process has left the alarm condition This is similar to the function of a limit controller More on Alarms For more details on how to set up alarms and for examples of various ways alarms can be set up refer to the section on Alarms in Chapter 7 3 INSTALLATION MOUNTING THE CONTROLLER The DPC 535 front face is NEMA 4X rated waterproof To obtain a waterproof seal between the controller and the panel follow these directions 1 The DPC 535 fits in a standard 1 4 DIN cutout Mount the DPC 535 in any panel with a thickness from 06 in to 275 in 1 5 mm to 7 0 mm PA
124. s if communications is lost 8 DESIG SP Value of the setpoint if controller sheds For more information about Pretune and Adaptive Tune refer to section on Tuning applications in Chapter 7 66 DPC 535 User s Manual 6 TUNING OVERVIEW The self tune function of the DPC 535 consists of two distinct components Pretune and Adaptive Tune In addition you may choose from three type of Pretune TYPE for slow thermal processes TYPE 2 for fast fluid or pressure processes TYPE 3 for level control applications You choose the type of Pretune in the SELF TUNE menu The Pretune and Adaptive Tune components may be used separately or together On the following pages is the step by step guide to the TUNING menu paramters OPERATION s Either Manual for TUNING mode Automatic Control TUNING DISPLAY or SET PT DISPLAY FAST _ OPERATION mode or SET PT for SET FAST to return to UP mode for SET OPERATION UP mode mode SET UP SELF TUNE Fig 6 1 Access the Tuning Menu Block DPC 535 User s Manual TUNING ADAPTIVE Activates the self tune algorithm upon transfer to automatic control D DISABLED ENABLED 2 PRETUNE Activates the pretune algorithm if unit is under manual control To initiate the Pretune cycle press the or W Confirm by pressing ACK within two seconds D NO 3 POWR BACK Reduces setpoint overshoot at
125. s in a block in serial form by a predetermined binary number CSA Acronym for Canadian Standards Association cycle time The time necessary to complete a full ON through OFF period in a time proportioning control system damping The decrease in amplitude of an oscillation due to the dissipation of energy damped 1 4 amplitude The loss of one quarter of the amount of amplitude with every oscillation dead band A temperature band between heating and cooling functions the range through which an input can be varied without initiating observable change in output dead time The interval of time between initiation of an input change or stimulus and the start of the resulting observable response default settings Parameters selections that have been made at the factory derivative Anticipatory action that senses the rate of change of temperature and compensates to minimize overshoot and undershoot Also rate derivative action See control action derivative deviation The difference between the value of the controlled variable and the value at which it is being controlled digital input Used in this manual to indicate the status of a dry contact also called gate DIN Deutsche Industrial Norms a German agency that sets standard for engineering units and dimensions display 1st The top largest display of controller face that is used to display the process variable value DPC 535
126. selectable from the front panel Duplex outputs each use the same algorithm except On Off may be used with PID The PID algorithm used is non interacting Tuning Parameters Proportional Band 0 1 to 999 of input range Integral to 9999 seconds repeat Derivative 0 to 600 seconds Manual Reset Load Line 0 to 100 output Cycle Time 0 3 to 120 seconds On Off Deadband up to 15 of input range eng units Up to eight sets of PID values may be stored in memory and selected automatically based on setpoint value process variable value or the corresponding local setpoint 5 1 5 8 DPC 535 User s Manual SELF TUNING OF PID VALUES POWERTUNE On demand This is an open loop algorithm that may be used on its own to calculate PID variables or it can be used to provide preliminary PID values as well as process identification information to be used by the adaptive tune Three pretune types are available TYPE for slow thermal processes TYPE 2 for fast fluid or pressure applications and TYPE 3 for level control applications Adaptive tune Our exclusive POWERTUNE adaptive tuning algorithm automatically adjusts the PID values whenever a process upset occurs Preliminary information may be input manually or automatically calculated by our pretune algorithm OVERSHOOT PROTECTION POWERBACK is Dynisco s proprietary user invoked setpoint overshoot protection algorithm When invoked POWERBACK reduces or
127. t the output value will be equal to the last output value while in automatic Choose values based on the process Standard Control On Off Control Velocity Prop Control e 5 to 105 ON CW D LAST OUT D OFF CCW D OUTS OFF 6 PWR UP SP Defines the setpoint upon power up D LAST SP Powers up with the same setpoint local or remote that was active prior to power down e LOCAL Powers up using primary local setpoint e REMOTE Powers up using remote setpoint if available 7 NO OF SP Defines the number of local setpoints up to 8 to be stored for selection by BCD binary coded decimal digital inputs or front SET PT key I through 8 D I SECURITY For configuring the security function SEC CODE Defines the security code temporarily unlocking the instrument R 9999 to 99999 D 0 2 SP ADJUST Defines lockout status setpoint changes D UNLOCKED e LOCKED PWR UP OUT PWR UP SP LAST SP SECURITY 75 SP ADJUST UNLOCKED AUTO MAN UNLOCKED SP SELECT UNLOCKED ALARM ACK UNLOCKED TUNING UNLOCKED CONFIGURE UNLOCKED SER COMM 54 DPC 535 User s Manual 3 AUTO MAN Defines lockout status of the MANUAL key D UNLOCKED e LOCKED 4 SP SELECT Defines lockout status of the SET PT key D UNLOCKED LOCKED 5 ALARM ACK Defines lockout status of the ACK key D UNLOCKED LO
128. t the specified rate 2 Onatransfer from manual to automatic control the setpoint will ramp from the process variable value to the setpoint value at the specified rate 3 On any setpoint change the setpoint will ramp from the current setpoint to the new target setpoint When triggered the display will automatically change to indicate the ramping setpoint Software Configuration 1 Goto the PV INPUT menu 2 Setthe SP RAMP parameter to the desired rate of change K INPUT LINEARIZATION Thermocouple and RTD Linearization For a thermocouple or RTD input the incoming signal is automatically linearized The DPC535 has lookup tables that it uses to provide an accurate reading of the temperature being sensed Square Root Linearization Many flow transmitters generate a nonlinear signal corresponding to the flow being measured To linearize this signal for use by the DPC 535 the square root of the signal must be calculated The DPC 535 has the capability to perform this square root linearization For the first 196 of the input span the input is treated in a linear 99 00 DPC 535 User s Manual PV Low Range Hi Range Low Range J V m V iw m V1 Hi Range is the high end of the process variable Low Range is the low end of the process variable the actual voltage or current value of the input input is the high end of the input signal range e g 5 volts or 20 mA high is the low
129. tal error and requires and EPROM change Call factory for assistance Enter calibration menu and recalibrate the controller Call factory for assistance This is a fatal error and requires an EPROM or EEPROM change Call factory for assistance Install the 535 chassis into the actual case with which it was shipped then run calibration again If further problems call factory for assistance 109 10 APPENDIX 3 SPECIFICATIONS Accuracy LINEAR Voltage Current 0 050 of full scale 0 150 of full scale RID 0 050 of span 0 150 of span 0 1 0 095 of span 0 225 of span THERMOCOUPLE J K N E gt 090 0 060 of span 0 150 of span J K N E lt 090 0 150 of span 0 375 of span T 090 0 100 of span 0 250 of span T lt 0 C 0 250 of span 0 625 of span R 5 gt 500 C 0 150 of span 0 375 of span R lt 500 C 0 375 of span 0 925 of span B gt 500 C 0 150 of span 0 375 of span B lt 500 C 0 500 of span 1 000 of span W W5 amp Platinel II 0 125 of span 0 325 of span Typical 0 025 of full scale DPC 535 User s Manual Maximum 0 100 of full scale Display accuracy is digit These accuracy specifications are at reference conditions 25 C and only apply for NIST ranges Detailed accuracy information is available upon request CONTROL ALGORITHM PID with manual reset Pl PD with manual reset and On Off are
130. ten DPC 535 User s Manual ADDING AND CHANGING OUTPUT MODULES The DPC 535 has provisions for four output modules A controller ordered with output module options already has the modules properly installed Follow these instruction to add modules change module type s or change module location s Equipment needed Wrist grounding strap Phillips screwdriver 3 2 Small flat blade screwdriver Wire cutters 1 With power off loosen four front screws and remove them 2 Side the chassis out of the case by pulling firmly on the bezel 3 Use a flat screwdriver to carefully pry apart the clips that hold the front face assembly to the chassis as in Photo 3 Separate the printed circuit board assembly from the front face assembly Use care not to break the clips or scratch the circuit boards 4 Asshown in Photo 4 carefully pry apart using hands or a small flat screwdriver the smaller Option board and the Power Supply board the one with 3 modules 5 To change modules 2 or 3 Output modules 1 2 and 3 are firmly held in place by a retention plate and tie wrap Carefully snip the tie wrap with a wire cutter To prevent damage to the surface mount components AL WAYS snip the tie wrap on TOP of the Retention Plate as shown in Photo 5 Remove the retention plate 3 Pry Clips 4 Separate Boards 5 Remove Retention Plate 26 DPC 535 User s Manual 10 11 12 To change module 4 Output Module 4 on t
131. the process variable signal where it trips to manual control at a predetermined output RATE TIME For RATE alarms defines the time period over which a discrete change in process variable must occur for the rate alarm to be activated The amount of change is defined by the alarm setpoint The rate of change is defined as the amount of change divided by the time period Example A If the alarm setpoint is set to 10 and the time base is set to 1 second the rate of change is 10 units per second B If the alarm setpoint is set to 100 and the time base set to 10 the rate of change is also 10 units per second In example A the process variable would only have to experience a ten unit change over a short period of time while in Example B it would require a 100 unit change over a ten second period Example A is much more sensitive than Example B In general for a given rate of change the shorter the time period the more sensitive the rate alarm BAND ALARM HIGH PROCESS VARIABLE ALARM ALARM IN ALARMJ IN ALARM CONDITION CONDITION CONDITION C SP A SP C SP ASP TIME RELAY RELAY RELAY DE ENERGIZED ENERGIZED DE ENERGIZED RELAY RELAY RELAY RELAY ENERGIZED DE ENERGIZED ENERGIZED DE ENERGIZED ICON OFF ICON ON ICON OFF ICON OFF ICON ON Icon oFF ICON ON NO ALARM MAY NO ALARM ACKNOWLEDGE NO ALARM CANNOT NOALARM CANNOT ACKNOWLEDGE A
132. thod by which the 535 controller initiates an output value change monitors the manner of the corresponding process variable change and then determines the appropriate PID control parameters primary loop The outer loop in a cascade system process variable In the treatment of material any characteristic or measurable attribute whose value changes with changes in prevailing conditions Common variables are level pressure and temperature proportional band The change in input required to produce a full range change in output due to proportional control action ramping see setpoint ramping DPC 535 User s Manual rate Anticipatory action that senses the rate of change of temperature and compensates to minimize overshoot Also derivative rate action The derivative function of a controller rate time The time interval over which the system temperature is sampled for the derivative function regulate The act of maintaining a controlled variable at or near its setpoint in the face of load disturbances relay mechanical An electromechanical device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other relay solid state A solid state switching device which completes or interrupts a circuit electrically with no moving parts reset Control action that automatically eliminates offset or droop between setpoint and actual process temperatur
133. ting outputs Duplex with a gap between outputs A reverse acting output 1 and a direct acting output 2 react with a positive offset for output 1 and a negative offset for output 2 assume no restrictive output limits and a neutral relative gain with PID control On the graph a positive offset refers to an offset to the left of 50 a 63 negative offset is to the right of 50 84 DPC 535 User s Manual PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT Out 1 Out 2 PID OFST 1 VALUE Heat Cool PID OFST 2 VALUE 100 LOW OUT 0 100 HIGH OUT 100 REL GAIN 1 0 Out 1 Out 2 0 1 L 0 100 1 750 7 0 PID OUTPUT Fig 7 5 Duplex with a gap between outputs Duplex with a overlapping outputs and output limits A reverse acting output 1 and a direct acting output 2 with a negative offset for output 1 a positive offset for output 2 and restrictive high and low output limits with PID control This combination of offsets results in an overlap where both outputs are active simultaneously when the PID output is around 5096 The output limits are applied directly to the PID output This in turn limits the actual output values In this example the high output maximum limits the maximum value for output 1 while the low output minimum limits the maximum value for output 2 The value the actual outputs are limited to depends on offset settings control action and relative gain s
134. tioning readout instrumentation with a six wire shielded cable assembly Dynisco six wire shielded cable assembly is recommended the cable should not be run in the same conduit as the AC power cables The cable shield should be grounded at one end only Highest shunt calibration accuracy R CAL is obtained with recommended six wire cable and the transducer internal calibration resistor a Useoffou wire bn nnn nen systems with remote external calibration is not recommended 3 For more detailed information see the manual shipped with the transducer P N 974097 Rev 10 00 23134 DYNISCO INSTRUMENTS 38 Forge Parkway Franklin MA 02038 Tel 508 541 9400 Fax 508 541 9436
135. tive velocity position proportioning This is a control technique where valve position is determined by calculating the amount of time it takes to open close a valve by moving the valve for a portion of that time windup Saturation of the integral mode of a controller developing during times when control cannot be achieved which causes the controlled variable to overshoot its setpoint when the obstacle to control is removed wild stream In mixing applications that require materials to be mixed to a desired ratio this is the one part of the material that is uncontrolled NOTES WARRANTY AND SERVICE This equipment is sold subject to the mutual agreement that it is warranted to be free from defects of material and construction but our liability in connection with it shall be limited to repairing or replacing without charge at our factory any material or construction defects which become apparent within one year from the date on which the equipment is shipped that we have no liability for damages of any kind arising from the installation and or use of this equipment by anyone and that the purchaser by the acceptance of this equipment will assume all liability for any damages which may result from its misuse by the purchaser his or its employees or by others There is no guarantee or warranty or liability except as here stated Should the equipment require service or repair please return it along with a brief description
136. two ON OFF 86 Figure 7 10 Staged Outputs Example er ttes 86 Figure 7 11 Pretune TYPE 1 2 and 3 with Adaptive Tune 92 Figure 7 12 Noise Band Calculation Example 95 Figure 7 13 Noise Band Values for Temperature Inputs 96 Figure 7 14 Deadtime and Time 96 Figure 7 15 Square Root Linearization Formula 100 Figure 7 16 15 point Linearization 100 Figure 7 17 Load Line Example vdd fe dett treten 101 DPC 535 User s Manual 1 INTRODUCTION From its surge resistant power supply to its rugged construction the DPC 535 process controller is designed to ensure the integrity of your process with maximum reliability hour after hour day after day The isolated inputs and outputs guard against the dangers of electrical interference the front face meets NEMA 4X standards for watertight operation and exposure to corrosive environments and the solid metal housing and sturdy rubber keys enhance durability and ESD protection The DPC 535 has been engineered to be the industry s most user friendly process controller With three digital display areas two offering up to 9 characters of true alphanumerics the DPC 535 effectively eliminates the cryptic messages th
137. ue press or V To change from auto to manual control bumpless transfer 1 When in automatic control press the MANUAL key at any time except while in the TUNING mode 2 The MANUAL key will light in red and the 2nd display will immediately change to indicate current output level To change from manual to auto 1 When in manual control press MANUAL at any time except while in the TUNING or SET UP mode 2 The 2nd display will not change and the MANUAL key will no longer be lit once control changes To change manual output values 1 Make sure the controller is under manual control 2 Usethe DISPLAY key to toggle 2nd display to output level 3 Use the A or key to change the value To override security If a locked operation is attmpted SECURITY appears in the 2nd display for two seconds DPC 535 User s Manual 1 Use the A and keys to quickly enter the security code which will show in the 3rd display The starting value is O Note Two seconds of key inactivity will clear the display 2 If the code is correct CORRECT appears in the 3rd display The display will clear after two seconds allowing full access 4 f code is incorrect INCORRECT appears in the 3rd display INCORRECT will disappear after two seconds and a new security code can then be entered 5 The controller will revert back to full security lock after one minute of key inactivity To display control output value 1 Toggle DIS
138. unctions Select values for each parameter depending on the specific application Use the MENU key to access parameters for a particular menu the parameter name will replace the menu name in the 2nd display and the parameter value will show in the 3rd display This chapter outlines all the available parameters for the DPC 535 Some parameters are independent of any special configuration and others are dependent on the individual configuration This manual displays these two types of parameters differently refer to Figure 5 2 A special feature of the DPC 535 called Smart Menus determines the correct parameters to display for the specific configuration so not all the listed parameters will appear TUNE PT CONTACT 1 AUTOMATIC MANUAL Fig 5 2 Independent vs Dependent Parameters MANUAL OPERATION TUNING mode TUNING DISPLAY FAST DISPLAY or or SET PT for SET UP SET Pifor FAST Renee mode OPERATION mode for SET UP OPERATION mode mode FAST to toggle through the 12 menu blocks in SET UP mode 27 Fig 5 3 Configuration Flowchart menu DPC 535 User s Manual CONFIGURATION AND OPERATION Figure 5 3 shows the relationships among the different modes of the 535and the configuration menus SET UP menus can only be accessed from manual control To transfer the DPC 535 from automatic to manual control press MANUAL To access the SET UP menus hold down FAST
139. values in the 2nd display for setpoint ramping setpoint deviation PV1 PV2 output and valve position each if available In Tuning or Set Up mode press to return controller to Operation mode display will show current setpoint Press to increase the value or selection of displayed parameter FAST A Press to scroll through values at a faster rate Press to decrease the value or selection of displayed parameter FAST V Press to scroll through values at a faster rate ACK Press to acknowledge an alarm s When lit indicates there is an acknowledgeable alarm MENU In Operation Mode press to access the Tuning Menu In Set Up or Tuning mode press to advance through a menu s parameters Use FAST MENU to advance to to the next menu When lit indicates the controller is in Set Up mode FAST MENU Press to access the Set Up menus DPC 535 User s Manual mer In Set Up mode press to advance through menus Use MENU by itself to access the parameters of a particular menu BASIC OPERATING PROCEDURES Use the following as a quick guide to key operating functions of the DPC 535 To select change a setpoint 1 Use DISPLAY key to toggle display to Set Point 2 Use SET PT key to toggle to active setpoint Before the newly selected setpoint is made active there is two second delay to prevent any disruptive bumps If the setpoint displayed is ramping RAMPING will show the 3rd display 3 To change val
140. with alarm 2 21 FAULT Alarm relay status if fault condition is detected 22 OUTPUT Output if the rate of change alarm is tripped 23 RATE TIME Time period over which a rate of change alarm is determined CUST DPC 535 User s Manual Parameter Description Value 1 1stINPUT Input signal for the 1st point of the 15 point curve 2 1stPV Engineering unit value for the 1st point 3 Xth INPUT Input signal for the Xth Point of the 15 point curve 4 XthPV Engineering unit value for the Xth point 5 2ndINPUT Input signal for the 2nd point of the 15 point curve 6 2ndPV Engineering unit value for the 2nd point 7 8rd INPUT Input signal for the 3rd point of the 15 point curve 8 3rd PV Engineering unit value for the 3rd point 9 4th INPUT Input signal for the 4th point of the 15 point curve 10 4thPV Engineering unit value for the 4th point 11 5th INPUT Input signal for the 5th point of the 15 point curve 12 bthPV Engineering unit value for the 5th point 13 6th INPUT Input signal for the 6th point of the 15 point curve 14 6thPV Engineering unit value for the 6th point 15 7th INPUT Input signal for the 7th point of the 15 point curve 16 7thPV Engineering unit value for the 7th point 17 8th INPUT Input signal for the 8th point of the 15 point curve 18 8thPV Enginee

notes - Sensors Incorporated

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