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INSTRUCTION MANUAL

FOR

PROGRAMMABLE CONTROLLER

PCD-33A

Summary of Contents for PCD-33A

Page 1: ...INSTRUCTION MANUAL FOR PROGRAMMABLE CONTROLLER PCD 33A ...

Page 2: ...has been taken to assure that the contents of this instruction manual are correct but if there are any doubts mistakes or questions please inform us through the shop where you purchased the unit Any unauthorized transfer or copying of this document in part or in whole is prohibited Shinko Technos CO LTD is not responsible for any damages or secondary damages incurred as a result of using this prod...

Page 3: ... side of the terminal and fastened with the terminal screw M3 Tighten the terminal screw M3 within the specified torque If excessive force is applied to the screw when tightening the screw M3 or case may be damaged Do not apply a commercial power source to the sensor which is connected to the input terminal nor allow the power source to come into contact with the sensor as the input circuit may be...

Page 4: ...ID parameter setting mode 28 7 Wait parameter setting mode 29 8 Auxiliary function setting mode 1 31 9 Auxiliary function setting mode 2 33 10 Data clearing function 33 7 Running 7 1 How to set the program 34 7 2 How to perform the program control 34 7 3 How to stop the program control 39 7 4 Advance function 39 7 5 How to switch to Fixed value control Hold function 40 7 6 How to correct PV Sensor...

Page 5: ... RS 485 4 SVTC Setting value digital transmission 4 P24 Isolated power output 5 TC Electrical shock protection terminal cover Options Color Black Front panel Dark gray Case Black 1 9 types of alarm action and no alarm action can be selected by the front keypad operation 2 One input type can be selected from 10 thermocouple types K J R S B E T N PL C W Re5 26 2 RTD types Pt100 JPt100 2 DC current t...

Page 6: ...999 to 9999 1 1 0 to 10V DC 1999 to 9999 1 1 1 to 5V DC 1999 to 9999 1 1 DC current DC voltage 0 to 5V DC 1999 to 9999 1 1 1 For DC current and voltage inputs scaling and decimal point place change are possible 2 For DC current input 50 shunt resistor sold separately must be installed 1 3 How to read the model nameplate Warning Do not take the inner assembly out or touch the terminal with the powe...

Page 7: ...tor Green Lights when the control output is on For the current output type it blinks at a cycle of every 0 25 second corresponding to the output manipulated variable 6 RUN indicator Red Lights while program control is performing Blinks while program control is held 7 A1 indicator Red Lights when Alarm 1 A1 output is on 8 A2 indicator Red Lights when Alarm 2 A2 output is on 9 EVT indicator Red Ligh...

Page 8: ...to the Program standby mode or Program control run mode 3 Mounting to controlpanel 3 1 Site selection This instrument is intended to be used under the following environmental conditions IEC61010 1 Overvoltage category Pollution degree 2 Mount the controller in a place with 1 A minimum of dust and an absence of corrosive gases 2 No flammable explosive gasses 3 No mechanical vibrations or shocks 4 N...

Page 9: ...ting Mounting panel thickness is 1 to 15mm Insert the PCD 33A from the front of the control panel Slot the mounting bracket to the holes at the top and bottom of the case and screw in place Notice As the case is made of resin do not use excessive force while screwing in the mounting bracket The torque is approximately 0 12N m Fig 3 3 1 130 nX96 3 0 5 0 92 0 5 0 92 0 8 0 96 91 106 2 11 5 98 5 104 5...

Page 10: ...fastened with the terminal screw Tighten the terminal screw to the specified torque If the screw is tightened too hard the screw or case may be damaged Use a thermocouple compensating lead wire and 3 wire system RTD according to the input specification of this controller In the case of 24V DC for power source do not confuse the polarity With the relay contact output type externally use an auxiliar...

Page 11: ...es CO LTD 1 25Y 3 Y type Japan Solderless Terminal MFG CO LTD VD1 25 B3A 0 6N m Nichifu Terminal Industries CO LTD 1 25 3 Max 1 0N m Round type Japan Solderless Terminal MFG CO LTD V1 25 3 Fig 4 1 2 3 2mm 5 8mm or less 3 2mm 5 8mm or less 100 to 240V AC or 24V AC 24V DC Power supply Ground Alarm 1 A1 Alarm 2 A2 10 9 8 2 3 4 5 6 7 11 12 13 14 15 16 17 18 19 20 YA COM 2 3 11 14 17 YB 18 19 20 A B B ...

Page 12: ...l ends pattern end output stops by opening the terminals 14 and 17 Fig 4 1 4 4 2 Wiring examples PCD 33A R M Fig 4 2 1 14 15 16 17 14 15 16 17 Electro magnetic switch Heater Thermocouple Electric furnace Alarm unit 3 phase Alarm unit 100 to 240V AC or 24V AC DC Performs program control Program control RUN Standby mode Controller status Contact Closed Contact Open Standby mode Contact Closed Contac...

Page 13: ...Fig 4 2 2 PCD 33A A M Fig 4 2 3 Alarm unit 1 2 3 4 5 6 7 8 9 10 11 14 12 13 15 16 17 18 19 20 3 4 2 1 Alarm unit Solid state relay SA 220 Z Thermocouple Electric furnace Heater Single phase 100 to 240V AC or 24V AC DC Alarm unit Alarm unit Thermocouple Electric furnace Heater 1 2 3 4 U V W u v w 1 2 3 4 5 6 7 8 9 10 11 14 12 13 15 16 17 18 19 20 3 phase Phase control Power controller PA 215 H3 100...

Page 14: ...imal point place No decimal point 5 PV filter time constant setting Sets the PV filter time constant 0 0 seconds 6 Step time unit selection Selects the step time unit Hour Minute 7 Step SV setting when control starts Sets step SV when program control starts 0 8 Program control start form selection Selects the program control start form PV start 9 Control output high limit setting Sets control outp...

Page 15: ...tual temp STEP SV for 3s Press the key for 3 seconds while holding down the and keys Auxiliary function setting mode 2 will show up and the Input type selection item will appear Auxiliary function setting mode 2 PTN PV STEP SV Input type selection Select a sensor type to match with users with the or key Default K 200 to 1370 PTN PV STEP SV DC voltage input 0 to 1V DC has been selected in this exam...

Page 16: ...to 20mA 1999 to 9999 0 to 1V 1999 to 9999 0 to 5V 1999 to 9999 1 to 5V 1999 to 9999 DC current DC voltage 0 to 10V 1999 to 9999 2 Scaling high limit setting 3 Scaling low limit setting 4 Decimal point placeselection For DC current and voltage inputs the input indication can be freely set Default value Scaling high limit value 9999 Scaling low limit value 1999 No decimal point For example if DC vol...

Page 17: ... SV and time are advanced to the PV and the control starts However if the value set in 7 Step SV setting when control starts is larger than the PV PV start is cancelled and the control starts from the value which has been set during 7 Step SV setting when control starts SV start When the program control starts the control starts from the value which has been set during 7 Step SV setting when contr...

Page 18: ... selected in Alarm 2 A2 action selection The selecting item and default value are the same as those of Alarm 1 A1 Energized Deenergized selection 16 Alarm 1 A1 hysteresis setting Sets Alarm 1 A1 hysteresis Not available if No alarm action is selected in Alarm 1 A1 action selection Setting range 0 1 to 100 0 For DC input 1 to 1000 The placement of the decimal point follows the selection Default val...

Page 19: ... program control starts When Time signal output ON time has passed Time signal output is turned OFF Setting Time signal output OFF time 1 hour 20 minutes Time signal output ON time 30 minutes Fig 5 3 1 Pattern end output Fig 5 3 2 After the program control ends pattern end output is turned on for the time set at the Pattern end output time setting Fig 5 3 2 500 1000 OFF ON 01 00 1 hour 01 00 1 hou...

Page 20: ...e action selection Selects the Direct Cooling or Reverse Heating action Direct action When PV process variable is higher than SV Setting value the control output is turned ON This is a direct action This is used for cooling control for devices such as refrigerators Reverse action When PV process variable is lower than SV Setting value the control output is turned ON This is a reverse action This i...

Page 21: ...peration flow chart Step 1 Step SV setting PTN PV STEP SV Set value on the display means the vacancy which is not indicated Step 1 Step time setting PTN PV STEP SV Set value Explanation of Operations For the explanation of each setting item pp 24 to 33 current status of each display is indicated with diagrams on the left side and its item name and operation method are described on the right side B...

Page 22: ...EP SV Set value Step 9 step time setting PTN PV STEP SV Set value Alarm 2 A2 action point PTN PV STEP SV Set value Time signal OFF time setting PTN PV STEP SV Set value Time signal ON time setting PTN PV STEP SV Set value Proportional band setting PTN PV STEP SV Set value Integral time setting PTN PV STEP SV Set value Derivative time setting PTN PV STEP SV Set value ARW setting PTN PV STEP SV Set ...

Page 23: ... timer setting PTN PV STEP SV Set value Alarm 2 A2 action delayed timer setting PTN PV STEP SV Set value Event output function PTN PV STEP SV Selected value Communication protocol PTN PV STEP SV Selected value Instrument number setting PTN PV STEP SV Set value Communication speed PTN PV STEP SV Selected value Parity selection PTN PV STEP SV Selected value Stop bit selection PTN PV STEP SV Selected...

Page 24: ... 0 to 4200 Pt100 199 9 to 850 0 199 9 to 999 9 JPt100 199 9 to 500 0 199 9 to 900 0 Pt100 200 to 850 300 to 1500 JPt100 200 to 500 300 to 900 4 to 20mA DC 1999 to 9999 0 to 20mA DC 1999 to 9999 0 to 1V DC 1999 to 9999 0 to 5V DC 1999 to 9999 1 to 5V DC 1999 to 9999 0 to 10V DC 1999 to 9999 2 Program standby mode This is a program standby mode Therefore the control is not performed during this mode...

Page 25: ... for 1 hour and stays at 200 for 2 hours In this case Step 1 step SV is 200 and Step 1 step time is 1 hour Fig 6 2 1 Program standby mode or program control run mode Press the key Step 1 step SV setting mode is selected Step 1 step SV setting Set the step SV to 200 using or key Setting range SV low limit to SV high limit Default value 0 Program pattern 1 is selected Program pattern 2 is selected P...

Page 26: ...p SV is registered and Step 2 step time setting mode is selected Step 2 step time setting Set the step time to 2 00 using or key Setting range to 00 00 to 99 59 Hour Minute or Minute Second Default value 00 00 Hour Minute Press the key Step 2 step time is registered and Step 3 step SV setting mode is selected Step 3 step SV setting Step 3 and after can be set in the same way as the above Press key...

Page 27: ...tting range Refer to Table 6 2 2 below Default value 0 Alarm 1 A1 Alarm 2 A2 setting range Table 6 2 2 Alarm type Setting range High limit alarm Input span to Input span Low limit alarm Input span to Input span High Low limits alarm 0 to Input span High Low limit range alarm 0 to Input span Process high alarm Input range minimum to Input range maximum Process low alarm Input range minimum to Input...

Page 28: ...orm Cancel P I D and Proportional cycle etc The settings in this mode are applied to all program pattern numbers Program standby mode or program control run mode Press the key while holding down the key PID parameter setting mode is selected and PID auto tuning Perform Cancel is indicated PID parameter setting mode PID auto tuning Perform Cancel selection PID auto tuning Perform or Cancel can be s...

Page 29: ...al cycle Not available for ON OFF action and for DC current output type With the relay contact output type if the proportional cycle time is decreased the frequency of relay action increases and the life of the relay contact is shortened Setting range 0 to 120 seconds Default value 30s for relay contact output 3s for non contact voltage output type Program standby mode or program control run mode ...

Page 30: ...ection Selects Step 1 Wait function Used or Not used Not available if Wait value is set to 0 or 0 0 during Wait value setting Selecting item Wait function Not used Wait function Used Default value Wait function Not used Step 2 Wait function selection Selects Step 2 Wait function Used or Not used Not available if Wait value is set to 0 or 0 0 during Wait value setting Selecting item Wait function N...

Page 31: ...ck None of the setting values can be changed Selecting item Unlock Lock Default value Unlock SV Setting value high limit setting Sets the step SV high limit Setting range SV low limit to input range high limit value For DC input SV low limit to scaling high limit value Default value 1370 SV Setting value low limit setting Sets the step SV low limit Setting range Input range low limit value to SV h...

Page 32: ...lue 0 Communication speed selection Selects the communication speed Available only when C5 option is applied Selecting item 2400bps 4800bps 9600bps 19200bps Default value 9600bps Parity selection Selects the parity type from a choice of No parity Even and Odd parity in accordance with the host computer Available when C5 option is applied and when Modbus ASCII or RTU mode is selected Selecting item...

Page 33: ... for all patterns before clearing data using the photocopiable pages at the end of this manual If data has been cleared once the setting values have to be inputted again since the lost data can not be restored Program standby mode Press the key while for 3 seconds holding down the and keys 3s Data clearing All setting values are cleared and they return to their default values During data clearing ...

Page 34: ...ol 1 Select a program pattern number Select a desired program pattern number to perform program control by pressing the key in the program standby mode Each time the key is pressed the program pattern number is switched Indication when Program pattern 1 is selected PTN display Selected program pattern number PV display Current actual temperature STEP display Unlit SV display Unlit All indicators U...

Page 35: ... setting when control starts Indication during program control run PTN display Selected program pattern number PV display Current actual temperature STEP display Step number of the program control which is running SV display Current step temperature RUN indicator Lit during program control run Other indicators Lit or unlit according to the controller status Step SV or Step time change during runni...

Page 36: ...ion During the program control run the program does not proceed to the next step until the deviation between PV and SV enters SV Wait temperature when the step ends While the Wait function is working the numeric value on the Step display blinks The Wait function is cancelled on the condition that SV Wait temperature PV SV Wait temperature When the program pattern is rising The Wait function is can...

Page 37: ...t resumes Program pattern Fig 7 2 5 PV Program pattern which is delayed as much as T time due to Wait function T Wait time Time The step at which the Wait funtion was set Temperature C SV 500 490 T T ON ON OFF OFF 510 Wait temperature 10 C Time signal output Usual time signal output Time signal output delayed by the Wait function Wait cancellation range The control proceeds to the next step at 490...

Page 38: ...or the time which has been set at the Pattern end output time setting If Pattern end output time has passed Event output is turned off If Pattern end output time is set to 0 the output continues to work By pressing the key for 1 second or greater the pattern end output is turned off and the controller reverts to the program standby mode The following shows the indication during pattern end output ...

Page 39: ...rogram control run To cancel the current step and advance to the next step during the program control press the key for 1 second or greater This function is also available during Wait action or during Fixed value control action Indication when Advance function is used at Step 1 PTN display Selected program pattern number PV display Current actual temperature STEP display Step 2 after the Advance f...

Page 40: ...erforms fixed value control Indication when switched to fixed value control at Step 2 PTN display Selected program pattern number PV display Current actual temperature STEP display Step 2 after switched to the Fixed value control SV display Step 2 step temperature RUN indicator Blinks during fixed value control Other indicators Lit or unlit according to the controller status 500 1000 OFF ON Turned...

Page 41: ...hen controlling with multiple controllers the accuracy of the sensors or dispersion of load capacity has influence on the control Therefore sometimes the measured temperature input value does not concur with the same setting value In such a case the control can be set at the desired temperature by correcting the input value of the sensors PV Current actual temperature Sensor correction value How t...

Page 42: ...de each value of P I D and ARW automatically this system makes the controlled object s temperature fluctuate Notice Perform the PID auto tuning during the trial run During the PID auto tuning none of the setting items can be set If PID auto tuning is performed PID auto tuning starts at the same time as performance and step time and time signal time do not progress until the auto tuning ends After ...

Page 43: ... calculation 2 PID values decided 3 Controlling action is performed with the values set by PID auto tuning Fig 7 7 3 3 When the processing temperature is higher than setting value 20 40 Fluctuation is applied at the temperature 20 40 higher than the setting value Temperature 20 40 higher than the setting value 1 PID calculation 2 PID values decided 3 Controlling action is performed with the value ...

Page 44: ...Program control run mode Press the key while holding down the key PID parameter setting mode is selected and Auto tuning Perform Cancel item is selected PID parameter setting mode AT Perform Cancel selection Press the key Press the key The controller reverts to the Program control run mode and PID auto tuning is performed Program control run mode Indication during auto tuning Perform PTN display S...

Page 45: ...light variation of the processing temperature better control results can be obtained as the offset decreases However if the proportional band is narrowed too much even slight disturbances may cause variation in the processing temperature control action changes to ON OFF action and the so called hunting phenomenon occurs Therefore when the processing temperature comes to the balanced position near ...

Page 46: ... the closest MV manipulated variable when the control is stabilized 8 2 Standard action Heating reverse action Cooling direct action Proportional band OUT1 Green Indication Lit Acts ON lit or OFF unlit Cycle action is performed according to deviation Cycle action is performed according to deviation Changes continuously according to deviation OFF ON OFF ON 12V DC 12 0V DC 0V DC 0V DC 12V DC 0 12V D...

Page 47: ...2V DC 0V DC 0V DC 12V DC 20mA DC 4mA DC 4mA DC 20mA DC H C L H C L H C L H C L OFF ON OFF ON Lit Unlit Lit SV setting Non contact voltage output Relay contact output R S DC current output A 4 6 5 4 6 5 4 6 5 4 6 5 5 6 5 6 5 6 5 6 5 6 5 6 5 6 5 6 Pattern end output ON Indication EVT Red Pattern end output OFF Program end Press the STOP key Unlit Unlit Lit 12 13 12 13 12 13 ...

Page 48: ...ide side A1 set point A1 set point A1 set point A1 set point A1 set point A1 set point A1 set point A1 set point Alarm output Alarm action Alarm action Alarm output Alarm action High limit alarm with standby Low limit alarm with standby Alarm output side side side side A1 set point A1 set point A1 set point A1 set point A1 set point A1 hysteresis A1 hysteresis A1 hysteresis A1 hysteresis A1 hyster...

Page 49: ... standby function the standby function is released 9 Other functions Power failure countermeasure The setting data is backed up in the non volatile IC memory If power failure occurs during the program control run and if the power failure is restored the program control resumes from the point at which power failure occurred If power failure occurs during the fixed value control and if the power fai...

Page 50: ...imit value Relay contact OFF Non contact voltage 0V Current output 4mA or Control output low limit value Thermocouple input Input Input range Indication range Control range 199 9 to 400 0 199 9 to 450 0 205 0 to 450 0 K T 199 9 to 750 0 199 9 to 850 0 209 0 to 850 0 Indication range and Control range of thermocouple inputs other than the above Input range low limit value 50 100 to Input range high...

Page 51: ...le input voltage 5V DC or less Allowable signal source resistance 2k or less 0 to 5V DC 1 to 5V DC 0 to 10V DC Input impedance 100k or greater Allowable input voltage 15V DC or less Allowable signal source resistance 100 or less Input sampling period 0 25 seconds Accuracy Indication and setting Thermocouple Within 0 2 of each input span 1digit or within 2 4 whichever is greater However for R or S ...

Page 52: ...imit low limit 0 to 100 for DC current output 5 to 105 Default Output high limit 100 Output low limit 0 Control output OUT Relay contact 1a1b Control capacity 250V AC 3A resistive load 250V AC 1A inductive load cosø 0 4 Electric life 100 000 times Non contact voltage For SSR drive 12 2 0V DC maximum 40mA DC short circuit protected Current 4 to 20mA DC Load resistance maximum 550 Alarm 1 A1 and Ala...

Page 53: ...on during time signal output ON time Time signal output ON time follows time signal output OFF time Setting range OFF time 00 00 to 99 59 Hour Minute or Minute Second ON time 00 00 to 99 59 Hour Minute or Minute Second The time unit can be selected from the Step time unit selection Default value 00 00 Hour Minute Pattern end output After program control is complete pattern end output is turned on ...

Page 54: ...ht gray Attached functions Setting value lock function Sensor correction function Power failure countermeasure Self diagnosis Automatic cold junction temperature compensation Burnout function overscale Input burnout Warm up indication Accessories Mounting bracket 1 set Instruction manual 1 copy Terminal cover 2 pieces When the option TC is applied 10 2 Optional specifications Serial communication ...

Page 55: ...function is not available If Setting value digital transmission is selected from Communication protocol selection step SV of the PCD 33A can be transmitted digitally to a maximum of 31 units of Shinko controllers with communication function option C5 If Setting value digital reception is selected from Communication protocol selection step SV can be received from Shinko PC 935 PCD 13A PCD 33A with ...

Page 56: ...input is improper Temperature unit or is mistaken Set the sensor type which is the same as users and the temperature unit from the Input type selection p 16 Sensor correction value is unsuitable Set the value properly from the Sensor correction setting in Auxiliary function setting mode 1 pp 31 41 42 AC may be leaking into thermocouple or the RTD circuit There may be equipment nearby producing an ...

Page 57: ...g mode 2 p 17 The proportional band is set to extremely small value Set the value appropriately p 28 If the control output OUT remains OFF status Main output high limit setting value is set to 0 or less in Auxiliary function setting mode 2 p 17 The proportional band is set an extremely high value Set the value appropriately p 28 Step numbers progress fast and program control stops soon after it is...

Page 58: ...0 00 H M Alarm Time signal setting mode Step No PV display Setting item Default value Data Alarm 1 A1 action point 0 Alarm 2 A2 action point 0 Time signal OFF time 00 00 H M Time signal ON time 00 00 H M PID parameter setting mode Step No PV display Setting item Default value Data PID Auto tuning Perform Cancel Cancel Proportional band 10 Integral time 200sec Derivative time 50sec Anti reset windu...

Page 59: ...ault value Data Input type selection K 200 to 1370 Scaling high limit value 9999 Scaling low limit value 1999 Decimal point place No decimal point PV filter time constant 0 0 seconds Step time unit selection Hour Minute Step SV setting when control starts 0 Program control start form PV start Control output high limit 100 Control output low limit 0 Control output ON OFF action hysteresis 1 0 Alarm...

Page 60: ...d step time is considered to be the step processing time The relation between the step SV and step time can be explained as follows Step 1 The control is performed so that the temperature reaches 500 in 30 minutes 0 30 1 Step 2 The control is performed at 500 for 1 hour 1 00 1 When the control starts SV differs depending on the program control start form If the SV start is selected in the Program ...

Page 61: ... 4 3 SV P Proportional band ON OFF Step number Setting value Step temperature C Step time Hour Minute Wait function Used Not used Wait value setting I Integral time D derivative time Anti reset windup Proportional cycle Time signal output ...

Page 62: ...62 5 7 6 8 9 ...

Page 63: ...63 Revisions The manual number is noted at the lower right of the back cover Print date Manual number Revision Jan 2003 PCD31E1 First edition ...

Page 64: ... the shop where you purchased the unit after checking the following Example Model PCD 33A R M Option C5 Instrument number No xxxxxx In addition to the above please let us know the details of the malfunction if any and the operating conditions No PCD31E1 2003 01 ...

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